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Discussion Starter #1 (Edited)
The Razor 800 & 800S Pinion Nut Repair Video by Les Hansen (Pullerguy)

Hopefully, this video will help those many Razor 800 and 800S owners with doing the pinion nut repair on their rides. We have Pullerguy (Les) and Pirate (Stuart) to thank for their engineering expertise in developing a tool that will make this repair much easier.

I am so fortunate that out of the goodness in his heart, Les came to my home in Utah from his home in Nevada (a 6 hr drive one way) to do the repair on my 2012 800S rzr that had only 590 miles on it. My small contribution in doing the video pales in comparison what these two fine men have done for their fellow members. I have a new YouTube channel (yeah ... I'm a rookie with the GoPro) and my youtube name is Bigjeep man.

I apologize ahead of time for the compressor noise so I added some warnings to turn down the volume. Here it is ... hope it is some benefit ...


I defer all questions on the mechanical content of the video to Pullerguy and Pirate ... because I am lacking all but the very basic mechanical abilities like screwing in a light bulb.
 

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Just so everyone will know I made a mistake in the video around 7:25 minutes I have to watch again to get the exact time, the piece around the rear on the muffler does come off of the 50 inch models, I said it doesn't. How is it said "My Bad"
Hope you enjoy all of Doug's hard work in making this video.
Pullerguy aka Les

A suggestion to put the parts list near the front of this thread.
Here are the parts, Polaris numbers.
7547243 Nut, Pinion
3610102, Seal, Oil, Pinion
3234516 O-ring
Les
 

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Very well done this video will save alot of effort and time for those of us that have tried to explain how important it is to do this repair/fix as soon as possible "ASAP"
I have done this fix on 2 of my 800s and on 2 of my buddy's 800s and in all 4 of them the pinion nuts where loose so it's not a matter of if it will happen to my machine BUT when it will happen
(The only thing I can add to this great video is after torquing the pinion nut I stake the nut to the treads)

"Site administrators should make this a sticky at the top of the 800 Forum"
 

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Cant wait to get time to watch!
 

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Watched the video... Thank you so much for doing this! I'm pretty mechanically inclined but have very little experience working on these machines. Between this video and Les's written directions this should be a piece of cake. Great video, and again... Thanks to you and Les for doing this. There really are still good people in the world.
 

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Thank you All. For those that haven't followed the threads covering this issue, A gentleman in Colorado has been a very large part of this project. Every project has to have an engineer so let me introduce him Pirate aka Stuart. As you read through the various threads on the forum Stuart is one of the first to jump in with trouble shooting suggestions. If you ask a question and Stuart makes a suggestion you better check it because he is spot on nearly all the time.
Phantomusa aka Pappy, All bow to our "Fearless Leader." Pappy is another gentleman that had input on this project way back at the start, Stuart and Pappy kicked around the idea after I built the first set of tools to discuss if this old redneck really knew what he was doing. Lets keep on doing what we do, help out when we can. The "Fearless Leader" for those that didn't follow that conversation came about with great honor and skinned knuckles, hand built special tools. It is in one of the many threads about the pinion nut issue.
Pullerguy aka Les
 

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Everyone involved with this issue deserve credit Pirate (Stuart) ...Pullerguy (Les) ...and many more have helped bringing it to the front as a must fix it now item or be ready to spend $1200.00 or more to fix it.....in steady of $50.00 to fix it before it fails (labor not included)

I repaired my 2008 800 before I sold it at that time it wasn't a issue
Then I got my 2012 800 s and joined this forum that's when it became clear to me that every one should know about this fix....Every time I drove into the woods it was on my mind "will I be walking home or driving home" now I can rest assured I can drive any place and return ... :D

Spread the word :eek:;)
 

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Discussion Starter #11
Everyone involved with this issue deserve credit Pirate (Stuart) ...Pullerguy (Les) ...and many more have helped bringing it to the front as a must fix it now item or be ready to spend $1200.00 or more to fix it.....in steady of $50.00 to fix it before it fails (labor not included)

I repaired my 2008 800 before I sold it at that time it wasn't a issue
Then I got my 2012 800 s and joined this forum that's when it became clear to me that every one should know about this fix....Every time I drove into the woods it was on my mind "will I be walking home or driving home" now I can rest assured I can drive any place and return ... :D

Spread the word :eek:;)
Thank you for that Pappy. I just didn't know at the time who all had been involved in this. I kept reading posts and reading posts and got more concerned by the day. Then Pirate suggest I get a hold of Pullerguy and that's what I did. I'm hoping Pirate has a lot more suggestions for me 'cause that last one got me and my wife some new "real" friends.

Thank you Pappy for all you have done. While here at the house, Les talked about all of you guys. Maybe some day we can all get together for a hootenanny.
 

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I'm in the middle of doing mine I contacted Les and he was and is more then happy to help .I live in Canada so I can't really borrow the tool but I'm working on getting it finished so me and my 2 kids can enjoy it again . thanks to guys like Les and the others who share their experience and knowledge to help and not expect anything in return. well all I can say is thank you a real bunch of stand up guys
 

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nice video but how do you do it without that nice tool? im getting my stuff together and im trying to figure out how to tighten the nut.
 

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I am also wondering where I can get the tool to fix this. It looks like a two day project for me. Or one really frustrating day. Great Video!

Jon
 

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Excellent video! Wish I had the know how to make those tools and tricks tearing it down. I am far to impatient to attempt this project so I guess I'll just have to hope I'm one of the lucky ones that don't have this issue. I have 1400 miles so far and going strong. My luck I would finally get it out and find it was tight!
 

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SWDoodle:
the project looks worst than it is, it just takes a bit of time, just walk away and take a break then come back and work on it a little more. If you have the basic tools I'm sure you can do it. Send me a PM and I'll send you the instruction booklet that goes along with the video.
Les
 

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Thanks tons for making the video. Definitely need to do this, but can't for a few weeks. I've been using my 2008 daily on the job site, just replaced a broken shifter cable in it. My 2010 S is idle at the moment as I have it apart doing a couple other maintenance items.

Any warning signs to watch out for in the meantime or is this issue just one that happens with no notice?
 
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