2009 Polaris 800 Dragons Reflash Blowing Up Motors

[indyxcr]

So far 50% of the 800 Dragons with the new reflash run excellent but 50% are blowing up under 100 miles!!
What has anybody else found out?
The dealer told me 3 out of 6 burned down the motor under 100 miles.
So I did not want to take the chance, but the reclutching from 68 grams to 70 grams major difference put on 400+ miles this last week.

[btmik11x]

I had my Assault reflashed last week, it does seem to run alot better. I only have 70 miles since reflash but no troubles yet. I did read on HCS that there is more then one version of the reflash and to ask for the most current. They had a list of the exact codes available. My dealer told me they have had only one Dragon with similar trouble. I will update if any further issues.

[zimmbob]

My buddy just bought a 800 Dragon RMK 155 and has 400 miles on it. Reflashed when he got it. No problems.

[bigdog700]

I just bought a 09 800 switchback last week. same motor as the dragon. The dealer did the latest flash before it left. put on 225 miles this week on it seems to run great. Squeezed the throttle for a short, easy 105mph

[10denalio]

Had the reflash doneand it runs alot better.Buddy has a 05 fusion 900 and we were side by side now I just walk away.

[indyxcr]

I thought there was only one reflash from Polaris that came out in Febuary??

[jeff]

there were two reflashes. there is one more coming. This last one is THE TICKET!

[indyxcr]

Thanks, I only did the 70 gram weights in the clutch, big difference from the 68 gram weights waiting on the latest reflash for my 800 dragon and 800 IQ.

[10denalio]

There was three re-flashes that came out,because there is three different injectors red,blue and yellow.The way to tell which injectors u have on your sled is to lossen two screws on clutch cover(plastic piece sits right on top of clutch cover)lift up cover and it is written on a sticker which injector u have.Now I heard there is another re-flash coming out but since mine has been running better with the first re-flash i'm waiting till the end of season to find out if they indeed come out with another.

[jeff]

I havent heard anything about diff injecters? I have only heard of TWO reflashes and the third is on its way. I have only had the latest of the two and it runs great with the exception of a 4500-5000 burp oncwe in a while

[indyxcr]

The dealer told me when you do the reflash thats it, no 3rd reflash, you can only do one reflash is this true?

[kraven700]

Straight scoop

log onto: www.dynotechresearch.com (http://www.dynotechresearch.com)

and www.hardcoresledder.com (http://www.hardcoresledder.com)

[jeff]

NOT TRUE 3rd flash is the one you need. Most current. you could have had all three it doesnt matter its just a reprogram

[indyxcr]

The dealer said Polaris has found the piston rings are breaking and might have a recall on all 800's for new pistons and rings this is what they found that is causing all the motors to lock up?

Dealers from Ill, and the dealer in Wisconsin, 10 out of 25, 800's range 100 miles to 1,500 miles the pistons break.
50/50 chance it will happen.

[chad66]

If anybody is looking for one of these sleds I have a 2008 Dragon 800 RMK with 2500 miles and a 2009 Shift 800 RMK with 2400 miles and a white hood. Both have fresh rebuilds and have been reflashed however I'm unsure if they have the latest reflash.

Chad@M&M

[whiskey_jim]

Dealer in wyoming told me they were takeing the thermostats out because it was a heating issue that was making them blow. But they would not do it for everybody because some people would not let them warm up properly before rideing.

[marty__kms]

Chad...hmmmm I could think of a better thread to post this on...LOL

Just had to give you a bad time.

[chad66]

He Marty I have a 2007 Summit 800R also if you have anything worth trading for it!!!

Chad@M&M

[favoritos]

Still have the belt eating turbo sitting there Chad?

That is a story worth telling.

[chad66]

Yea I still have that here too however we did make a little headway on the clutching but I'm thinkin the bikeman clutching is going to hit the road! Haven't figure out how long a belt should last with 230hp but I'm hoping it's going to be more than a 100 miles!

Chad@M&M

[skylar]

Chad, why don't you park that 230 horse sled at Krupp's tomorrow, and I, uh, well, I'll take 'er for a rip and see if I can help ya try to make a belt last longer than 100 miles. C'mon, just one pull on it! LOL.

