My 4K mile maintenance job

[94fordguy]

So I've had my 900 for 2 seasons now and knock on wood she's treated me pretty well, but it's time for a check-up. With some noticeable vibration and belt heat issues last season I knew it was time for motor mounts and with stubborn Y-pipe bolts that did not want to stay tight I was leaking oil all over the place... and that also gunked up my factory oiler cable to the point it was sticking open at idle or at least very slow to return

So Saturday Mark and I tore into the old girl (that has just a touch under 4K miles total on her now - 2K on a complete motor rebuild) and gave her a bit of a face-lift.......

I'm just glad the EPA wasn't nearby to see all the oil covering EVERYTHING, lol.......

Here's some pics of the 12 hours worth of fun we had Saturday

The dis-assembly begins with Mark pulling the pipe!

And the Engine is out!

Stupid oiler cable and Gaskets.....

Much better now.....

Brand new '06 Motor Mounts all the way around

Old mounts...

And the motor is back in the chassis

We got everything hooked up that we could - Tank, plastics, all the connections behind the motor, etc... Just need to order a new oil cable, torque stop, and fuel filter and then I can get her closed up and breathing fire again...

 

[94fordguy]

Oh ya, Pistons, Jugs, and Throttle Body boots all look great... What a P.O.S.

 

[dktraw]

looks good. get to do the same to the wifes 755 here in a week or so! not looking forward to all the cleaning, but it will be worth it in the end. its got over 3400 miles all stock with no issues, knock on wood as well.

 

[heavy d]

Good stuff, tnx for the pix

 

[donbrown]

Now is a good time to put a zirc fitting in the jack shaft bearing

 

[Z-Man]

Why you still running the stock oiler cable that every 900 has problems with doing exactly what you described? I had mine in the shop three ties because the cable was sticking in in the first 1500 miles and it wasn't because of oil leaks because my engine was clean as can be at the time.

 

[donbrown]

Why you still running the stock oiler cable that every 900 has problems with doing exactly what you described? I had mine in the shop three ties because the cable was sticking in in the first 1500 miles and it wasn't because of oil leaks because my engine was clean as can be at the time.

He ordered one from me and it did not fit. So my bad. Still trying to get a deal on them ... in the mean time motionpro can get one in a couple weeks.

 

[94fordguy]

Why you still running the stock oiler cable that every 900 has problems with doing exactly what you described? I had mine in the shop three ties because the cable was sticking in in the first 1500 miles and it wasn't because of oil leaks because my engine was clean as can be at the time.

Basically because my cable lasted 4K miles with no issues till now and my dealer can get a new one for me before the end of the week so I can ride this weekend. I may pick up a motion pro in the future, but keep in mind that my sled has 4K miles on it and it isn't going to last forever when I put 1K miles/yr on......

 

[hdkawi]

thanks for the pics just put a new engine back in mine nice to see an outher sled apart with pics that point out what i have been reading on here for weeks
now it's all starting to make sence. there is a lot of good info on here.fired
mine up third pull just have to do a few odd parts to finish up

 

[Z-Man]

I have one sitting outside in my trailer but it is the longer one and I want to swap it with the one on my sled that has 3 rides on it.

 

[Newfusion900]

Now is a good time to put a zirc fitting in the jack shaft bearing

Haven't heard of this before. Would love to hear the details, I'm always up to do more updates on my sled.

 

[donbrown]

Haven't heard of this before. Would love to hear the details, I'm always up to do more updates on my sled.

The bearing behind the secondary clutch which aligns the jackshaft and is the initial load bearing from the clutch HAS NO WAY TO GREASE IT.

So you can pull the shaft and replace the bearing with a factory installed grease fitting or you can drill and put one into the existing bearing.

If you want to pull the jackshaft and replace the bearing .... MOUNTAINHORSE wrote a procedure along with part numbers to perform the mod.

 

[Newfusion900]

I was wondering about that because I believe the repair manual tells you to remove the secondary to grease the bearing but I could never find the fitting. Some pics and details of where to drill would be nice. Thanks.

 

[94fordguy]

Success!

The 900 lives again!!!!!!!!!

She fired up on the 6th pull.... then died and ran great on the 7th pull... no trouble codes, no odd sounds... purred like a kitten

Finally got my parts in... a lot later than expected but oh well....

New factory Oil Cable and Torque stop

Oil cable attached and set to factory spec

Throttle Bodies all cleaned up

Almost there..... Dang this thing is CLEAN now!!!!!!

New Y-pipe gaskets and bolts

SHE'S ALIVE!!!!!

 

[94fordguy]

All that is left to do is bleed the coolant system and I'm going to run some oil in the gas tank to help insure no damage if there are any air bubbles in the oil lines.

Can't wait to ride!

 

[BROX]

Looks Good, nice job. You headed out this weekend? Based on the weather it looks like Friday is the day, I am hoping to get out for the first ride.

 

[caboussleman]

where did you get that front bumper? that thing is nice i really like it.

 

[94fordguy]

Looks Good, nice job. You headed out this weekend? Based on the weather it looks like Friday is the day, I am hoping to get out for the first ride.

Thanks! I'm not sure, I really want to... just have to see if my riding buddies want to.

where did you get that front bumper? that thing is nice i really like it.

Thanks! That is a Skinz bumper... I purchased it from Sled Solutions 2 years ago}

 

[VTMTcowboy]

Really cool post! I love the 900's, good to see people still repping them!

 

[Z-Man]

Where do I get a cool Snowest sticker like that to put on my windshield?