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701Dakota 03-10-2019 03:56 PM

09 Polaris switchback 800
Engine locked up. No idea why. What can I expect to pay for a rebuild or a new motor?
Could I have a 600 put in it instead?

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FaceDeAce 03-11-2019 07:43 AM

09 Polaris switchback 800
Depends on what is found.
Start with a 500$-700$ budget for basic parts such as: pistons, rings, gaskets, cylinders cleaning/honing, fluids and consumables.
Are you doing the work or handing to the shop? Near double the cost if paying shop rate for the work.

701Dakota 03-11-2019 11:24 AM

Shop will do the work. I got what I thought was a great deal on the sled. 1260 miles and it locked up on me after about 60 miles. Did not run it hard at all. Could I down grade to a 600? I dont need the extra power. I'm older and my crazy days are long past.

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KCCats2 03-11-2019 08:11 PM

The Poo 800 have all had crank issues!
Send it in to John at Northern Crankshaft Thief River, Mn


701Dakota 03-12-2019 12:22 PM

I was told they dont make the 2009 800 engine any more. Are there others that would fit if my damaged one cant be rebuilt for a reasonable price? I'd prefer a 600 or 550

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KCCats2 03-13-2019 08:58 AM

I bet it will be over $1000!

Yes you could possibly find a crashed 600?
At that point is it worth the effort to refit it, the pipes, the carbs/air box?

I would part it out and look for something better!

BC_Dan 03-13-2019 11:06 AM

The 600 and 800 use the same airbox and the same computer, but you will need to get the pipe for the 600 if you switch. Dimensionally, they are pretty close to the same size on the bottom end and use the same mounting system. Like KC said, finding a wrecked 600 would be the best bet. There are a few cooling hose differences, so you should look closely at that to see what the differences are.

A different 600 engine will be pretty spendy, you may be better off rebuilding the 800, especially if you can do the work. It's not difficult tearing one of those engines down, you may need a few specialized tools but if you have any mechanical skill, it's definitely do-able and will save you the labor costs... like Face said, that can double the cost...

dougbuckmaster 03-14-2019 04:44 PM

hi I am new to the group. I have a few questions and any advice would be great.
I have a 1993 Polaris 440 indy with a 121x15 track. first question is it possible to convert to a 136 inch track? if so what is the deepest/biggest lug I can put on my sled? will I have to change gearing in the chain case?

FaceDeAce 03-14-2019 07:08 PM

Doug, yes you can put a 136 with minor fitting. Lug size is entirely dependent on how much clearance there is at the front of the tunnel, where the track curves around the driver sprockets. Tip the machine up on its side. Then get in elbow deep and measure track to tunnel space at the smallest space point.

701Dakota 03-19-2019 11:00 AM

I can get a 600 motor from a 2012 Shift. Would this work? Any compatability problems with the computer/wiring? Thanks

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FaceDeAce 03-22-2019 10:02 PM

09 Polaris switchback 800
I believe BCDan covered as much as could be possible above wrt a swap in cc.
Imho, repair the 800. That should be your lowest cost option.
Also, you may may not think you need it. However, I can confidently assure you that you will be missing the grunt and thrust of the 800, when your friends are stopped sipping their beverage while waiting for you to come along over that last 15 mile stretch of trail or field, when you are digging put track and pulling on skis instead of having just cracked the throttle, when you are humming and singing along instead of clenched buttocks, white knuckles, and gritting teeth ...
Fix the 8. Or at least start with the disassembly of the engine so you know what you have to deal with. Then make a decision. If you want to downgrade just fix then sell it and buy something else. Or if repairs are too high rip it all to pieces and start the listings of parting out sales.
Those are the options as I see them.

KCCats2 03-23-2019 08:30 AM

I agree at least take it apart and see?

701Dakota 03-29-2019 05:56 PM

It was beyond repair. I had a shop put a used 2012 600 in it.

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MTsledder83 03-30-2019 02:59 AM

Hope it works well for you. People always underestimate the 600, and yeah, it's not going to beat an 800... until the 800 blows up. I've got an earlier 600 with 4500 miles – runs great, good compression, and the crank runout barely moves the needle. I'd go so far as to say most 600s will outlast their 800 brother 2-1 in hard riding. If you want to be king of the hill, you're going with the 800. If you're just looking for a pull and go sled that's still fun to ride, it's the 600. You'll get the same money or better if you sell it too. Hard to go wrong with the 600, in my opinion.

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