Polaris RZR 800 Top End Rebuild Part 3 - Engine Reassemble

Well its time to put this top end back together. Come join me in showing the steps to reassembling the engine. Also this is same procedure for any of the fuji built twins that came in the Sportsman 600, 700 & 800, RZR 800S, Ranger Fullsize 700 & 800, Ranger Midsize 800.
#RZR800 #Polaris #PolarisRZR

[@shawnlamb4869]

Thank you for making this video helped me out a ton. Much appreciated

[@errolpoxleitner7901]

Very good.

[@jmg36344]

Need help!!! 2012 Polaris 800XP. Hard crank with spark plugs in to point where starter burns out. Without plugs engine turns over easily. Compression of 175psi on both cylinders. 45psi fuel pressure. Sparks at both plugs. Thnks you.

[@whitez06king]

nice video i am tearing mine down to complete rebuild pretty sure my rattle is a rod ..

[@montemania198210]

Thank you. Rod very common to go in these. Replace with hot cams crank. Much better over oem.

[@Onewheelinndylan]

So when u say using the clutch to bring the piston heads up do I have to look at them and make sure there at dead top? First time doing this and I put the head gasket on with out bringing the pistons up to top. Or can I just turn the clutch and it will bring it up it’s self

[@pasaldi1]

Where is part 4?

[@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?

[@gabrielalvarez9570]

I wouldn't namura pistons on any rebuild

[@federaldlasierra]

Did you reuse the same head bolts?

[@montemania198210]

On this job yes customer didn’t want to do them. Polaris recommends to replace them. I’ve reused in pass with no issues.

[@danielhaskins519]

What tip end kit did you use?

[@montemania198210]

Rev6 with Wiseco pistons.

[@danielhaskins519]

@@montemania198210 I just picked up a sportsman 800 with only 115 hrs on it and it just started smoking. Is this likely to be a reoccurring issue on these twin 800’s?

[@montemania198210]

@@danielhaskins519 I usually see this happen from dirt and mud ingestion on these machine. Mainly cause people push these 800’s hard lol.

[@danielhaskins519]

@@montemania198210 I’d like to think that was the case. But it was owned by an old man and he had daughters that would ride it. He was the original owner. Granted I did still find a little mud here and there. The previous owner also told me the quad seems to foul plugs fairly quickly. Can lack of maintenance contribute to pre mature ring failure?

[@montemania198210]

@@danielhaskins519 absolutely it can. Also if it’s burning oil will 100% foul plugs out.

[@diegogiani]

L