I’m not talking about a random broken CV shaft or boot, or a bad thermostat, etc. If there is another thread or sticky or anything, please include the link. I wasn’t able to find one specific to the 800 HO.
I have my 2008 Sportsman 800 torn apart for a Fuel Pump replacement and would like to know if there are any other repairs I should perform in the downtime instead of IF they occur later.
Here is what I have. If you have others, please let me know.
- Overheating – Radiator clogging.
- Overheating – 25A self resetting circuit breaker corroded
- Overheating – The impeller on the water pump warps
- Fuel Pump – Gets hot and stops working until cooled or quits all together
- Right Leg Heat – Hot air around exhaust and from radiator exits at the right ankle.
- Melting plastics – Exhaust runs VERY close to plastics causing melting
- Motor Mount breaks – I have kept an eye on mine without issue, but there are several posts about it if you do a google search.
- TBAP wiring – Wires separate from the connector and either stops functioning or starts to melt the connector
- TPS – Improper adjustment from the factory/dealership
- Breather Oil Leak – Platsic breather on top of the motor warps and begins to seap oil
- Clutch cover sealing – The clutch cover and the clutch backing plate are not sealed well, or at all, letting water into the clutch/belt system
- Ignition Coil wire harness/connector – The harness is traditionally pulled too tight causing stress on the connector at the coil and causing a no spark issue
I’ve ran into MOST of these and fixed them by searching this and other sites. So I know the fixes are available and am not looking to get into that kind of detail. Just a list of the problems this model runs into so I can either watch out or fix it ahead of time.
And yes I know it’s OLD and I could upgrade to the 850/1000 or buy a rzr, but aside from looking out for the known gotcha’s it doesn’t give me many headaches.
Thanks in advance!!!
Ryan
