New pistons in 05 900, question

[Sxrlar]

OK, so I took my buds 05 900 apart last night. At the end of last season we noticed that the mag side piston had some pretty good scoring on it. The cylinder on that side does have some scoring also, will get new replated one from Millenium Technology's this week. Here is my question, we are going to replace both pistons/rings, but the PTO side cylinder looks fine, as does the piston. Should he get that cylinder replated also? Money is an issue with this job. I am thinking get the bad cylinder replaced, leave the PTO side, and put in the new pistons and rings. What's everyone's thoughts?

By the way I snapped off the nipple on the coolant bottle that the throttle body coolant line runs to. So I have to get a new one of those, think I will go with the 09 one, and remove the radiator also. Did the research on that last night. This forum rocks for the 900 owners by the way.

Also, the fat boy frenchy oil/throttle cable I put on last year is the cats ***! Love being able to get the throttle bodies out of the way easily!

 

[BIGGDAWG]

i would run the old cylinder with new piston if the cylinder looks ok. have done that on many a sleds and has worked for me. make sure to check the throttle body boots for cracks maybe leaking some air causing lean on the mag cylinder.

and yes this 900 section rocks!!

 

[Sxrlar]

Thanks Biggdawg, did the throttle body boots last year when I did the fat boy frenchy oil/throttle cable.

 

[donbrown]

Go with the Polaris pistons and no other after market. The Polaris piston is redesigned.

If money is an issue consider using the old cylinder BUT I think an exchange is only $235 for a refurbished cylinder?

 

[Sxrlar]

Just pulled the pistons off the connecting rods a little bit ago, very glad we are doing this. The mag side psiton skirt is cracked, no visible cracks in the PTO side. I will post pics later.

Initially he wanted to do both cylinders and pistons, but with the PTO side looking good, we will just replace the mag side cylinder.

He has definitly had his share of issues with this thing, that 900 torque must be very addicting, he isn't ready to give up on it. LOL.

Thanks guys.

Of course, since I do all the wrenching, for free, why would he give up on it? LOL.

 

[guidoxpress]

FYI..

you cannot use the 09 coolant bottle on the 05 900, ONLY on the 06 900....it mounts differently..

i am pretty sure everyone has busted this nipple off the bottle..first time i opened the hood on mine and moved something..BAM..broke off...great design do you think

 

[BIGGDAWG]

FYI..

you cannot use the 09 coolant bottle on the 05 900, ONLY on the 06 900....it mounts differently..

i am pretty sure everyone has busted this nipple off the bottle..first time i opened the hood on mine and moved something..BAM..broke off...great design do you think

Well Sean, not everybody has broke that nipple off

 

[ghostwhite]

Well Sean, not everybody has broke that nipple off

 

[guidoxpress]

Well Sean, not everybody has broke that nipple off

YET!!!

 

[BIGGDAWG]

YET!!!

lmao!!

 

[SLDHVN]

YET!!!

Sean and his nipples...

 

[Sxrlar]

Ya know usually I like long hard nipples, but not in this case! LOL. Thanks for the heads up Guido on the coolant bottle, I didn't look at the microfiche until after I posted. I then saw that I have to use an 05 bottle.

Here is a pic of the cylinder and the crack in the skirt on the piston. I wonder how much longer that piston would have lasted?

 

[AKSNOWRIDER]

if you reuse the old cylinder...run a nicasil hone thru it..otherwise you may end up low on compression on that side after engine is back togeather....

 

[diamonddave]

FYI..

you cannot use the 09 coolant bottle on the 05 900, ONLY on the 06 900....it mounts differently..

i am pretty sure everyone has busted this nipple off the bottle..first time i opened the hood on mine and moved something..BAM..broke off...great design do you think

Guys....Things like this happen to those who launch their sleds into the back of their new trucks.

 

[guidoxpress]

Guys....Things like this happen to those who launch their sleds into the back of their new trucks.

HA!!

man with you, and Polzinhunter..i will never forget this..well, and if the wife didnt bring it up at least 1x a week...minimum..

Thanks Dave...where the hell you been..

Regardless...if you smack a truck, tree or an outhouse (i forsee that next )...a $10K sled "new", should hold up to something

 

[happyfast79]

Ya know usually I like long hard nipples, but not in this case! LOL. Thanks for the heads up Guido on the coolant bottle, I didn't look at the microfiche until after I posted. I then saw that I have to use an 05 bottle.

Here is a pic of the cylinder and the crack in the skirt on the piston. I wonder how much longer that piston would have lasted?

what intake is he using on his sled? stock, fire n ice, timber sled?

 

[Sxrlar]

Stock intake

 

[Super Dave3]

I am sure I dont have to mention this but I am going to anyway. If your using a 05 service manual they have you putting the pistons in backwards. Make sure that the transfer port and piston ring locating pin is away from the exhaust port.

 

[mountainhorse]

ttt for ya John

 

[Mech Engr]

pistons

Another tradegy avoided thanks to Mountainhorse and Superdave3!!

I hate the 05 Polaris manual!!! If Honda made a mistake like showing you to put the pistons in backwards they would have sent a tech memo and a new page for the manual pronto!!

I should have listened to my instincs that told me the arrow always goes towardes the intake (and exhaust) in the 900's case. Oh well, just another hours taking it back apart and turning the pistons around.

Thanks,

John