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09 Assault down.

Me and my cousin were out for a ride yesterday. Stopped for a bit on the lake to chat with some other riders and we all decided to check out a new spot together. Went up over a hill and on the way down the other side it cut out on one cylinder and started running like crap.
I shut it down right away and pulled the plugs. Mag side plug had little flakes of aluminum onto it. I figured the piston was fried so I wasnt going to start it anymore. Had to take the belt off and get towed home by my cousins m8.
Got it into my garage last night and let it thaw out and I went out today and tore it down. I noticed that the engine would not turn over all the way just like something was sticking and not permitting a full rotation. Found that one of the little ears onto the cylinder on the mag side had broken off and fell down into the crankcase. It had damaged the piston skirt, the reed, and there are marks on the crankshaft and the crankcase from where the little piece was moving around.
I am going to need a new cylinder, new reed for the mag side, pistons and rings (Only the mag side skirt is damaged but just as well to do them both), and there are marks on the outside of the crank and crankcase. I dont know if they will have to be changed because of this. Either way Im looking at a nice bit of coin to repair it.
My sled is out of warranty by only 1 month. And I was wondering if Polaris would cover the parts on goodwill as this will be the only thing that I have ever had to bring the sled to the dealer for (except for the top end recall, and I paid them to change my track for me). Anyone out there have parts covered under goodwill?
I was thinking that if Polaris or my dealer wont do anything for me, I will buy a 2011 and gradually acquire the parts off of the swapmeet and ebay to fix it and sell it next fall. The only thing is that I want a new Pro but I wanted to wait the full year before I bought one just to see if the motor will tough it out. Whats a guy to do?

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Good luck on having it covered under good will... I'm going to say no. Polaris is running from any out of warranty coverage on these motors like the teenage victims in a horror movie.

The '10s have thicker walls on the bottom of the cylinders to try and keep this from happening. Others are having the '08/'09s lose the other side of the cylinder.

Why would you buy a 2011 if you have had this luck with your '09? Afterall the Polaris track record on motors over 700cc isn't too good for the past 11 years.

sled_guy
 
I think this is the result of the "piston rocking" issue. Side clearance is so bad that the piston rocks from day one, starts to scuff, gets worse and then takes out the case flange.

This has happened to me 2 times now. We are installing the PMS kit to try and resolve this. During assembly we got a .0042 piston to wall clearance.
 
WORTH A SHOT

I was in the same boat as you! My crank was out as well as my top end and Polaris covered my parts only. I paid labor + the extra parts my dealer said I should try. I would take it in to your dealer and have them go to bat for you! Good Luck!
 
I saw my dealer about it today and he told me to email him the pics and he would send it to Polaris to see what they will do. They're pretty strict about photos of the airbox. If they pay for the parts, I won't mind covering the labor but it will be down for over a month because pistons are backordered until feb 18th. Im going to sell it once it's back together. It's a real shame because I haven't had an issue until now and I love the sled.
 
i also had my 09 assault go down this weekend. the mag side piston ring appears to have broke by the exhaust port and then took out my head, cylinder and piston. crank is still good but its just frustrating that with 1200 miles on the sled that an engine would do this, kinda disappointed with polaris.
 
i also had my 09 assault go down this weekend. the mag side piston ring appears to have broke by the exhaust port and then took out my head, cylinder and piston. crank is still good but its just frustrating that with 1200 miles on the sled that an engine would do this, kinda disappointed with polaris.

I hear ya! These are incredible sled when they are running....but that seems to be a rare occasion anymore.....sooner or later, warranty will expire, then what??
 
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