03 polaris xcedge 800 burned down need some thoughts

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snowmobiler

New member
I went on a trip did 150 miles no problems. it has been sitting for a week, I go out today and make it to next block and just died. go to pull it and ya seized up. pulled it out tonight clutch side piston took the most damage. but plugs are still brown and I was only doing about 10 mph when it went. so im guessing maybe crank seal? anyways whats some thoughts to do. i want from bottom up rebuilt. but do i get some work done to motor nothing crazy or leave it to stock. also do i try and find another 800 motor, instead of rebuilding? i was also wondering what i am looking at cost wise. any input would be great thanks.
 
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ezra

Well-known member
Indy Dan is the only guy I would let touch my poo crank.
952-445-7745
at least give him a call he is a deep fountain of knowledge on poo cranks.
 
G

G

Guest
They actually make a kit for these to beef up the PTO side bearing. This motor was known to tear up the crank seals on the PTO side resulting in carnage. This motor was also known to injest power valves. This was not one of pol's best efforts. Go find yourself a 700 motor and slap that in there. You will get by cheaper and you will have reliability and you will be happy.
 
indy_500

indy_500

Well-known member
I'd try to find a 700 motor no matter what you do those 800 pto bearings will never last if you ride it like your supposed to ride an 800...
 
indy_500

indy_500

Well-known member
snowmobiler said:
ok thank you. now if I find a same year 700 motor can I slap it in there and go?
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pretty much. Any ves 700 from 02-05 should work (98-01 was non ves but would still work fine if you wanted to run one). You may have to change jetting and possibly a size lighter clutch weights. Obviously you could do the whole works and change jetting, gearing, clutching, timing, etc. to 700 specs but it really imo would just need the weights and jets.
 
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ezra

Well-known member
the 700 should drop in. But I am saying go to hcs and look up indy Dan and search is posts there is a huge forum on 800 cranks. he goes over the multitude of bearing options for the type of ridding u do etc etc.
u get some one to do the bearing and case correct it will last. slap a used power plant from some guy u never met have it shipped to your home u could be in the same spot before u get loaded on the trailer to go ride it.
remember not all machinists should be working on snowmobile parts. nor should a guy who specializes on doos or cats jump in and do your poo.
or just slap some new seals in it some cheep pistons and run it 300 she could run another 3k mi just fine
 
indy_500

indy_500

Well-known member
Well I have 2 99 700 non ves and both of them have 7600 and 8400 miles on them motors never been apart except mine just for base gaskets. Good compression good crank runout. You could get it rebuilt by indy dan but i doubt it will last 7 or 8k. Poo Case is not strong enough for 800.
 
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snowmobiler

New member
ok thank you. now if I send him hole motor because I have top end off, and its gonna need pistons. we he do all that put it back together. cause I was wondering about boring it out a bit, get little more power etc, or just have it stock. do you have any idea what im looking at price wise.
 
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ezra

Well-known member
no idea on cost.I know they are not the cheapest shop in town but I do know he is among the best on your sled. for performance I have never seen a jug that did not need a bit of grinding around the ports. A Quality port job is worth its weight in gold.I have seen some real hack work out there from "Big Marketing Performance" companies that look like JR high shop class in WI got the contract for the porting. they put out big bore kits that constantly get waxed buy 100cc less machines with just high quality porting and tuning.
If U hold up 2 sets of jugs 1 from a volume shop and one from a actual race sled builder it is laughable
 
M

motor_slut

New member
snowmobiler said:
I went on a trip did 150 miles no problems. it has been sitting for a week, I go out today and make it to next block and just died. go to pull it and ya seized up. pulled it out tonight clutch side piston took the most damage. but plugs are still brown and I was only doing about 10 mph when it went. so im guessing maybe crank seal? anyways whats some thoughts to do. i want from bottom up rebuilt. but do i get some work done to motor nothing crazy or leave it to stock. also do i try and find another 800 motor, instead of rebuilding? i was also wondering what i am looking at cost wise. any input would be great thanks.
Click to expand...
Most likely the PTO bearing went out and sent parts up through the cylinder.

indy_500 said:
Well I have 2 99 700 non ves and both of them have 7600 and 8400 miles on them motors never been apart except mine just for base gaskets. Good compression good crank runout. You could get it rebuilt by indy dan but i doubt it will last 7 or 8k. Poo Case is not strong enough for 800.
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I have a 700 that killed a crank at 4600 miles, I have seen 800's with over 9000 trouble free miles. It's all a gamble.

indy_500 said:
pretty much. Any ves 700 from 02-05 should work (98-01 was non ves but would still work fine if you wanted to run one). You may have to change jetting and possibly a size lighter clutch weights. Obviously you could do the whole works and change jetting, gearing, clutching, timing, etc. to 700 specs but it really imo would just need the weights and jets.
Click to expand...

You will also need a CDI for the 700 and the carbs are 40mm on the 800 and 38mm on the 700 so some special jetting will be required. Sure you can run the 700 on an 800 CDI but it will run like crap.
 
D

D.B. Cooper

Member
snowmobiler said:
I went on a trip did 150 miles no problems. it has been sitting for a week, I go out today and make it to next block and just died. go to pull it and ya seized up. pulled it out tonight clutch side piston took the most damage. but plugs are still brown and I was only doing about 10 mph when it went. so im guessing maybe crank seal? anyways whats some thoughts to do. i want from bottom up rebuilt. but do i get some work done to motor nothing crazy or leave it to stock. also do i try and find another 800 motor, instead of rebuilding? i was also wondering what i am looking at cost wise. any input would be great thanks.
Click to expand...

As others have said, Indy Dan is the way to go.

THEE ONLY guy out there with a 3 year warranty, period!

Backs up what he builds & sells!

He knows the POLARIS 800's inside and out

Crank PTO bearing will be replaced with a WIDER bearing as well

He'll probably discard the old aluminum exhaust valves and replace with the updated stainless valves as well

Send him your primary clutch as he'll want to balance that as well. Once you get it back and see how many lightening holes are newly added, you'll have a certain degree of disappointment as how POLARIS could have sent it out that way from the factory
 
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ezra

Well-known member
did u get a call in?this time of yr my guess is no.lol
he still have a message like if u are calling to ask why my xlt wont start do u know why dont call back
 
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ezra

Well-known member
20 more days and they will be giving them away.
just from mid jan to now a dealer around me has upped the cost 1g from his deep discount of mid jan with no snow any place.
early march they will be back down and 500 more.
 
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