Discover the Ultimate Guide on How to Change Spark Plug RZR 800 – Step by Step Instructions

The RZR 800 is a powerful and thrilling machine, but like any engine, it requires regular maintenance to keep it running smoothly. One of the most essential tasks is changing the spark plugs. Worn-out spark plugs can lead to decreased performance, rough idling, and even engine misfires. This comprehensive guide will walk you through the process of changing spark plugs on your RZR 800, ensuring you get back to conquering the trails with maximum power and efficiency.

Gather Your Tools and Supplies

Before you begin, make sure you have all the necessary tools and supplies at hand. This will make the process much smoother and prevent any unnecessary delays. Here’s a list of what you’ll need:

• New spark plugs: The correct spark plug for your RZR 800 is a **NGK CR8E or equivalent**. Ensure you purchase the correct type and quantity.
• Socket wrench: A 5/8-inch socket wrench is required to loosen and tighten the spark plug.
• Extension bar: An extension bar will help you reach the spark plugs in the rear cylinders.
• Torque wrench: A torque wrench is crucial for tightening the spark plugs to the correct specification (15-18 ft-lbs).
• Gloves: Protect your hands from dirt and grime.
• Safety glasses: Always wear safety glasses to protect your eyes from debris.
• Shop towel: Use a shop towel to clean the area around the spark plugs.
• Optional: A spark plug gap tool, if you need to adjust the gap on the new spark plugs.

Locate the Spark Plugs

The RZR 800 has two cylinders, each with its own spark plug. The spark plugs are located on the top of the engine, near the cylinder heads.

• Front cylinder: The front cylinder spark plug is easily accessible on the right side of the engine, near the front of the RZR.
• Rear cylinder: The rear cylinder spark plug is located behind the front cylinder, accessed from the left side of the engine.

Disconnect the Battery

Before you start working on any electrical components, it’s crucial to disconnect the battery. This prevents accidental electrical shocks and ensures your safety.

1. Locate the battery: The battery is usually located under the driver’s seat or in the front storage compartment.
2. Disconnect the negative terminal: Use a wrench to loosen the negative (-) terminal clamp and remove it from the battery post.

Remove the Old Spark Plugs

Now that you have the battery disconnected, you can start removing the old spark plugs.

1. Clean the area: Use a shop towel to clean the area around the spark plugs, removing any dirt or debris.
2. Loosen the spark plugs: Place the socket wrench over the spark plug and use it to loosen the plug. Be careful not to overtighten or strip the plug.
3. Remove the spark plugs: Once the spark plugs are loose, use the socket wrench to remove them completely.

Inspect the Old Spark Plugs

Before installing the new spark plugs, it’s essential to inspect the old ones for any signs of wear or damage. This will help you determine if the spark plugs were the cause of any performance issues.

1. Check the electrode gap: The electrode gap should be between 0.030 and 0.035 inches. If the gap is too wide or too narrow, it can affect engine performance.
2. Inspect for wear: Look for signs of wear on the electrodes, insulator, or shell. If the electrodes are worn down or the insulator is cracked, the spark plug needs to be replaced.
3. Check for fouling: If the spark plug is covered in carbon deposits, it may be fouled. This can be caused by a variety of factors, such as using the wrong fuel or a rich fuel mixture.

Install the New Spark Plugs

Once you’ve inspected the old spark plugs and are ready to install the new ones, follow these steps:

1. Install the new spark plugs: Carefully thread the new spark plugs into the cylinder heads. Do not overtighten them at this stage.
2. Tighten the spark plugs: Use the torque wrench to tighten the spark plugs to the correct specification (15-18 ft-lbs). Overtightening can damage the spark plugs or cylinder head.
3. Reconnect the battery: Once the new spark plugs are installed, reconnect the negative (-) terminal to the battery.

Start the Engine and Check for Issues

After you’ve installed the new spark plugs and reconnected the battery, start the engine and check for any issues.

1. Listen for any unusual noises: The engine should run smoothly without any unusual noises.
2. Check for misfires: If you hear any misfires or the engine runs rough, double-check that the spark plugs are properly installed and tightened.
3. Inspect the spark plugs: After a few minutes of running, shut off the engine and inspect the spark plugs again. Make sure they are not loose or damaged.

Final Thoughts: Maintaining Your RZR 800’s Spark Plugs

Changing spark plugs is a relatively straightforward task, but it’s essential to follow the proper steps to ensure that the job is done correctly. By regularly inspecting and replacing your spark plugs, you can keep your RZR 800 running at peak performance and enjoy countless hours of thrilling off-road adventures.

What You Need to Know

What is the recommended interval for changing spark plugs on a RZR 800?

The recommended interval for changing spark plugs on a RZR 800 is every 25,000 miles or 2 years, whichever comes first. However, you may need to replace them sooner if you notice any signs of wear or damage.

What are the signs of a worn-out spark plug?

Signs of a worn-out spark plug include:

• Decreased engine performance
• Rough idling
• Engine misfires
• Difficulty starting the engine
• Increased fuel consumption

Can I use any type of spark plug for my RZR 800?

No, it’s crucial to use the correct type of spark plug for your RZR 800. Using the wrong spark plug can damage the engine or cause performance issues.

What happens if I overtighten the spark plugs?

Overtightening the spark plugs can damage the spark plugs or the cylinder head. It’s essential to use a torque wrench and tighten the spark plugs to the correct specification.

What should I do if I encounter difficulties while changing the spark plugs?

If you encounter any difficulties while changing the spark plugs, it’s best to consult a qualified mechanic. Attempting to fix the problem yourself could lead to further damage.