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#556 Re: General Polaris Ranger and Polaris RZR Discussions » Need Help » 2009-07-07 16:36:52

Just for safety sake since you have done all that work on the TPS and Fuel Pump i would like you to keep an eye on how the plugs are burning since you do not have a AF gauge and all that work was done blind, you do not want it to run lean and hurt the engine.

#557 Re: The X Spot » Need help picking a family UTV » 2009-07-07 14:23:09

First i want to welcome you to the SideXSide site. In regards to your question this has been a debate that has gone on for years and every person has there own favorite UTV and if you spend about a half hour looking at similar threads on the SideXSide site you can see what i mean. The debate will always go on and on. If you are going to haul four plus passengers around there is only one Legal way to do it and that would be to get a Polaris Ranger Crew or any equivalent four passenger plus UTV built for this purpose. They do make kits for all makes of standard UTV's that convert the bed into a passenger area but that does not make them legal to carry people and if something happens it could cause legal issues for you, Now if i were going to do the non legal way i would look into the Ranger XP/HD for that purpose because of the bed size and its weight capacity, It is rated for 1000lbs in the box versus 500 or less with the competitors, remember when you add the seats and roll cage you need to deduct that weight along with the passengers as well. Till the other manufactures improve in there box capacity and size I will not recommend any of the others only for this reason as well as doing it illegally. I am sure others will chime in and argue about this point wink lol .

#558 Re: General Polaris Ranger and Polaris RZR Discussions » hard to get into gear » 2009-07-07 12:32:17

I had to re-read all your post and now i understand what you are saying. That part almost never goes bad but this is what i would try but first thing first. Is there any visible damage to the bearing :?: , If not I would blow the dirt out with brake cleaner and use air so all the trapped dirt can be washed out, then lube the bearing with a dry lubricant but make sure you keep it off the sheaves, clean the sheaves with a clean rag and brake cleaner and see what happens. as for the drive and driven clutch spinning in neutral that is normal but the the test is if you can stop the driven clutch easily with your hand while it is running it is good but use caution here on this. as for replacing the bearing you will need to buy or make the tool to remove the inner cage.

#560 Re: General Polaris Ranger and Polaris RZR Discussions » hard to get into gear » 2009-07-06 19:58:32

Well this is what the problem is and what to do with this new info. The Polaris primary clutch is RPM dependent and if the RPM is to high or the primary clutch spring is weak then drive belt will start to engage and it will be hard to go into gear, I had mentioned this on your other post on idle adjustment without a rpm gage. there is three options here. Back the idle down to where the transmission shifts easy. Replace the primary spring that is not tired. Do what everyone else does at some point and do the clutch kit that replaces the stock stuff and includes a stiffer then stock primary spring. All in all it should be serviced and looked over anyhow to see how the belt is doing. Now and what is happening on the other problems with the charging issues. It will all come to an end and you will have a great ride again once all the issues are fixed. I see light at the end of the tunnel big_smile .

#561 Re: Ranger and RZR Photo Gallery » New RZR paint job » 2009-07-06 17:31:59

Hey Jared, is that spray in bed liner you used the stuff from duplicolor or who makes it. how well is it bonding and holding up to the plastic because i am considering using it on the bed of my ranger xp. I do use it for hauling stuff in the bed and it is staring to show its age back there a little.

#562 Re: General Polaris Ranger and Polaris RZR Discussions » Used or after market part's » 2009-07-06 10:41:33

All i can tell you is Dana/Spicer corp builds the trans and diffs for the ranger and i know of no aftermarket diffs out there. As for them being used in another UTV, i think from what i have seen looking at the other manufactures is they are Polaris only. If a new one is needed now the only choice would be going OEM but if you can wait and search Craig's list and E-Bay one should show up out of a salvage at some point.

Good Luck in your search.

#563 Re: General Polaris Ranger and Polaris RZR Discussions » Need Help » 2009-07-05 11:37:59

I found this a little bit interesting.
VOLTAGE REGULATOR SKU: 4011925 SUBSTITUTED BY 4012384 $86.31.
Wounder why they updated the part unless there was a problem with it  :?: .

