Upgraded my '96 ZRT800's ride - Snowmobile Forum: Your #1 Snowmobile Forum

Greg_H · 10-05-2006, 05:38 PM

I'm just about done with the suspension mods to my sled. All I have left to do is raise the steering rack, and install the new sway bar. As you can see I swapped out the old skid for an ETT skid, and I modded the front end by using front end parts from a 43" AWS 5 sled. The front end now has 12.5" of travel and a 45" stance center to center. My final mod before winter is going to be raising the bars to make riding it stand up possible.

Here you can see the new skid, but the front end is harder to tell:

Here is a front view. Here you can really see the wider stance.

IndianRvrShiver · 10-05-2006, 06:44 PM

Clean machine!!

You've done some tasty mods to it you will see & feel as you drive!! Can't believe you didn't put a "real sweet soundin' pipe" on it!! J/K, dude!!

Greg_H · 10-05-2006, 07:28 PM

Quote:

Originally Posted by IndianRvrShiver

Can't believe you didn't put a "real sweet soundin' pipe" on it!! J/K, dude!!

Thanks man. As a matter of fact, I used to had Black Magic silencers on it, and it sounded damn sweet, but none of my daughters would ride with me when it was that loud, so I went back to the stock can. You might think that would be an advantage, but I think back to all the times I was my oldest daughter's age and all the fun I had riding with my dad.....I want her to have those same memories. Those memories have kept the fire burning to ride for 33 years now.

**smallengineguy** · 10-05-2006, 09:03 PM

Looks like a great sled!

PolarisINDY500 · 10-05-2006, 09:04 PM

sweet looking sled!

you got any before pics so we can compare??

**RJ Gleason** · 10-05-2006, 09:31 PM

Very nice ride there.

Greg_H · 10-05-2006, 10:03 PM

Here are some pics before and after for comparison:
Front before

Front after

Side before

Side after

There are 8 or 9 other guys I know of that have '96 zerts that have done both mods, and all of them have said that the sled is as good or better than anything new out there. The weight of the sled becomes about the only drawback when in the tight, twisty trails. Other guys that have '97 or '98 zerts have done the front end mod to compliment the ETT rear. I cannot wait to get this thing on the roughest trail I can find and just blast through it!

IndianRvrShiver · 10-05-2006, 10:44 PM

Quote:

Originally Posted by Greg_H

Thanks man. As a matter of fact, I used to had Black Magic silencers on it, and it sounded damn sweet, but none of my daughters would ride with me when it was that loud, so I went back to the stock can. You might think that would be an advantage, but I think back to all the times I was my oldest daughter's age and all the fun I had riding with my dad.....I want her to have those same memories. Those memories have kept the fire burning to ride for 33 years now.

Amen, Brother!!

SnowRida · 10-06-2006, 12:08 AM

Nice skid replacement!

You should have some better cushion for the pushin with that suspension!

Greg_H · 10-08-2006, 10:31 AM

Quote:

Originally Posted by mrbodyman21

i have a 95zr580 with a ett put in. I also have a front end from a 00zl600 with the upgraded shocks and longer a arms. I tried to install them but the a arms werent as wide and i hate to put like 4 washers to fill the little gap. How did yours work out. Anyhelpful idears would be great. thanks

All my new front end parts are from a 43" stance AWS 5 ZR. I'm not sure if the '00 ZL had the 43" stance or not. The shocks I used are from an '01 ZRT, which isn't as important as having an extended length of 18". If the ZL arms are different length, you'll have to make sure you check for bump steer through the whole length of travel. That is very important. To fix the problem of narrower arms, you want to measure the gap between the arm and the bulkhead. Have some spacers machined to that size. Also make sure that it is a tight fit when the spacer is installed, and put the arms to the back, spacers toward the front. Something else to think about is raising the steering rack up as high as possible in the bulkhead. This too will help reduce bump steer, since the new arms will allow alot more travel, this mod just about doubled mine.

Greg_H · 10-08-2006, 10:41 AM

Quote:

Originally Posted by mrbodyman21

also what year are those spindles off of? along with the a arms. Looks Like its the same as the origional. My zr580 spindles and a arms look the same as what you have. I dont see how a different shock would raise the front end? am i missing something here Lol

The spindles are my stock ones that have been cut to allow clearance for the new A-arm cross brace at full extension. This is the one part that will possibly need changing on my sled. All others that have done this mod have used '97 or
'98 AWS 4 aluminum spindles, as they bolt right on the new arms. I had to do some "helping" to get my spindles on, and until I measure very carefully for bump steer, and actually ride it, I'm not sure that I'll be using these or getting some newer aluminum ones myself. The different shock length won't necessarily raise the front end, when my sled is sitting on the ground, it's only about 1/2" higher than stock, as I have the spring preload light enough to allow for almost half of the suspension travel to sag. This is to allow for droop travel for the real big moguls. You need the longer shock due to the longer distance between the mounts with the longer arms. I have been told that mounting the stock ZRT shocks to my setup is perfect for lowering the front end for a drag setup.

Greg_H · 10-08-2006, 12:10 PM

Quote:

Originally Posted by mrbodyman21

so your saying for it to work i would have to modify my spindle somewhat or get one from the 97zr-98-99? and use those a arms. I do not understand the bump steer? how to i raise my steering rack? and what kind of mod did you have to do on your stock spindles?

Here is a link to a thead with everything about the mod.

ArcticChat.com >> It's All About the Pride®

You'll find everything you need to know about it there, including the spindles. What you need to do is notch them out. If you look at the front view photo above, you'll notice that the spindles have to be notched out between the a-arm mounting holes so that the cross brace on the lower a-arm will clear the spindle at full extension. Bump steer is when the ski turns when the suspension extends or compresses fully. To check for it, what you need to do is install the shocks without the springs and using a jack, measure the front and rear ends of the skis with the suspension fully compressed and fully extended. If the skis both point out or in too far in these positions, it can be very dangerous when happening at speed when riding. On that thread there is a guy AG...he is the one that came up with this mod, and he can answer any and all questions about it. He also has a mod for moving the steering post to make it much better to stand and ride, if that is something you like doing.