Polaris 800 Stuck Oil Pressure Relief Valve Repair At D-Ray's Shop

[@DM-rp7ps]

Howdy Guys, Wanted to Thank You both for taking the time to post this vid, it proved invaluable while working on my 800 Ranger last night. My test gauge showed it was spiking well over 100 lb's cold, and floating the valves off their seats, causing it to idle rough, if at all. Using your allen wrench trick with very little initial success; even after soaking it with Deep Creep, PB Blaster and carb cleaner for two nights, this thing was stuck!, I even tried lightly tapping the slug back down using a small rod hoping it would un-freeze, but felt like I'd lost ground and just jammed it further down. Using your allen wrench trick and a wide array of tools to pry with as the gap grew, even a heat gun hoping to expand the case to persuade it back up into the bore. The progress was un-noticeable at first, but realized I was able to tap it back down slightly. Eventually; it felt like the largest allen wrench I could fit after carefully profiling it with a grinder to make the turn ran out of leg, and it still seemed tight. I was about to quit, then noticed the slug had cleared the upper port, and couldn't feel it with an O-ring pick. I dropped my magnet down the hole on a lark, and the damn thing jumped up to meet it! You're vid is the only reason I was able to get this bugger out - Thank You, Couldn't have done it without you. Eternally grateful, D McB

[@RonaldHambrick]

As an interested observer and friend of the guys in the shop I can say without question D-Ray and Randy are the Batman and Robin of atv repairs. They will get it done quicker and for a more reasonable charge and stand behind their work. Give 'em a call if you need atv work done.

[@DRaysShop]

Holy stuck regulator, Batman, lol! Thanks Ronnie!

[@alanvincent1615]

Thank you for taking the time to make this video so informative, easy to watch and not filling it with irrelevant bs

[@rockbay79]

Way too technical for me! However, I'm glad I have friends like D-Ray that have big brains and can perform technical things such as this operation! Great video guys!

[@DRaysShop]

Thanks!

[@jaygarvin625]

Luckily I came across this video due to me being in the middle of an overhaul and shorted a set of piston rings I was on hold and viewing some of your videos. After watching it I pulled my oil pump and sure enough my relief valve was stuck big time and after a lot of work I got it out. Thanks D-Ray

[@RealSuburbanCowboy]

Thank you so much for this video. Your use of the allen wrench was great, but I needed to add a separate piece (extension cut from another allen wrench) in order to get mine out. I would not have known how to get that stupid part out of there without your help. I should have filmed mine, to show how difficult it can be to get a really stuck one out. It can be done with some patience, a bit of wd-40, an allen wrench + extension, and I even used a small screwdriver and a magnet jb welded to the end of a bolt.

[@dashlamb9318]

Thanks for the information. I'm not working on a Polaris, but I'm curious if these principals apply to most engines. I recently rebuilt a 3.5 Mitsubishi Montero and when I started it up it blew the oil seal on the crankshaft and now I have low oil pressure. It has a full flow oil cooler that is fed from the pump through the filter then through the cooler and back to the engine. It has a pressure relief valve on it at the pump housing, which I'm digging into today to try and figure out what is going on. Any ideas or opinions would be appreciated. Thanks.

[@theveteranfarmer6633]

wanted to share my experience with yall on my rzr. i got LUCKY. mine wasnt stuck so i just removed the bolt, spring, and washer. then i started the rzr and reved half throttle. oil shot out as well as the plunger. if you rebuild your top end do this at the same time! biggest question from me is are the ball bearings still the best solution or has anyone used the part found on ebay or amazon? id rather put in an entire assembly to avoid stuck parts later but if it doesnt work i dont wanna risk blowing my rods. thx in advance.

[@matthewleecochran]

This is my question as well.

[@theveteranfarmer6633]

@matthewleecochran go to a local hardware store. Not lowes or home depot like an ace or something like that. I went to mine and they had the exact size. I got 2 ball bearings and stuck them in when I did my top end and haven't had an issue yet.

[@street_wise_gamgee]

Seen this and did it to my rzr 800 when I was doing a complete rebuilt recently had a push rod break not sure what was going on. So I installed an oil pressure gauge here I had no oil pressure the ball bearing got jammed in the case as well. Luckily I caught it before any major damage was done. Will be installed an oem dowel back in. Or I'll try one of those fancy pressure guard dowels.

[@l.ym.g7258]

I really enjoyed the video you were very well prepared you laid it out very nicely I have to do the same thing and by you offering the information and showing us how we can do it going to save me a lot of time I really appreciate watching and learning thank you very much

[@axelmensch3369]

Hi guys Thanks for this helpful video. Do you put a bit oil in the bore after install the balls, before get the spring back in place?

