2005 fusion900 head bolt question - HCS Snowmobile Forums

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Old 03-15-2019, 05:13 PM   #1 (permalink)
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Default 2005 fusion900 head bolt question

So I’m just fininishing putting the 900 engine back together just wondering I’ve read twice on other posts people say the head bolts should have a washer just wondering cause I ordered new head bolts but they didn’t come with a washer so just wondering if I need them or not
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Old 03-15-2019, 05:23 PM   #2 (permalink)
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The washer is to raise the bolts a little.Some of the 900's bolt holes weren't drilled/tapped far enough,thus the bolts bottomed and did not torque the head down enough.

If I can find the TSB I will post it.
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Old 03-15-2019, 09:30 PM   #3 (permalink)
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Ok thanks so do I need them? Sled has 8500 miles and had at least one rebuild for sure so I’m just wondering if there needed with the new bolts I ordered or if it’s good to go and do I need to use loctite or anything with them and if I remember correctly it’s torqued to 25 and the jug bolts are 40?
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Old 03-15-2019, 09:51 PM   #4 (permalink)
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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.
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Old 03-15-2019, 09:53 PM   #5 (permalink)
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As far as torque specs read past Post #3 here as the repair manual quoted in post #3 had some incorrect values I guess:

https://www.snowest.com/forum/showthread.php?t=104942
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Old 04-01-2019, 08:00 AM   #6 (permalink)
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This tsb is for the cylinder(base) bolts, not the head bolts.
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