09 Outlander Max - hot engine starting problem

[jonniecat]

I have a 2009 Outlander Max LTD which I swamped a few weeks back. Went through the routine of draining everything and changing the oil & filter until I had everything flushed out and good clean oil.

Now my machine fires up no problem when cold, does not appear to be burning any oil, no active P codes.

After I ride for about an hour and everything is good and warm, when I shut the machine off and go to fire it up again, it turns over really hard like the battery is dead. It will start again after some coaxing. Then I can ride again no problem and it starts fine after I get it loaded, get back to town and unload.

This has me worried that I am going to get stuck out in the woods with a problem machine.

I suspect that maybe I have a scuffed piston or stuck rings? But before I go tearing down the engine and spending a bunch of cash, I was wondering if anyone out there has seen the same type of problem?

[GEARHEAD01]

to me it sounds like your rod bearings or your main bearings are swelling when they get hot. there could be the possibility of a spun bearing as well. i don't think it is stuck rings or any thing like that. the first thing to do is get it hot then try and pull start it. if it is almost impossible to pull if it even moves at all then your engine is siezing up when hot. i would sure suspect that just by what you explained. good luck.

your friendly neighbourhood mechanic

[jonniecat]

Thanks for the information...

Ran it up to temperature again this morning and pulled the plugs and was able to roll the engine over by hand, but when I dropped the oil - theres metal filings, so it looks like a tear down & rebuild is next.

[DirtDemon]

I would think that after dunking it, you could have a battery or connection problem somewhere. Metal flakes in the oil would certainly have me looking well past that though. Rotax is one of the only manufacturers that I have ever seen that uses a plain bearing for the crankshaft main and rod bearings in ATV engines. I think that Gearhead may be on to something with the bad or spun bearing theory. If that were the case, you don't want to be riding that thing until you get it fixed. If you were to lose one of those bearings completely, it could be catostrophic.

[colescycle]

Jonniecat,I have a 800 with the same problem.Have you figured out what it is yet.If so please give me a tip if you can?