[@derekg8220]

Has anyone had any issues with the pressure relief valve being replaced with 2 x 8mm ball bearings? I'm about to do it on a 800 rzr that keeps taking out one of the connecting rods at the crank.

[@leebenson3201]

Glad to see a new video from you

[@DRaysShop]

Thanks!

[@stevenertle2876]

A great great video enjoyed it I don't have that type of machine but you explained it to a tea and thank you for that.... If I can pick your brain I have a 2001 Polaris sportsman 400 I put a remanufactured Polaris Head CamNew exhaust rockerBecause we know they go badNew piston everything hold top end what my question is but my question is the Cam slides back-and-forth now I know it will tighten up a little bit once I put the Cam tensioner on it and I noticed on the 3 screws that you take off to get the Cam into the head has a perfect circle from the compression release on the old one everything is everything is new and at that camp there's nothing that keeps it in 1 place is that normal Now again everything is new new head new Cam the Cam chain is in good shape if if you could help me I'd appreciate it

[@lonestarangler8407]

D-Ray!!! I dont have a Polaris but Awesome to see a new vid!!! Keep them coming!!!! More Honda ATV vids! lol!

[@DRaysShop]

Thanks!

[@JamesParus]

Nice. What is the best place to install oil pressure gauge?. If my oil valve is still working. I can probably remove it without opening the cases.

[@DRaysShop]

There's an oil galley plug on the engine case just above the belt cover. Some folks even install a sender there for a pressure gauge.

[@rafarrell2]

@@DRaysShop would be great if you could show video of installing pressure Guage. 2011 RZR 800. As FYI, the RZR 800 has same engine but due to orientation, it must be removed to perform pressure dowel "push-out". I couldn't remove dowel with magnet so I placed Magnetic tray over hole & started engine. It was pushed out with oil pressure. Still would like to install pressure Guage to know if oil is low. I've got 4-point harnesses so accessing dip-stick is a chore.

[@richardprice7107]

Thank you for the video...always informative and educational.

[@DRaysShop]

Thanks!

[@derekmaloney6706]

Where did ya go D-Ray

[@SuperNova-Steve]

Hi there. Thanks for the video. Does this fix apply to the green 2000 ish ranger 500 4x4’s Cheers

[@ManCaveMayhem]

That is a brilliant fix guys! Thanks so much for the help!!

[@TheTarrMan]

You would think they would make a wearable part such as that more easier to replace. Nice to know how to repeal and replace this issue though. Thanks for sharing.

[@DRaysShop]

Thanks Ben!

[@jeffnajmowicz5634]

I want to take a year off of life and work for D-Ray. He's the Neil deGrasse Tyson of repair shops... #Legend

[@jeffnajmowicz5634]

Polaris engineers are watching this wishing they had D-Ray on the payroll... They need him

[@timdenton7646]

We have a 2007 Polaris sportsman 800 and when you turn the crank by hand it has a spot where it locks then you can spin it backwards and get back to that same point and it locks again about 3/4 or full round. What would cause it to lock just in that one position

[@jacobbanks4200]

Hey D Ray so I have a question about your old 3 wheeler you worked on with the throttle system, is there a rubber boot that goes anywhere on the carb or throttle because I just bought a carb repair kit and it is getting air from somewhere it shouldn't.

[@robloiola9543]

D-Ray is there any clocking you need to worry about when you assembly the oil pump. Or can you just assembly and not worry about position of oil pump and gear itself. mine fell apart when I disassembled it so I was worried not to put it back together wrong.

[@mikey1297]

So I’ve done some google, KZbin, utilized the search function... The bike idles in all choke positions, but it idles better in half choke. So.. 1) I adjusted the air/fuel mix and really didn’t notice a difference. 2) adjusted the throttle at the carb and it would like go into 50% rpm by itself so I backed that back off. I rebuilt the carb with a shindy kit, ran it through ultrasonic, blasted everything with air. Do I need to clean everything again?

[@tayzer9999]

Hey d Ray I think I have this problem on my 2016 850. Have you seen this before?

[@mikesmotoshop]

Can you remove the pressure relief valve from the outside? With a magnet?

[@cgilpen]

What would make a whistling or a coo sound when you turn off a sportsman 800 . it's the first time I heard it and first time I got it super warm but not to hot. Almost sounds like air sucking back in..

[@RoxerBasho]

Grinding camshaft no oil probably

[@cgilpen]

@@RoxerBasho it has oil

[@RoxerBasho]

I mean oil not getting to head, my katana 600 was making that sound and opened the head, saw camshaft grinding on intake side no oil getting to it, I'm in the process of tearing it down, so far the only thing I've see out of whack is seal behind timing was leaking perhaps leading to low pressure in my oil

[@classicxl]

Is the ball bearings better then the pressure relief guard . i was just trying to install a cheap relief guard when the top part snapped off now i’m trying to get it out with a easy out . What’s the best choice ball bearings or valve guard

[@MrBigokhunter]

I have the same over pressure problem in my 2016 Ranger 900. My question is, will any 5/16" SS. ball bearing due? any links? Thanks in advance

[@michaelbittof4106]

D-Ray Smith my Polaris is blowing oil into the air box could also be a result of that valve

[@michaelbittof4106]

That was meant as a question

[@tayzer9999]

Im experiencing the same thing with my 2016 sportsman 850 sp. Blowing out my oil filter. Just woundering if its the same problem with 850?

