What to watch for on 08 XP 800

[CUSO]

• Change out the bolts that hold the rear bumper to dome head machine screws,
  
• Check your motor alignment, I am ordering a jackshaft shim kit. Will post my findings
• Grease the spindle bushings, they don't come greased
• let out your front limiter strap as far as it goes
• ditch all the plastic dividers in the engine bay
• Put reflective heat tape on the starter
• wipe off all the excess grease inside the starter. It gums up fast
• some people reccomend swapping left skis with right, they find it handles better
• quick clickers are a good addition, the clutching is fussy at elevation
• I have turboals thing can and clutch tower brace. great products
• just bought the rear scissor arm relocator, we will see how that works
• Take your sway bar out....unless you are Farmer Mike, the speed wobbble king...LOL

 

[zeeberg7]

I bought my 2008 early because of the excitement. I have to say the best thing I ever did to my sled is put the DJ kit in. It makes the Doo climb like they said it would stock! This year I did the 880 Big Bore. I have 2300km and figured I would need a rebuild, thought I might as well punch it out a few CC's.

Before I did this I noticed at idle that my engine light would come on and my dash lights and headlights would be very dim. The engine light shuts off as soon as I hit 2000 RPM. It idles fine. I am assuming that this is a power issue.I noticed it again today and thought that I better look into this before I get stranded or end up having a yamahaha or Poolaris outclimb me because I broke down at the bottom or halfway up.

Has anyone seen this issue in there 2008? any ideas?

Thanks,

 

[mcrc]

I got an 08 and all the upgrades were warranty. I have yet to have a single issue aside from the sled running to hot. Its never overheated on me but they definitely need vent kits and scratchers. Oh ya I did clutch mine as well.

I had problems with mine running hot. It started to get worse. Turns out the thermosat was sticking. Changed it out and it now runs much cooler. I only need skratchers to avoid slider wear now.

 

[Brentk]

Great thread, just what i was looking for.
Just picked up my 08 800 2 weeks ago, it had 600 km's on it, pretty much mint and pretty much stock. the biggest problem for me so far after 3 days on it, has been the intake clogging with snow when you finally hit the real deep stuff. What's the best fix for this?? Some one mentioned a BRP kit for this. the screen up on the hood must just be a screen and the filter must be further back inside. if that is the case i was going to just drill holes in the bottom of the intake boot where it is close to the pipe...it's gotta breath!
otherwise buy yourself an aftermarket can and peel off the foam as a start. I moved my clutch to the 3 setting and that helped, but i think quick clickers would be nice too. So far, mine does not run hot and i have no scratchers, but i make sure to fill the track with snow often when on the groomers going in. i think i am going to order the 120 thermostat and it sounds like i'll have to look at the clutch alignment so i don't burn up belts.

 

[CUSO]

Another thing,
Pull the primary off and check the runout on the cranks.
Buddy of mine just bought one, it had some cosmetic, and busted parts, no biggie, While he had the clutch off to service it, I checked the runout. It was at 9 thou, He took it into Mot's, and the crank was shot, bearings were shot, gonna cost him 2 grand to have her back together running.

I usually check mine every time I clean the clutches.

 

[MrMorgan]

First ride out today and the clutching is spot on and she pulls great....WHEN ITS NOT OVER HEATING!

The oil did leak, so thanks to whomever suggested switching with gas cap, as it stopped it nicely on the hill.

As for this overheating thing, wtf. Heat exchanger gets hot, so no air bubbles. Coolant up and new. Sticky thermostat? It's driving me nuts already. It seems like it has some safeguard when the light comes on, cuz mid pull it the light came on and stopped making power. Damn near wrecked me.

Any quick fix? There won't be new thermostat in Valemount on a Sunday, so that's out.

 

[ryan#1]

If you don't have scratchers put some on. My 146 overheated on hard pack once and i put scratchers on and never a problem since. Without the scratchers it was overheating in the first couple km (hardpack). I heard of some guys just making up a bolt set up for the back of the skis but i just bought a proper set for 80bucks or whatever it was. Easy to install...just drill a couple of holes on the skid and bolt it on. They don't work so well in reverse though...

 

[MrMorgan]

scratchers didn't help. I just sent a long-winded pm to Maxwell to see how smart he is. Today was way worse and there was lots of snow. It was fine when I was rodding on it in the powder, but anything over 5000 rpm on the trail would set the lights off and kick in some weird engine retarder (timing or something). I checked for air bubbles and everthing seems to be flowing fine. I'm going to change the thermostat next. Maybe it is sticking closed for too long? It has to be opening eventually, which I would think would solve the issue, as my heat exchangers get nice and hot. Maybe a bad temp sensor?

 

[ryan#1]

Chitty. My engine retarded when it overheated...it would still go on the overheat light but went into limp when chk engine came on. I then got off the hardpack ang got some snow moving and was ok. Im no mechanic but thermostat or head gasket would be next chks. If no coolant loss or leaks head gasket should be ok. Is your coolant overflowing like its truly overheating...if not then maybe just computer related...good luck

 

[CUSO]

Do you have a snow flap?

 

[sledderdoc]

First ride out today and the clutching is spot on and she pulls great....WHEN ITS NOT OVER HEATING!

The oil did leak, so thanks to whomever suggested switching with gas cap, as it stopped it nicely on the hill.

As for this overheating thing, wtf. Heat exchanger gets hot, so no air bubbles. Coolant up and new. Sticky thermostat? It's driving me nuts already. It seems like it has some safeguard when the light comes on, cuz mid pull it the light came on and stopped making power. Damn near wrecked me.

