I'm changing to a better filter, but the dealer did infer that a fix for the box is in the works. One of my claps broke on the air box, so I hope something gets done right away...'can't ride with a defective clamp on the box, so I'm counting on the dealer getting this problem fixed in all respects under warranty. H

 

The dealers should take care of it. RZR's built before 8/1/2007 are the ones affected. (Model #'s R08vh76ad and R08vh76ag)

They will replace the air filter, foam filter, clamp, (2) 20" seal strips and a 20 inch" intake seal.

 

Thanks. I'm taking it in for service and filter work tomorrow. It is one BAD little machine, so I'm anxious to get it out in the woods soon. H

 

So, anything after 8/1/07 is O.K.??

 

Yes

 

Thanks to this forum I researched this air box question. My RZR was built before Aug 1, 2008 and it was in the recall. I had to call the dealer to find this out. They ordered the parts last week and fixed it on Wed Nov 14th. I found that the parts mentioned by HotRide4U on Nov 14th are correct. I got mine back from the dealer on Wed evening and checked it out at home Thursday morning. THANK GOD I did. They installed the new parts BUT DID NOT clean the inside of the box. nor did they clean the small crankcase filter inside the box. It was completely covered with oil soaked dust (DIRT).
I went to another dealer yesterday and ordered 2 crankcase filters. BE CAREFUL.

 

Giddyupgo, what is the dealer you had problems with?

And what dealer is doing a better job?

I'm just what to know which Polaris dealer to do business with.

 

Yes, I found out today that getting a top-notch dealer get the fix done well, having the initial and periodic services for all fluid changes, etc. is pricy: $230 is pretty expensive for 125+miles...yet, you tend to get what you pay for. Nevertheless, I feel much better about getting the oil-drenched filter kit. For those who have converted over, it seems to have greatly diminished the concerns about dirt getting into the throttle body and combustion chambers, thus causing major repairs, haggles about warranty, etc. Anyhow, petal down and ride on. H

 

Valley Cycle & Motorsports is a honest dealership. The prices are good and the service dept. is great. Brian in Service notified us about the service bulletin the day they got it. They do a great job and get your toy back quick.
valleycycleandmotorsports.com
3917 Buck Owens Blvd
Bakersfield, CA 93308
(661) 324-0768

 

Some owners are reporting that Polaris hasn't addressed ALL the potential leaks so later units are NOT necessarily OK. Potential leak spots:
Top of access door -- intake hood sucks dust thru gap. Picture "french smoking" LOL
Intake box floor gasket -- Big gaps here allow dust to enter & get sucked into filter box.
Filter box duct -- some have small gaps where it screws to the filter box.
Filter Box Lid -- Ungreased or poor O-ring seal or broken clamps allow dirt into filter box.
Filter box clamp -- Some units left the factory with the box not clamped to the throttle body.
Filter collar -- loose or ungreased collar can let dust leak past & into throttle body.

The Polaris TSB (it's NOT a recall--you won't get a notice) only addresses 1 & 2...plus a little foam disc they put in the lid pushes on the fiilter to help keep it from wiggling loose but this may make the lid fit even worse.

I have a July unit and never had any problems. I gasketed & clamped the access door & caulked the intake box ducts as extra insurance. If I had a later unit I'd still keep a close watch on it until I knew for sure I had a good one.

 

Anyone please
How do you find when your razor was built? and where can you find out what changes or service bullitins apply to your particular vehicle?

 

Dealer told me based on the S/N. It is found on a structural upright just inside the right-front strut/shock. H

 

Not to over whelm to many here but for those with the earlier ones you might check your oil immediately and pull your filter (air) and check the cleanliness of your throttle bodies. My dealer has four already returned to the shop and the first one (mine) has shown to have ingested enough dust that it is getting a whole new piston kit, basically the whole upper motor.. My opinion is that any system designed to draw air for combustion right from the dusty area between the rear wheels has a moron for a designer.. Even the ranger was designed to draw air from up under the hood. I ask how could something like this be missed.. Well I own two and feel I was forced just last week to spend a good chunk of money on the extended warranties cause it was suggested that it is owner error for not checking the filter every time I went out. The part I don't find funny is I only went out once, my rig has less than 300 miles on it.. Again this is for your information and not to disrupt your riding pleasure.. We are going to modify the intake to bring in air from the cabin area of the machine.. I will post more as we move forward with this project.

 

I don't understand your post. The Rzr gets it's air from the cabin--the airhood is between the seats, facing forward, and it's sealed off (not very well unfortunately) from the swirling duststorm on the other side of the bulkhead. The Rzr design isn't bad, but the assembly can be. Most probably never have a problem but when the fresh air system uses so many thin plastic parts and relies on several flimsy foam gaskets there are going to be problems on some.

I'd bet money that all the testing Polaris did in the desert was done on early hand built prototypes. These would have been carefully built and sealed. This the called Design Validation in the industry. Once a model passes DV and is being built by low wage assembly line workers the manufacturer then takes a sample every now and then (called Production Validation) and tests them. Guess what? WE'RE the PV testers.

