I'm helping my friend fix his 2000 500 magnum. It was overheated at one time( I think) and the oil rings are shot. Every thing, rings ,cylinder etc. are at the max limits. We decided an aftermarket cylinder kit was the most economical. The problem lies in that the lower 90 degree coolant elbow didn't come in the new cylinder. Has anyone ever replaced that lower elbow and what is the best procedure? Thanks in advance.

 

You have to heat this area up super hot with a propane torch while slowly twisting the elbow back and forth with a large pair of vice grips. May take a little while,but should pull out. Let the elbow cool(freezer helps) then heat the new cylinder. Smear a little coating of JB Weld 5 minute epoxy around the outer parts of the elbow(not too much!) and while still using the vice grips insert it into the new cylinder maintaining proper elbow alignment. "IF" you crack it,new ones are available. Item #32.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

Thanks for the reply. I kind of figured that was the case. Would locktight 271 sub for the JBWeld?

 

Probably be just as good since once this area cools the elbow will be really tight in the cylinder.Actually the ones I've taken out looked dry with no sealant,lock tite,etc,but I'm not one to take any chances on leaking.