RUNNING LIKE CRAP, ONCE AGAIN!!
- Thread starter MacDawg productions
- Start date
M
MacDawg productions
Well-known member
Just spoke to indy dan, and he is sending out a new gasket kit. So I will be putting in new base gasket, o rings, and hope fully that should do it. 20hrs on this motor. Hurtin!
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M
MacDawg productions
Well-known member
So boys, should I pull the motor, or can I conveniently replace a base gasket with the motor in? It's an 05. Will there be enough clearance to rotate the pistons forward to get the cylinder off to replace the base gasket? I'm going to throw new o rings in at the same time.I really don't want to pull the motor, because It's been out, and after 20hours of riding,there is no need to check the motor mounts etc....blah blah blah. You know the story. What cha all thinkin?
the cylinders on the 05 can be pulled with motor in...but i think the 06 cant...
good luck man..
good luck man..
This is correct. No-go on the 06's, go on the 05's.
Base gasket leaking...Check your upper crankcase/cylinder gasket surfaces VERY CLOSE. I just repaired a repeat offender that someone had rebuilt 3 times by an expert for base gasket leaking and found that when the motor had been apart, at some point, the rod must've jammed itself into the upper crankcase surface putting a huge bulge/burr on the leading edge probably while turning over the crank/pistons without the cylinders on. It was real evident in this case what was causing the issue. There was zero retention of the cylinder/gasket when removing the jug. The leaking cylinder simply lifted off by hand without a love tap. The other/good cylinder needed it's love tap. This bulge/burr of the upper crank case sealing surface to clylinder that retains the base gasket to the bottom of the cylinder wasn't allowing full contact of the surface of the cylinder thus allowing coolant to enter the engine.
Flat stoned, installed anerobic sealant, re-assembled, torqued to spec, it's now fixed.
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M
MacDawg productions
Well-known member
Which gasket surface Dave, the base gasket surface?
Correct. I guess I left that out. Typically when removing cylinders, I always seem to have tap them with a soft faced hammer to break that seal from the base gasket. This particular jug simply lifted right off after the 4 nuts were removed.
The nice thing about using the Anerobic sealant in conjunction with the base gaskets (prefer the oem Metal ones from Polaris BTW) is the sealant will make up for any possible low spots on the sealing surfaces of the upper crankcase to cylinder surface. It will also resist vibration, stress, and flexing. Other kinds of sealants do not provide this type of sealing retention.
Also check/measure those bolt lengths very closely. I would think that probably was addressed but I would make sure.
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M
MacDawg productions
Well-known member
What about the injectors? Do they need to be unbolted at the back before lifting up on the cylinders?
On the 05's the injectors go into the case only, that is what allows you to pull the jugs on an 05 and not an 06 while the motor is still in the chassis.
M
MacDawg productions
Well-known member
On the 05's the injectors go into the case only, that is what allows you to pull the jugs on an 05 and not an 06 while the motor is still in the chassis.
Ofcourse! Thanks Seth. I guess the 06 have 2 in the case, and two in the cylinders? Where as the 05 just have 2, and they are in the case. I just thought that the top of the supported fuel lines bolt into the back of the cylinder. I guess not. I'm just mentally preparing myself, so when the gasket kit comes in this week, I won't loose any sleep!!
NO they are on the cases
M
MacDawg productions
Well-known member
Update for you guys. Finally got the gaskets in , and put her all back together. Using some anerobic sealant on the upper crankcase/cylinder surfaces with new base gaskets and new orings. She started on the 2nd pull. Stoked!! Went for a ride yesterday, and she pulled real hard. Leaving the two xps, stuck on a steep hill climb. Lol!! I gave them a hand getting out, but only after I high marked right between them!! Checked the plugs multiple times, and they look great. Thanks again for helping me get my 900 dialed in this year. It's finally running amazingly, but with only a few weeks of riding left, time to put her away for the summer. Truly depressing.
Good to hear, must have had a gasket leaking somewhere.
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