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  1. #1

    2004 Polaris Freedom coolant rail breaking

    I have 2 2004 Polaris Freedoms that I bought this past January I noticed both had cracks in the coolant rails. So I replaced them both and thought problems were fixed. I took them to the lake last weekend and one ski broke the coolant rail again. So I replaced, we went back to lake again this past weekend and had a good time rode for about 2.5 - 3hrs straight no problems. Then my wife and my daughter wanted to take one more spin. After about 15 mins one ski had no power and limped back to dock opened seat to find full of water and rail had broke again same ski. Gauge was not working (broke had one on order) so she didn't know it was overheating. So my question is why is the same ski breaking the coolant rail? High vibration, broke motor mount? I can not shake or move the motor doesn't shake when running either.


  2. #2
    Click avatar for tech links/info, donation request K447's Avatar
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    Welcome

    Have you checked the cylinder base mounting nuts for correct tightness?
    Hard to get at them underneath the exhaust manifold, but the cylinders should not be shifting around. Breaking water manifolds is not common, at all.

    Do you have the correct gaskets between the water bar and the cylinder heads?

  3. #3
    I don't think the cylinder heads are shifting but I will check and yes I ordered OEM replacement gaskets. I should have mentioned that it is breaking between the thermostat and the bolts mounting to the cylinder.

  4. #4
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by haus38741 View Post
    I don't think the cylinder heads are shifting but I will check and yes I ordered OEM replacement gaskets. I should have mentioned that it is breaking between the thermostat and the bolts mounting to the cylinder.
    Can you post a few clear photos of this area?

    Seems very strange to fracture there, with the thermostat housing positioned in free space behind the rear cylinder.

    I am wondering if something is non-standard on your engine configuration.

  5. #5
    Here are some pics of rail and other ski that is ok.
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  6. #6
    Rasta Mon Condoms We Be Jammin!!!!! TxVirageTx's Avatar
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    tie bar is missing across the head covers,check the motor mounts as well,thats a lot of vibration doing that

  7. #7
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    That motor is missing the brace that goes between cylinder heads on the intake side of the motor.........

  8. #8
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    Quote Originally Posted by TxPro1200 View Post
    tie bar is missing across the head covers

    Typing at the same time lol......

  9. #9
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    See the brace between cylinders near the FA? Your motor is missing that.

    Click image for larger version. 

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  10. #10
    ripcuda's Avatar
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    Nothing on the underside of the seat protruding down there putting pressure on it from above? (fat chance... get it?)

    Cheers!

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