LOL JB Weld had actually crossed my mind, just wasn't sure of it's ability to take high temps and/or unsure what sort of temps occur.

TB

 

well sounds like a try cause jb quick is reversable.

 

Thanks guys!

I DO like the idea of studs, at least in the outboard locations - sure would make reassembly much easier!

TB

 

Well nothing has worked yet. One outboard position I tried the Permatex thread repair system, the 2 inboard bolts got high temp Locktite, and the last outboard bolt got JB Weld.

The Permatex'd bolt fell out within a mile, but didn't cause the gasket (glued in place) to leak - so I went on. About a mile later I had to cross water and when I came out the otherside the header FELL OFF!

I had gone to the fastener store to try to match something up but Polaris used a non-standard thread count (not course or fine) and I couldn't match it up. I guess I'm going to have to tap the holes out to a standard thread, a size larger, and insert studs.

My question is, does everyone think they'll just fall out also?

Any solutions that have worked will be appreciated, along with general thoughts and comments.

Perplexed,
TB

 

hey,i think i have another try for you. pm me...........its not affected by heat........

 

When i had my 2002 700 and replaced my exhaust with an 06 header i used the studs that came with it and throwed away the old bolts.
Studs are much better i had no problems with mine.
I put a thousand miles on it ,sold it two months ago and the new owners had no problems with the exhaust. only the carb sticking again.boy those needle and seats are crap dont last.
By the way when i put the studs in i use red locktite an torqued to 25 pounds.
sorry to hear your problems.
I think if you pouched the threads get it fixed right!!!!!,to expencive toy to duck around with...

 

Thanks Lobodog!

I've been thinking all along that bolts seemed to be such a poor choice for this application - and that surely Polaris must have had this problem on the 800. My kit didn't come with studs, and my attempts to match up something at the hardware store have been naught. So I look at the microflich for the SP800 and YES, studs!
But, what I didn't realize - and would have helped me match something up is that they are METRIC! METRIC? Since when on a Polaris? Everything else has been SAE. The studs are clearly defined as: M8X1.25X30 FULL THREAD, and the coresponding nuts as: M8.

METRIC? Since when?

TB