Category Archives: RZR 800 Specific Discussion

Trouble bleeding brakes

My brothers mud bike is a 2009 50" Rzr. After swapping a used master cylinder, I can’t get the brakes to bleed. Question 1 is how do I troubleshoot the master cylinder. Question2 is after using my Mityvac I can’t get any fluid to dra from the master cylinder. I would appreciate any useful ideas.

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Engine rebuild

Getting ready to pull my engine (2009 800 EFI) to get it rebuilt from the crank up. Due to inexperience and stupidity I created about a $2500 mistake. I was doing a top end rebuild due to the dirt down the intake history that so many have had. Anyway, as I was putting cylinders back on the engine, per D-Ray’s you tube series, I was putting wrist pins in and all seemed good until I turned the key and heard the dreaded noise that I never want to hear again. I thought a clip had popped out and maybe the wrist pin came out but upon dis-assembly the clips were perfectly seated. Problem was that the front cylinder connecting rod had slid out of the aligned position and I only put the pin in the piston, hence the terrible sound. Scored cylinder, cracked piston, bent exhaust valve which is all is all pretty much an easy fix except that I also have egg shaped connecting rod hole which means new crank and pretty much the bottom end as well. local mechanic says head is not damaged and rebuildable but doesn’t want to tackle the lower end because he doesn’t have the correct Polaris tools and the close bearing/crank tolerances. I have estimate from Hy-Tech (utvrebuilds.com) in Arizona for $2400 plus $100 return shipping with a 6 month warranty, just wondering if there is a good place in northern Michigan that anyone knows about that can do the job?

Engine rebuild

Getting ready to pull my engine (2009 800 EFI) to get it rebuilt from the crank up. Due to inexperience and stupidity I created about a $2500 mistake. I was doing a top end rebuild due to the dirt down the intake history that so many have had. Anyway, as I was putting cylinders back on the engine, per D-Ray’s you tube series, I was putting wrist pins in and all seemed good until I turned the key and heard the dreaded noise that I never want to hear again. I thought a clip had popped out and maybe the wrist pin came out but upon dis-assembly the clips were perfectly seated. Problem was that the front cylinder connecting rod had slid out of the aligned position and I only put the pin in the piston, hence the terrible sound. Scored cylinder, cracked piston, bent exhaust valve which is all is all pretty much an easy fix except that I also have egg shaped connecting rod hole which means new crank and pretty much the bottom end as well. local mechanic says head is not damaged and rebuildable but doesn’t want to tackle the lower end because he doesn’t have the correct Polaris tools and the close bearing/crank tolerances. I have estimate from Hy-Tech (utvrebuilds.com) in Arizona for $2400 plus $100 return shipping with a 6 month warranty, just wondering if there is a good place in northern Michigan that anyone knows about that can do the job?

Fuel pump or relay?

I have a 2008 RZR 800 and when I turn my key on the pump primes for 1/2 second then the relay clicks, I will start the RZR and it idles like garbage, If i rev it up high it will run better…. I havent checked the fuel pressure yet but Just looking at where to start. I talked to a buddy who has a 09 RZR and his pump primes for 2-3 Seconds…. Mine almost seems like the relay is killing the power before it primes

Wicked Built PS install question

Currently installing power steering on my 2011 800 50". I notice with the unit in place it will be real hard to get to the factory fuse block. Has anyone relocated the fuse block for easier access to the fuses. I am also planning on getting my power from the winch contactor or should I go to the battery as the instructions say?

20″ Led Under Windshield

I recently bought a 20 inch bar that has the bottom mounts on it not the side and was wondering if anyone has any mounts they’ve used to mount them under the windshield. I know the mounts will probably fit on that small section of plastic above the hood but didn’t know if it would bend it/break it. Pictures would help thanks in advance!

20″ Led Under Windshield

I recently bought a 20 inch bar that has the bottom mounts on it not the side and was wondering if anyone has any mounts they’ve used to mount them under the windshield. I know the mounts will probably fit on that small section of plastic above the hood but didn’t know if it would bend it/break it. Pictures would help thanks in advance!