TB04-06-01

 

 

Website: www.atkusa.com                                                      TECHNICAL BULLETIN

 

BULLETIN:                  TB04-06-01

MODELS:                     ALL 2002 & 2003 Motorcycles
ALL 2002 & 2003 ATV's

ISSUED:                       June 10, 2004

SUBJECT:                    Coolant Corrosion in Engine Causing Severe Engine Damage

CONDITION:                 A chemical reaction occurs between the dissimilar metals of the
cylinder head and the cam cover and the water in the cooling system.
The magnesium cam cover corrodes to the point that it no longer
separates the coolant and engine oil. This corrosion occurs even
if the machine has been sitting idle with coolant in the system.
Cannondales remedy to fix this problem was to powder-coat the
cam cover to stop the electrolysis. Un-fortunetly this remedy did
NOT work. Cavitations in the cooling system pulls the powder-coating
off the cam cover exposing the magnesium to the coolant.

SOLUTION:                  Replace Cannondale Magnesium valve cover with new ATK Aluminum
                                    valve cover

WARNING:                   Failure to take action may result in severe engine damage due to
                                    engine overheating.

PARTS:                        5001126-ATK Motorcycle Aluminum Cam Cover (Available July 1, 2004)
6000496-ATK ATV Aluminum Cam Cover (Available July 1, 2004)
5000916 Cam Cover Gasket Kit
5000180 Water Pump Gasket

INSTALLATION:           The Engine needs to be removed from Chassis. Refer to Service Manual
for removal and re-installation of engine.

 

                        

                Coolant Chemical Reaction                                                                         Valve Cover Corrosion