I got one setup with recommendations I read on here today and it is running great. Cleaned carbs, and valves. I have found that both sets of carbs are 34mm, one set has a smaller “old” style intake and other is wider and newer. Thanks!

 

There are a handful of minor & major differences between the 97 & 98. Hopefully the 97 you picked up has had the engine update done.

 

CanadianXCR I sent you a PM

 

Guys I have a 98 Red Rocket, bought it with 1500 miles on it which had a fresh rebuilt top end, broke in and ran great over the last 3yrs reaching good RPM's and 90+mph, machine now has 2800 miles on it and I rode last weekend and could only get 6500 rpm and maybe 60mph, I did not change any carb settings and it was 35* last weekend. When I brought it in the shop check the needles and the eclip was on the top setting, I did pull the spark plugs and the PTO has slight piston wash or small aluminum deposits on the plug. Possible a bad carb boot or what other things should I start to look at?

 

Carbs clean? Fuel system in proper working condition? Aged/cracked intake boot? Poor fuel? Resistance causing excess load on motor?
Aluminum on the plug requires plug hole inspection, minimum. Likely more.
Let us know how the sled is set up. Condition of components is critical. A lot of guys with experience on the machines, just need good info to help.

 

Fuel is good but I need to check carb boot, I will hopefully get time tomorrow night to report what I have for current specs. Thanks for the info so far

 

Got the carbs tore apart and here are my current specs, they didn't seem too dirty but running them thru Ultrasonic Cleaner
1.5 Needle Valve
159 P4 Nozzle
350 Main
6DH7 #2 Position
4.5 Pilot
7/8 Turn on Air Screw

 

That appears to be fine, those settings are even rich. You sucked air into the motor somewhere as RRXCR has indicated. Time for the ether spray test or a engine leak down test. Show us the plugs. Whats compression at?

 

Both Cylinders are at 120psi

 

Check this out. 120 is low. A lot of gray ... not good. Dig into it in the off-season.

Plugs from my 98 XCR 440. Still a bit fat, but close and running well.
https://www.snowmobilefanatics.com/forums/members/14695-albums2896-picture350939.jpg

 

120 psi is low for this engine. Some testers vary quite a bit from my experience so you might want to try another first to verify your compression readings. Pull the manifold to get a better look at the pistons on the exhaust side.

Hopefully there isn’t too much damage.

 

Thanks for the information guys, snow has all melted and yup good summer project, hope I caught things in time with little to no damage. I will post more info later on my findings.

 

Anyone have a line on some good ol factory Polaris pistons? Im going to have my motor completly re-done by a shop most likely I hope @ Iantomasi even get it put on the Dyno to see where it peaks. I plan on brining my sled to Alberta and I would like to completly pull all the bolts of of it and re-do everything. But I want the motor to go somewhere where they can properly do all the checks. IIRC I think guys are dropping IQr pistons into these now?

Good to see things are still mobile on here with this thread.

 

This is correct, the 440 IQR pistons are still currently available directly from any Polaris dealer, and a perfect drop in if you have a 98 engine with the 20mm wrist pins.

 

Hi everyone, new member here, just finished reading all 700+ pages of this thread! Tons of info here, glad I stumbled across it!
I just picked up my first red rocket, it’s a 1997 XCR 440, it’s seen better days as it has 5000+ miles. Luckily the chassis is very nice, and very straight, the foot wells aren’t bent up like the most of them. My plan with this one is a full ground up restore. I’ve restored 70’s TX/TXL/Starfire’s in the past and recent got interested in the newer stuff, so I figure this would be a worthy and rare sled (559 built) to give the full treatment. The motor is currently apart, waiting on some seals and gaskets to come in for it. It’s the original 97 bottom end & silver head cover, with the updated 065 cylinders and power valves. It still runs the 18mm wrist pin crank, and luckily I was able to track down a few sets of original 18mm Polaris pistons for it (including a set of the first L ring pistons, which will stay in the closet as a nostalgia piece LOL).
My hood & nose cone are from an Indy 500, that someone painted too dark of red years ago, and it now busted up in a few spots, so ill be using an NOS white domestic hood that we will be painting the correct red. I was lucky to find an original nose cone with the correct colour, and have a very good painter who is confident he will can mix up a batch with the correct metal flake and make it perfect. I’m excited to get it torn down and start the restoration which will include with all new OEM bolts & hardware with a professional paint job, NOS decals & as many NOS parts that I can find etc. My goal is to make it as close as I can to how it came from the factory. Currently just gathering the parts together to make assembly a quick & easy process without having to find parts along the way when that time comes.
Here’s some pics!

 

I'm looking for a set of 1994 to 1996 440 xcr sp cylinders with 68.25 bore and heads I have a 1997 440 xc with the 440 xcr sp engine but it has 68.19 bore and it doesnt come with removal head shims for higher compression

 

I'm also gonna put 38mm carbs on it so any info on this build would be much appreciated

 

Thanks Canadian! I work for a Polaris dealer here in Manitoba, unfortunately the quart of red is NLA through Polaris. The spray can is still available, but for my resto we’ll be using high grade automotive paint, so having the original colour scanned will hopefully give us the colour i need!
Here’s a couple updated pics. The engine is built and ready to roll, I’ve now started on restoring the chassis. Bulkhead was bent back in the right front corner, so luckily I found a good one and am in the process of swapping that over.
The joys of restoring an old race sled!!

 

Right on SB its looking good! I spent a few years out in Manitoba. Old man was in the army posted in CFB Shilo, back then we had a Citation 4500, I can only remember going to the Ski-Doo dealer in Brandon, can't remember a Polaris dealer in that area? This is going back nearly 30 years now.

Did you put new carb boots on? Did you have trouble finding them?

 

Small world it is! There is a Polaris dealer in Brandon, C&C Rentals. Not sure if they would have been there 30 years ago, there was a few in that area back then so I have heard. The dealer I work for in just in Winnipeg.
I used the original carb boots on the engine, I tried searching high and low for new OEM but I didn’t have any luck, and it doesn’t appear there’s anything in the aftermarket either. These ones are in pretty good shape, so for the few miles it will get after the restoration is complete they should be sufficient.

 

The carb boots are a tough one, that's I was curious. I managed to source a NOS set from a dealer in Michigan when I was building my spare motor 5-6 seasons back, but since then I haven't been able to find any, and there isn't anything available aftermarket. Would like to have a spare set just in case. The closest thing I could find that might be able to work would be a set of an XC500 that runs the TM38's.

 

I had a new 98 XCR 440 and like most I'm disappointed I sold it with 500 trail miles on it.
If someone has a super-nice 98 that they would consider parting with please PM me.

Thanks

 

Updated on the 97 resto! Chassis is all stripped, decals removed, and bent bulkhead switched out. Going to straighten up the running boards and send it to the paint shop in the next week or two... stay tuned!!
Had to drop the motor in for fun too.....

 

Anyone have pics of routing the remote dial adjuster limiter hose through the bulkhead on 96 xcr 440 sp. where is the hole location?

 

How are the fellow XCR 440 owners doing this year?
Here’s an update from Canada! Finished up my 97 XCR 440 restoration in July and finally got it out on the snow and wow, what a blast! Very happy with how it turned out. Also pictures are my 95 and 96 SP’s. Enjoy!

 

Is there anyone out there willing to part ways with a '98 Red Rocket? If so, I'm willing to drive anywhere in the lower 48 for it. Please PM me if interested!