[mxz500rider]

you serious 230hp? i wanna see pics.

[chad66]

It's pretty easy when you dealing with turbo'd four strokes. Not much to it really, just a Z1 turbo Sno Pro with the Boondocker/Hijacker box on it. You can run it up to 230hp on pump fuel and I think 260 on race fuel. Did I mention it's for sale:-)

Chad@M&M

[marty__kms]

Chad,

I have a T660 Turbo, Red with White racing stripes so it has to be fast. I will trade you that and a 07 F6 SP (low miles) for the Summit… (we told you not to take it)

Marty @ KMS

[marty__kms]

Think we are going to get in trouble for "threadjack"

[samc]

230?* For sale - how much?

[Firecatguy]

looks like poo is sending out crate motors for everyone with the 800 problem

friends all got letters from polaris --said to stop riding them...

[jeff]

What???????? no way! I have a 09 IQ 800 and have not seen such a letter. I just got off the phone with local dealer. No one knows of such a claim!

[indyxcr]

This guy is an idiot, I have a 2009 800 IQ, and 2009 dragon 800!

All you need to do is have it reflashed, to get the bog out at 45 to 50 mph, also redo the clutch take out the 68 gram weights put in 70 gram weights, makes it real fast low and midrange. I was told that some have piston rings braking from the Il dealer, have not heard that from my dealer in Wisconsin.

Also stay with the champion plugs no NGK's the dealer said people are having problems with them!
One more thing use only 92 or 93 octane gas and plug the wires in big differnce otherwise you will foul plugs every 100 miles I did plug them in no problems, also once you get over 400 miles the 800 gets faster.

[Firecatguy]

im an idiot well my friends you will see and indyyxcr I will get a copy of the letter for you as I ride with 3 assaults and 4 dragon 800 and every one 0f them got the letter

as for the idiot comment maybe you should think about what you say before you start typing.

[Firecatguy]

oya indy here a video and everyone with a d8 in this video smoked their motor and they also got the LETTER that I talk of..

http://www.youtube.com/watch?v=q1p81XhRW-w&feature=channel_page

indy, so how many miles do you have on that D8 of yours?
and are you not the guy who said 3 out of 6 melt down?mmmmm maybe polaris has found a problem but then you did not get the letter so keep riding..

[indyxcr]

The dealers said Polaris might replace the pistons and rings, thats all I heard? the 3 out of 6 sleds, I said had that had a melt down, had the first reflash and to find out the dealer said they where using 87, to 89 octane. My sleds
700 miles on the 800 IQ, 500 miles on the 800 Dragon.
The season has been over, no letters from Polaris, same with my friends when did you get yours?
This is why I never had the reflash done yet only the people who had reflashs had sleds lock up,50% at 3 different dealers in 2 states. The new reflash is suppost to be out by fall.

So you are saying Polaris is sending out new 800 motors in a crate????

[Firecatguy]

http://www.hardcoresledder.com/forums/lofiversion/index.php/t414146.html

[indyxcr]

I will contact my Polaris dealer in Wisconsin, and talk to my friend at the Polaris dealer in Il, I will post what I found out, 10 days ago I bought a new trailer, and they didn't know anything yet? Only the new reflash and maybe new pistons and rings, but nothing is for sure yet, that was 10 days ago.

[Firecatguy]

yep letter was sent out on march 19th

[indyxcr]

I have a good dealer I'm not worried he always takes care of any problems, the letter is not there on hardcoresledder,it says errors, also did you get a letter from Polaris?

Unlike my friends who bought new 700 firecats from artic cat back in 2005 and the motors blew up in 25 miles on both of them, Artic cat did not want to cover them it took a month they never did run good, I was with them in Mercer Wi when they locked up. They are back with Polaris this year, this is the problem with any new high end motor sled from any of the 4 brands new motors risk of problems the first year.

[Firecatguy]

you didn&#39;t hear it from me as you like to kill the messenger but-<font color="ff0000">•</font><font color="ff0000">•</font><font color="ff0000">•</font><font color="ff0000">•</font><font color="ff0000">•</font> sounds like the fix for the 800 is in just a little more r&amp;d it looks like it is a cooling issue too small of something so coolant is too cold at back side of motor? everyone is getting a motor? time will tell

what have you found out indyxcr?

