2013 Polaris 800 Top End - Input Needed

1

1moresnow

New member
Preparing to do a top end on my 2013 Polaris 800, mag side down on psi (~107). Planning on using OEM piston and rings (same as 2014 800).

Any tips prior to entering this area?

Suggestions for preparing the cylinders (i.e. honing, etc)?

With ~5,700 miles, any need for crank service (bearings or seals)? It does not appear to be a concern even with 7-8K miles on these motors.
 
G

G

Guest
You should check to see if your cylinders are still actually round.
 
M

mikedrh

Member
What was the PTO side? Send your cylinders and new pistons to a reputable machine shop to be measured and honed. Always a good idea to have pistons in hand when checking cylinders.
 
F

fastcat800

Member
Get the aftermarket updated piston kit. It comes with a spacer that goes between the crankcase and the cylinder and uses different pistons. There is a serious design flaw in the 800 and most don't make it 2500 miles before the go down. We had two burn down in West Yellowstone last year. That will ruin your week. Both were 2013's with under 2500 miles. The locals said they sell them before they get 2000 miles on them. Chrome cylinders do not wear. The plating is only about .0002 thick so there is no need to measure them. They are either good or you need a replated cylinder. A light diamond hone will help the rings seat faster. Seals should be good for 12-15K miles. When Polaris came out with the latest version of the 800 they fixed the piston problem. I think it was 2016. I am sure if you research Polaris forums you can find a lot of info on the subject.
 
1

1moresnow

New member
Thanks for the input!

Compression: Mag=115 PTO=107 (sled seems to still run fine, no concern with damaged cylinders... hopefully)

I've looked into the durability kits. Reviewed mixed feedback on aftermarket pistons, durability kits, and OEM pistons. I have a better perspective around cast vs. forged pistons. Is there a recommended durability kit with cast pistons?
 
srt20

srt20

Active member
You have to open it up and start measuring. Find out the health of the engine by measuring.

As far as what to use if you need it is up to you to research. I use forged pistons at .0045 clearance. But if you want to use cast, thats fine too. I dont, and wont use the spacer, but many people have successfully.

As long as you are measuring everything, there is no reason not to measure the crankshaft as well. I measure mine every year. And trust me when I say it changes.
 
S

Skylar

Super Moderator
Staff member
My 2012 went down with around 2800 miles on it, i had a bikeman durability kit put in it, then ended up trading the sled in with about 3200 miles on it, it was running fine when i traded it in.
 
S

stormrider3

New member
1moresnow said:
Thanks for the input!

Compression: Mag=115 PTO=107 (sled seems to still run fine, no concern with damaged cylinders... hopefully)

I've looked into the durability kits. Reviewed mixed feedback on aftermarket pistons, durability kits, and OEM pistons. I have a better perspective around cast vs. forged pistons. Is there a recommended durability kit with cast pistons?
Click to expand...

http://www.snowxparts.com/polaris-dragon-fix-kit/ This is what I have. More than 3500 mi. runs great, no special concerns with application.
 
1

1moresnow

New member
Thanks for all the input. I'll be replacing the piston and rings with stock. Original piston and rings lasted 5,700 miles.
 
1

1moresnow

New member
Completed the top-end on my 800. Everything seems to be working great, but the idle is low ~1300 to 1400 RPM. I've made a few adjustments that include turning up the oil 1.5 turns, replaced reeds with Vforce reeds, and used diluted 2-cycle oil on the rod connections prior to assembling the top-end. Could the extra oil cause the rpm to be low?

A touch of the throttle and rpm come right up! Sleds seems to run fine with just a little throttle.
 
srt20

srt20

Active member
1moresnow said:
Completed the top-end on my 800. Everything seems to be working great, but the idle is low ~1300 to 1400 RPM. I've made a few adjustments that include turning up the oil 1.5 turns, replaced reeds with Vforce reeds, and used diluted 2-cycle oil on the rod connections prior to assembling the top-end. Could the extra oil cause the rpm to be low?

A touch of the throttle and rpm come right up! Sleds seems to run fine with just a little throttle.
Click to expand...

The V-force reeds are causing the low rpm at Idle. It will come back after a few rides. Dont worry about it.

What is diluted 2-cycle oil?
 
1

1moresnow

New member
Thanks for the response!

Diluted 2-cycle oil is 2 cycle oil mixed with a little gas. Seem to work well for lubricating all the top-end parts for reassembly.
 
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