Top 3 common RZR 800 problems [Air filter, Power, and Rear Differential]

[@RuggedAdventures]

We're super close to 1,000 subs! Be sure to subscribe and let me know what has gone wrong with your rig below!

[@iansgarage8603]

I’m trying to hit 50 subscribers lol

[@RuggedAdventures]

@@iansgarage8603 it takes forever!

[@iansgarage8603]

@@RuggedAdventures Ikr! I love your videos btw!!

[@RuggedAdventures]

@@iansgarage8603 thanks! I need to get out and make some more!

[@iansgarage8603]

@@RuggedAdventures Can we see some more RZR videos soon?

[@C-L-A-W]

My 14' 4 800 with 2k miles rear diff pinion nut was about 3 threads from coming off. Thankfully, I saw someone mentioned it in the comments for your previous video. Took the diff out myself in about an hour and took it to a local offroad shop where they used red loctite and gave it 3 ugga duggas.

[@RuggedAdventures]

Did you just reuse the old parts? Glad you caught it in time!

[@C-L-A-W]

@@RuggedAdventures @Rugged Adventures Me too, rear diffs are expensive and hard to find. I reused everything except the seal which normally gets damaged on removal. Bigjeepman10 has has a great how to video on the repair.

[@blakeholmes8691]

I’ve a 2013 800s. I love it for what I do. Where I go is pretty much rock crawling and it does great.

[@MrTommy001]

Right after I bought my 2011 800s in 2016 but before it blew up (ahem), I took my RZR out to the gentleman in Winnemucca, NV and he got me into the "tight nut club". He didn't charge me anything (GASP!) but I left a hefty 'donation'. And as I mentioned in the comment section on your other video on why to buy 800's, I now have a 2018 800s engine in my 2011. It has all the power I need. When we used to have ATV's, I always said if you could do 60 mph, you were on the wrong road . . . Just sayin'.

[@Marine450x]

Who in Winnemucca NV?

[@CSERepair]

I actually just blew up my Robby Gordon 2012 800 and am super tired of the low powered engine and weak trans. Will a 2018 drop right in ?? Looking to upgrade this to a wheel spinnin monster

[@shanefawcett225]

Great video but forgot to mention the oil pressure relief valve issue

[@fredluther3476]

Also forgot the rod knock it will eventually get..lol

[@bigb6548]

Good info. Not ready to throw 30k on new turbo unit. Till then thanks for the info.

[@gerryvienneau8933]

I had problems with my rear diff. Something let go and it made a big hole through the differential so hard to buy a new one. I have the 2014 rzr 800 s le and had 7500 km on it

[@jeffking6672]

I've seen several of them grenade like that, and it's the pinion nut issue described in the video that causes it. The nut backs off, the pinion rides up on the ring gear more often than not busting the shaft just in front of the gear itself and then hits the case and busts out the side of it. Polaris never has admitted to the issue, never did a recal and never made an official repair. If you get a new differential it will have the same issue so due the DIY repair on it yourself prior to installation. Most dealers won't admit to knowing what you're talking about so get online and track down a set of tools to borrow or make your own if you have the skillset. There is also a Facebook group on the problem where you can buy the tools or potentially borrow them.

[@Marine450x]

@@jeffking6672 mine just granaded today :( Thank you for posting this regarding the fb group, (Update: I can't find any such on FB. Can you post a link, or the name of the group?)

[@gabesullivan4151]

I think I definitely would have covered the dowel pin in the motor as a motor problem point too, if they get stuck your motor looses oil pressure, best way to avoid it is when doing a fluid change take it out with a magnet polish it yourself or take it to a jeweler and have them do it for like 5-10$! Totally worth doing.

