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Our polaris 1000 is 5 years, and recently developped a phenomenon where after starting in the morning (not too cold here in Dubai, like 20 degrees C), the gasket of the oil filter blows causing a major oil leak straight away.
So we changed oil filter and oil before (original) but same thing after a few rides.
Since the buggy has approx. 12.000 km, we figured it was time for a rebuild.
That is also what our technician here recommended after opening it up.
So we put new cylinder block, new pistons, new crankshaft, new gaskets all around. Nothing much done to the cylinder head did not seem necessary

Got our Polaris back rebuild, engine runs great, but on the second day of use the same thing happens again! Oil filter gasket blows.

Has anyone else experienced this, and what can be the root cause? Was thinking about blocked oil channels after the oil filter and not sure if these were inspected / cleaned during the rebuild...

Any suggestions please?

thanks a lot
Johan
 

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Are you using the same brand oil filter found in the US? Not sure where the oil pressure regulator is on a General, but it may be allownig too much oil pressure at the filter. I would usually suspect double-gasketing of the filter, but not twice in a row.
 

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Isn’t there a vent tube for the engine case? If so it could be clogged causing it to build up pressure and that is the weakest point for it to release from….Just a thought……
 

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2016 Polaris General Deluxe, 10% OEM
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Is your Technician cleaning the surface of the engine block where the oil filter mates after the filter is removed?
Then applying a thin coat of new oil to the rubber gasket on the new oil filter.
After the new filter gasket makes contact with the engine block, is the Technician tightening the oil filter an additional
3/4 turn?
Pirate
 
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