2008 Polaris RZR 800 Problems and Solutions

The 2008 Polaris RZR 800 was a groundbreaking machine, offering a new level of sport performance in a side-by-side format. It was agile, relatively lightweight, and packed a decent punch for trail riding and light recreation. However, being an early model in a new segment, it has some common issues that dedicated owners have learned to address. Many of these problems are related to the vehicle’s design (being a first-generation product) or simply the age and wear of components over time.

1. Engine Performance Issues (Rough Running, Loss of Power, Idling Problems)

Symptoms:

• Engine misfires or runs rough.
• Lacks power, especially under load.
• Stalls at idle or won’t hold a steady idle.
• Check Engine Light (CEL) illuminates.

Common Causes & Solutions:

• Dirty/Clogged Throttle Body:
  • Problem: Carbon and debris can build up in the throttle body, especially around the throttle plate, causing poor idle quality and rough running.
  • Solution: Remove the air intake boot and thoroughly clean the throttle body (especially the bore and throttle plate edges) with a dedicated throttle body cleaner.
• Failing Throttle Position Sensor (TPS):
  • Problem: A faulty TPS can send incorrect signals to the ECU, leading to erratic engine behavior, stalling, and often a Check Engine Light.
  • Solution: Test the TPS output voltage with a multimeter (refer to service manual for specs). If out of spec or erratic, replace the TPS. Sometimes, simply cleaning the throttle body can help, as carbon buildup can affect its calibration.
• Clogged Fuel Injectors:
  • Problem: Dirt or fuel varnish can clog the fine nozzles of the fuel injectors, leading to misfires and power loss.
  • Solution: Use a quality fuel system cleaner (e.g., Seafoam, Techron) in the fuel tank. If persistent, professional ultrasonic cleaning or replacement of injectors may be necessary.
• Dirty Air Filter:
  • Problem: Restricts airflow, causing a rich mixture and reduced power.
  • Solution: Regularly inspect, clean, or replace the air filter, especially if riding in dusty conditions.
• Fouled Spark Plugs:
  • Problem: Worn or carbon-fouled spark plugs can cause misfires.
  • Solution: Inspect spark plugs. Clean or replace if fouled or worn. Ensure correct gap.

2. Drivetrain / AWD Issues

Symptoms:

• All-Wheel Drive (AWD) not engaging or disengaging properly.
• Grinding noises from front differential.
• Vehicle feels “bound up” in turns.

Common Causes & Solutions:

• AWD Coil Failure:
  • Problem: The electromagnetic coil that engages the front differential can fail.
  • Solution: Test the resistance of the AWD coil (check service manual for proper Ohm readings). If out of spec, replace the coil.
• Dirty Hilliard Clutch (Front Differential):
  • Problem: Wear particles and contaminated fluid in the front differential can prevent the Hilliard clutch from engaging/disengaging smoothly.
  • Solution: Drain and refill the front differential fluid with Polaris-specific AWD fluid. This should be done regularly.
• Wiring/Connector Issues:
  • Problem: Loose or corroded electrical connections to the AWD system (AWD switch, differential connector).
  • Solution: Inspect and clean all relevant electrical connectors.
• U-Joint/CV Joint Wear:
  • Problem: Worn universal joints (U-joints) or constant velocity (CV) joints in the prop shafts or axle shafts can cause clunking, grinding, or binding.
  • Solution: Inspect U-joints and CV boots for tears or damage. Replace worn components.

3. Suspension & Bushing Wear

Symptoms:

• Excessive play in the wheels.
• Squeaking or clunking noises from the suspension.
• Poor handling or ride quality.

Common Causes & Solutions:

• Worn A-Arm Bushings:
  • Problem: These are common wear items, especially with aggressive riding in mud or water, leading to excessive play and noise.
  • Solution: Inspect A-arm bushings for wear. Replace with OEM or aftermarket heavy-duty bushings (e.g., SuperATV, Garage Products) for improved longevity. Regular greasing (if applicable) can extend life.
• Worn Ball Joints:
  • Problem: Contribute to loose steering and clunking.
  • Solution: Inspect ball joints for play. Replace if worn.
• Shock Absorber Issues:
  • Problem: Leaking seals, worn shafts, or faded damping can lead to a harsh or bouncy ride.
  • Solution: Inspect shocks for leaks. Rebuild or replace worn shocks.

4. Belt Life & Clutch Issues (CVT)

Symptoms:

• Belt slipping, causing loss of power or burning smell.
• Rapid belt wear.
• Engine revs high but vehicle doesn’t accelerate.
• Clunking or squealing from the clutch area.

