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overheating issues 2011 rzr 800

This is a discussion on overheating issues 2011 rzr 800 within the Engine and Drivetrain forums, part of the Technical category; fan cycles normal, the first 4 times, after that, it becomes eratic, allowing engine to overheat, the longer you ride, the worst it gets, changed ...


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Old July 7th, 2011, 02:23 PM   #1
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overheating issues 2011 rzr 800

fan cycles normal, the first 4 times, after that, it becomes eratic, allowing
engine to overheat, the longer you ride, the worst it gets, changed ect sensor, removed thermostat, replaced fan relay, has anyone else, had this problem.
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Old July 7th, 2011, 02:36 PM   #2
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Re: overheating issues 2011 rzr 800

I punctured my rad last month and brought it to a rad repair dude...he looked in it with some mini camera doohickie thing and said the baffle inside wasnt welded in right and would cause overheating due to only half the rad was working...said it was a defect and when I called my dealer of course he said unless we take it apart and inspect it popo wont cover it...did you notice if only half the rad was getting hot? I went with an aftermarket one to avoid any issues...although prior to damaging my rad it really only got extra hot on long rides and if it was warm out when I was plowing snow.
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Old July 7th, 2011, 02:57 PM   #3
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Re: overheating issues 2011 rzr 800

this problem, just started over the weekend, i also removed rad., and washed out the fins, it was dirty, of course, but did not stop problem, the fan works fine, for a while, then it want kick on at 205, temp will go to 215, 220, when it does decide to kick on, it kicks off befor it gets to 194, 204, or something like that, if i stop the engine, and restart the engine, fan will kick on, but will not bring temp to 194, so i have to restart engine several times, to cool this machine down..
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Old July 7th, 2011, 03:26 PM   #4
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Re: overheating issues 2011 rzr 800

You need to bleed the radiator of all the air. There is a bleed screw on top of the head. I have found its easiest to remove the bed to due this and jack the front of the rzr up.
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Old July 7th, 2011, 09:05 PM   #5
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Re: overheating issues 2011 rzr 800

Quote: Originally Posted by Askin View Post
You need to bleed the radiator of all the air. There is a bleed screw on top of the head. I have found its easiest to remove the bed to due this and jack the front of the rzr up.
I read you can get at the bleed valve from behind the passenger seat...think thats possible? I also read you have to jack up the front end high to get any trapped air out and run it till the thermostat opens and add more til the bubbles stop coming out...does that sound right to anyone? First time filling up new radiator, unfortunately every time I wreck my machine I learn another new skill and the rzr cooling system is my current project...and btw putting in the new steering rack was a b$#@h!!!
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Old July 7th, 2011, 09:52 PM   #6
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Red face Re: overheating issues 2011 rzr 800

Quote: Originally Posted by ADKrzrlvr View Post
Quote: Originally Posted by Askin View Post
You need to bleed the radiator of all the air. There is a bleed screw on top of the head. I have found its easiest to remove the bed to due this and jack the front of the rzr up.
I read you can get at the bleed valve from behind the passenger seat...think thats possible? I also read you have to jack up the front end high to get any trapped air out and run it till the thermostat opens and add more til the bubbles stop coming out...does that sound right to anyone? First time filling up new radiator, unfortunately every time I wreck my machine I learn another new skill and the rzr cooling system is my current project...and btw putting in the new steering rack was a b$#@h!!!
I found it much easier to remove the bed. Keep In mind this is on a 2011 model 800. The earlier model 08 2010 is easy to access from behind the seat the bleed off is on the side of the head/thermostat. It can be done without removing the bed but its tough.

