Just blew the pto cylinder. Checked compression. Got 115, 115, 20 on the pto side cylinder. THis is the 2nd time in a year this has happened. Last time I got about 200 miles on it after the rebuild. This time, got 16 miles out, and took a sh....t again. The guy that rebuilt the sled is a good Polaris mechanic but I'm reluctant to go back to him for a third time because I think he's doing something wrong. TO ALL YOU XLT guys out there, what could be the problem. When we rebuilt it last year, put rebuilt crank, new rods, bearings, pistons, rings, honed cylinders, new gasket kit, cleaned carbs, readjusted, rebuilt clutch, new secondary spring and buttons, new belt on water pump, new water pump rebuilt, new drive belt. Its always the pto cylinder! Please help!!

I have the same sled. Just got it but I know there are problems with these sleds.
Here's what I think. I don't thing the crank was properly fixed by your mechanic. While I by no means an expert, but it sounds very suspicious. Was the crank trued? What was the run-out on the crank? New bearings on the PTO side?
I don't think the pistons, etc had anything to do with it. The other thing that comes to mind is a bad PTO crank seal.
Let us know what happens.
Dman

check the oil lines and oil pump. make sure there are no obstructions and the lines are getting bled.

Two thoughts come to mind, both have been said already, check the end seals, most likely you need to do a leak down test ( BOTH PRESSURE AS WELL AS SUCTION!!) and the already mention oiling system. The factory oilers at the bottom of the intake tend to come loose or get plugged up and fail. Had that exact same problem last year with a buddy's sled, he rebuilt it twice before he found out that it was the oilers not working/ sealing properly.

I would think you would still be running pre mix at the time this burned is that true? I run premix on the first tank of a rebuild. That would rule out an oil issue

Yes! But not this year. Had the 2nd piston put in last February. Ran the sled around the farm, put about 75 miles on it. That tank was premixed. I checked plugs at that time and they looked good. all even. Not now though.

Well, the broke XLT is no more. I traded it in today for a Polaris 550 Classic. I want to thank everyone who responded to my problem. I learned alot. Thanks so much.