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Rzr 800 "Cutting Out"

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6.6K views 12 replies 5 participants last post by  sndnsno  
#1 · (Edited)
Hey everyone I just want to start off by introducing myself, my names Tyler but everyone calls me Spud. I have been a creeper for the last few months and now that I finally bought my 2012 Rzr 800s and ran into my first problem I figured I'd create a user.

Alright so here is the deal. I bought a 2012 800s with 650 miles, I trailer-ed it about 35 mins home in about 40 degree weather. I test drove it twice at the dealers little test lot with no problems. Now coincidentally or not when I went to go start it when I brought it home to get it off the trailer.. click click. I jumped it and let it run for awhile with no problems. A week later I brought my Rzr to my uncles cabin for a few hours messing around on some trails with some puddles and what not with no problems. A week after that I did something similar with all dry land with no problems. Now this weekend I went trail riding and put on around 50 miles, there was the average puddles here and there but nothing crazy or "swamping" going on. Here is where it gets interesting, I was about 20 mins from my truck doing about 30ish MPH my Rzr just bogged down for a quick second or two I didn't really think anything about it thought I was just imagining something. The second time it happened I knew i wasn't going crazy I was doing about 45ish MPH and it bogged down again shortly after the first time it happened, but this time I watched the dash for any lights and literally everything shut off then all the lights came on and went back to normal except for my seat belt light so i unclipped my belt and put it back on and it went away. I finally made it back to my truck and I let my Rzr just run for a couple mins. I tried to re-enact the situations since I felt safe near the truck so I drove down the trail a little ways, this section was completely dry and i was about 3/4 throttle and it happened again for a quick second, I don't believe it bogged long enough to cut the dash power? Anyways I loaded up and went back to camp. Sadly there was no parts store open and for a piece of mind i wanted to get my battery tested, my only option was Wal-Mart. The battery tester printed out a sheet "Battery tested good, low on charge, recharge and replace into vehicle". So I put the battery back in and drove around the campground a few times with random puddles and what not, no problems at all. When I got home I tested the battery with the Rzr off and i got 12.4 volts, I then started it and it went up to around 14.2 volts. I am now stumped and scared to get stranded a couple hours from camp. Sorry it was such a long post but i wanted to be detailed for better answers. Again thanks for your help and any help will always be appreciated.

PS: Its all stock except for an Airaid intake and Snorkels.
 
#2 ·
Still could be a bad battery. It is not always easy to find someone that understands how to test the battery. Shucks, I bought a brand new car and the dealer did not know how to test a battery, but all my weirds problem left with a new battery. Batteries do not like to set not being fully charged. The easiest and best test is to put it on a charger and get it fully charged. Connect a volt meter to the battery terminals. Start it while watching the meter. IF it drops under 12 volts while cranking, the battery is bad. If it stays above 12 volts battery is OK. The other thing one can do is to put the speedo to volts as you drive it. Watch the battery to see if it stays up in the 13.8 to 14 plus voltage while running. If it stays up the battery and charge system is OK. Be sure all the terminals and grounds are clean and tight. I'm thinking you probably have a bad cell or cell connection in the battery, could also be a bad connection.

Oh yes! When it sets put a battery tender on it.
 
#3 ·
Sounds like a bad battery or possibly a bad connection to me. Starting at the batery work you down the cables and check the connections. Another quick test you can do at home is check your battery voltage with the machine off. Then turn the headlights on for a minute or two. And then re-check voltage. It shouldn't drop much, if any. If it does your battery is just getting very weak.
 
#5 ·
Did you see any error codes? The reason I ask is last fall I had a similar issue. Driving along and the RZR would cut out. We were 18 miles from the trailer and it was getting dark. We saw error codes pop up that don't even exist. After a lot of searching we found a bad wire on the ignition switch. Sounds to me like you should check all the grounds.
 
#6 ·
Alright guys Im going with my gut instinct and all of your ideas, I have a PC925L Odyssey on the way! I had to do something or else I would just worry the whole time on the trail. Sometime before my next ride Im also gonna go through the whole machine while checking all the electrical connections and put some dielectric grease on them. I sadly bought my Rzr with out a manual, If the error codes pop up to be obvious I have not seen any. Thanks for all the great ideas, all answers help!
 
#8 ·
Alright anybody who is following along, I took the Rzr out again over the weekend trail riding, the problem still existed. I made it maybe a mile down the trail and it cut out again, I figured I would just continue to drive it and try to find the problem. After about 2 miles and the machine cutting in and out a few times it completely shut off and died, even when I turned the key it wouldn't do anything. I crawled out of the machine and shook it, walla it started. While it was idling I started shaking wires around looking for shorts. After I shook one plug it died again, this plug is on the driver side right in front of the rear wheel, looks to be part of the main harness. This plug doesn't connect another plug, it goes into a black cover or cap type thing. I pushed this cover all the way back on since it was pretty loose. After I did that, no problems at all. Anybody know what this plug does?
 
#10 ·
Well, it sounds like you may have already found the problem, but I will tell ya I had the same problem with my 2010 RZR4. My problem ended up being the connector on the back of the ignition switch. One of the connector inside the harness was open too wide and not making a good connection with the adjoining harness on the back of the switch. The RZR ran great up and down the street and around the neighborhood, but once I got it offroad it would start cutting out. A small screwdriver to close the metal connector a bit and I haven't had a problem since.


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