The most common 2008 Polaris RZR 800 problems are drive belt wear and jerky engagement, overheating, battery and charging failures, a broken reverse chain, worn ball joints and bearings, and steering slop. After 15+ years, most of these are wear items, and the cheapest fixes usually come first.
The 2008 Ranger RZR 800 was Polaris’s first RZR, a narrow 50-inch sport side-by-side built for tight trails. It uses a twin-cylinder Polaris 800 engine and a belt-driven CVT (Polaris calls it PVT), so the drive belt is one of the most important parts to look after.
2008 Polaris RZR 800 Problems at a Glance
| Problem | Common symptom | Most likely cause | First fix to try | Part you may need |
|---|---|---|---|---|
| Belt wear / jerky engagement | Jerky take-off, slipping, burning smell | Worn or burned belt, heat | Inspect and replace the belt | Drive belt |
| Overheating | Limp mode, temp light | Clogged radiator, coolant leak, water pump | Clean radiator, check hoses and coolant | Coolant, hoses, water pump |
| Battery / charging | No start, dead battery after rides | Old battery, accessory drain, stator | Test voltage, check accessory wiring | Battery, stator |
| Reverse chain failure | Loud pop in reverse, no reverse | Worn or broken reverse chain | Inspect transmission and chain | Reverse chain |
| Ball joints and bearings | Wobbly wheels, clunks | Wear from mud and water | Check for play, replace worn parts | Ball joints, wheel bearings, bushings |
| Steering slop | Wandering, loose steering | Worn tie rod ends or rack | Check tie rods and rack | Tie rod ends |
1. Drive Belt Wear and Jerky Engagement
One owner of a 2008 RZR 800 with over 3,200 miles found it shifted smoothly at speed but was jerky off the line and at low speed, such as when backing up or loading onto a trailer. He suspected a burned spot on the belt, and a new belt fixed the problem completely.
- Inspect the belt for glazing, flat spots, cracks and narrow width.
- Replace a worn or burned belt; carry a spare and the tools to change it on the trail.
- Use low range for slow, technical driving and for loading on a trailer, which reduces belt heat.
- Keep water out of the clutch housing and dry it after water crossings.
Parts you may need: drive belt.
2. Overheating
- Let the engine cool before opening the radiator cap.
- Wash mud and grass out of the radiator.
- Check coolant hoses under the machine; debris can damage them.
- Top up with 50/50 premixed coolant if the level is low.
- If the engine still overheats with a clean radiator, check the fan and water pump.
Parts you may need: coolant, coolant hoses, water pump.
3. Battery and Charging Problems
- Replace batteries more than a few years old if they don’t hold a charge.
- Check that lights and accessories are wired to a key-on circuit so they don’t drain the battery.
- With a digital multimeter, check running voltage. If the battery charges fine at home but dies after several starts on the trail, test the stator.
- Use a battery maintainer during storage.
Parts you may need: battery, stator, regulator/rectifier.
4. Broken Reverse Chain
Older RZRs use a chain for reverse. When it fails, you usually hear a loud pop in reverse and then lose reverse completely. A broken chain can also damage the transmission case, so check for oil leaks before driving. Replacement options include a new chain or a heavy-duty chain.
Parts you may need: reverse chain, transmission case seals.
5. Worn Ball Joints, Bearings and Bushings
- Lift each corner and rock the wheel top-to-bottom. Play points to ball joints or wheel bearings.
- Check A-arm bushings for clunks over bumps.
- Look for leaking shocks, which need replacing.
Parts you may need: ball joints, wheel bearings, A-arm bushings, shocks.
6. Steering Slop
Worn tie rod ends make a wheel point the wrong way or add play to the steering. A worn steering rack causes wandering and clunking. Replace worn tie rod ends first, since they are cheaper and more common.
Parts you may need: tie rod ends, steering rack.
Maintenance That Prevents Most RZR 800 Problems
| How often | What to do |
|---|---|
| After every ride | Wash radiator, check belt housing for water |
| Monthly | Check coolant, battery voltage and tire pressure |
| Every season | Check ball joints, bearings, bushings and tie rods |
| Per owner’s manual | Engine oil and filter, transmission fluid, spark plugs |
| Before storage | Fresh fuel with fuel stabilizer, battery maintainer |
Frequently Asked Questions
Is there a recall on the 2008 Polaris RZR 800?
Yes. Polaris recalled 2008 Ranger RZRs built between August 21 and October 3, 2007, because the fuel tank seam could leak. Dealers inspect the tank date code and replace the tank if needed, free of charge. Ask a Polaris dealer to check your VIN.
Why is my RZR 800 jerky at low speed?
A worn or burned drive belt is the most common cause. Replace the belt before changing clutch parts.
Why did my RZR 800 lose reverse?
On older RZRs, a broken reverse chain is a common cause, especially if you heard a loud pop first.
Is a 2008 RZR 800 worth buying?
It can be a fun, affordable trail machine, but check the belt, reverse, ball joints, bearings and cooling system, and confirm the fuel tank recall was done.
Conclusion
Most 2008 Polaris RZR 800 problems are age and wear. Keep a spare belt, keep the radiator clean, test the battery and charging system, and check the suspension and steering often, and the original RZR can still handle the trails.
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