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.
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
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 !!
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.
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.
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?
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
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. ..
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 :-)
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
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.
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.
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.
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
This man is my kind of guy: knows his stuff and can explain it even better. THANKS
Your videos are great in explaining and showing each step.
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 !!
Excellent step by step video. There were never any 'what did he do there?' moments. Covered it all. Thanks a lot.
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.
Absolutely excellent top end rebuild series! I really enjoy your video’s! Thanks again!!
awesome videos.....informative without the pointless banter of soooooooo many others
Best step by step video I have ever seen, congrats and thanks!
Great Job, I am doing my 04 Sportsman 700 this weekend..
Thanks! I enjoy makin' 'em.
Yep, I like workin' on clean stuff! lol
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.
Puttin' all those years in Polaris boot camp to good use, I see!
Nice Work on the Video D-Ray.
Not yet, but I will do a series on the next one that comes in to my shop, thanks.
Your the man D-Ray... cool video
looks like a huge job!! tell tile signs are smoking? and heavily burning oil?
Thanks so much for your vary well done video. You got a gift for instruction.
First....wow...this is quite the little movie....very informative!
hi there. i know this is a big request but i'm wondering if you can do a video on a crank tear down.
Thanks Fletch!
Looks like the lack of preventative maintenance strikes again!
Thanks Shelly, be carefull, you keep watchin' this kinda stuff and you'll turn into a gearhead like me! lol
What did you use and how did you clean the cylinder head and valves? How long did it take to clean? Thanks!
where is the thermostat on the machine i think mine is sticking it over heats but not all the time
Fantastic video! Keep them coming!
Video was great..do you have and videos on doing 08 rzr bottom end?
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?
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.
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
Love these vids would like to see you do a complete overhaul on a ATV I have a Honda fourtrax 300 a 1993
Awsome vid D-Ray! It all looks so intersting! Yay! :)
Are you taking on any more work right now I live here in Cabot Arkansas
The 2012 rzr 800 and 800s has the same motor?
D-Ray do you have any info on doing the bottom end. Thanks
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...
awesome video keep them coming!!
What size torque bit did you use to get the manifold off?
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.
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. ..
Steven Richey you could snorkel it
Sorry, but I've not done a 900 as of yet,
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 :-)
Thanks, I have to be careful with that pressure washer, it'll remove everything, dirt, decals, and paint! lol
Thanks!
D-Ray will this be the same on a 2012 RZR 800? And you make good vids
i live in arkansas and need a rebuild on my rzr 800. how much do you charge?
great video man! thanks alot
D-Ray, What kind of Lift are you using?
Tom Cote!!!! lol! Thanks man.
what year is it?
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
Did you ever find a solution. I have the same problem
Really enjoyed the vid. =D
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.
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.
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.
Yep, Ive seen several do this and worse! Thanks for watchin', more vids on this project will be up shortly.
Thanks for vid!!
Yep, partially and a poorly designed air intake system.
I just could'nt resist......lol!
700 polaris side by side dies going forward but not in rev
Sir, Yessir! lol
Help
Buy some power tools.
there's your problem right there....lol
SHHHH! lol!