[@219fisherman4]

What speed are you seeing out of your rzr 4 800? I’m only seeing 42mph at 6300 rpms

[@josephoverstreet5584]

I guess he didn’t see your comment. I’m pretty sure you should be able to get more speed than that

[@erniejohnson4364]

My 800 developed a gas leak on the fuel injector, specifically from the Schrader valve. If you detect a gas drip from that jet nozzle (looks just like a threaded bicycle tire valve), tighten the inner portion of the nozzle by using a pair of tweezers. There's a KZbin video on how to do this for tire valves, same process.

[@ericsmith3141]

I installed an epi clutch with a green spring and that has made a hug difference.

[@RuggedAdventures]

I did a Dalton clutch kit and it really helped mine as well

[@ericstyer2890]

@@RuggedAdventures mines coming tomorrow for my 2 seat 14 800s, looking forward to a noticeable difference I’ve heard so much about.

[@vetteguy]

best air filter you can buy is the donaldson double filter set up!

[@davepo6443]

Would appreciate any suggestions. 2012 Polaris 800 Razor EFI hesitates at 45-50 mph. 45 is about 6350rpm. Not really a sputter or cough. Repairman just cleaned throttle body and fuel injectors and said idle air circuit was partially open causing a misfire at that speed. None of the work performed solved the issue. One person suggested the primary and secondary cluthes might be fighting each other. Need to get it fixed pretty quick so we can sell it and move, but I want it to be right. I should also mention that it has full power no issues 0-45. No codes, no engine light. Always at that speed only.Thanks folks. Appreciate anything.

[@RuggedAdventures]

99.99% probably a bad fuel pump

[@davepo6443]

@@RuggedAdventures Thank You for your response. I have some new information on the 2012 Polaris 800 Razor having issues at 45mph. I was asked if it could go faster than 45mph. Just took it for another test. As usual it hesitates at 45mph. I pushed it on a longer stretch and when it gets to 50mph it stops hesitating. When I get to 55mph it hesitates again. Top speed is 60 mph at a maximum of 6500 rpm. To obtain codes, one video suggested turning the key off and on 3 times and it will show a code. Didn’t see anything pop up when I tried it. I don’t know if this 800 has the ability to display any codes? I’d like to include some responses from folks kind enough to offer suggestions to see if it triggers any other ideas pointing to one thing. The spark plugs were replaced about 1.5 years ago. They were examined recently and found to be good. I still might replace them as that’s a cheaper item. I suppose it could be a bad spark plug wire.. or coil wire. Your thoughts? Suggestions: fuel pressure check, sounds like fuel pump, spray water on spark plug wires and coil wire, Fuel stabilizer, Belt might be slipping, inspect clutches and belts, don’t think its clutch related, sounds like clutches sticking, check belt for damage, weights in primary clutch are too light, was IAC mechanically stuck open or electrically being opened. Thanks again. I’m hoping this new information might directly point to something that I will try and tackle on my own. Taking it in is a last resort for me. I promise, to get back to you once I find the issue! Thank you kindly. Very much appreciated. Dave

[@ottojames2623]

Keep in mind when using a K&N filter you MUST spray the oil on it. This will keep the dust out.

[@RuggedAdventures]

Even so they let tons of dust through and will junk your 800 engine.

[@666dynomax]

@@RuggedAdventures I have never seen good things from any k&n air filter. People think they work better and want to feel they do because of the money they spent only thing I’ve ever seen was CHeck engine lights on pickups. I’ll steer clear

[@chubbyb5718]

You absolutely HAVE to have a pre filter with KN. No exceptions

[@rrrrsorry8408]

I and n filters sprayed with oil is nothing more than a oily mud pie .

[@BradFFA]

hahaha rolling the dice man love that ive been doing maintanance on my 2010 800s and now im scared this could happen to me but its looking like a tough job! right now im getting a whining sound at certain rpms kinda like a gear whine or somthing in the clutch im not sure but its pretty annoying an loud i replaced the belt didnt help it does yours have a whine during accelerating or driving?

[@earlgolding5845]

Have you come across a solution to the 800 ‘s not starting when their hot?