[kraven700]

THE FACTS ON POLARIS 800&#39;S
1&#41;ORBITAL, the Australian company that does the E.C.U. fuel mapping for MERCURY MARINE has been hired by POLARIS &#40;as in 2 months ago&#41; to do ALL e.c.u. programming from here going forward.

2&#41;NEW PISTONS FOR ALL 800&#39;s and possibly new jugs

3&#41; Free extended warranty until APRIL 1, 2010

4&#41; IF you want your 800 to fly, go to www.dynotechresearch.com (http://www.dynotechresearch.com)
Buy the PC III from Jim with the programming that he developed after countless hours of dynotesting. Just plug &amp; play. The BEST $ 365.00 YOU&#39;LL SPEND.

[mustsled2]

can somebody please tell me why I should upgrade?

[Firecatguy]

http://www.snowest.com/forum/attachment.php?attachmentid=62215&amp;d=1237673850
the letter

I was talking with a friend who works at a poo dealer out west WHO is working with polaris as I type to come up with a solution for this problem and what it looks to be is a COLLING issue its toooooo cold on the back side of the pistons and it has something to do with a port that is to small

[dan_flagg]

So...bottom line...should I buy a used &#39;09 Switchback 800 ? After all of these comments, it makes one rethink the purchase of a used sled even though this one has 1200&#43; miles.

Any thoughts ?

[grub]

No dan flagg you should not buy a used &#39;09 Switchback 800. This is the 42nd post on this topic. You should be getting the picture by now. The &#39;09 800s are a problem child. Pol may or may not fix them. They may think they have a fix now but nobody is riding so who knows? They may warranty them for a couple of extra years but who cares - it is still no fun to blow up on a trip whether it is paid for or not. At this time there are better choices if you want 800 type torque and power and like things to stay together.

[indyxcr]

I did not found out anything yet it was Easter weekend my friend at the dealer was gone, I should have a answer Monday night or Tuesday at the latest.

My dad received a letter from Polaris Saturday, only for 600, and 700 IQs 2007,2008s the return fuel line some had been leaking they would replace the hose free of charge.

Dad sold his 600 and bought an 800 IQ in December 2008,he has no problems with his 800 IQ over 700 miles on it.

NO LETTERS FOR 800 DRAGONS OR 800 IQ YET

[indyxcr]

The dealers out west in the mountains in high and lower altitude, they say the fuel pump or fuel controller is making the 800 IQ and 800 Dragons run lean and burning down a piston, the remapping is still not right yet, this is just what I said from the start, they will hopefully have it right by late summer or fall.

The dealer in Wisconsin that I bought my 800s only the people who remapped blew up there sleds so far that was 50 % of the 800s sold at his dealer.

This is why my 800s didn&#39;t lock up, no remap yet the dealer told me to wait thank god.

I can see out west with the fuel mapping problem everybody is blowing motors with all the altitude changes they are trying to get a class action law suite against Polaris for all 800 owners.
www.snowwest.com (http://www.snowwest.com)

[indyxcr]

sorry www.snowest.com (http://www.snowest.com) sorry my fault!

[Firecatguy]

friends did not remap their sleds and everyone of them &#34;4&#34;sleds have 70psi pto side

and we live here in the LOW ALTITUDE...

[indyxcr]

Talked to the dealer in Wisconsin, no recall on 800 IQ or 800 Dragon. The problem is the single ring breaking on the piston. The 2010 models will have 2 rings, so Polaris is testing this and will have a answer to fix the piston with a double ring. Some 800 sleds are perfect and others are locking up, the new reflash will lean out the motor and run alot better.

The il dealer I talked to today also said the same thing piston rings breaking leading to motor locking up.

Polaris has a 2 year warranty on the 800 IQ and 800 Dragon, so we are covered for all of 2009 and 2010.

What it looks like Polaris will have the dealer inspect all 800&#39;s this fall and check the piston and rings, if bad replace piston and rings.

Polaris also claims the reflash did not cause the pistons to fail, some pistons are defective, is what they are finding out.
So it is a gamble some 800&#39;s are good for thousands of miles, others blow up under thousand miles.

