"The Gizmo" Is dead '09 800 with the kit burned down.

owenbstory · Mar 12, 2011

Hi my name is Owen and I'm polaris partsaholic. We should all start a help group for each other. My '09 failed again today stuck the pto side about a mile from the pickup. Let it warm up over a hundred degrees before taking off. Made it about a mile, I've had the kit on for the last 4 rides. Put it on after having the motor apart for a new crank and my third primary clutch of the year. Along with the new motor mounts that the clutch took out. I'm so diappionted with this thing. What can we do? :brokenheart::face-icon-small-fro

PowderMiner · Mar 12, 2011

is this "the fix" the new pistons with spacer, or the gizmo coolant bypass, or aomething else?

rmkboxer · Mar 12, 2011

how much oil are you going through, I have one with over 1700 miles and no problems, mine goes through oil

diamonddave · Mar 13, 2011

rmkboxer said:
how much oil are you going through, I have one with over 1700 miles and no problems, mine goes through oil

I agree. I've been running mine set around 32:1. which is much higher than the 65:1 the sled came adjusted with.

owenbstory · Mar 13, 2011

Coolant bypass gizmo

I've been going through normal amounts of oil haven't measured it out or anything, It's prob. set at the factory ratio, as I have not adjusted it. Factory set up is around 65:1? that seems awfully low on lube. Prob. need to be at least 40:1 or more?

theshadowrider · Mar 13, 2011

owenbstory said:
Hi my name is Owen and I'm polaris partsaholic. We should all start a help group for each other. My '09 failed again today stuck the pto side about a mile from the pickup. Let it warm up over a hundred degrees before taking off. Made it about a mile, I've had the kit on for the last 4 rides. Put it on after having the motor apart for a new crank and my third primary clutch of the year. Along with the new motor mounts that the clutch took out. I'm so diappionted with this thing. What can we do? :brokenheart::face-icon-small-fro

What fix are you referring to? What else is done to the sled?

diamonddave · Mar 13, 2011

owenbstory said:
I've been going through normal amounts of oil haven't measured it out or anything, It's prob. set at the factory ratio, as I have not adjusted it. Factory set up is around 65:1? that seems awfully low on lube. Prob. need to be at least 40:1 or more?

That's where mine was set. Thankfully I had added quite a bit of oil of oil to the tank for the first 2 rides before I could make an accurate assesment of oil-fuel ratio.

The are a few other things I would look at with repeat engine failures:

1) Fuel pressure verified to spec
2) Fuel injectors cleaned and flow tested

The other strikingly large annamoly with your sled is 3 clutches in one year? Something very abnormal is going on with this sled unless you are riding 5,6,7 thousand miles a year.

owenbstory · Mar 13, 2011

Clutches

Shadow I'm refering to the coolant gizmo as the fix.

Dave my clutch issues started with the first one seperating at the base or the inner sheave and the next one got mangled when my crank, motor mounts broke. I'm on #3 right now.

harrysmith500 · Mar 13, 2011

The gizmo is not "the fix". Please edit your post, very misleading.....

owenbstory · Mar 13, 2011

Didn't mean to mislead anyone.

Adobe-Al · Mar 13, 2011

owenbstory said:
Didn't mean to mislead anyone.

Sounds like a good time to rebuild it with the "The REAL FIX!"= PMS Kit
Do you have a PCV on it? I have been watching and reading the threads for over a year now and I think if you cure the lean fuel problem(PCV) and limit the piston slap(PMS Kit) it might just be combo that makes these sled a winner! IMO
How bad is the cylinder?

skibreeze · Mar 13, 2011

Adobe-Al said:
Sounds like a good time to rebuild it with the "The REAL FIX!"= PMS Kit
Do you have a PCV on it? I have been watching and reading the threads for over a year now and I think if you cure the lean fuel problem(PCV) and limit the piston slap(PMS Kit) it might just be combo that makes these sled a winner! IMO
How bad is the cylinder?