[@RuggedAdventures]

Probably a bad fuel pump. I had that, swapped the pump, and never had it again.

[@tommyblakley2284]

Good morning, I have a 2011 rzr 4 800. I have a chirping noise in the belt area when slowing down. Have changed ujoints, carrier bearing and belt but still have the chirping noise. I just noticed that the rear end is out of alignment, the left tire is about 2" closer to the front than the right tire. To me that explains the chirping noise, alignment problem at tranny. Is there any way to adjust this alignment? Thanks

[@danielaragon6058]

Love my 800s

[@RuggedAdventures]

They are great machines!

[@Chad-Dion]

is there a way to tell if you have 1 or the other pinion nut ?

[@RuggedAdventures]

Very, very early 2008s supposedly don't have any issues but the rest of the 800s do.

[@ScottGriffin-g2t]

I have a2010 800s,runs great then spits and sputters like I'm out of gas and dies,not out of gas,fire's right up and down the the road we go,does it over and over and the more it continues the less miles i can get(sometimes less than 100yards) any advice would be appreciated

[@RuggedAdventures]

Sounds like a bad fuel pump (highly common)or clogged fuel tank vent.

[@macpac3803]

What was it? Maybe bad coil?

[@lucastucker3484]

I had a problem with mine shutting off after it warmed up and wouldn’t run good until it cooled off….turned out it was bad plugs…blew my mind, had a friend with a Harley acting the same turned out to plugs also it’s unreal

[@ruezga_2295]

Do you have any maintenance videos ? I just got my rzr 800 and all I know how to do is the oil change ...

[@RuggedAdventures]

Only the boot change. I need to do a little service soon and I'll grab the gopro too!

[@jarrettwoodward2585]

link to the hardware?

[@garycasto8220]

Wish I saw this before I bought the K&N :(. I did get the pre-filter sock. Will that help any? Or just go paper?

[@BigRedGuy]

The pre-filter makes a huge difference .

[@garycasto8220]

@@BigRedGuy thank you, man! Just like everything else, it seems as though maintenance is the key

[@chiphazzard8173]

The 570 is the toughest I've got a 2012 570, 2014 800. The 570 is by far a more reliable machine.

[@Toolaholic7]

My youngest brother has seen engine failures due to air filter problems

[@larrymcquality6344]

Did they fix the diff problem on the 2010

[@RuggedAdventures]

The diff problem affected all 800s other than maybe some of the very early 2008s.

[@brianhammons2614]

My 2013 rzr800s just started reving up and down on its own while driving. It will not idle without giving more gas. Anyone else have this issue

[@chriskirtland7542]

Why is your rear stabilizer un done

[@RuggedAdventures]

Flex and ride quality. Much, much better.

[@billyweston949]

Maintenance ! It will run for ever Polaris has built fine machines if you drive them respectively and do Maintenance

[@lesterxxx7642]

wife bought me a surprise 2011 rzr 4 800 Bobbie Gordon, anybody got suggestion. ya i'm stuck with it

[@TheSkoto1]

what about the rod knocking....

[@RuggedAdventures]

I haven't heard that as much as the other 3.

[@ME-tp6kr]

Bolt on turbo kit

[@governmentequalsmindcontrol]

Nitrous is also bolt on!! 😉

[@lexsa637]

my rzr 800s does 75mph

[@DougBolden-i3w]

Header glows red

[@RuggedAdventures]

I've never had that. Either a lean condition, often a weak fuel pump, or a plugged exhaust likely.

[@ogc_prawn3252]

1:07 what da dog doing?

[@chubbyb5718]

You have to run a pre filter on a KN. And sorry your wrong. Polaris actually put out an article that the air intake boots were leaking …. And how to fix. Which was silicone. Yes I have all this paperwork from Polaris. Aftermarket air filters are fine … Polaris filters are junk. A uni good r something similar is fine

[@couchrider6228]

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