Early 08-10 RZR 800's were notorious for having leaking fuel tanks. The main area everyone has problems with is the area where the fuel pump bolts to the tank. The flange is notorious for leaking because the tank is a poor design. There is a solution though. It works better than the OE tank, it's WAY better made (tougher) and it holds more fuel than the OE tank (7 vs 9 gallons). The solution is made by Trail Tank.

I installed one in my 2008 RZR 800 and love it. They say you might have to enlarge the pump flange holes but I did not have to. I did have to cut the engine cover but that was easy and simple. I got it installed in about 1 hr. Now I have no leaks (no risk of fire!) and it holds 2 gallons more fuel. The only slight negative I have found is the fuel gauge isn't accurate any more. When it says it's empty, it actually has about 4 gallons left.

I have no link to this company. Just a satisfied customer.

https://www.trailtank.net/product-pa...r-800-rzr4-800