Broken Intake Boot Bolt!!!

Jonce · Sep 9, 2009

Same thing happened on my '07 RMK 600, 3 of the bolts snapped off. The dealer had to pull the engine and drill them out (warranty work). They were not going to do it at first but I argued that there is no reason for red loctite. They told me I should have heated the bolts up first before removing. I said "that would be a great idea but tell me how I'm supposed to do that without melting rubber intakes boots?" It turns out that they saw my post on here and wanted to send out a Polaris rep to see me sled and take pics at the dealership.

If you don't have a welder as stated, pulling the engine isn't so bad. It's pretty easy and its also a good time to clean up the engine compartment. Judging from the red dirt, it looks like you ride up in Michigan.

crix · Sep 9, 2009

Hey jack If you want a hand pulling the motor let me know Also I may have a hook up for a welder if need be

Let me know I have pulled 900's out a few times

jafraune · Sep 9, 2009

Clint, thank you for the offer....I may be needing it....

Tonight I am going to try to propane torch it out of there....so if that doesnt work I may be giving you a call if thats cool.

Thanks for the responses everyone..seems like Im not the only one with this problem.

I will use the new "thanks" feature for everyone lol.

crix · Sep 9, 2009

no problem If I dont answer leave a message we will get it out of there

jafraune · Sep 9, 2009

Jonce said:
Same thing happened on my '07 RMK 600, 3 of the bolts snapped off. The dealer had to pull the engine and drill them out (warranty work). They were not going to do it at first but I argued that there is no reason for red loctite. They told me I should have heated the bolts up first before removing. I said "that would be a great idea but tell me how I'm supposed to do that without melting rubber intakes boots?" It turns out that they saw my post on here and wanted to send out a Polaris rep to see me sled and take pics at the dealership.

If you don't have a welder as stated, pulling the engine isn't so bad. It's pretty easy and its also a good time to clean up the engine compartment. Judging from the red dirt, it looks like you ride up in Michigan.

Sounds like this could turn into a little project....

I have never ridden THIS sled in Michigan but others...

A good time to clean it is...

trikerider · Sep 9, 2009

If you have a Dremel tool or a hacksaw you can try putting a groove in it and use a plain screwdriver to turn it out.

jafraune · Sep 9, 2009

crix said:
no problem If I dont answer leave a message we will get it out of there

ok sounds good clint. I will let you know....:beer;

Jack

skibreeze · Sep 9, 2009

trikerider said:
If you have a Dremel tool or a hacksaw you can try putting a groove in it and use a plain screwdriver to turn it out.

If he snapped a 10mm head off, it's not coming off w/o heat and torque.

jafraune · Sep 9, 2009

There is no way on gods green earth that bolt is coming out of there!!! I torched the sh*t out of it as much as could with my little propane torch with no success....what a pain in the as*....

So I guess next is to weld a nut on there or pull the engine....

AKSNOWRIDER · Sep 9, 2009

MacDawg productions said:
I'm not sure, I would like to use blue as well when my motor goes back in. I guess they are important bolts, but red is overkill I think. Any thoughts guys?

I would use blue if your going to use any at all..the red is designed to be permanent..where as the blue is designed to be more replacement friendly...I know the 9's vibrate quite a bit but I have always put all my 8's togeather without any locktight...which ever you use, make sure you spray some brakleen in the holes and blow out good to remove all the old locktight or you may have more broke bolts on assembly...

AKSNOWRIDER · Sep 9, 2009

jafraune said:
There is no way on gods green earth that bolt is coming out of there!!! I torched the sh*t out of it as much as could with my little propane torch with no success....what a pain in the as*....

So I guess next is to weld a nut on there or pull the engine....

weld the nut..it will come right out..if it does twist the nut off weld another on..remember..the weld wont stick to the aluminum..also make sure you start removing it as soon as the nut looses the orange glow...once removed and cooled down use a fine tooth file to smooth down any rough spots on the aluminum....

skibreeze · Sep 10, 2009

AKSNOWRIDER said:
I would use blue if your going to use any at all..the red is designed to be permanent..where as the blue is designed to be more replacement friendly...I know the 9's vibrate quite a bit but I have always put all my 8's togeather without any locktight...which ever you use, make sure you spray some brakleen in the holes and blow out good to remove all the old locktight or you may have more broke bolts on assembly...

Exactly, I have also had so much crap left over inside the holes (differential holes) that I ran a tap through to clean the threads.

IMO, everyone who wrenches on stuff needs to have tap and die sets. I just have the harbor freight sets for close to ten years now with few issues at all.

MacDawg productions · Sep 11, 2009

Any word on the nasty little bolt?

jafraune · Sep 11, 2009

MacDawg productions said:
Any word on the nasty little bolt?

Its stuck....tried heating it up several different times with no success. So i will be doing the welding trick. Hopefully I can take care of this soon. I talked to Crix on the phone the yesterday, he is going to help me pull it and weld, and we are aiming for Sunday. I will update with pics.......Jack

MacDawg productions · Sep 11, 2009

****ty. Nothing a case of beer and a sunday afternoon/night tinker time session can't fix!

jafraune · Sep 23, 2009

UPDATE:

So even with the welder the bolt still broke...motors off to the machine shop....

POLZIN · Sep 23, 2009

jafraune said:
UPDATE:

So even with the welder the bolt still broke...motors off to the machine shop....

If I can help Just let me Know

jafraune · Sep 23, 2009

POLZINHUNTER said:
If I can help Just let me Know

Thanks POLZIN, actually I havent been working on the sled too much myself...I have to give the credit to crix, he has done 99% of the work....but I think he knows a place that can get this done..so I think we will be ok. But I do apprieciate it a lot. :beer;

So it will probably be another week before its together again...oh well snows not falling to hard...

Jack

MacDawg productions · Sep 24, 2009

painful project. Sorry to dude.

mcfly13 · Sep 24, 2009

when i worked in a machine shop we had some stuff from a company called goodson
was a wax stick that looked like a pencil
you would heat up the stubborn bolt then melt this stuff in and walla the bolt would usually come out

Broken Intake Boot Bolt!!!

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