There has not been a recall so far on the 800 IQ or 800 Dragon, everybody who says so is full of BS!

If so prove it!

[Firecatguy]

indyxcr
did you get your motor yet?

[grub]

Pol has the 2010 800 right. They have been testing all summer on some glacier in Iceland. The new 800 will have a two ring piston. It makes more power than the single ring piston and it stays together. If your &#39;09 hasn&#39;t locked up tight but if you are missing 2-3 hundred rpm&#39;s you probably stuck a ring at some point. If you have an &#39;09 you should keep harping on your dealer until you get a new and improved top end. The only ones that didn&#39;t blow were the ones with super low miles. Those folks should also get updated. The stock &#39;09s are time bombs. When you get updated get it in writing from your dealer or Pol or your resale will be affected. I had the same problem when I bought an &#39;01 800 Cat. There was a recall on the pistons that year. When I went to trade it the first question they asked was if the recall had been done. It gets to be a bunch of b.s. that the average customer shouldn&#39;t have to go through but that is how it is.

[whitedust]

I feel bad for you Poo 09 800 guyshttp://www.johndee.com/discuss/clipart/sad.gif What a mess to wade thru! Poo snomo div. can not afford another massive engine failure. Rush has to be huge 1st year gamble too lucky they limited production on Rush as could be another big problem for them.

[snoughnut]

Grub you don&#39;t know what the <font color="ff0000">•</font><font color="ff0000">•</font><font color="ff0000">•</font><font color="ff0000">•</font> you&#39;re talking about, some &#39;09 800&#39;s have 3 - 4000 miles on them and all &#39;08 - &#39;09 800&#39;s will be updated to 2010 specs, Polaris already announced it. Polaris will also be giving an additional year on the warranty. New 2 ring pistons, cylinder heads and new mapping, some sleds will get a new silencer also.

[jeff]

OK GUYS I WANT TO SET THE RUMOR MILL STRAIGHT! I called my local poo dealer today and he told me it will be by the end of august that ALL poo 800 sleds will get new double ring pistons,heads,and reflash,as well as anything else needed to correct the problems that have occured. Regaurdless of the miles! so bacically a new engine with warranty. NO questions asked! The only diff. between the 2010 800 and 2009 800 will be the exhaust. The revised 800 will once again be a force to be reconned with!<font color="ff0000">•</font><font color="ff0000">•</font><font color="ff0000">•</font><font color="ff0000">•</font><font color="ff0000">•</font><font color="ff0000">•</font>

[crskidoo]

You polaris guys need a three wolves howling at the moon t-shirt. That will fix all of your issues. It worked for me.

[jeff]

what does that mean?

[crskidoo]

sorry its a joke. Must be local, the three wolves shirt it pretty dumb actually.. If you haven&#39;t heard of it no biggy.

[vx700xtc]

I miss 2- strokes. &#40;not&#41;

[jeff]

I love my two-stroke! 200ccs less than the four strokes and I can still smoke-em

[indyxcr]

Both the 800 Dragon and 800 IQ only needed the latest reflash I was lucky engine is perfect. And the heavy rear springs for the sleds is a must also it will be a rocket this year! After last year it was about to go off the cliff.

I also think the 600 RUSH will be a big disappointment to people compared to the 600 Dragon.

[zimmbob]

Spoke to my dealer. Change outs of all 800&#39;s is starting next week. Or ordering the parts is anyway. The issue, according to them, was back-presure. Too much, depending on how the rider was driving, was causing an over heat of the exhaust port and piston, and creating all the issues. Anyone who put a can on it right away, likely didn&#39;t have problems. And driving habbits also had a factor. Thus why some are good, and some are bad. But all are covered.

[Firecatguy]

zimmbob
my friend put a can on his dragon 800 right out of the box and his motor was loss of psi first ride out last dec, it died twice then ran like crap. he had that motor rebuild and then it lasted till march and lost psi in pto side AGAIN.

[jeff]

single ring piston is to blame.

[2buckchuck]

Talking to my buddy with his 800, Polaris was telling him it was because the motor was missing 2 strokes, plus it stinks when it runs. http://www.johndee.com/discuss/clipart/happy.gif Just kidding, but those extra strokes sure add reliability!