Any quick fix? There won't be new thermostat in Valemount on a Sunday, so that's out.

It will go into limp mode if it is too hot. Two things here. One is a faulty sensor which my buddies machine had but it would overheat immediately. We knew the machine wasn't actually hot. Two it is overheating which it sounds like in your case. Vent kit and scratchers solve that problem guarranteed.

 

[maxwell]

i dont think the vent kit/scratchers will solve anything.

i run a 163 with a higher 2.5" track and no snowflap and it has never overheated.

- thermostat is bad - replace/ get the engine tech one. ( shouldnt have to go aftermarket there is no way it should be overheating with factory equipment)

- temperature sending unit is malfunctioning ( replace )

- air bubbles ( bleed )

- coolant mixture is incorrect. flush and replace with 50/50

- water pump impeller is toast ( replace )

- ECU issue


the 5000rpm isse is what has me thinking its computer related...

i would suggest trying someone elses ECU for a day.

if that doesnt work replace the temp sending unit

 

[sledderdoc]

i dont think the vent kit/scratchers will solve anything.

i run a 163 with a higher 2.5" track and no snowflap and it has never overheated.

- thermostat is bad - replace/ get the engine tech one. ( shouldnt have to go aftermarket there is no way it should be overheating with factory equipment)

- temperature sending unit is malfunctioning ( replace )

- air bubbles ( bleed )

- coolant mixture is incorrect. flush and replace with 50/50

- water pump impeller is toast ( replace )

- ECU issue


the 5000rpm isse is what has me thinking its computer related...

i would suggest trying someone elses ECU for a day.

if that doesnt work replace the temp sending unit

Ya you wouldn't think so ......... last year I started to bubble antifreeze out the resevoir. Happen twice, once in Cooke and at Blue River. This year I pulled all the foam out. Installed Vent kit. added scratchers for the trail rides up and so far have ridden without issue.

I did however check that I had no air locks etc. in the system and checked it at regular intervals. Snow on the Dec. 3 weekend was thin in Mcbride and I had no issues.

I would therefore disagree with you just because those are the only changes I made and the problem is gone.

Computer issues are a definite possibilty and we tried switching ECU's etc. on my buddies machine when he had issues as we all pretty much ride the same machines. Even when we took my buddies machine to the dealer they switched out therm. and said nothing wrong with sensor. Problem persisted and the sensor was switched out machine fine now.
His machine though would overheat after 300 yards!! We knew it had to be a sensor or something. But mine leaking antifreeze is an obvious thermostat problem or legitimate overheat. I checked thermostat it was fine so thats when I vented and scratched ( my machine not balls). For me it fixed it .......... jmo.

 

[maxwell]

while it may have worked for you skidoo did not design a machine that will overheat because of poor venting and noise reduction features. YES venting will get some nasty heat out of the engine bay and it should be the first thign done on any xp machine. same with ditching the foam and seperators. spring riding i sometimes even ditch the hood.

i still feel the issue lies elesewhere. but who knows you could be right ive seen weirrder chit.

if your machine is in fact actually overheating you wont be able to touch the coolers for more than a second.

a sled at operating temperature is warm to the touch but not HOT

 

[sledderdoc]

while it may have worked for you skidoo did not design a machine that will overheat because of poor venting and noise reduction features. YES venting will get some nasty heat out of the engine bay and it should be the first thign done on any xp machine. same with ditching the foam and seperators. spring riding i sometimes even ditch the hood.

i still feel the issue lies elesewhere. but who knows you could be right ive seen weirrder chit.

Can't really be too many things, engines pretty basic. Either the water pump is too small, rad is inefficient. Clutches are hotter than hell, that stock exhaust suitcase is a waste of time etc. etc.

All I know is a pipe, y-pipe, can, de foam, and vents made a world of difference. Not crazy about the new design, I actually still liked my ZX the best. Wierd I know but it was a bullit proof machine.

 

[MrMorgan]

All the foam is out, dividers out, and a good vent kit. When the temp light comes on, the tunnel melts snow quickly, but I can still touch the top. It's warm, but doesn't burn my hand. I'm thinking either the thermostat is not opening completely or the impeller/water pump is not circulating enough. I suppose it could be a sensor, as it seemed tied to the 5000 rpm mark. 10 seconds over 5k and the light would come on when I was coming down the trail. 10 seconds under 5k and it would go out, but the rev limiter/engine retarder was still in effect. Also, I never lost any antifreeze, even when the temp and check engine lights were on.

 

[maxwell]

there is a test we can do for the temp sensor before replacing it. but as for the thermostat its about 30 bux i would just replace it. doesnt last forever anyways.

if that doesnt work then i would pull off the water pump housing ( not fun ) or try another ECU


heres a photo of an overheated water pump gear. this was a severe overheating though not your case

 

[MrMorgan]

yuck. Thermostat will go in today and I'll take the machine for a trail ride. I should know in 5 min if that was the issue. I really don't want to deal with water pump.

 

[maxwell]

cool let us know what happens

 

[MrMorgan]

cool let us know what happens

Thermostat seems fine now. Good flow and pressure rules out the impeller. I could not diagnose the issue so I took it in to a shop. They could not get it to overheat again. Go figure.

Perhaps there was a bubble and I got it out after all? The shop said that sometimes the heat exchanger gets totally iced up and it will not cool properly, so they suggested that was the problem. That seems weird to me, as you would think ice is the coldest thing you could have on the heat exchanger and it would just melt off.

I will be running it over the Christmas break, so well see how much cursing I'll be doing over the holidays.