I am starting to believe it is the crank seals too. And No, I haven't had a chance to wiggle the flywheel yet. Got called into work today (suppose to be off) and am working Sunday (supposed to have off) So my only day off this week is going to be Monday. Hopefully I can get a chance to do it then. I was reading on how to do a vacuum and pressure test on the engine in the Haynes manual. Basically what ftwflh said about blocking off the exhaust port and the intake and pressurizing the engine and then drawing a vacuum through the spark plug hole and then listening for leaks everywhere. I am convinced it is some kind of leak somewhere. I never had to split a case and do the bearings and seals on a crank. That would probably be the most expensive thing to have done at a dealer. Any idea what they would charge?? I still may attempt it, I just need to be sure that is the problem before I do it.

 

You dont have to split the cases to replace the seals.Just pull the clutches and the flywheel.

 

Check the intake side of piston and see if it is broken. I have seen this several times, engine has good compression and spits back into airbox. Piston skirt breaks on the intake side and won't seal to pump fuel up in to cylinder and blows air out the intake instead. Good luck, TORK.

 

<div class="FTQUOTE"><begin quote>Originally posted by: ftwflh

You dont have to split the cases to replace the seals.Just pull the clutches and the flywheel.</end quote></div>

OK, I read up on it today. The book said something about a special tool needed to pull the clutch...do you really need that? and once you do get to the seals, how do you pop them out without destroying things? do the new ones pop in pretty easy then? this is all assuming that I don't feel a lot of free play in the bearings.

When I take off the Pull starter, the Flywheel will be right behind that I assume to check for excessive play. Is that correct?
Thanks for tolerating all my stupid questions by the way, you guys have been a great help already.

 

<div class="FTQUOTE"><begin quote>Originally posted by: TORK

Check the intake side of piston and see if it is broken. I have seen this several times, engine has good compression and spits back into airbox. Piston skirt breaks on the intake side and won't seal to pump fuel up in to cylinder and blows air out the intake instead. Good luck, TORK.</end quote></div>

Thanks, I really have to do a pressure test on this engine and try to see exactly where the leak is. I'm trying to avoid just replacing things randomly until I get it right. If and when I take the piston out I will check it for any cracks in the base. Thing is, it does run great, its just VERY hard to start. I mean, like you gotta mess with it for about an hour. When its running, it seems fine.

 

Read some threads on clutch puller on here you can make on But if you plan on staying with Polaris invest in a good one you will use it more than you think.
you can get the seals out try drilling small holes and put in small metal screws to get hold of the seal to work it out