The Polaris Dragon 800, a snowmobile known for its powerful engine and aggressive styling, carved a significant path in the snowmobiling world during its production years. However, like any machine pushing the boundaries of performance, the Dragon 800 wasn't without its quirks and potential issues. Understanding these common problems is key for owners looking to maintain, repair, or even consider purchasing one of these iconic sleds. Knowing what to watch out for can save you time, money, and potentially a frustrating experience out on the trails.

So, What Were the Dragon 800's Biggest Headaches?

The Dragon 800, while a blast to ride, developed a reputation for certain mechanical vulnerabilities. While not every Dragon 800 owner experienced all of these issues, they were prevalent enough to warrant attention. Let's dive into some of the most frequently reported problems.

Piston Woes: The Heart of the Matter

The 800 Liberty engine, the heart of the Dragon, was notorious for piston failures. This was arguably the most significant and well-documented problem. Several factors contributed to this, including:

  • Lean Fuel Mixture: The fuel injection system, particularly in earlier models, was prone to running lean, especially at higher RPMs. A lean mixture generates excessive heat, leading to piston overheating and eventual failure.
  • Poor Piston Design: Some believe the original piston design itself was a contributing factor. The pistons were perceived as being less robust than those used in previous Polaris engines.
  • Detonation: The lean fuel mixture and high compression ratio of the engine made it susceptible to detonation, a destructive form of combustion that can quickly damage pistons.
  • Insufficient Oiling: Some users reported inadequate oil delivery to critical engine components, further exacerbating the heat and friction issues.

The Fix: Addressing the piston issue involved a multi-pronged approach:

  • Fuel Mapping Adjustments: Dealerships offered updated fuel maps to richen the mixture, particularly at higher RPMs. Aftermarket fuel controllers also became popular for fine-tuning the fuel delivery.
  • Piston Upgrades: Many owners opted for aftermarket pistons, often forged pistons, known for their increased strength and durability. These pistons are better able to withstand the stresses of the 800 Liberty engine.
  • Proper Jetting (for Carbureted Models): For the carbureted versions, meticulous jetting adjustments were crucial to ensure the correct fuel-air ratio.
  • Oil Pump Adjustment/Verification: Ensuring the oil pump was delivering the correct amount of oil was essential. This included checking the oil pump cable adjustment and verifying oil pump output.

Crankshaft Concerns: Another Engine Weak Point

Closely related to the piston problems were issues with the crankshaft. When a piston failed, debris could damage the crankshaft bearings, leading to premature wear and failure. Even without piston failure, some Dragon 800 owners reported crankshaft issues.

The Fix:

  • Regular Inspection: Regularly inspecting the crankshaft for play and wear is essential.
  • Crankshaft Balancing: When rebuilding the engine, having the crankshaft balanced is highly recommended.
  • High-Quality Bearings: Using high-quality crankshaft bearings during a rebuild can significantly improve the engine's longevity.
  • Addressing Piston Issues First: Preventing piston failures is the best way to protect the crankshaft.

Electrical Gremlins: A Common Headache

The Dragon 800, like many snowmobiles, could suffer from various electrical problems. These could range from minor annoyances to more serious issues that could leave you stranded.

  • Voltage Regulator Failure: The voltage regulator, responsible for maintaining a stable voltage to the electrical system, was known to fail. This could lead to battery problems, headlight issues, and other electrical malfunctions.
  • Stator Issues: The stator, which generates electricity for the snowmobile, could also be a source of problems. Symptoms of a failing stator include weak or no spark, dim headlights, and difficulty starting.
  • Wiring Harness Problems: The wiring harness, particularly in areas exposed to vibration and the elements, could develop shorts, breaks, and corrosion.

The Fix:

  • Thorough Inspection: Regularly inspect the wiring harness for signs of damage.
  • Proper Grounding: Ensure all ground connections are clean and secure.
  • Voltage Regulator Replacement: If the voltage regulator is suspected, replacing it with a known good unit is the best course of action.
  • Stator Testing: A multimeter can be used to test the stator's output.
  • Dielectric Grease: Applying dielectric grease to electrical connections can help prevent corrosion.

Fuel System Foibles: Beyond the Lean Mixture

While the lean fuel mixture was a major contributor to engine problems, the fuel system itself could also present challenges.

