Couldn't resist. Just sold a mower & trailer, and this popped up on CL 7min drive south of my house. Bingo!

2010 RZR 800 EFI with winch, roof w/ speakers & cd/fm, roof lights, front & rear bumpers, snorkel, stiffer front springs, 4pt harnesses, front & rear windshields, and 4 new tires. Has 147hrs and 1100 miles. Bed, seats, etc are not shown in pics. Straight frame, straight axles with good boots

Seller was a good dude, too. Original owner with title. He was asking $4k, and I got it for $3.5k. He even delivered it! Helps it was down the road. Farmers are good people. Period. Said all his buddies sold theirs a couple years ago and its been sitting in the barn since the clutch broke. Then he broke the starter gear.

It needs...
- Desperately power-washed
- New driven clutch installed (new parts included)
- New starter bendix installed (new parts included)
- Seats & bed reinstalled
- Battery
- Headlight bulb
- Few minor aesthetics
- Basic carb cleaning, new filters, new fluids, safety check

Plan is to just get it together and bugs worked out and tool around. Roof halogens will be replaced with an LED bar. Plugged in a battery and all the accessories and dash work fine.

Will be working on it all week after kids are in bed.

-D$

I'm calling the cops.
You stole it.
You should be ashamed of yourself.
Why do I never get a chance to steal anything

Here's the ad...

Listed it 9pm last night and i was on my way at 3pm today. He had 6 calls on it today, but I was the closest and had cash ready to spend. Money talks!

Congrats dude!

Meh!

LOL! your good!

Sell it. Junk.
It's not an oddy.

NO! Its a keeper.

My wife asked me "So which one of your other buggies are you selling?" And I replied "Uhhh well how many purses do you sell hen you buy a new one? Shoes when you get a new pair??" Conversation over. lol Good news is that my wife loves this thing.

Got the manual downloaded and ready to get this starter bendix replaced. I've got 3500 reasons to see/hear this thing run!!

In order to swap the bendix, i need to remove the flywheel. And in order to pull the flywheel, i need to pull the Engine. Sooo...i will be getting to know this machine quite well this weekend!

Engine mount bolts, coolant lines, and fuel line....and this baby is free. Need to fetch my Engine goist from my old man. I see why the seller eas hesitant to make this repair! Solid 2.5hrs on this tonight after kids were in bed. Feels good to burn some midnight oil!

Also pulled the valve cover to make sure she didnt sit in a pond for a weekend, ha. Looks fine.

Tell you what, the only way i could get all the mud off is to tear it down. Good Lord!

Added rear carrier bearings to the list, and might as well do fronts as well. Cv's look great.

What else should i replace or upgrade while i'm spelunked this deep??

Yeap while ya on a roll Dan...go buy a Looto ticket. I only want half Mate!

That head reminds me of a type 1 VW head...... but it's missing the valve adjusters!

Rand

Engine/trans/diff are out. Came out with not much fuss, but a lot of steps. Tedious.

Will be replacing the bendix, plus performing 2 preventative mods as recommended by the RZR forums while I've got it apart:

1. Changing rear diff pinion nut from the RZR nyloc to the Ranger steel nut with loctite. Its a nut that is known to backoff. You gotta keep your nuts in check, eh!

2. Removing trans brake pawl bolts, and reinstalling them with loctite. Some have backed off and trashed the trans case.

Besides cleanup everywhere, will also replace all 4 wheel bearings and the rear diff seals.

Good times!

Found some metal flake in the trans fluid. Upon deep dive inspection...

Drive gear in trans is broken. Polaris only sells the whole trans shaft, gears, bearings, etc as a kit....for $581. Will be in this rig $4250 (so far). Still in it to win it.

Trans parts ordered.

Starter fix is done and Engine buttoned up again. Energized the starter and works great.

Pinion nut upgrade done, too.

Tell you what, i appreciate the 2-stroke boards and members a lot more. Too many "under warranty" discussions on the SxS boards where money talks and know-how seems to be no-where.

Yeah I gota second this comment. This site for one is the best for sharing info, and no clowns on this site so kudos to Hoser.

Nice job D-Mo, your haulin azz on that thing!

Nice find, running yet?

Consider just putting some fresh grease in the wheel bearings mine has over 10k miles on them and doing fine.

Details on the repairs would be a nice touch in case I have to perform them myself some day

Now mine has 10k miles I am replacing all the factory suspension bushings, need/want to pull the bed off and inspect everything real good, also need to find a take off factory skid plate.

I just separated the trans from the Engine last night, and then gutted the rest of the trans. Its logically yard-sale'd in my shop right now, lol.

