There’s nothing that kills a perfect day on the trails faster than a sputtering engine or the sudden, unnerving smell of gasoline. When your RZR starts acting up, it’s easy to suspect the engine, but the real culprit is often hiding in plain sight: the fuel system.
We’ve all been there. You’re miles from the truck, and your machine starts losing power on a climb. You’re wondering if you have a serious problem on your hands. We promise that by the end of this guide, you’ll have the confidence and knowledge to diagnose, maintain, and even replace your 2008 Polaris RZR 800 fuel tank and its components.
In this ultimate guide from FatBoysOffroad, we’re going to break down everything you need to know. We’ll cover the common problems that plague these fuel systems, provide a step-by-step guide for inspection and removal, and share some pro tips to keep your RZR running strong for years to come. Let’s get those wrenches turning.
Understanding Your RZR’s Fuel System: More Than Just a Tank
Before you can fix it, you need to understand how it works. The fuel tank on your 2008 RZR 800 isn’t just a plastic container; it’s the heart of a system responsible for safely storing and delivering fuel to your engine. Knowing the key players makes troubleshooting a whole lot easier.
Key Components of the Fuel Delivery System
Your RZR’s fuel system is a team effort. Here are the main parts you’ll be dealing with:
- The Fuel Tank: On the 2008 model, this is a durable, molded plastic tank with a capacity of 7.25 gallons (27.4 liters). Its job is to hold the fuel and house the pump assembly.
- The Fuel Pump Assembly: This is the workhorse. It sits inside the tank and includes the electric fuel pump, a pressure regulator, a fuel level sending unit, and a primary fuel filter (often called a “sock”).
- Fuel Level Sending Unit: This component has a float that moves up and down with the fuel level, telling your fuel gauge how much go-juice you have left.
- Filler Neck and Cap: This is where you add fuel. A properly sealing cap is crucial for preventing leaks and maintaining system pressure.
- Vent Lines: These lines allow air to enter the tank as fuel is used and allow fuel vapors to escape, preventing a vacuum or excessive pressure buildup.
Common Problems with the 2008 Polaris RZR 800 Fuel Tank (and How to Spot Them)
Over time and with rough use, even the toughest parts can fail. The fuel system on the early RZR 800s has a few known weak points. Here are some of the most common problems with the 2008 Polaris RZR 800 fuel tank you might encounter.
The Dreaded Fuel Leak
A fuel leak is a serious safety hazard that you must address immediately. The smell of raw gas is your first and most obvious clue.
Look for leaks around the large sealing ring where the fuel pump assembly mounts to the top of the tank. These seals can dry out and crack over time. Also, inspect the tank itself for any cracks, especially around the mounting points where vibration can cause stress.
Clogged Fuel Pump or Filter
This is one of the most frequent causes of poor performance. Symptoms include the engine sputtering under load, struggling to start, or a noticeable loss of power.
Dirt, debris, and water can get into your tank from contaminated fuel cans or just from riding in dusty, muddy conditions. This gunk gets sucked up and clogs the fuel pump’s pre-filter sock, starving your engine of fuel.
Faulty Fuel Gauge
Is your fuel gauge stuck on full, stuck on empty, or jumping around erratically? The problem is almost always the fuel level sending unit inside the tank.
The electrical contacts on the sending unit can wear out or get corroded, leading to inaccurate readings. While not a critical failure, it’s incredibly frustrating not knowing how much range you have left on a long trail.
Fuel Tank Venting Issues
If you hear a loud “whoosh” of air when you open your gas cap, you likely have a blocked vent line. The tank needs to breathe. A clogged vent can create a vacuum, making it hard for the fuel pump to draw fuel, which can lead to engine stalling.
Conversely, a different type of blockage can cause pressure to build up, which can stress the tank and seals, potentially causing leaks.
How to Inspect and Remove Your 2008 Polaris RZR 800 Fuel Tank: A Step-by-Step Guide
Ready to get hands-on? This 2008 Polaris RZR 800 fuel tank guide will walk you through the process safely. Take your time, stay organized, and always prioritize safety.
Safety First! Before You Begin
We can’t stress this enough: you are working with gasoline. It is extremely flammable. Follow these rules without exception.
- Work in a well-ventilated area, preferably outdoors or with a garage door wide open.
- Disconnect the negative terminal of your battery before you do anything else.
- Have a Class B (or ABC) fire extinguisher within arm’s reach.
- Do not smoke, create sparks, or have any open flames nearby. This includes pilot lights on water heaters or furnaces.
- Wear safety glasses and nitrile gloves to protect yourself from fuel splashes.