Last edited by Askin; July 7th, 2011 at 09:56 PM.
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Old July 8th, 2011, 01:19 PM   #7
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Re: overheating issues 2011 rzr 800

you can access the bleed screw from behind passenger seat, its hard for me to believe, that a little air in the system, would cause the fan to work so eratic, but i have bleed all the air, or so it seems, out of the system, did this yesterday, and run the rzr thru 6 cycles, on at 205, off 194, here in the yard, came back this morning, resivoir, was empty, so i added more coolant, started the bastard, kicked on at 204, off at 194, 2 times, now its 204, off at 199, this may be normal, but its friday,tired of fooling with it, gonna take it to the hills, and see if all is well..also wanna think everyone, who has gave me some advice, on what is going on, with this machine, i need all the help i can get...i also have a 2011 service manuall, in my pc, if anyone needs this just ask, was a bitch to find, but i did...
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Old July 8th, 2011, 05:00 PM   #8
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Re: overheating issues 2011 rzr 800

Quote: Originally Posted by gordo View Post
you can access the bleed screw from behind passenger seat, its hard for me to believe, that a little air in the system, would cause the fan to work so eratic, but i have bleed all the air, or so it seems, out of the system, did this yesterday, and run the rzr thru 6 cycles, on at 205, off 194, here in the yard, came back this morning, resivoir, was empty, so i added more coolant, started the bastard, kicked on at 204, off at 194, 2 times, now its 204, off at 199, this may be normal, but its friday,tired of fooling with it, gonna take it to the hills, and see if all is well..also wanna think everyone, who has gave me some advice, on what is going on, with this machine, i need all the help i can get...i also have a 2011 service manuall, in my pc, if anyone needs this just ask, was a bitch to find, but i did...
Unfortunately the 2011 is very sensitive to air in the system. I have built up a few and every one was bitch to purge the air and make sure the fan was cycling correctly.
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Old July 8th, 2011, 11:30 PM   #9
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Re: overheating issues 2011 rzr 800

Coolant sensor will be erratic if air surrounds them. They have to be completely immersed in liquid to operate correctly. Some manufactures recommend putting a cooling systems in a vacuum, when coolant is added. (Special tool) If it was mine I would lift the front end up as high as I could 4 or 5 feet, I use to have to do this with some cars, after over hauls. Manufactures have been fighting air lock for years now, do to where certain sensors have to be placed. Another trick was to drill a bleed hole in the thermostat flange and place it where any air that is trapped when filling could bleed out on it's own and get you ahead in the bleeding process.
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Old July 10th, 2011, 05:43 PM   #10
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Re: overheating issues 2011 rzr 800

ok, fellows, heres what i did, to find out what was going on. took to the hills, friday, pitch the front end up hill, big time, then bleed coolant out bleed screw, then brought it home, still fan did not work right, took my volt meter, attached it to plug in going to fan plug, wired the fan on a toggle switch, straight to battery.. velcroed the volt meter to the dash, where i could watch it, and road the hell out of it saturday, every time, at 204, meter showed power of 14.1 volts, i kicked on fan with toggle switch, every time, meter lost power at 194, i would kick the fan off. this showes me that ecm is telling the fan to cool the engine, stayed 14 hours, volt meter showed power, every time, on at 204 degrees, off at 194 degrees, just like book says. fan worked every time also, no problem with overheating, however, i would not advise anyone, to use this method, except to test for problems, it is very easy to forget, about toggle switch. now, there is only 1 part that i have not checked, and that is the 20 amp circuit breaked, which i will replace, monday, and see what happens, could be when breaker is under a load, fan being the load, that it trips out, stoping power to the fan... the breaker isin a bad place, also, always covered with mud and water.. wil let everyone know, if that is the problem, soon.
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Old July 10th, 2011, 06:33 PM   #11
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Re: overheating issues 2011 rzr 800

