Washers under head bolts????

[paramuir]

I was reading a topic on another forum about guys loosing anti-freeze. One guy on there mentioned that when the 05 900 came out the head bolts were abit too long to get the proper torque and some of them were leaking and allowing coolant into the engine. Some are fine some arent...

Has anyone on here herd of this and has anyone added the washers?

 

[LUBA]

Yes I added the washers. It was a team tip from polaris.

 

[paramuir]

size?? thickness?? can you show me some pics....

 

[skibreeze]

I would not add washers under any circumstances. If the bolts were bottoming out a slight bit, I would grind them down. I honestly doubt that this is the issue though. If it leaks, I would put a very, very small amount of pipe sealanton the head of the bolt and it should fix it right up.

 

[paramuir]

mine seems to be good now..not leaking..but just wondering about this because as i mentioned some other guys on another forum were talking about it

 

[jsledder]

I thought the washer "update" was for the cylinder to case bolts?

 

[CompFusion]

The problem was not with the head bolts but rather the cylinder bolts that hold the cylinder to the crankcase. Adding the washers to the cylinder bolts will do no harm even when leakage is not an issue. They are 10mm flat washers....3/8" will be too tight.

 

[paramuir]

ahh i see sorry my mistake, then what is the benefit to this if you arent having any problems...

 

[Super Dave3]

I thought the washer "update" was for the cylinder to case bolts?

That is correct. The problem was some cases didnt get drilled and tapped deep enough, so the cyl bolt would bottom out before reaching the proper torque. Polaris highly recommended that if you ever replaced the case to install the eight washers. Part # is 7556234.

 

[paramuir]

ahh to bad i didnt know this last season when i replaced both pistons.....bah...

 

[welb]

It is pretty easy to do.Just remove one bolt at a time,add washer,loctite,and re-torque.

 

[paramuir]

ya but first you have to pull the heaed off to get at them correct?

 

[Super Dave3]

ya but first you have to pull the heaed off to get at them correct?

Yeah you have to remove the cyl head to get at the cyl bolts.

 

[paramuir]

well this might become a next summer job....and the list begins...lol

 

[motonoggin]

?

Anybody know if the 2006's had this issue as well???

I'm missing a bit of antifreeze and gonna have the motor out soon to swap in compfusions motor mounts, so now is a good time to fix this.

 

[motonoggin]

Anybody know if the 2006's had this issue as well???

I'm missing a bit of antifreeze and gonna have the motor out soon to swap in compfusions motor mounts, so now is a good time to fix this.

Anybody?

 

[Super Dave3]

Anybody know if the 2006's had this issue as well???

I'm missing a bit of antifreeze and gonna have the motor out soon to swap in compfusions motor mounts, so now is a good time to fix this.

If I remember right, Polaris recommended that anytime you had the cyl bolts out to install the washers.

 

[mountainhorse]

Dave... I belive you have a good memory!

 

[jsledder]

I'm sure you've seen this in the tips.... but just in case.

Team Tip S-05-09-02 Reminder: 2005 900 Cleanfire Engine Cylinder Bolt Washer Addition
The possibility exists where the bores drilled for the cylinder bolts in the upper crankcase may not have been
drilled deep enough or metal shavings may be at the bottom of the bore(s). When this occurs, the cylinder bolt
clamp force is reduced even while the desired cylinder bolt torque has been reached.
The primary symptom is a white-carbon build-up on one spark plug metal casing wall.
If this symptom occurs, Polaris recommends the following action:
1. Drain the engine coolant.
2. Remove the cylinder head. Discard the o-rings.
3. Loosen and remove the cylinder bolts. Install a washer, PN 7556234, on each bolt. Re-install the cylinder
bolts and torque to 34 lb.ft. (46 Nm) following the torque sequence in the service manual.
4. Re-install the cylinder using new o-rings and fasteners. Follow the recommended torque specifications and
torque sequences in the service manual.
5. Re-fill the cooling system. Bleed the air out of the system and test.
Polaris recommends the washers, PN 7556234, be added to the cylinder bolts WHENEVER the engine is
removed or re-built for any reason.

 

[paramuir]

what do they mean by this?? Like inside the spark plug hole or on the outside of the cylinder?

"The primary symptom is a white-carbon build-up on one spark plug metal casing wall."