By the way can 2-strokes make back pressure with the pipe not the can...

Cheers,
Ralph

[Firecatguy]

&#34;The Recall is out new piston,head and reflash
Let the games begin letter to mailed to consumer Sept 9 2009&#34;


right out the polaris dealers lips

[jeff]

got a call today from my dealer. Parts are in for the engine upgrade. taking mine in this week!

[coach]

How big of a job will this be? Any idea of how long it will take to finish the overhaul? &#40;Providing they can do it w/o interuptions&#41;

Thanks

[jeff]

done in one day also installing an slp can FREE of charge! Complements of polaris!

[indyxcr]

The new 2 ring pistons and new heads and a new reflash for the 800&#39;s Polaris will be replacing this fall for all the 2009 800&#39;s with a extra 1 year warranty on the motor witch means the next 2 winters. Most of the problems the dealer said was when people used poor gas up in the UP or some old gas stations in Wisconsin and this caused the single ring piston to fail this happen to me years ago in the Up with bad gas 10 miles down the railroad grade problems!

The down side is that it will take all day for 1 or 2 800&#39;s to be done if there is no problems with the old pistons coming out!
I&#39;m going to get both the 800 dragon and 800 IQ done in October.
Polaris lost sales this year because of this screw up this last year with the 800&#39;s.

[indyxcr]

One more thing the plugging and unplugging the wires due to different blends of gas did not retard the motor like it should have, and they did not have the right reflash for the the 800&#39;s
and they should have had 2 ring pistons from the start, Polaris should have had this right from the start!!!
Hopefully this winter everyone will have there 800 run like it should have. If not its gone..

[2buckchuck]

indy-
should the doo 800 have 2 rings too? What does 2 rings do for you instead of one?

[zimmbob]

Just got letters today about the replacement process. Posted a copy here for all to see. Glad to see they are doing the right thing.

http://www.johndee.com/discuss/messages/6/114285.jpg
http://www.johndee.com/discuss/messages/6/114286.jpg

[indyxcr]

I don&#39;t know about ski-Doo sleds but the rare case of heat if you run the sled hard alot causes the single ring to maybe fail the 2 ring piston should take extreme heat without a failure.
I have no problem with my 2009 800 IQ and 800 Dragon but the dealer said replace the pistons to be on the safe side the parts are $1,000&#43; per sled Polaris has to pay for it plus an extra year warranty and a new reflash the dealer does all of this should run faster and a higher top end when I have the new reflash done in October. The 800 sleds produce alot more heat than my 700 Polaris sled ever did!

[indyxcr]

You better have your dealer order the parts for your 800&#39;s fast, they told me they will not have the parts until Nov 16th! Polaris needs to get there act together.

[btmik11x]

I have an Assault that I am taking in for warranty work. I am wondering what everyone is paying for the SLP can. My dealer told me around 200 and I see Jeff got his for free. I do not consider $50 off a substantial price reduction as stated in the recall letter. Any response appreciated.

[whitedust]

Polaris is doing the RIGHT THING with this recall. Painful I know but Poo did not always do the the right thing just discountinued engines. I hope this works out ok.

[indyxcr]

I also heard about a new silencer in the exhaust?? This is for all 800&#39;s thats what the dealer told me when he gets the parts in the middle of Nov hopefully sooner.

[catlin72]

I read on Snowest that the SLP can was $125 extra. There is some very good infornation on there about changing out the stock exhaust and what to use if you do. If you are planning on running anything accept stock can or SLP can, read the thread in forum under polaris IQ sleds.

[ubee]

Is it legal to run anything but a stock exhaust in wisconsin? maybe thats why they are charging xtra for the can?

[indyxcr]

Unreal still alot of people like me waiting for 800 rebuild kits for 800&#39;s 6 of us still waiting 3/4 of the 800 kits still on backorder they should be all shipped by this weekend thats what Polaris said????

Maybe 1 to 2 inches of slushy snow Wednesday night, central IL 1 to 3 inches ST. Louis MO, and west, this year we will have to go south, I can&#39;t beleive it Dec 1st no snow in northern WI, lakes not frozen we should have 6 to 12 inches hope it changes fast!