Pt.1 Polaris RZR 800 Top End Overhaul At D-Ray's Shop

[@wagonroad534]

Your videos gave me the courage to replace the pistons in my 08 Polaris RZR. The hardest part was taking off the body work. I used different colors of fingernail polish to mark where the various wires went. It took a while to figure out how to detach the exhaust pipe springs. The cylinder looked good, the thin layer of nikasail on the cylinder walls was intact, so I ordered stock pistons, and had to do some light sanding to get the oil rings on one piston to fit into the bottom grove. I put it all back together and the engine runs beautifully. Thank you for your videos.

[@sandydamico2389]

This man is my kind of guy: knows his stuff and can explain it even better. THANKS

[@fncindel]

Hey D-Ray, I just watched this last night and I have to say, you are clear, easy to follow and a huge help. I have no problem trying this for myself. I have also put your link on PolarisATVForums so others can find it too!! Thanks again !!

[@josephf7720]

Your videos are great in explaining and showing each step.

[@DRaysShop]

Thanks, it's not a real problem with the regular ranger and crew, just the RZR. mostly because of the location of the air intake, and the fact that most RZR riders use the throttle pedal like a freakin' toggle switch! lol

[@justingeorge8894]

Excellent step by step video. There were never any 'what did he do there?' moments. Covered it all. Thanks a lot.

[@robertopenuelas8373]

Best step by step video I have ever seen, congrats and thanks!

[@garyclagett1848]

Absolutely excellent top end rebuild series! I really enjoy your video’s! Thanks again!!

[@timbest8970]

awesome videos.....informative without the pointless banter of soooooooo many others

[@DRaysShop]

Thanks! I enjoy makin' 'em.

[@dalepeters1690]

Nice Work on the Video D-Ray.

[@randallpeterson7511]

Great Job, I am doing my 04 Sportsman 700 this weekend..

[@gravytrainoutdoors]

Fantastic video! Keep them coming!

[@trailshark3122]

Your the man D-Ray... cool video

[@kflashcarr]

Thanks so much for your vary well done video. You got a gift for instruction.

[@Shellywriter81]

Awsome vid D-Ray! It all looks so intersting! Yay! :)

[@lastcallbeam]

First....wow...this is quite the little movie....very informative!

[@trevoringram247]

awesome video keep them coming!!

[@wagonroad534]

Oh yeah, one more thing. You must push in the rear portion of the piston pin circlip in first, that is: the portion opposite the circlip gap. Once that portion is set in the grove you can push in the rest of the circlip using a small screwdriver with a grove cut into the blade wirh a dremel tool. Only Godzilla can push in the circlip with his fingers. And put paper towels everywhere, cause when that circlip goes flinging off into space, it's impossible to find.

[@DRaysShop]

I bought it online from a company called panther lifts, but I think they're out of business. But I have seen a few other companies selling the same lift.

[@VJMazalin]

hi there. i know this is a big request but i'm wondering if you can do a video on a crank tear down.

[@DRaysShop]

Not yet, but I will do a series on the next one that comes in to my shop, thanks.

[@DRaysShop]

Yep, I like workin' on clean stuff! lol

[@lacindabailey6870]

Love these vids would like to see you do a complete overhaul on a ATV I have a Honda fourtrax 300 a 1993

[@rnh4547]

Puttin' all those years in Polaris boot camp to good use, I see!

[@traditionsportsrec6047]

great video man! thanks alot

[@SunSandAndSea]

looks like a huge job!! tell tile signs are smoking? and heavily burning oil?

[@DRaysShop]

Yep, Ive seen several do this and worse! Thanks for watchin', more vids on this project will be up shortly.

[@DRaysShop]

Thanks Fletch!

[@coreypeterson513]

Hello Ray, I enjoy the videos. I have an 08 rzr doing the same thing except I dont see any smoke or smell any burning oil with no leaks and yet it still consuming oil, 1/2 quart every 80 miles or so. I am looking to buy the top end rebuild kit that includes the cylinder any sugestions on best place to pick these parts up from?

[@davedavis590]

Video was great..do you have and videos on doing 08 rzr bottom end?

