parts ordered and on their way. thanks for the advice! If i may, lol I got the service manual downloaded and went out to get familiar with things and when i walked into the garage theres oil under the bike. Best i can tell its coming from between the jug and the crankcase. If the seal is bad and i have to pull the jug, ill prob just replace the whole top end, found them anywhere from 60 bucks to 189 bucks. If i do the "big bore kit" which i understand is only 2mm difference, will i need to rejet? Also since the throttle is not real responsive i can only imagine the reeds need replacing too. The PO ziptied off the line from the oil injection pump to the carb and has been premixing at 40:1. Ive read the proper is 32:1 so if i rebuild the top end im going to drain all the gass and start over. Since the oil pump is probably burned up ill just premix, any idea where i can get a single throttle cable? I havent decided if i want to mess with pulling the pump or just unhook the cable and leave it in the case. Thoughts?

 

Sorry to be so long winded and bombarding you with questions, i really appreciate the advice.

 

Just stick with a std size rebuild kit as you're not going to make a speed demon out of these small ones anyway..Predator,Outlaw,Sportsman 90s are all the same engine. Doesn't matter what kit you get. People freak out over these pumps,most times over nothing.Most wait until a piston is worn out and seizes and blames it on the pumps.. If po has disabled it,blocked off the carb injector,then imo 36:1 is plenty enough on these small compression engines.Have had plenty of folks premix 40:1. On high compression Ktm race bikes we mixed 32:1. You can leave the pump connected,drain the oil tank and use the stock cable. Wouldn't go to the trouble of getting a single cable.Plenty of options on kits. http://www.ebay.com/sch/i.html?_odkw...+kits&_sacat=0

 

Read somewhere that using a single cable would make it easier to operate for little man and wouldnt cause as much fatigue on his thumb. Guess i cpuld just cut the cable at the y and call it done.

 

Since i wasnt clear in that post, am i probably accurate in assuming the seal between the jug and case is bad?

 

Base gasket? If that's what you mean, a new one comes in the kits.

 

Two last questions and i should be all set (i think). If i do a big bore kit on it would i need to rejet the carb due to the higher compression, change exhaust etc? I bought a name brand 2 stroke so i could keep him happy with it for as long as possible with upgrades (clutch springs, pipe etc.) and since i have to change the top end anyhow (pulled it last night and wow!!) would i be better off doing it now as opposed to later and having to do it twice? Id rather not have to buy another top end down the road, but i dont want to dump a bunch of $ into it with a different carb, pipes etc. right now either until he can handle it.

 

Major alterations other than stock you may have to rejet carbs. If you're determined to make it a speed demon,then places like these are willing to take your $$ Polaris Predator 90
Speedwerx, Inc. | Polaris 90cc Speed Kits

 

Again thankyou for the fast response!! About ten minutes after i posted it i ordered a stock top end kit. Ill cross the "speed demon" bridge when he needs more oomph. Think when the time comes ill look at clutch and roller up grades.

 

Ok last one. I promise lol. What is the small hexigonal ring in the upper left? When i took the top end apart i didnt see one of those. Exhaust gasket?