[Swagracin]

Ok ill look at that when i get home And i also see ppl talking about reshimming the pinion is that something that has to be done or is it just a personal want to thing to get clearances tighter? Sorry noobie here

 

[CA 800]

The "standard" pinion nut fix is to discard nylock nut, apply red thread locker, torque steel nut, replace seal, and reinstall diff.

Some have blueprinted the differential, but that involves complete disassembly, and I am not sure you can buy the small shims.

 

[AZ 2011 RZR 800]

Working with Pullerguy, I've begun keeping track of the Diffs we do, what we find and what the SN on the Diff tag is.

All the ones with the staked nut are in the SN 141xxx, and those RZRs have build dates in 2007 and the first half of 2008. But clearly still have a lot of diffs to figure out when the change was made a little more accurately.

Now, a recent thought. The current recall on 900 and 1000 machines affects 133,000 units. So got any idea how many RZR 800 machines there are out there?

And now that Polaris has discontinued the 800 machines, how long will one be able to get a replacement diff if you bust one?

So my recommendation. It takes me about 2 hours to get the diff out of the chassis and on the bench. Pulling the pinion seal is about another 5 - 10 minutes. And then you know what you have and using a 1 3/4" socket you can tell if its torqued to 250 ft-lbs or not. And whether the pinion nut is staked or Nylock.

Then if its loose, or Nylock you can contact Pullerguy about borrowing a tool.

That takes time. So contact Pullerguy to borrow a tool. Get a new tunnel O-ring, pinion seal and non-Nylock nut. Then just go ahead and replace the nut, follow the instructions, and you can rest at ease knowing your diff isn't going to grenade out on the trail.

So a little cost, for a lot of peace of mind!

JMHO

Pirate

On the Pinion nut issue for the Razor 800’s, how do I know if it’s loose? Let me know if you have any troubleshooting steps I can take. I have a 2011 Razor 800 EPS Robby Gordon Version. Thanks for the help. Mike

 

[CA 800]

The only way to tell is to take it apart, or wait till it self destructs.
Read thru below thread for comments or to ask about borrowing tools to do the job.

The Razor 800 Pinion Nut Repair Video by Les Hansen...

Need a set of RZR 800 pinion nut tools. New to Forum and really don't know how to use, but it won't let me PM/enter discussion. I am located in West Richland, WA. Thank you Dan

www.rzrforums.net

 

[Rzrider2022]

@Pullerguy do you still have this tool to rent out? I need to check the nut on my 800 and can’t find a top anywhere

 

[Clothier]

@Pullerguy do you still have this tool to rent out? I need to check the nut on my 800 and can’t find a top anywhere

PM Pullerguy maybe faster to get in touch with him that way. Where are you located? Someone close may have a set you can borrow.

 

[Rzrider2022]

PM Pullerguy maybe faster to get in touch with him that way. Where are you located? Someone close may have a set you can borrow.

I sent him a message once I found out you could do that. Thank you. And I’m located in northeastern Ohio.

 

[busanostra]

I opened mine 2009 and still intack and tight.
I made my own tools (Shit so expensive for just one job)

 

[jseines]

Working with Pullerguy, I've begun keeping track of the Diffs we do, what we find and what the SN on the Diff tag is.

All the ones with the staked nut are in the SN 141xxx, and those RZRs have build dates in 2007 and the first half of 2008. But clearly still have a lot of diffs to figure out when the change was made a little more accurately.

Now, a recent thought. The current recall on 900 and 1000 machines affects 133,000 units. So got any idea how many RZR 800 machines there are out there?

And now that Polaris has discontinued the 800 machines, how long will one be able to get a replacement diff if you bust one?

So my recommendation. It takes me about 2 hours to get the diff out of the chassis and on the bench. Pulling the pinion seal is about another 5 - 10 minutes. And then you know what you have and using a 1 3/4" socket you can tell if its torqued to 250 ft-lbs or not. And whether the pinion nut is staked or Nylock.

Then if its loose, or Nylock you can contact Pullerguy about borrowing a tool.

That takes time. So contact Pullerguy to borrow a tool. Get a new tunnel O-ring, pinion seal and non-Nylock nut. Then just go ahead and replace the nut, follow the instructions, and you can rest at ease knowing your diff isn't going to grenade out on the trail.

So a little cost, for a lot of peace of mind!

JMHO

Pirate

Where is the ser# tag located...mine is a 2008 Polaris rzr 800, purchased new April 2008...Thanks,John

 

[jseines]

Can someone take a photo for the location of the serial # on the rear differential...my RZR 800 was purchased in April 2008, I am the second owner and trying to get a good "tally'ho" on what I have...Thanks/John

 

[CA 800]

It is a sticker, and may have washed off in the last 14 years.

 

[jseines]

It is a sticker, and may have washed off in the last 14 years.

View attachment 712875

Thanks...

 

[Pullerguy]

seines:

Chances are if your RZR was built before mid June of 2008 it has the good staked nut. Without the SN # or build date of the diff to be 100% sure you would need to pull the diff and take a look. The build date of the RZR can be found on the decal on a frame member in the right front wheel well, if prior to June you should be safe.

Les

 

[jseines]

Thanks Les, I will check the date...best I can find this RZR was bought new April 2008...

 

[snd27613]

Anyone in the North Carolina area have access to a set of tools modified for this by chance?

 

[jseines]

Anyone in the North Carolina area have access to a set of tools modified for this by chance?

Les, my RZR was manufactured 28 Feb 2008...what I'm reading that's before the nylon pinion nut was installed...thanks for the quick reply...Cheers/John

 

[jseines]

Thanks Les, I will check the date...best I can find this RZR was bought new April 2008...

 

[jseines]

Les, my RZR was manufactured 28 Feb 2008...it should be good...Thanks for the fast reply...