I believe somebody else mentioned this, and it is located under the floor? If that is correct I think mine is coming apart and being relocated before I am 20 miles into the back contry and it decides to fail. Poor placement for electrical, just like the fuse box in font of the left rear tire.
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Old July 13th, 2011, 05:55 PM   #12
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Re: overheating issues 2011 rzr 800

ok fellows, the 20 amp circuit breaker was the problem, it was not triping out though, it was just not making contact good enough, full of mud and water, and a poor design, they used slip on connectors, once they got mud there, that was it, wire going to the breaker, and going to the relay was discolored, because of heat backup, dam wonder it lasted this long, so i bought a new breaker, at local advanced auto, with eyes, mounted it on the shelf behind the driver seat, used eye connectors, and the nuts that came with the breaker, no loss contact now, everything is as it should be, also soildered all connections, this machine, has only 850 miles, so everyone who has a 2011 rzr, should check this breaker problem out, the breaker is not the problem, it is the connectors they used, you would think that they would at least, have done a better job, with this item, being that it is so important, or maybe, that is why they did it, 850 miles , or 10 months, i think my warranty was only for 6 months, but i bought extra 5 years, dam well gonna need it, if everything else is like this..good luck fellows, if you all need help with this item, let me know, if your machine is overheating, and the fan is not working right, this is the problem...
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Old July 13th, 2011, 10:57 PM   #13
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Re: overheating issues 2011 rzr 800

Quote: Originally Posted by gordo View Post
ok fellows, the 20 amp circuit breaker was the problem, it was not triping out though, it was just not making contact good enough, full of mud and water, and a poor design, they used slip on connectors, once they got mud there, that was it, wire going to the breaker, and going to the relay was discolored, because of heat backup, dam wonder it lasted this long, so i bought a new breaker, at local advanced auto, with eyes, mounted it on the shelf behind the driver seat, used eye connectors, and the nuts that came with the breaker, no loss contact now, everything is as it should be, also soildered all connections, this machine, has only 850 miles, so everyone who has a 2011 rzr, should check this breaker problem out, the breaker is not the problem, it is the connectors they used, you would think that they would at least, have done a better job, with this item, being that it is so important, or maybe, that is why they did it, 850 miles , or 10 months, i think my warranty was only for 6 months, but i bought extra 5 years, dam well gonna need it, if everything else is like this..good luck fellows, if you all need help with this item, let me know, if your machine is overheating, and the fan is not working right, this is the problem...
Where is the breaker anyway? I've been having fan issues on several trips and I haven't found that to check it yet.
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Old July 14th, 2011, 03:05 PM   #14
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Re: overheating issues 2011 rzr 800

remove the driver seat, right behind the battery box, the wire loom, that comes from the ecm, going towards the front of the rzr, the breaker is taped to the wire loom, and down near the bottom of the battery box, if you remove the tape, you will see a small rusted 1 inch long x 1/2 inch thick metal gadget, this is the breaker, connectors are upside down within the wire loom, breaker is taped to the outside of the wire loom. this is where mine was located 2011 rzr le edition.. if this item is in this area, on all 2011 models, and you all ride your machines thru mud and water, it will be a problem, sooner or later, i can't go 1000 yards, befor we are riding thru swamps, here in eastern ky. so just check it out, make sure it is getting good contact..
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Old July 14th, 2011, 09:24 PM   #15
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Quote: Originally Posted by gordo View Post
remove the driver seat, right behind the battery box, the wire loom, that comes from the ecm, going towards the front of the rzr, the breaker is taped to the wire loom, and down near the bottom of the battery box, if you remove the tape, you will see a small rusted 1 inch long x 1/2 inch thick metal gadget, this is the breaker, connectors are upside down within the wire loom, breaker is taped to the outside of the wire loom. this is where mine was located 2011 rzr le edition.. if this item is in this area, on all 2011 models, and you all ride your machines thru mud and water, it will be a problem, sooner or later, i can't go 1000 yards, befor we are riding thru swamps, here in eastern ky. so just check it out, make sure it is getting good contact..
Im in london so probably not too far from you then. I'll check it out tomorrow and see what I come up with. It could be the root of my problems. Thanks
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