Crack in front bulkhead/ frame. Need ideas.

F

FLASH1970

Free Member

Jan 14, 2009

133

10

18

41

• Aug 30, 2009

• #1

Greetings all. I started looking at the sled and pulling things apart to do the radiator delete and found this...

So, my question would be... What's the easiest way to fix it? Replace it? Weld it? Do I need to pull the engine to fix it? Maybe just pull the throttle bodies to get enough room to weld...

Any help would be much appreciated. Thank you.

 

C

CompFusion

Well-known member

Dec 10, 2005

133

62

28

Newfoundland, Canada

• Aug 30, 2009

• #2

Thats the front cross-member. It has cracked from the steering cutout up through to the top. It's only about a $40 piece to replace. You will have to lift the engine though.

 

E

Ex-Member

ACCOUNT CLOSED

Mar 14, 2007

45,084

1,681

113

• Aug 30, 2009

• #3

Eh, if you know a welder in town that can do aluminum, i'd just repair it. Maybe plate it up to reinforce the weld area, but you should be okay repairing it.

 

KSH

Steering Wheel Holder

Staff member

Lifetime Membership

Mar 22, 2005

3,774

1,857

113

56

Larkspur, CO

• Aug 30, 2009

• #4

FLASH1970 said:

Greetings all. I started looking at the sled and pulling things apart to do the radiator delete and found this...

So, my question would be... What's the easiest way to fix it? Replace it? Weld it? Do I need to pull the engine to fix it? Maybe just pull the throttle bodies to get enough room to weld...

Any help would be much appreciated. Thank you.

Click to expand...

Completly remove the motor, and replace the cross member.

While you have the motor out, completly check out the bulk head for any cracks.

 

F

FLASH1970

Free Member

Jan 14, 2009

133

10

18

41

• Aug 31, 2009

• #5

Anyone know where I can get a repair manual? I've found a couple but they all say for 2005 Polaris 900's and I know there are some changes for the 06's.

 

KSH

Steering Wheel Holder

Staff member

Lifetime Membership

Mar 22, 2005

3,774

1,857

113

56

Larkspur, CO

• Aug 31, 2009

• #6

The 05 that you can down load will get you through pulling the motor and reinstalling, "the changes in this area small" until you can find a 06.

 

F

FLASH1970

Free Member

Jan 14, 2009

133

10

18

41

• Aug 31, 2009

• #7

KillSwitchHitter said:

The 05 that you can down load will get you through pulling the motor and reinstalling, "the changes in this area small" until you can find a 06.

Click to expand...

Where can I download this manual? Thanks in advance.

Nevermind. I found it.

 

Last edited: Aug 31, 2009

A

Aussie Niko

Well-known member

Jan 10, 2008

638

91

28

Fallscreek, Austraila, Truckee,Lake Tahoe, USA.

• Aug 31, 2009

• #8

Replace it , welding cast alloy will never be as strong and to do a good weld it would need to come out and be prepaired and cleaned.

 

H

happyfast79

Free Member

Nov 26, 2007

545

26

28

37

gillette, WY

• Sep 7, 2009

• #9

niko said:

Replace it , welding cast alloy will never be as strong and to do a good weld it would need to come out and be prepaired and cleaned.

Click to expand...

the cross member isnt cast, but yeah replacing it would be the best option and check your motor mounts when you have it out and replace the cross member bolts with grade 8 or 10 bolts when you put it back in.

 

H

High Velocity

Well-known member

Nov 27, 2007

1,050

497

83

61

Hinton, Alberta

• Sep 10, 2009

• #10

My crossmember broke last season. Being an extruded piece, I think it is actually weakened quite a bit by the notch cut in for the steering linkage. I made my own from 3/4" X 3" 6061 solid flat bar. It took a fair bit of time making sure all measurements were dead-on to ensure proper belt alignment, but I feel it's significantly stronger than the factory piece. So far, no cracks and no belt issues.