Rod Knock. You know what that means. Engine rebuild time for this RZR 800S! Episode 1.

Unfortunately, Jerry's 2014 Polaris RZR 800S has developed a pretty bad rod knock. We were hoping it was the clutch, but no... it's the engine knocking. Today is the day we bring it into the garage and start the rebuild process.
In this 5 part series, we will be removing the engine from the chassis, rebuilding it, then installing the engine back into the frame. It is going to be quite a process with obstacles along the way, but all in all we had a lot of fun. I invite you to come along on this journey with us as we get this thing up and running, then back on the trails!
Episode 2 is here:
• Fixing rod knock on a ...

[@ken3700]

The owner ….. wow ‘I don’t know why it blew up?” Heat/filth.. you earned it

[@3DayWeekend]

We drive them pretty hard around here. Sometimes things like this happen, no matter how much preventative maintenance is done. This particular machine was used, so who knows the history. Probably had weak rod bearings when we got it, or maybe not. In any case, we don't dwell on it - just rebuild them and get rolling again! Thanks for watching!

[@redrider533]

I know it’s been said but the engine easily unbolts from the transmission and lifts out with all that extra work. The clutch’s and rear clutch housing need removed. There are two bolts under the motor then there’s the motor mount and then a upper connecting plate that need removed. In terms of this engine failing, my guess is that the pressure regulator system failed. It’s common. There’s a boat facing up near the oil filter that has a spring and a small dowel that sits in a bore. It’s common for this dowel to seize up. Make sure it’s addressed and that oil pressure is verified after rebuild

[@3DayWeekend]

Hi there! Yeah, the service manual wanted it done that way, so we did it. The second time around though, we did it a bit differently! Good pointer about the oil pressure! We did verify it after the build and it's right up where it is supposed to be. So far so good! Thanks for watching and for the comment!

[@danielg.1707]

First thing to do before tearing apart is to hit it with the preassure washer.

[@3DayWeekend]

I agree! But it never seems to matter how much time you spend with that power washer - start pulling body panels off and mud is everywhere! Thanks for watching!

[@danlzlz8405]

I just spent hours in garage getting ready to pull mine. It just died on me one day last summer, never ran properly again. Time for a rebuild anyways. I WILL be using an engine hoist as Im doing it myself.....slowly. Tomorrow it comes out. Its also a 2014 800s but with an MCX Turbo!

[@3DayWeekend]

Engine hoist is the way to go. Pull the cage out as well and she will come right out. Good luck to you!

[@ericstyer2890]

I pulled mine last night solo. Turbo here too, putting the P&W crank In. I managed to get it out with tranny intact. 2 nuts on bottom, 4 bolts on plate in top and the motor mount. Used the cage as a hoist point. Good luck with reassembly dudes.

[@danlzlz8405]

@@ericstyer2890 yah.. I was thinking to do same with those 2 nuts and 4 bolts.. But didn't. Anyways it's all rebuild and reinstalled and running great!

[@overdosed51]

I feel like my 800 that has 5900 miles has sounded like that it's entire life 🤣. Probably just the 🎤 but made me laugh.

[@3DayWeekend]

I've heard that some of them are just noisy, or the noise can be confused with clutch noise, but it was driving me absolutely crazy. Had to tear it down to find out! 5900 mils is a good run! You must be doing something right!

[@barkerfmx]

Mines made a similar noise for the last 1000 miles lol still runs great tho

[@3DayWeekend]

Haha nice! These engines do seem pretty resilient! This one was running fine, but we just didn't want to see a rod go through the side of the case. It was also burning some oil. Two reasons to just tear it down and get it done.

[@striker1211]

You should add the part 2 link to the description, it's not coming up in recommended after the video. Excellent video though.

[@3DayWeekend]

Great suggestion. Added! Thanks for watching!

[@DeathMonk069]

Mine sounds like that and I replaced everything internal. The 800 is a noisy engine. Could just be hard to tell from the video.

[@3DayWeekend]

Yeah, it is hard to hear it in the video, but there's an extra special knock noise in the background, plus it was burning oil (pistons were scuffed, cylinder walls had gouges). We have 3 of these on the property and this one definitely had a bit more than normal! Thanks for watching!

[@jimbarber2947]

u can pull just the motor, I just pulled one

[@3DayWeekend]

That's what I've heard. Followed the service manual this time around. We'll probably just pull the engine if we have to do it again. Don't necessarily want to do it again, but you never know! Thanks for watching and for the comment!

[@jimsturm6493]

You do not have to pull the whole motor and trans to get out. There is a way to just pull the motor only if thats all you need to get to.

[@3DayWeekend]

I have heard that, but never attempted. I followed the service manual for this project, and it does have you remove the whole engine. Heaven forbid I have to do another one in the future, I'll try to leave the trans in place and only pull the motor! The rear diff/trans/engine assembly is a nightmare to get back into position!

[@blakewhite5627]

Probably could have just pulled the top and bottom end for that rebuild. I did mine that way.

[@3DayWeekend]

I've heard that as well, but some would argue that it is easier to separate and line back up as an entire unit. Now that we've pulled one, the next one would go much smoother. Thanks for the tip!

[@eddieavarez1132]

Mine makes similar noise much more faint should i be worried

[@3DayWeekend]

Not necessarily. These 800's are known for noisy clutches so you could be hearing that. If you want to be sure, pull the clutch and run the engine again. If it's still making the noise, then you know it's in the engine. I'll keep my fingers crossed for you!

[@APOffroad]

What lift is that?

[@3DayWeekend]

That's the Dannmar MX6. I love that lift, and there is almost always something on it! Had to make a couple modifications, but it has been great! Here's a video I did about it a few years back: kzbin.info/www/bejne/o4TCd5WAaLqNn7s

[@egorstarodubov2759]

Hello. tell me a new set of cylinders and pistons NICHE Cylinder Kit Part Number: MK1003421. What sets did you install? is this good quality or not?

[@3DayWeekend]

I'm pretty sure the cylinder was a NICHE. Pistons and rings were Wiseco. Crankshaft was by Hot Cams.

[@smittyranchanrodeo4681]

Maybe show you guys pulling the engine please

[@3DayWeekend]

Yes, that was the original plan but we had a camera failure. We do show how to put it back into the chassis in a later episode which should help show the general method.

[@everydaycar3518]

You do know you can take just the motor out me and my dad did the same the first time on are 800 it’s much easier just take the 2 nuts off on bottom and motor mount on the one side and boom much easier

[@3DayWeekend]

Really... I did not, nor have I ever tried. The service manual says to take it out with the transmission and differential as a whole so that's what I have always done. I'll have to try it next time. I wish you said something a week ago, as we just pulled another one out! Maybe when I finish rebuilding this one I'll put the transmission and differential back in first, THEN put in the engine just to try it. Thanks for sharing!

[@everydaycar3518]

@@3DayWeekend no problem didn’t know myself until we pull are 800 the other day got her fully rebuilt and about to go in I’m ready to hit the trails again like I says there’s 2 bolts under the bottom 6 bolts on the plate in the middle and the 2 motor mount bolts and bam can pick it right out with 2 people by hand hope this helps next time

[@barkerfmx]

Mines made a similar noise for the last 1000 miles lol still runs great tho

[@3DayWeekend]

Haha nice! These engines do seem pretty resilient! This one was running fine, but we just didn't want to see a rod go through the side of the case. It was also burning some oil. Two reasons to just tear it down and get it done.

[@barkerfmx]

@@3DayWeekend yea man no oil burn or anything here just that little tick buddy’s got a 800s has the same noise as mine