Mountainhorse: Nov 21 2006, 08:50 AM
The 800R
WILL loosen the exhaust bolts on the new ones just like the old 800's. They use the same fastners as the older 800's. This is especially true if you have disturbed them by removing them or periodically tightening them. A lot of the dealers are aware of the issues with the exhaust bolts and "checking" each one trying to avoid warranty issues and are making the problem worse by disturbing the bolts.
DO NOT USE LOCKTITE RED ON THESE FASTENERS!!! If you ever have to remove these you will have a mother of a time getting them out and will probably strip out the threads on the cylinders. Locking compounds on the soft aluminum of the threads around the exhaust ports is asking for trouble when removal time comes around (damaged Y-pipe, cylinder work, etc).
Use the
NORDLOCK washers to secure these bolts. They will not fatigue with the heat and actually hold tighter when they get hot. They are resuable, easy to assemble and dissasemble and are not affected by oil.
There is no need to safety wire on the bolts especially with how tight it is in there. It makes threading and twisting the siezing wire a pain. Aircraft "allens" are pretty hard to find in M6 sizes but you can always drill your own with a bunch of cobalt bits if you have to go this route.
Change out the bolts to stainless steel socket cap screws [M6 x 20mm] and use the silver (nickle based) anti sieze on the threads so you dont have to deal with corrosion problems down the road as all exhaust bolts look like shyte after a while. This compound will not give you corosion problems. Don't use copper antisieze on the threads as this will promote galvanic corrosion with the aluminum and steel or stainless steel.
You can order all of these fasteners and the ball hex driver that will keep you from teaching your kids new words(***#@^&&&*###) when you try to remove the old ones and install the new. You can get them from
McMASTER CARR The following are McMaster Carr part numbers. Anyone can order these parts with a credit card over the phone or online.
Nordlock washers for M6 Part #91812A229=> $8.49 for 10 pair (enough for 1 sled)
316 stainless steel M6x20 1mm pitch Part #92290A326 => $7.30 per pack of 25 (3 sleds)
Nickle antisieze compound Part #10295K29 => $5.54 for 1/4 oz tube (4 sleds worth)
5mm extra long 3/8 drive ball-hex driver
Part # 54185A23 => $13.48 each
You may be saying to yourself (since sledders are some of the cheapest bastiges on the face of the earth, me included) that that is some serious money for little washers and bolts... but these things
ABSOULETLY work and will keep you riding and not wrenching. Go in on this stuff with your friends with 800's if you feel the need. If you've ever dropped anything under the motor on the REV's or RT's you will see the value in these "expensive" parts.
I have to give credit to REV*BARON for turning me on to these issues and the solution.