Tools and Supplies You’ll Need
Having the right tools makes the job much smoother. Gather these before you start:
- Socket and ratchet set (metric)
- Screwdrivers (Phillips and flathead)
- Pliers (standard and needle-nose)
- Siphon pump or fluid extractor
- DOT-approved fuel container
- Clean rags or shop towels
- A lock ring tool for the fuel pump (or a brass punch and hammer as a careful alternative)
Step-by-Step Removal Process
- Access the Tank: Start by removing the driver and passenger seats. Then, you’ll need to remove the center plastic console that sits between them. This is usually held in with a few screws and plastic push-pins.
- Drain the Fuel: This is the most important step for safety and for making the tank light enough to handle. Use a siphon pump to transfer as much fuel as possible from the tank into your approved fuel container.
- Disconnect the Lines: Carefully disconnect the filler neck hose and the vent lines from the top of the tank. You may need pliers to release the hose clamps. Place a rag underneath to catch any residual fuel drips.
- Unplug the Electrics: Locate the main electrical connector going to the top of the fuel pump assembly. Press the release tab and pull it straight off.
- Disconnect the Fuel Line: This line is under pressure. Wrap a rag around the connection point before disconnecting it to catch any spray. There is usually a quick-disconnect fitting here.
- Remove the Tank Straps: Your tank is held in place by one or two metal straps bolted to the frame. Use your socket set to remove these bolts.
- Lift the Tank Out: With everything disconnected, you should now be able to carefully maneuver the tank and lift it out of the RZR frame. Be mindful of catching any remaining hoses or wires.
Benefits of Proper Fuel System Maintenance
Following a good maintenance routine offers huge payoffs. Thinking about the benefits of 2008 Polaris RZR 800 fuel tank care isn’t just about fixing problems—it’s about preventing them and improving your ride.
Trail-Ready Reliability
The biggest benefit is peace of mind. A clean fuel system with a healthy pump means you can hit the trails with confidence, knowing your machine won’t leave you stranded due to fuel starvation.
Restored Performance and Efficiency
A clogged filter or weak pump robs your engine of power and can hurt fuel economy. By ensuring your engine gets a consistent, clean supply of fuel at the correct pressure, you restore the crisp throttle response and power your RZR had when it was new.
Enhanced Safety
This goes without saying. Regularly inspecting for and fixing fuel leaks is one of the most critical safety checks you can perform. It protects you, your passengers, and your machine from the risk of fire.
2008 Polaris RZR 800 Fuel Tank Best Practices: A Care Guide for Longevity
Your fuel system will treat you well if you treat it well. This 2008 Polaris RZR 800 fuel tank care guide is all about simple, preventative habits. Following these tips will save you headaches and money down the road.
Use High-Quality Fuel and Stabilizer
Always use fresh, high-quality fuel from a reputable station. If your RZR is going to sit for more than a month, treat the fuel with a quality stabilizer to prevent varnish and gum from forming and clogging your system.
Keep Dirt Out During Fill-Ups
Before you even open the gas cap, wipe the area around it with a clean rag. This simple step prevents the dirt, dust, and water collected on your plastics from falling directly into your fuel tank. It’s one of the easiest 2008 Polaris RZR 800 fuel tank tips to follow.
The Sustainable & Eco-Friendly Approach
Proper maintenance is inherently green. A sustainable 2008 Polaris RZR 800 fuel tank system is one that doesn’t leak raw fuel into the environment. By ensuring your engine is burning fuel efficiently, you also minimize emissions. Taking care of your equipment is taking care of the trails we all love to ride.
Frequently Asked Questions About the 2008 Polaris RZR 800 Fuel Tank
What is the fuel capacity of a 2008 Polaris RZR 800?
The standard fuel tank capacity for the 2008 Polaris RZR 800 is 7.25 U.S. gallons, which is equivalent to 27.4 liters.
How do I know if my RZR’s fuel pump is going bad?
Common signs of a failing fuel pump include the engine sputtering or bogging down under acceleration, difficulty starting, a noticeable loss of top-end power, or a constant whining noise coming from the fuel tank area.
Can I repair a cracked plastic fuel tank on my RZR?
While plastic welding kits and epoxies for fuel tanks exist, we strongly advise against it for a permanent fix. Given the vibrations and stresses of off-roading, a repair is likely to fail. For safety and reliability, replacement is always the best and safest option.
Why does my RZR smell strongly of gas, especially after a ride?
A strong gasoline smell is a major red flag. It could be something simple like a loose gas cap, but it could also indicate a saturated charcoal canister, a leaking fuel line connection, a bad fuel pump seal, or a crack in the tank itself. You should stop riding and inspect the entire system immediately.
Your RZR’s fuel system is a critical part of every adventure. By understanding how it works, what can go wrong, and how to care for it, you’re not just performing maintenance—you’re investing in future fun and reliable performance. Now that you have the knowledge and the steps, you can tackle any fuel system issue with confidence.
Stay safe, get those hands dirty, and we’ll see you out on the trail!
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