Polaris RZR Air Intake Information

Hopefully, the following will help clear up some areas of concern for current RZR owners. The ultimate goal is to have every current RZR owner happy with their machine. PRC will continue to work with both Polaris and RZR owners until everyone is satisfied that the fix works for their riding conditions.

The issue with dirt getting into engines was first discovered last summer. Not long after this began to happen, Polaris issued a bulletin for airbox work to be performed by dealers. After completing this and changing the build of new units to reflect the updated method, Polaris saw warranty claims drop substantially. Still, there was a very small percentage of RZR owners that had problems. To Polaris, this was still too many and for PRC, we could tell that the issue was still alive and well. So, we went to the dealer show with hopes of finding more answers and to see what would be coming forth on the new RZR units any retrofit of older units.

The following is a summary of the Model Year 2009 changes.
--Better Throttle Body boot and connection
--Better sealed airbox lid. This was accomplished by adding a 3rd clip
--Hose clamp was replaced with a new injection molded air filter sealing ring
--New “closed cell” foam was placed around intake dog house
--The filter was changed to have 100% more pleated surface area and 2 ½ times the pleat depth. A new severe duty environment type media was spec’d.

All of these changes are positive moves and an attempt to get this issue behind everyone. There were many hours spent over the past few months to get to this point. According to the folks there in Vegas, this issue was tops on their list.

Below are some more points that were brought up.

--This new filter is NOT a snowmobile media. A water resistant coating that is used on the filter media of snow plow trucks to prolong their life in high snow dust environments, was utilized in the new filter.
--You can’t just throw a bigger filter on the RZR and be done with it. Large surface area filters look nice but must function. In that regard a new media was chosen for its exceptional efficiency and higher burst strength. What this last fancy statement boils down to is this; the baby powder sized, high velocity dust particles will stay on the outside of the filter where they belong. In this manner, the performance of the filter over time, is significantly improved.
--Many different intake locations were studied, including a front, remote mount. But, it was determined that the filter media construction had the greatest bearing on the desired outcome. If the media can’t perform in the environment it is put in, it doesn’t matter where you put it at. Plus, any mod/fix that was developed had to be compatible with existing RZR’s. If it were not, there would have been many frustrated owners, more than there are now.
--All changes are completely compatible with the 2008 model RZR. From what we are hearing, current owners should be satisfied and very happy with the improvements.


Now, for the really good news. ALL RZR customers will be getting a letter in the mail addressing proper filter maintenance, especially in severe environments, and a coupon for a FREE new and improved air filter setup. There will be one free setup per VIN, so for those of you that own more than one, each one will get the fix. They will be available through your local dealer as they become available.

A very important note here as well. I have inquired if this is “it” and we have been assured that when EVERYONE’S machine is working correctly, then this will be considered closed and fixed. Until then, Polaris stands ready to help.


If you still have questions, please list them below. Once again, I ask for a civil tone. Also, whether you think it will work or not, try it and see first. A lot of hours trying many different things brought Polaris to this fix. I do know that they would like this problem taken care of, so everyone can move on.
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Bruce
Member #2
'05 4X4 Ranger
Rangerware accessories

Will this be issued to people with Gen 3 Razors?

That good news (I think). Maybe now we can all stop checking are oil and filter every 1/2 hour.

Great news. I'm awaiting the BTI box from DFR but I will still be claiming for my new bits - until then I will be wrapping some self amalgamating tape around the throttle body connections as that will be the only remaining vulnerability.

One curious thing - the move to "closed cell" foam around the intake box between the seats - is that already what Gen 3 RZRs have?

Great news, even though I haven't experienced any problems in this area yet. Just nice to know that they've taked the issue seriously.

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2007 Dodge Ram 1500 Quad Cab
2007 Suzuki Z400
2007 Arctic Cat DVX250
2008 Polaris RZR (Red)

When will they be sending the coupons and what all will it consist of? just a filter or the entire new set up that they are doing on the 09's?

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"I THINK we can make it"

has there ever been anything said about the front end clicking and weak hubs? perhaps the front differential?

these are the real issues that i would like to see addressed.

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If you're gonna buy it, then really ride it!!
26" maxxis bighorns, rock sliders, snapon windshield, aftermarket back glass, acc. rack, additional rear worklights, spare tire rack, K&N air filter, sport hardtop, front brush guard, and aftermarket fender flares

Posted: Tue Jul 29, 2008 8:02 pm Post subject:

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Folks, sorry for the delay as I am just now getting home. Ok, lets dive in.

First, yes the coupon will be for a filter and ring along with a letter for maintenance. But, please do not stop reading there as there are some important points to consider.

#1. Polaris has included EVERY VIN for the filter and ring.
#2. Just because the coupon is for the filter and ring, that is not necessarily all that yours may have done to it. Polaris, as always, will be working with and through their dealers to assess each machine and provide what is needed on a machine by machine basis. The only standard for every machine will be the filter and ring. If you ride in areas that are not as dusty as some, this may be all you need. If you ride in the severest of terrain, then expect to see more done. This will be a decision that Polaris makes with your dealers input.
#3. According to Polaris, just the filter and ring takes care of the problem in the vast majority of cases. Not every case though, so that is the reason for all the different pieces.
#4. Probably the most important statement I wrote was the one that I have put in BOLD print. Please read this carefully.


No, you are not going to be left in the cold or to foot the bill on this. Will everyone get the same stuff, probably not. It will depend on the situation. BUT, this matter will not be closed until EVERYONE'S machine is fixed to their satisfaction. There may be a case of someone who just can't be satisfied no matter what, but, this is a pretty definitive statement on just how serious Polaris is on getting this issue behind them. You must remember that the solution they have come up with has been proven to be the best solution to make everyone's machine live up to its potential. This is not some half baked, meager attempt to shut people up. Lets work with Polaris and see how this turns out. Remember, read the paragraph in BOLD again. I do believe they are serious, at least in my conversations with them, I believe them.
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Bruce

I travel all over the country with mine my riding conditions vary day to day. If they feel the need to change the throttle body lip on the 09's we should be extended the same equipment. After all were not talking about new options here simply fixing a faulty design. I'm not trying to get a bunch of stuff free i simply want what 10k should buy you.

Couldn't find this on PRC, so I'll ask it here, when it says "ALL" does it mean ALL in the US or ALL round the whole world?

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I've phoned my dealer about it, hadn't heard a thing about it - probably thought I was making it up! If I wasn't receiving the DFR canister tomorrow I would have phoned Polaris GB by now. I'm still interested in getting any relevant parts that will stop the throttle body tube from slipping off, though I realise the chance of this is all but eliminated with the fixed-in-place DFR/Holz BTI jobbie.

good stuff.

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2008 Polaris RZR Green
27" Swamp Witch
2" EMP Lift
3500 Viper Max