[@everydaycar3518]

Please I need help if you know the answer I just rebuilt a rzr 800 top to bottom took it out put 120 miles on it and the crank locked up would low oil pressure cause this I was told the crank picks the oil up from the oil pan and slings it up to lubricate

[@henryhenry5897]

I have a ranger I wonder how do I get the the relive valve out of it’s stick and don’t wanna take evrything apart ...

[@rafarrell2]

I'm sure you've already done something about this issue. However, for me, I Have a RZR 800. The engine is mounted sideways and the only way to remove the stator cover is to pull the engine. I couldn't get a magnet to "stick" to the dowel to pull it out from the top. I placed a magnetic parts dish (Harbor Freight $0.99) over the hole with bolt and spring removed. The engine oil pressure pushed the dowel out. Don't run long as you'll dump oil on the floor but it's how mine came out. Good Luck!!!

[@Pitman556]

@@rafarrell2 awesome idea. You did this without removing the stator cover?

[@romkasgarage173]

Hey D-Ray Smith, i have a problem with my 2009 polaris twin, the oil pressure is so high that the lifters get pumped up and is causing a no compression situation, i have already cleaned my pressure relieve port and got a new dowel and spring and the problem is still there. I also have all 4 brand new lifters, what would you do in this case to solve this problem, Thank you.

[@Dantelo131]

Will this work on a Polaris predator 500? I removed my pressure relief valve and it looks different, the spring sits inside the actual valve

[@bardinkurtis]

D-Ray 86 XL600R trying to adjust the valves in your how to video years ago. However when getting it to TDC valves move so I turn it another full rotation back to TDC and valve's still move please help!

[@genepagel3156]

I did the two ball bearing 6 on my pressure oil pressure relief valve rode it for 2 hours run great cut it off crank it up the next morning and it froze up again .I mean blew oli gasket

[@tommyc8333]

I thought the "ball bearing fix" was found to do more harm in the long run ?? People on multiple forums are advising against this "fix".

[@rafarrell2]

Anyone else hear or experience this???

[@street_wise_gamgee]

I've heard this as well but no one has proof that it causes more harm then good. So ill stick with the ball bearings since I needed a hammer to get my old dowel out which blew the motor.

[@robertkeating11]

Do you have to time the oil pump?

[@rodneyfinley6367]

So did this actually work? I’m on my 2nd rebuild due to this oil relief valve

[@henrypena5103]

It appears im not having any oil pressure to my 2011 polaris ranger 800 crew. Im having no start & fuel coming out at the bottom of exhaust header. Could this be the issue im having?

[@willardnelson2724]

Thanks for the great video.

[@toddkurtz1976]

hey i got a '14 ranger 800 that after its started make a ticking noise n bad power could that be the problem?

[@Chuyito_Lsx]

Is it okay if I put a 2500 winch on my ranger it doesn’t weight much

[@RealIrishTexan]

Yes sir thank you!

[@josepeixoto3715]

i'd be scared to death on doing that,i'd rather polish the plunger (and *never* break the (wiping) edges on the bore ! ; but if you have tried it for a while and it works....fine, great idea the efective length of the 2 balls will be less than 16mm due to the curvature of the front ball; this means that the spring force will be less,and the oil presure less too ; maybe need to install a mechanical gauge to make sure? edit: oops,you've done that already, guess it's a hit...

[@charlesmoser7727]

suzuki eiger lt-a 400 (2007) read wheel hub is frozen to axle spline, can anyone tell me how to get it off?

[@hansbor7839]

Hey mate got the standard piston and spring and there seems to be a 7mm gap between spring and valve nut is this standard?

[@redrider533]

what did you find out on this issue with the length / gap

[@josholson3383]

Genius!

[@iowafarmer6622]

Great video...

[@DRaysShop]

Thanks!

[@mihaiturcanu2315]

Salve.non capisco come registrare le valvole.se mi può darmi un elenco. Grazie tanto

[@g6qwerty]

Huh so Original problem is oil contamination, wonder where that is coming from.

[@DRaysShop]

On this one I suspect a worn cam lobe.

[@golfernky1687]

Sell that junkie Polaris and buy a Honda.. Lol

[@DRaysShop]

Sounds like somethin' a ford guy would say......LOL!