Really not that many options when you start talking upgrade v. rebuilds.
The stroker crank is a TON of money compared to the other costs.

How many miles are on your engine and what do you have to do to it?
Is it just a top-end rebuild that is needed or are you looking at also doing the bottom-end of it?

 

It has about 3800 miles on it so I was thinking/planning on a full rebuild, crank and all but haven't even started to price stuff.

 

Right now I am just trying to get a game plan and figure how much $ I'm going to need to save, I would love to just throw a quick top end on it and get back to the trails but I figure if I'm going to dive into the engine I might as well do it right.

 

Just to give you an idea of cost...
The Polaris Parts alone are somewhere in the $1,000 range the items below.
You should also get a new woodruff key; and now with what I know I'd get a new starter and a new bendix and along with the bushings that go in the case and the cover.

Look at Hot Rod Cranks; they had the best pricing on those.
If you want a BBK there are a lot of good options.
I like the kit that Muzzy has put together.

You'll need pistons; rings; rods...

These prices are old so just use them as a guide not written in stone.
Give FixMyToys a call and have Jeff put a kit together for you.
You can email him too: jeff@fixmytoys.com

Call him first and let him know what you're looking to do.

• Part# QTY Description Retail, EA. Total
• 5811511 1 GASKET-EXHAUST,27 .25 MM $25.00 $25.00
• 7516734 1 SCREW $2.50 $2.50
• 7518984 4 SCR-M8X1.25X22,HX/SO $3.25 $13.00
• 3610047 1 SEAL,EXH.SOCKET $16.00 $16.00
• 5137264 2 VALVE-EXHAUST HIGH TEMP 30MM $31.00 $62.00
• 5136197 2 VALVE-INTAKE, 35MM $17.00 $34.00
• 5910329 2 SEAT-VALVE SPRING,DT800/700 $3.00 $6.00
• 5411895 2 SEAL-VALVE GUIDE $16.00 $32.00
• 5247360 1 Polaris Base Gasket $15 $15
• 3585704 2 Main Bearing (split) $16 $32
• 5412676 1 Crank Seal $15 $15
• 2203012 1 Oil Pump Assy $105 $105
• 1204082 1 Oil Pump P/U $16 $16
• 5412455 1 Oil Seal $20 $20
• 3610075 1 WP Seal $34 $34
• 5132753 4 Counter Bal. Bearing $15 $60
• P5247360 1 Polaris Base Gasket $15.99 $15.99
• 3585704 2 Main Bearing (split) $19.38 $38.76
• 5412676 1 Crank Seal $18.96 $18.96
• 2203012 1 Oil Pump Assy $126.44 $126.44
• 1204082 1 Oil Pump P/U $19.08 $19.08
• 5412455 1 Oil Seal $25.28 $25.28
• 3610075 1 WP Seal $42.99 $42.99
• 5132753 4 Counter Bal. Bearing $18.96 $75.84
• _______ 3 Break-In Oil $8 $24
• _______ 1 81.5mm Piston Ring Compressor $10 $10
• _______ 1 Gearcase Lift Plates $20 $20
• _______ 1 Assembly Lube $3 $3
• _______ 2 NGK Spark Plugs $12 $24

 

Why would you replace the crank if there's no plans to put a turbo in it? I'd just plan for something like Wiseco pistons and rings and be done with it...

 

well he did say it had a knock..... if alot is needed it might be best to order a crate motor..

 

... or he could just keep an eye out for a used engine...

 

Getting a whole new or used engine doesn't sound like a half bad idea, do I have to stick with a standard rzr engine or can I put a 800s in it?

 

Either.

A top-end rebuild on yours isn't expensive.
It's the low end stuff that cost ya'.

 

If its knocking the bottom end is probably going to need rebuilt though isn't it? How many miles/hours is the bottom end normally good for? I have about 3800 miles and around 800hrs

 

just above Idol it kinda sounds like....ummm maybe taking a 2x4 and tapping the case, doesn't matter if its under a load or not, has no power and smoking quite bad.

 

If you take the clutch cover off and focus on the primary, does it wobble or appear to make off-center movements of any kind? From the sounds of what you describe, it is not looking good.

John: How often do cranks crap-out on non modified 800s? I guess it could be his bearings, or pulled oil pickup in the case..