800cc Polaris Ranger
Had some serious issues so we are removing and rebuilding the engine.
Rebuild and install will be in Part 2.

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By YTB

14 thoughts on “Polaris ranger 800 engine rebuild part 1: removal and disassembly”
  1. Avataaar/Circle Created with python_avatars jason mitchell says:

    You guys should’ve watched some videos on how to remove the clutch before starting this project

  2. Avataaar/Circle Created with python_avatars Holy Moly says:

    Mark nick and chip Polaris repair 🤣

  3. Avataaar/Circle Created with python_avatars Jefre Bugni says:

    These guys have no idea what they are doing

  4. Avataaar/Circle Created with python_avatars brian carle says:

    Great video showing what not to do.

  5. Avataaar/Circle Created with python_avatars ty kirkham says:

    Hey how did you guys get that clutch off that you guys broke?

  6. Avataaar/Circle Created with python_avatars Uncle Swilly says:

    What kind of flywheel puller did y’all use

  7. Avataaar/Circle Created with python_avatars Dan Cammack says:

    As a owner of a Powersport shop, like everyone here, I cringed when they put a standard three jaw puller on the drive clutch…🤪 I counted 3…2…1.. But I commend their can do spirit!! It's how I learned by tearing shit apart….

  8. Avataaar/Circle Created with python_avatars ExplainYourself says:

    Ha, there’s an ass for every seat!!

  9. Avataaar/Circle Created with python_avatars Russell Lund says:

    OMG watching you do this knowing what I know about this engine, I kept wanting to shout out warnings like that you absolutely have to take off the clutch & you are wasting your time trying to get around it and now your destroying the clutch cover, oh! There goes the clutch, I saw that coming. And then when you were trying to get the crankcase apart without taking off the cam & balancer gears, I was like NOOOO you are going to end up buying a new engine! Well I guess you learned a lot of hard lessons, too bad it was someone else's machine. Next time maybe get a manual.

  10. Avataaar/Circle Created with python_avatars unsaltedlife says:

    Question if you drill holes in the back cover plate won’t you lose the purpose of water tight. Not trying to be a troll. Also we all have learned the hard way too.

  11. Avataaar/Circle Created with python_avatars vapa 02 says:

    What a amateur mistake when clutch crakked

  12. Avataaar/Circle Created with python_avatars tristan price says:

    Polaris has a clutch puller

  13. Avataaar/Circle Created with python_avatars stuart crosbie says:

    When u put that puller on cringed I knew what was coming but lesson learned we all make boo boos

  14. Avataaar/Circle Created with python_avatars MIKE H says:

    good times! i learned just like you guys did when i was younger, tear it apart and learn from your mistakes… but to avoid some of those invest in an oem manual it will save you loads of time like when you went to seperate the case. But yea its all pretty simple, cant figure out why the dealer wants to charge 125hr for this. Also the right tool for the job can not only save you time but costly mistakes..
    and hoping you either put a new clutch housing or sealed it bc that is designed to keep water out and that hole you made will not bode well when the owner hits a water hole

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