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800 backfiring

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18K views 24 replies 7 participants last post by  sheriflittle  
#1 ·
my 09 rzr 800 has been back firing. went out today and it is more often and louder. any suggestions? plugs, better gas????
 
#3 ·
any part in particular? i do have 1 spring missing from the manifold to pipe but it was backfiring sometimes before the spring went missing.
 
#5 ·
If it's backfiring on deceleration, the cause is most likely a crack in the exhaust header at the "Y". Check both top and bottom for the crack. You can either replace the header with another one or the "S" header will also work with some mods or you can have the original header crack welded and be good to go again. You should replace the missing spring too.

Mike
 
#6 ·
what mods are needed for the "s" header? besides the rest of the pipe? would imagine some kind of fuel optimizer.
 
#9 ·
looked it up the stock y pipe is $120
 
#10 ·
i got whole exhaust with aftermarket muffler for around 120 just have to post it up in the "want to buy" section and look in the classifieds

so is your exhaust header cracked? that was my probem
 
#11 ·
i havent had a chance to take it off yet. working 5 12hr shifts this week:sad: but i may try to get it off this weekend. thanks for all of the replies.
 
#13 ·
lol may just clean it up and jb weld it for now until i decide if i want the looney tunes exhaust. lol
 
#15 ·
lol i know but it sounds soooooo goooood.:rofl3: ill probably stay stock and put my money somewhere else.
 
#17 ·
yeah 200 miles in west virginia would be terrible. im gonna pull it off today and clean it up and check it. i looked at it yesterday but couldnt find a crack due to the caked on mud. im wondering if the header to pipe gasket os blown if so ive got one on the shelf.
 
#18 ·
got the manifold off finally with 1 broken bolt. there was 3 cracks 2-3 inches long. now to deal with the broken bolt. how close are the water jackets on these things? im gonna have to helicore it and hope for the best.
 
#19 ·
it it did not break off clean and u have some left to grab or even if it did use an ez out-- soak it with synthetic atf and acetone mixed 50/50--best penetrate the ever is wayyyy better than anything u can buy
 
#21 ·
True statement right here. We have cans we mix up and pressurize. Works like a champ.
 
#20 ·
had about 1/4 inch left sticking out so we drilled it and tried and easy out but it just split the bolt. had to cut it off flush and redrill then we got into the threads so have to to figure out where the water jackets are so i can figure next plan. i think im gonna put studs in instead of bolts.
 
#23 ·
yeah my brother is an engineer at his work so he is gonna do it next weekend. just gotta go pick up the heli cores.
 
#25 ·
ill keep that in mind. i think i may try to build my own header. just dont know which way im gonna go with it yet.