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Stock PRV parts.

NOTE: Chamfered end of dowel pin is down when installed.
 

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Pretty important. If it wont come all the way out it has carbon and gunk stuck to it. That means it probably isnt regulating the oil pressure correctly. Which could be the cause of your problem.
 
Sure seems like these rzrs are more of a pain in the ass then enjoyable. When I had my artic cat atv, never had any issues. I buy this and only get 1 ride out of it and find everything wrong with it.
I'll say they do require alot of maintenance, but really no more than most offroad toys. I'm assuming you purchased this used, if that is the case sounds like the previous owner may not have did enough maintenance. Thats where most problems come from in my opinion. When I bought mine used it looked new, so I thought great its should be ready to ride. Well I was wrong, all the bushings were bad, tie-rods shot, wheel bearings were getting loose, brake pads close to needing replaced. This was at 1000 miles/100 hours. The person I got it from was a honest guy and I still believe him now, he said he washed it every ride and greased it after washing. He obviously didnt mistreat it, it hardly had a scratch on it anywhere, but stuff still wears. And if you dont do dilagent maintenance then you are living on borrowed time. Most people dont know to clean the oil prv, its not in the owners manual to do it. Also the air filter is very important to keep clean and alot of people overlook it.
 
Discussion starter · #26 ·
Ok here's issue. Dowl pin stuck. Tried magnet and nothing. Had someone else start bike and give it some gas and nothing. I can leave the whole open with no towel or anything and no oil comes out the hole. I can watch oil move around over the top of pin, but nothing is coming out of the hole with it open. What's my next plan of action to get the pin out? Removing the motor is not a option.

That header pipe gets extremely hot and quick. I could just feel the hear pouring off of it
 
Yikes! Only option then would be soak, soak, soak with solvent. Have you tried putting the bolt and spring back in to see if the dowel is bottomed out?
 
After re-reading some old threads on stuck prv's, maybe try putting the spring and bolt back in. Start the engine and let in warm up to operating temp, but I wouldnt rev in more than necessary because who knows how high the oil pressure is with it stuck. Anyhow, with the engine warm the prv bore may expand enough to let the dowel move. If so then get in ther while its hot and try to work it up and down with the magnet until you can get it out.
 
How far did have to push the bolt and spring down to get it started threading? Just trying to determine if the dowel stuck all the way down, half way down or where.
 
I would get the engine as warm as i could get it then keeping working the prv up and down. Maybe spray some kind of solvent in there to help clean some of the gunk off of it. And after hou get it out and cleaned up, change the engine oil. Good luck! Keep us informed of your progress.
 
If you get it to moving fairly easy but it still doesnt come out, try the bolt out and crank the engine over trick again with the engine hot. You are making progress, just stay after it!
 
Carburetor Cleaner is great for dissolving oil varnish.
 

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I would get a round wire brush and run it down the hole to clean it up as much as I could.
 
Use a 30 caliber (.308) bore brush (Nylon) to to scrub bore, with a little solvent.
 
Oil change is cheaper than a motor from the prv sticking.
 
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