The (2) actual repairs needed here both required the Engine to be pulled were:

[1] Starter bendix was stuck retracted, and
[2] eventually discovered the "high" drive gear to be broken + shaft damaged.

Well you can't get inside the stator case or trans box without pulling the whole Engine/trans/diff assembly.

Bendix repair was as simple as pulling the cover, pulling flywheel, replacing bendix and its 2 washers, installing new o-ring on cover, and sealing back up.

Trans repair required complete and utter tear-down to replace the main drive gear set & shaft. The trans kit was $539.99 and includes oil seals. They won't sell the gear I needed by itself (list price is $265), so they sell the whole kit. I see why though. When something in that set grenades, its will also affect the other parts include in that kit. Also good piece of mind.

While the entire powertrain unit is out, I'm also doing a couple of rzr-forum-recommended proactive fixes:
[1] Rear pinion nut swap/loctite/torque. Its a well-known issue that the 08-14 rear diff pinon nyloc nuts do not stay put. Plenty of horror stories out there where the gears come loose & aluminum cases shred, costing a couple thousand dollars to repair. Requires some special non-standard tools that you have to make yourself (which I did) or borrow from someone else who made them. Replace the nyloc nut with an all-steel nut with 272 loctite and then torque to factory spec of 250 ft-lb. When I removed my nyloc nut, it came off with only 30 ft-lb (measured with torque wrench w/ gage). You can make this upgrade by only having to remove the bed and rear diff.
[2] Parking brake pawl bolt loctite and torque. Few stories (not as many as the pinion nut issue) where one of the (5) bolts back off, get caught in the main geartrain and grenade the main trans cases. The factory lightly torque steel bolts into the aluminum case without any thread locker. The fix essentially costs $0, but it requires a DEEEEEEP dive into the transmission.

Along the way I also found....
[1] Rear axle bearings were shot, so replaced both front & rear set with Pivot Works branded parts. When I pulled the axles, both rear bearings were stuck to the hub and just looked nasty anyways.
[2] Side-posts on main frame under rocker panel were a little bent. Will straighten and hit 'em with rattle-can.
[3] PO sealed the clutch cover with some high-strength sealant, so I had to junk the old base plate and buy a new base & gasket.
[4] The middle #9205 bearing on the trans input shaft was a little "noisy", so replacing it.
[5] Needed a new belt
[6] Needs a couple light bulbs
[7] One of the rear diff axle oil seals was leaking, so replaced both
[8] Cleaned about 4-5 kitty-litter buckets + lots of shop-vac'ing hard mud out of this thing. The dude was having fun, broke, and basically parked it.

So far I'm in this thing about $4300-$4400. Cleaned out the $4k cash I got when I sold my Exmark mower plus wiped out most my Paypal account, lol. So still running on cash and haven't had to touch bank money. =)

I'm 10000% confident I'll get this all back together. My only worry is if there's something up with the Engine. I've never heard/seen it run. After the bendix fix was done, I hot wired the starter and the Engine rolls-over with what sounds like good compression. Didn't test comp yet. I've also removed the valve cover and everything looks super-clean; Engine oil is VERY clean and still golden translucent. Been a fast & fun learning curve, though!

Have to put a new radiator and p/s cooler in my Ram tonight, but planning on spending many hours wrenching the RZR back together this weekend. A lot of tedious clean-up and prep involved, too.

Trans action...



-Dan

Take a close look at the intake tract, see if its been sucking dust another known problem....

Nice project, nice find. I am tuned in.

I have a 2013 RZRs that I bought when new. It's got maybe half the miles of Hoser's. I have been thinking I should do the pinion nut mod myself. I just cant imagine a Polaris part even accepting a torque of 250 ft lb.

Air filter was def dirty, but the throttle body and intake are clean. Had a snorkel kit on it, too, which may have helped.

Trans is back together. Was a pretty simple job. The manual is pretty spot-on with clear diagrams & pics.

Just need to weld a couple ugly spots on the rear hitch, and this rig is getting re-assembled.

RZR powerplant is back in the frame. They go in a lot easier than they come out! New starter solenoid installed and cleaned up some shotty wiring of the roof stereo & lights. Will be glad when the power-sucking halogens are gone and replaced with LEDs. The wiring to the lights and stereo were 100% fire hazard! He was running a 30A fuse on lights & 30A fuse to light bar powered both off the same single 12ga hot wire. Eek. That's a potential 60A draw on wire that's designed for 20A.

Also gave the exhaust parts a face-lift with some high-temp paint.


Hoping to have it together and running this weekend.