800r owners!!! Check your Y-pipe bolts!!!

[chazzer]

Just doing a once over on my xp and seen black sludge all over the front of my moter. After checking the 8 bolts I found one gone, 5 loose, and 2 were snug.

I removed the pipe and Y-pipe, changed all bolts and gaskets. I used a 5mm allen socket with around 14" of 1/4" extensions. Made removing and installing the y-pipe easy.

Just thought i'd let yall know!

Chaz

 

[spadoo]

bolts

use nordlock washers ,before you retighten. your best off to replace the bolts also . fastenal is a supplier of the nordlocks. good luck

 

[BigRed118]

Check with SkippyH20 on here. He has the nordlocks.

 

[elvis69]

i had the same thing on my 05. just got new bolts and lock tight

 

[wweverett]

MIne came loose on the trail (best place to work on sled friends have to help) I lost a couple bolts and blew the gasket apart pulled it off removed the rest of the gasket and reinstalled now I keep a close eye on it. To bad I didn't read a post like this two months ago.

 

[chazzer]

Sorry dude. Wish I KNEW 2 months ago.

Good idea to check em once in a while.

Chaz

 

[wweverett]

Half the fun of riding is drinking bee.....er soda and fixing a machine. As long as you get it fixed and don't have to go home.

 

[enis750]

Norlock washers are the answer dudes
mine came loose after every ride...until i insatlled the Norlocks
even w just locktite, they cameloose..and then the loctite gets all gooey in the threads and you will have a hard time properly threading your "new" bolts in

google FASTENAL in your area and order them up
i keep a few spare bolts AND Nodlocak washers in my tool kit
you know for when a "buddy" looses one or two...oh yeah and there $30 a bolt and $30 per washer!! ha ha ha ha

now i only check them every 3 rides and they still havent budges and no stupid oil leaking on the front of your engine

 

[Skidoox]

Pickup a set of long ball end sockets from Harbor freight. They make the job much easier.

 

[BlackSummit]

Are these all 08's or are the 09's also having this problem?

 

[BC-XP]

Are these all 08's or are the 09's also having this problem?

and '07's & '06's

 

[sledhed]

and '07's & '06's

And the 02's... lost some of mine once too, ended the ride for the day since I did not have the right size allen wrench along... ever since then tightening them is one of my maintenance items.

 

[cjgodden]

Its been a problem since 2001, and doo can't seem to get the hint. NORDLOCK washers will fix the problem...They are starting to try different bolts, the 09 600's have a larger bolt but if they came with the nord's problem would be solved.

 

[wyoscott]

Mine came loose on 06 rev. Gasket went bad too and replaced it and used the nordlock washers. Fastenal has em I think it was 11 bucks or thereabouts for 25 washers but worth it since you can do three sleds The ball tip 5 mm sockets are the way to go I. had to cut the end off a 5mm ball tip allen wrench and used a 1/4 inch drive ratchet with.5mm socket and extension No more problems with loose bolts

 

[Unklsnomobile]

another solution

My bolts fell out the first ride after my 500km checkup last year. Blew the gasket out too. I let the dealer replace them, and the next ride they were loose at 85km. So we tightened them up when the motor was smokin hot. It's not fun and Markoo still has the burn scars to prove it, but they did stay tight the rest of the year. Thanks Markoo. I have the nordlock washers now just incase they come loose again.