Rebuild order?

[Icefishr]

ok guys this is my first rebuild and im doin a 2005 900 RMK 166" with my uncle. sled came already torn apart as a friend of ours started into it but didnt have time to finish it.

i was just wondering if there was a specific order you follow when rebuilding these sleds from the bottom up. we are not powdercoating or anything just putting the parts back in after we rebuild the engine and get a new crank in it since the guy before us blew the stock one.

as of now the only parts still in the sled are the electrical wiring, the chaincase, steering system, track, along with the front and rear suspension. Pretty much all other parts are out of the engine compartment.

Any help would be greatly apprectiated. i have also been diggin through the past posts in the forum taking notes of recommended updates and things to do while the sled is torn apart. just tryin to figure out what order to do them in

thanks
Alex

 

[guidoxpress]

oh man,

dont have time to get into this one.

but real fast and simple inputs..

ONLY use 06 OEM pistons

only use 06 front and rear motor mounts

check your reed pedals carefully for chips and replace is worn at all

replace your throttle body boots with new ones and cover the new ones with heat reflective tape to protect them from heat from exhaust.

do not pull on any wiring harness, they will break inside insulation, same with being gentle using zip ties..

are you starting with all new parts? what are you reusing from the old engine?

find out why the old engine blew...

locktite everything and torque it to specs..

download the 05 service manual

make sure the dot on the OEM pistons faces the exhuast port

bleed the oil line and pump, new oil/fuel filters

balance your primary

i can go on for days..

 

[Icefishr]

hey i appreciate your reply.

i was lookin more for what order do you suggest putting the parts back in the sled in. i have read several threads about the updates such as the pistons and motor mounts etc. we will be attempting to use the original engine and it blew due to no oil being put in by a previous owner. a bushing on the crank failed and caused one of the pistons to crack slightly. Not near as bad as it coulda been but still a blown engine.

my main thing is since i didnt take the sled apart i didnt get to take not of what order things came out of the sled in order to get to where it is now (empty).

any suggestions on that?

thanks again!

 

[guidoxpress]

oh i know what you were asking for..but its one of those things where there SOOO muc info and so many ways to do it, that people dont wanna take the time and walk you through it. including myself..

did you get an 05 deep sno service manual...

basically assemble the motor, install front crossmember, when its complete, leave 2 lower recoil bolts off..set the motor in the bulkhead gently, put the 2 lower bolts on the front crossmember only that way it will support the engine and you can rotate it fwd to get behind motor to work there first, (put in ALL grade 8 motor mount bolts), connect oil hose from tank to oil pump NOW, route stator wiring through by coolant tank, put on the PINA rear water pump coolant hose, route injector/DET/TPS wiring and lay motor back, put in rear motor mount bolts, upper front cross member bolts (torque everything and use red locktite, start wiring it up by the ECU, connect the oil hose from above engine to the connection on the oil tank (must go between cylinders, and pre fill hose with oil)

all wiring should be connected now, as well as the 2 oil lines...

now connect the oil pump cable...i HOPE you have the FBF cable, do not use the stock oiler cable..

after oil cable is installed, line up the 2 marks on the oil pump lever to the oil pump housing, must have tension on the cable, so must be installed to the throttle bodies and the throttle lever

now bleed the oil pump using the front bleed screw on the pump, do it for 20 seconds or so...now connect a piece of wire to oil pump lever and route it to the clutch side, when you first start the sled, you will need to pull this wire to fully bleed oil lines from air bubbles, after 20 secs idling with lever wide open, wiggle this wire off the pump

install throttle bodies, instake, exhaust, hood harness, ect ect..

make sure you mix oil in your gas for first tank (like 50:1) and then always run 100:1 in your tank forever..trust me, thats on top of your stock oil injection..

stock up on plugs too, lol.

hopefully someone else will chime in...ahem...ZANE

im off to sled...!!!!!!!!!!!!!

 

[Icefishr]

haha wow man that was one heck of a run down. thanks! that is exactly what i needed. i will be using the fbf cables and 06 pistons updated motor mounts etc. we are even looking into a tm1 crank for a little extra peace of mind.

i really appreciate you taking the time to type all that up its gonna help alot. right now im workin on a way to register the sled once we get it done then we will be diggin in and hopefully be done by winter

if anyone else has anything to add im open to any tips or advice i can get. we are in for one h#ll of a project here. gonna need new lower plastics and dash along with the handlebar adjustment piece (broke off i guess?)

thanks again!!

 

[guidoxpress]

are you anywhere near Waverly Iowa??

my buddy Bruce (Biggdawg) on the forum lives there and he is a master mechanic and knows this sled the same if not better then me

you could send him a PM and see if he can help you out..he is a great guy

 

[05900]

Take your time and do not force anything ( of course) Ck wiring while engine is out for rubbing,chafing etc. Now is the time to secure it and protect it.
You may want to replace TPS harness etc now also. You can ck routing and slack around gas tank and steering post.
Easy to clean now!
Read stickies for setting TPS etc while out and accessible?

 

[Icefishr]

will do. thanks guys.

Guido: I live in Estherville IA in the Northwest corner of the state just east of the Iowa Great Lakes. Waverly is about 3 hours from here to the South and east.

i really do appreciate the info and cant wait to get into this sled and hopefully ride it in the winter.