Common Causes & Solutions:

• Worn or Incorrect Belt:
  • Problem: Using a non-OEM or worn belt will lead to slipping and poor performance.
  • Solution: Always use a genuine Polaris drive belt for optimal performance and longevity. Inspect the belt regularly and replace if worn, frayed, or glazed.
• Dirty Clutches (Primary & Secondary):
  • Problem: Dust and debris can build up in the clutch sheaves, causing sticking, slipping, and noise.
  • Solution: Periodically remove the clutch cover and clean the primary and secondary clutches with compressed air or a specialized clutch cleaner. Avoid using brake cleaner as it can damage rubber components.
• Worn Clutch Components:
  • Problem: Worn rollers, bushings, or springs within the clutches can affect engagement and power transfer.
  • Solution: Inspect clutch components for wear. Professional service may be required for rebuild or replacement.
• Operating Habits:
  • Problem: Aggressive throttle use from a dead stop, excessive low-speed crawling in high gear, or rapidly shifting between forward/reverse can accelerate belt wear.
  • Solution: Use low gear for slow-speed maneuvers, climbing, or heavy loads. Engage the throttle smoothly.

5. Electrical Issues

Symptoms:

• Intermittent starting.
• Lights flickering or not working.
• Accessories not functioning.
• Check Engine Light due to sensor issues.

Common Causes & Solutions:

• Corroded/Loose Connections:
  • Problem: Polaris vehicles are known for sensitive electrical connections, especially in wet/muddy environments.
  • Solution: Inspect all electrical connectors (especially those exposed to elements) for corrosion or looseness. Clean with electrical contact cleaner and apply dielectric grease. Pay close attention to grounds.
• Weak Battery:
  • Problem: Batteries lose capacity over time, especially with accessories.
  • Solution: Test battery voltage and load test. Replace if weak. Ensure charging system (stator/regulator) is functioning correctly.
• Faulty Relays/Fuses:
  • Problem: Blown fuses or failing relays can cause loss of power to specific circuits.
  • Solution: Check the fuse box and replace blown fuses. Test suspected relays.

6. Heat Management (Cockpit/Engine)

Symptoms:

• Excessive heat in the cockpit area.
• Engine bay feels extremely hot.

Common Causes & Solutions:

• Design Characteristic:
  • Problem: Early RZR 800s can naturally run a bit hot, particularly in the engine compartment due to packaging.
  • Solution: Ensure radiator is clean and free of mud/debris. Check coolant level. Some owners install aftermarket heat shields, insulated panels, or reroute exhaust.

2008 Polaris RZR 800 Specifications

The 2008 Polaris RZR 800 (officially known as the Ranger RZR 800) was a groundbreaking vehicle, essentially creating the “sport side-by-side” category. Its specifications reflect a focus on performance and agility in a compact package.

2008 Polaris RZR 800 Error Codes

The 2008 RZR 800 uses a relatively simple diagnostic system. It does not have an LCD screen that directly displays specific error codes in an easy-to-read format like newer models. Instead, it relies primarily on the “Check Engine” light (MIL – Malfunction Indicator Lamp) illuminating, and in some cases, a flashing sequence of the check engine light or other indicators on the instrument cluster.

When the “Check Engine” light comes on, it generally means the Engine Control Unit (ECU) has detected a fault in one of the monitored systems (engine, fuel, electrical, emissions).

To retrieve error codes (or verify a fault):

1. Observe the “Check Engine” Light: If it’s on solid, there’s an active fault. If it was on and then went off, the fault might be intermittent or cleared itself.
2. Refer to Service Manual: For the 2008 model, a specific fault may or may not flash a distinct code on the speedometer/digital display. Often, the diagnosis relies more on:
   • The symptom the vehicle is exhibiting (e.g., no start, rough idle, power loss).
   • Connecting a specialized Polaris diagnostic tool (like Digital Wrench) to the ECU. This tool can directly read the stored Diagnostic Trouble Codes (DTCs), which are often in a P-code format (e.g., P0XXX).

Common “Error” Symptoms and Associated Problem Areas (What the “Check Engine” Light Might Indicate):

Since you won’t get a direct digital code on the dash, here’s what the “Check Engine” light might be trying to tell you, based on common RZR 800 issues:

Fixing “Errors” (Troubleshooting Steps):

1. Basic Checks: Always start with the fundamentals: fuel level and quality, battery charge and connections, air filter cleanliness, and spark plug condition.
2. Listen and Feel: Pay attention to how the vehicle is behaving (e.g., where a noise is coming from, if there’s a burning smell).
3. Visual Inspection: Look for loose wires, damaged hoses, leaks, or obvious signs of wear.
4. Consult Service Manual: The official Polaris service manual for the 2008 RZR 800 is invaluable. It contains detailed diagnostic flowcharts for various symptoms and procedures for testing components.
5. Professional Diagnostic Tool (Digital Wrench): For definitive diagnosis, especially if the CEL is on and symptoms are ambiguous, connecting the vehicle to a Polaris Digital Wrench tool (typically available at dealerships) is the most effective way to read specific DTCs stored in the ECU.

Conclusion

The 2008 Polaris RZR 800 is a classic in the sport UTV world. While it has its share of common issues, most are well-documented and have proven solutions, often involving routine maintenance, cleaning, or replacing common wear items. Many owners continue to enjoy these machines by proactively addressing these areas. Regular cleaning, adherence to service intervals, and a good eye for worn components will keep your 2008 RZR 800 running strong for years of off-road fun.

David Holtzman

I’m David man behind Lawn Mowerly; I’ve been dealing with lawnmowers and Tractors with my father since I was a kid. I know every make and model and what each one is capable of and love helping people find the perfect equipment for their needs.