Oil Pressure relief valve stuck

Jeepbeav · Nov 17, 2019

My in-laws have the dreaded 2011 ranger 800xp it had a reman engine in it that ate the cam and lifters. I was able to replace that from the passenger side after removing the the gas tank. No I’m trying to repair mod the oil relief valve but I can’t get it out. I used a step bit and drilled it all the way through the motor mount for easy access now and in the future. I have tapped on it and tried using a magnet. And I have saturated it two nights in a row with WD-40. I have even started it and can’t get it out.
So I’m stuck with thinking about a left handed bit or something like that. I have already ordered a pack of 4 small block Chevy head pins that so many have recommended. But I still have to get this one out.
And obvious question if it was out it would leak oil from there correct? Especially when running??
It will run with out the y-pipe but I’m not sure I want to do that forever. Any help would be appreciated. Only 300 hrs on reman engine. But new cam lifters injectors and plugs from EBay

Rangerwhit · Dec 5, 2019

Any luck yet? Ready to put it on the shooting range yet?

Jeepbeav · Dec 5, 2019

Nope and nope. Next option is to have buddy put a stainless stick welder rod in there and see if we can slide hammer the rod and dowel out. Also on the hunt for half a case. As this one is going to be junk if this doesn’t work. Pm me if you have one

RJ · Dec 5, 2019

Just be sure to unhooked the ecu before hitting it with the welder.

Jeepbeav · Dec 5, 2019

For sure plus battery disconnected. Case set on eBay for $159. Is that a good price

BPS · Dec 5, 2019

Looks like Polaris sells the crankcase as a kit - $900.

Rangerwhit · Dec 5, 2019

How much are the oem's going for. China stuff is iffy if is the case. Whoever remanufactured it for the inlaws might have gone that route. You must love that bride!

Jeepbeav · Dec 5, 2019

It’s a used Polaris unit https://rover.ebay.com/rover/0/0/0?mpre=https://www.ebay.com/ulk/itm/293359094080

moser64 · Jan 10, 2020

so im having this same issue, did you ever get yours out??? and if so how did you do it?? another question is once you get it out what do we do to solve the problem? clean it and polish it and polish the inside bore? or keep it removed? ay info would be greatly appreciated. thanks

Jeepbeav · Jan 10, 2020

I have not got it out. I have tried everything but a very high end machinists drill bit and last resort will be using a welding rod and hoping it sticks enough without damaging the soft aluminum wall

moser64 · Jan 11, 2020

So what are we suppose to do to fix our problem once we get it out? Does anybody know?

Jungleman · Jan 11, 2020

moser64 · Jan 11, 2020

thank you i will try this soon

moser64 · Jan 11, 2020

update! ok i got mine out like the video, then i have a couple of machinst buddies i asked for there input on how to shave the oem dowel down from .800 mm to around .793 mm because i would like a little more oil psi than 4 psi on idling, and what we did was put it in a drill with about 3/4 of it sticking out used 600 grit sand paper and spun the drill till it measured .793 mm and flipped it in the drill and did it again to the other side. and the results after installing everything were 18 psi idling and around 60-62 psi wide open throttle with the engine warmer up for about 20 minutes of riding. im very satisfited with my results and will let you know the longevity of this fix, once again thanks for all the help ad input this site is amazing, thanks again

moser64 · Jan 15, 2020

I have a buddy with a 2018 900xp i think it's doing the same thing. Does anybody know if the oil pressure relief valve are the same designs as the 800s and 900s? Thanks

Jungleman · Jan 15, 2020

Mose, never heard of it happening to a 900 ...........0r a 700 for that matter.Only the 800's.

Oil Pressure relief valve stuck

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