BIG THANKS goes out to my friend Mark - SLEDDUDE - for helping me today put a new top end on my 05 900 166 with 4,780 total miles on it. For the complete back-story, please check out these threads here.....
Stripped head bolt
Time to rebuild it!
We tore the motor down this morning in the sled... it was so nice not having to dismantle the entire sled for this task as is necessary on the 06 models. Everything went very smooth and there weren't any problems with the process, but we did get a BIG surprise when we opened her up! As you recall the ONLY reason I decided to tear it down was for the coolant leak, otherwise my original plan was to run it 1 more season before doing a top end job. Boy am I glad we opened it up at 2,700 miles instead of waiting for 3,000 or more!!!!!
I have a 'deal' that I have made with my 900---- "If you treat me good, I will treat you good"---- never has that been more true than in the following picture, my 900 sure did treat me good holding together for me over the last 4 seasons that I have owned her, I'm glad that I timed it just right in showing her some 'love', lol.
MAG piston....
The piston is cracked all the way to the bottom of the lower ring land all the way through... you can see daylight through the bottom portion when you hold it to the light!!!
PTO piston looked just fine and both cylinders looked to be in great shape aside from my 1 stripped thread.... No scoring or cracks on either cylinder.
Getting the new pistons in and the newer cylinders installed. Install was done with all brand new gaskets everywhere.
We cleaned all the old loc-tite off the head bolts and installed them with new loc-tite and torqued to spec. VERY GLAD to say ALL bolts torqued to spec without any problems!!!!!
Lastly we completed the rebuild with fresh exhaust gaskets sandwiched with copper high-temp gasket maker and then refilled the coolant and elevated the front before firing the sled up. I'm glad to say it started on the 3rd pull and after smoking like a locomotive from all the oil we squirted everywhere, we burped the coolant system and put her back in the garage to await next season.
All that's left to do in the fall is put in a fresh fuel filter, primary and secondary clutch springs, change the chaincase oil, and mix a quart of oil in the gas for the first ride. I know the injection is set at 28:1 already, but I want those suckers drenched in oil for break in!!!
Stripped head bolt
Time to rebuild it!
We tore the motor down this morning in the sled... it was so nice not having to dismantle the entire sled for this task as is necessary on the 06 models. Everything went very smooth and there weren't any problems with the process, but we did get a BIG surprise when we opened her up! As you recall the ONLY reason I decided to tear it down was for the coolant leak, otherwise my original plan was to run it 1 more season before doing a top end job. Boy am I glad we opened it up at 2,700 miles instead of waiting for 3,000 or more!!!!!
I have a 'deal' that I have made with my 900---- "If you treat me good, I will treat you good"---- never has that been more true than in the following picture, my 900 sure did treat me good holding together for me over the last 4 seasons that I have owned her, I'm glad that I timed it just right in showing her some 'love', lol.
MAG piston....
The piston is cracked all the way to the bottom of the lower ring land all the way through... you can see daylight through the bottom portion when you hold it to the light!!!
PTO piston looked just fine and both cylinders looked to be in great shape aside from my 1 stripped thread.... No scoring or cracks on either cylinder.
Getting the new pistons in and the newer cylinders installed. Install was done with all brand new gaskets everywhere.
We cleaned all the old loc-tite off the head bolts and installed them with new loc-tite and torqued to spec. VERY GLAD to say ALL bolts torqued to spec without any problems!!!!!
Lastly we completed the rebuild with fresh exhaust gaskets sandwiched with copper high-temp gasket maker and then refilled the coolant and elevated the front before firing the sled up. I'm glad to say it started on the 3rd pull and after smoking like a locomotive from all the oil we squirted everywhere, we burped the coolant system and put her back in the garage to await next season.
All that's left to do in the fall is put in a fresh fuel filter, primary and secondary clutch springs, change the chaincase oil, and mix a quart of oil in the gas for the first ride. I know the injection is set at 28:1 already, but I want those suckers drenched in oil for break in!!!