  • Fuel Pump Issues: The fuel pump could fail, leading to fuel starvation and engine stalling.
  • Fuel Injector Problems: Fuel injectors could become clogged or malfunction, affecting fuel delivery.
  • Fuel Line Cracking: Fuel lines, particularly those exposed to the elements, could crack and leak.

The Fix:

  • Fuel Filter Replacement: Regularly replace the fuel filter to prevent contaminants from entering the fuel system.
  • Fuel Injector Cleaning/Replacement: Fuel injectors can be cleaned or replaced if they are suspected of malfunctioning.
  • Fuel Line Inspection: Inspect fuel lines regularly for cracks and leaks. Replace any damaged lines immediately.
  • Fuel Pump Testing: A fuel pressure gauge can be used to test the fuel pump's output.

Suspension and Chassis Concerns: Handling and Durability

Beyond the engine, the Dragon 800's suspension and chassis were also subject to certain issues.

  • Weak Suspension Components: Some owners reported issues with the suspension components, such as shocks and springs, wearing out prematurely.
  • Chassis Cracking: In some cases, the chassis could develop cracks, particularly in areas subjected to high stress.
  • Steering Issues: Steering components could wear out, leading to loose or sloppy steering.

The Fix:

  • Regular Maintenance: Regularly lubricate suspension components and inspect them for wear and damage.
  • Shock Rebuilding: Rebuilding shocks can restore their performance and extend their lifespan.
  • Chassis Reinforcement: If cracks are detected in the chassis, welding and reinforcement may be necessary.
  • Steering Component Replacement: Replace worn steering components to restore proper steering feel.

Living with a Dragon: Tips for Minimizing Problems

Owning a Dragon 800 doesn't have to be a constant battle against mechanical failures. By taking proactive steps, you can significantly reduce the risk of problems and enjoy the sled's performance.

  • Pre-Season Inspection: Before each riding season, perform a thorough inspection of the entire snowmobile. This includes checking the engine, fuel system, electrical system, suspension, and chassis.
  • Regular Maintenance: Adhere to the manufacturer's recommended maintenance schedule. This includes changing the oil, greasing fittings, and inspecting critical components.
  • Proper Fuel and Oil: Use high-quality fuel and oil that meet the manufacturer's specifications.
  • Warm-Up Procedure: Allow the engine to warm up properly before engaging in aggressive riding.
  • Listen to Your Sled: Pay attention to any unusual noises or vibrations. These could be early warning signs of a developing problem.
  • Don't Ignore Warning Lights: If a warning light illuminates, investigate the cause immediately.
  • Consider Upgrades: Upgrading certain components, such as the pistons, can improve the engine's reliability.
  • Find a Knowledgeable Mechanic: If you're not comfortable performing repairs yourself, find a mechanic who is familiar with the Dragon 800 and its potential issues.

Frequently Asked Questions About the Polaris Dragon 800

  • Why did the Dragon 800 have so many engine problems? The lean fuel mixture and potentially weaker piston design contributed to overheating and piston failures. Detonation and insufficient oiling further compounded these issues.
  • Are all Dragon 800s prone to piston failure? While not every Dragon 800 will experience piston failure, it was a common problem, especially in earlier models. Addressing the fuel mapping and considering piston upgrades can significantly reduce the risk.
  • What's the best way to prevent electrical problems on a Dragon 800? Regularly inspect the wiring harness, ensure proper grounding, and apply dielectric grease to electrical connections. Replacing the voltage regulator proactively can also be a good idea.
  • Is the Dragon 800 worth buying as a used snowmobile? With proper maintenance and upgrades to address known weaknesses, a Dragon 800 can still be a fun and capable snowmobile. However, be prepared for potential maintenance and repair costs.
  • What are some common upgrades that improve the reliability of the Dragon 800? Upgrading to forged pistons, adjusting the fuel mapping, and ensuring adequate oil delivery are all common and effective upgrades. Adding a fuel controller can also help fine-tune the fuel mixture.

The Dragon's Legacy: A Powerful, but Demanding Ride

The Polaris Dragon 800, despite its reputation for certain mechanical issues, remains a popular and desirable snowmobile for many riders. Its powerful engine and aggressive styling offer a thrilling riding experience. However, prospective owners should be aware of the potential problems and be prepared to address them through proper maintenance, upgrades, and a proactive approach.