Until someone makes a better complete air intake & filtration system the best you can do is carefully seal up the gaps, test the fit & tightness and check your filter often. The only fix I've heard of that seems to address all the intake problems is a snorkel. It gets its air from high above most of the dust (even the cabin air is dusty) and is ducted right into the filter box. You still need to check that your filter box lid is sealed, and that the rubber boot between the filter box and throttle body is tightly clamped at both ends.

 

just talked to dealer and he states that the only models effected w/ the air box issue has to do with a certain serial number/model number on machine; he also said that newer models are not effected by the airbox and that he's seen a an enourmous amount of these machines in his shop but none had dirt passed the filter; (he admitted that he'd seen some with dirt inside the box but that he'd not seen any with it passed it) he went on to say that polaris has used the same "open air box design" on atvs for over 50 yrs. without problems and that its normal for dirt to get inside box, just not to bypass filter. so who's right or wrong i don't really know. you decide-

m

 

Time will tell, but Polaris sure wouldn't replace my whole upper end just for kicks, Notice also I only mentioned the early units, my second one was surprisingly clean after it's first two hundred miles. It doesn't matter to me if they tested 10000 units under controlled environment, my concern is the ONE I took out for 1 weekend and now it's been down for 5 plus weeks, and to add insult corporate told my dealer to tell me that if I were beyond my six month warranty I would have dealt with it myself (financially).. This is a problem that they are aware of or there never would have been a bulletin to upgrade on about the 16th of Aug.. One last thing I am deep with Polaris so this is not me being "angry" this is me telling every one to CHECK your oil if it's low you may have suffered dust ingestion, and by all means check behind that filter..

 

that sucks man!! hope everything works out for the best and i hope that once i take delivery of mine next week i won't get a bunk one!! cross your fingers-

m

 

I'm sure your's will be just fine I also think mine will also as we've rebuilt it and have made a mod for the intake area. It is just my wish that all will keep a good eye on they're filter area..

 

What MOD did you make? I just ordered a K&N filter for mine.

 

i am going to put a k&n filter on as well and see how that will do. i don't have my rzr yet so really don't know what to do with the whole airbox issue. i just hope that since its a newer model they will have it corrected and w/ the combination of a k&n.

 

My rzr & k&n filter has 50 miles on it, i pulled off the air-box lid and found it to be clean. i raced it in IN a few weeks ago, very muddy conditions. production date is 9-7-07, i was happy to find it clean

 

I'll try to take pic's along the way if I can be there while it being done. I also feel a need to say, popping the lid and looking inside the air box for cleanliness is not the answer as no system can stop dust from entering the box, the concern is did any of that dust get through the filter into the throttle bodies.. This can only be checked by removing the filter and looking inside with a pen light..
The mod I'm doing will draw air 100% from the cab area and seal out the ingestion from the wheel well area that I have been subjected to.. There is a picture some where here of a company whom sells a orange colored aluminum cover for the area between the two seats, mine is a similar fix but I'm going to use those fine screened round air duct screens people insert in they're snowmobile hoods for more air.

 

Code Blue,
What Mod are you making?
I would like to see what you got going? i was looking at the lone-star air intake you refered too, but maybe you have a better mouse trap?

Good Luck!

 

Buudlight:
It's my understanding that all the air box issues are pertaining to RZR's built before 1 Aug 07. The best I can offer is, if you take the VIN number off your RZR to your dealer, he can check it with Polaris to see if it was made prior to 1 Aug 07. I would suggest that you purchase a reusable Pure filter from Polaris or other make (i.e UNI or K & N) so you can clean it and reuse it after oiling it. This will be better and cheaper than the paper filter that yor RZR comes with. Have a good ride and enjoy your Hummer/Ferrari all in one.
Giddyupgo

 

 

giddyupgo;

thanks sounds like if the build date is after aug. 3 then i'm safe. alot of other people are saying different and are still concerned that polaris still hasn't come up with a true fix. guess i'll just watch my air box like an eagle and hope for the best. thanks

m

 

Some owners of both 1st gen and 2nd gen units are convinced their filter box lid isn't sealing. They find dirt ON the O-ring, often at the top by the hinge. I personally haven't seen this problem. Polarises fix doesn't address this. If you find dust tracks across the seal then I would ask for a replacement filter box.

I don't dispute that there are owners of new & "old" Rzrs that are finding problems with dust getting all the way through the system and into the throttle body. I do believe they are a small minority. What I don't understand is why it affects the Rzr and not other machines? No matter what leaks there might be in the plumbing it's the filter that's supposed to catch the dirt. Many filter tests have shown paper to be the best at trapping fine dust. This same filter has been used for at least a couple years on the Sportsman. Why is the Rzr experiencing these problems? The only change to the filter has been to add a clamp to the collar. Still some folks are seeing dust on their throttle plate. Mass hysteria??