[@MrSpanky473]

Wished you'd do a vid on a 900 xp...I got a feeling the overhead cams are gonna be way different than this one.

[@Bunkers101]

Really enjoyed the vid. =D

[@jbranham4130]

my 13 rzr 800s just didn't want to start for me tonight...I had just shut it off,the engine light is on,and I have no letters for the selected gear.and it doesn't turn over at all...cant figure it out

[@urPOPPOP]

Are you taking on any more work right now I live here in Cabot Arkansas

[@jaychase8561]

I have a question hope you can help me in this one what those two hoses for the ones that goes to the frame thank you.

[@mikeyadams9947]

where is the thermostat on the machine i think mine is sticking it over heats but not all the time

[@stevenrichey5068]

Is there any way to get the air intake pipe higher up out of most of the dust ? I just got a 08 and the motor was completely redone. ..plus a new air filter...any help would be great. ..

[@michaelswiger2341]

Steven Richey you could snorkel it

[@RCT640]

What did you use and how did you clean the cylinder head and valves? How long did it take to clean? Thanks!

[@jman09ess]

D-Ray do you have any info on doing the bottom end. Thanks

[@thedustbuster1]

D-Ray will this be the same on a 2012 RZR 800? And you make good vids

[@DRaysShop]

Thanks!

[@alexlewis4563]

Do you have a video to re built a top end on a 900? Do you need special tools to re build it? Please help. Pismo beach coming and I need help ASAP...

[@gilbertoperez5698]

The 2012 rzr 800 and 800s has the same motor?

[@MorrisOutdoors98]

What size torque bit did you use to get the manifold off?

[@marklamiss]

Quick question for anybody that knows....How often are the dies used in a tap and die set, in the atv/utv/lawn equipment repair world? I know taps are used often, but does a repairman ever even use dies? Just answer me directly so theres not a long discussion under this video. Thanks a lot y'all.

[@DRaysShop]

marklamiss I use taps and dies often, usually just cleaning up threads on a damaged bolt, or a hole that someone has cross threaded a bolt into.

[@marklamiss]

Thanks D-ray. I'm just starting out trying to teach myself OPE repair work. I knew I would need taps for stripped bolt holes, but I wondered if I could get away with not having dies. Since taps come in helicoil kits, I thought i could cut corners for cheap and do without a kit. I went ahead and invested in a gearwrench 75 piece kit.

[@HornsbyAutosports]

Thanks for vid!!

[@DRaysShop]

Tom Cote!!!! lol! Thanks man.

[@davidanderson7956]

I have a question. I took my top end apart and my pistons are to low to pull the pin. I tried cranking the engine and caught the edge of the engine block. Chipped the block just a little but not enough to cause a problem. Any ideas on how I can get the cylinders to move up? Thanks

[@ojbudz]

Did you ever find a solution. I have the same problem

[@dexterhill4771]

i live in arkansas and need a rebuild on my rzr 800. how much do you charge?

[@DRaysShop]

I just could'nt resist......lol!

[@zx8401ztv]

Hell im not supprised the engine is ill, its like feeding the carb grinding paste :-( Your pressure washing did a smashing job, i can see an engine now :-)

[@pacsbratcher]

D-Ray, What kind of Lift are you using?

[@farmboy30117]

Looks like the lack of preventative maintenance strikes again!

[@DRaysShop]

Thanks, I have to be careful with that pressure washer, it'll remove everything, dirt, decals, and paint! lol

[@DRaysShop]

Sorry, but I've not done a 900 as of yet,

[@DRaysShop]

Thanks Shelly, be carefull, you keep watchin' this kinda stuff and you'll turn into a gearhead like me! lol

[@DRaysShop]

Sir, Yessir! lol

[@andresrojas5222]

what year is it?

[@pammedina7510]

700 polaris side by side dies going forward but not in rev

[@DRaysShop]

Yep, partially and a poorly designed air intake system.

[@DRaysShop]

SHHHH! lol!

[@alexlewis4563]

Help

[@lastcallbeam]

there's your problem right there....lol

[@briancarle]

Buy some power tools.