It has been my opinion that the "gizmo" would NOT fix the issues.

I have been very happy with mine after adding a PCV, have almost 700 miles w/o squeaking a piston now. I also think that the PMS is a great option to fix the piston clearance/failure issues.

My opinion the PCV and PMS will fix most of the issues with these 8's.

tree climber · Mar 14, 2011

skibreeze said:
It has been my opinion that the "gizmo" would NOT fix the issues.

I have been very happy with mine after adding a PCV, have almost 700 miles w/o squeaking a piston now. I also think that the PMS is a great option to fix the piston clearance/failure issues.

My opinion the PCV and PMS will fix most of the issues with these 8's.

i agree. i have said since the beginning that they were overstating a problem. that being said. this is the first i have heard of going down after the gizmo:face-icon-small-con

Adobe-Al · Mar 14, 2011

skibreeze said:
It has been my opinion that the "gizmo" would NOT fix the issues.

I have been very happy with mine after adding a PCV, have almost 700 miles w/o squeaking a piston now. I also think that the PMS is a great option to fix the piston clearance/failure issues.

My opinion the PCV and PMS will fix most of the issues with these 8's.

Skibreeze- So did you get your D8 back together? I got a chance to ride a Doo last year. And it handles way different than my D8. Also didn't you coat your piston to control the piston slap? and if so who did it and what does that cost?

skibreeze · Mar 14, 2011

I did, rode it this w/e. I did send my pistons to Swain tech and had them coated on the tops and the heavy skirt buildup. So far, so good.

milehighassassin · Mar 14, 2011

skibreeze said:
I did, rode it this w/e. I did send my pistons to Swain tech and had them coated on the tops and the heavy skirt buildup. So far, so good.

What pistons did you have coated? OEM?

skibreeze · Mar 14, 2011

milehighassassin said:
What pistons did you have coated? OEM?

Yup, did the single ring oem's before all the other options were available. Almost 700 miles on them.

escape6875 · Mar 14, 2011

Another one bites the dust...3-4-2011

Something to share,
My friend has a 09/10 D8 with the update.
About 1500 miles total on sled. That includes pre-update mileage.
Single ring pistons.
Lost a piston skirt, pistons had Eleven thousands clearance.
Yep Eleven wrote here in long hand so not to be thought a mistake.
I think Polaris spec's are six thousands max.
Polaris bought him a short block.
Short block= Head, Cylinder, Pistons, Rods, Crank, Case half's. Assembled

Kraven · Mar 15, 2011

escape6875 said:
Something to share,
My friend has a 09/10 D8 with the update.
About 1500 miles total on sled. That includes pre-update mileage.
Single ring pistons.
Lost a piston skirt, pistons had Eleven thousands clearance.
Yep Eleven wrote here in long hand so not to be thought a mistake.
I think Polaris spec's are six thousands max.
Polaris bought him a short block.
Short block= Head, Cylinder, Pistons, Rods, Crank, Case half's. Assembled

And that 11 THOUSANDTHS is consistent with DYNOTECH Jim's findings on a LOW mileage customer's 09 800, it had TWELVE THOUSANDTH'S piston to wall.

Un-friggin believable!!

Now I can see wear accounting for a little of that, but it looks like POLARIS was assembling these at around .010" and shipping them out the door.

For the guys thinking that extra oil pre-mixed into the tank and coolant temp control are going to remedy a piston-wall gap the size of the Grand Canyon need to take a second look........................

diamonddave · Mar 15, 2011

Kraven said:
For the guys thinking that extra oil pre-mixed into the tank and coolant temp control are going to remedy a piston-wall gap the size of the Grand Canyon need to take a second look........................

What about those who are not running around with excessive clearences but are running around with oil cap vents not opening when they should or those who have repeated air line bubbles in their oil supply lines?

"The Gizmo" Is dead '09 800 with the kit burned down.

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