#564 Re: General Polaris Ranger and Polaris RZR Discussions » Engine Knock, 2003 Ranger 500 4WD » 2009-07-04 14:22:53

On this one i need to know how loud the knock is and just a little more detail. try to isolate it by holding a large screwdriver to your ear and touching it around the block to pin point were the noise is. They sell a mechanics stethoscope at most auto parts stores and this i a great tool to have and is safer then the screwdriver method, Remember it could be coming from somewhere else like the driven clutch or something else like that. is there any metal in the oil, there is just not enough info to work with at this point for a engine with no hours  :?:  :idea: . One last thing, the 700 has a plug just by the oil filter that a gage can be hooked up, i would think the 500 should have one to so you can test the oil pressure :idea: .

Like i posted here at the beginning , Use a mechanics stethoscope and narrow down where it is. You need to put the drive belt back on and put it in gear so the transmission doesn't freewheel and if the noise is still there while in gear it could be the drive clutch or engine. If the noise is not there it could be either the driven clutch or the transmission  :idea: .

#565 Re: General Polaris Ranger and Polaris RZR Discussions » Need Help » 2009-07-04 12:00:49

You could maybe have a bad voltage regulator and Polaris has had issues with the 2008 location and moved it. yours could be bad because it has ran hot all of its life. The stator does not put full output till the RPM are up and very little at idle. low engine RPM can cause a charge light and turning the idle up could fix the problem. I would relocate the regulator as stated and put a full charge on the battery and raise the idle high enough that it doesn't go into gear hard. The RPM is in the manual and should be set with a meter if you have one but doing it by feel is good enough. Voltage at idle should be 13.5 or higher and With no load 14.5 to 14.8 at cruising speed. Engine Idle is 1150 RPM.

#566 Re: General Polaris Ranger and Polaris RZR Discussions » Need Help » 2009-07-04 10:25:05

I would go with what titan said and relocate the regulator with the kit. As for adjusting the idle were are you adjusting it from :?: . It is suppose to be done from the little half moon screw on the throttle body that requires a special driver that i had to make. It cant be done on the the cable. Here is the link that Titan put on before on the regulator problem and put a full charge on the battery as soon as you can.

http://www.utvguide.net/rzr_voltage_reg … cation.htm

1246730066418905.jpg

1246730597302153.jpg

#567 Re: General Polaris Ranger and Polaris RZR Discussions » Need Help » 2009-07-03 22:39:54

You may always get a little popping out of the exhaust going down the grade due to UN burnt fuel in the exhaust. As for the 11.2 volts that is low and a fully charged battery should not show that unless you are pulling to much amps and the stator and regulator is not keeping up. first thing first is adjust the TPS again and i will run the numbers and have an answer tomorrow. What i need to know is were are you testing for the known 11.2 voltage, that will help. also are you running anything after market other then what came with the factory unit power wise.

#568 Re: General Polaris Ranger and Polaris RZR Discussions » Need Help » 2009-07-03 12:38:17

I am really glade to hear the problem is finally fixed and taking the pump down and matching it up would correct yours and a lot of other peoples RZR fuel pump problems. Is the fuel gage still accurate :?: . Oh and yes I would readjust the TPS because you now have the proper fuel pressure and that will change things a little  :!:  big_smile . Since You fixed the problem you should do the thread posting on "Aftermarket Polaris RzR Fuel pump Replacement" on this site so others will know out there. big_smile .

#569 Re: General Polaris Ranger and Polaris RZR Discussions » Need Help » 2009-07-02 17:42:28

Polaris or whoever is buying the factory pumps from Bosch Taiwan and it is not easily available in the USA because it is not slated for automotive use. I think that this Airtex pump will work fine and it sure will beat the hell out of $450 a pop even if it needs an aftermarket fuel regulator it will save you and allot of others a lot of headaches down the road. What Polaris has done is take a $60 fuel pump and raised it 800% and chose one that would be hard to get for there benefit. It is there way to stick it to you after your big initial purchase from them and to make you come to them for the parts roll . A good money maker Idea would to reverse engineer this stuff and charge half the price and start a new business not just on Polaris replacement parts but other manufactures as well.

#570 Re: General Polaris Ranger and Polaris RZR Discussions » Need Help » 2009-07-02 14:40:42

The worst case scenario is that the new pump may deliver to much PSI and we would have to install an external regulator and bypass the internal regulator. they are not that much money.

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