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Old 12-21-2012, 09:12 AM   #1 (permalink)
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Custom Sled build Advice

Hey all,

Ive got a 80's Yamaha 440SS sled that Im going to highly modify. Engine, clutches, etc Im wanting to keep the way they are, but looking to change the riding stance, steering colum angle, track, skid, suspention etc.

I was wanting to find a 99 RMK 600 track and skid to put on it and found it on craigslist, but obviously there is the issue of the engine and its ability to turn a heavier and more agressive track.

Im really just looking for "helpful" insight on this. Idealy someone with experience, or a friend who has done it etc.

Thanks guys!
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Old 12-22-2012, 06:31 AM   #2 (permalink)
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I'll go out on a limb here and say that there is likely No one has extended a SS!
They were barely a decent trail sled! To go to a 136" you would have to get more hp AND gear it down!
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Old 12-22-2012, 08:11 PM   #3 (permalink)
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Quote:
Originally Posted by kccats View Post
I'll go out on a limb here and say that there is likely No one has extended a SS!
They were barely a decent trail sled! To go to a 136" you would have to get more hp AND gear it down!
X2. I wouldnt bother on the track extension. Maybe widening the skis.
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Old 12-23-2012, 06:57 AM   #4 (permalink)
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I had a SS440 and Im not saying it's a bad sled, not at all! But for your project you might be better off to start with something new and bigger!
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Old 12-23-2012, 08:22 PM   #5 (permalink)
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you would be surprised at what that sled would pull track wise. no problem with that polaris skid and track, you will run into more issues finding parts to adapt.

there used to be ski spreader kits available. simple design, an offset bracket to spread the stance.

working the bars isnt so bad either, but finding compatable cables can factor in.

lots of lower cc sleds pulling 136 tracks. sky's the limit for your goals.
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Old 12-24-2012, 05:05 AM   #6 (permalink)
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Spreaders are still available.
https://www.denniskirk.com/sno-stuff...0.prd/1020.sku
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Old 12-24-2012, 06:37 AM   #7 (permalink)
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Old 01-23-2013, 11:13 AM   #8 (permalink)
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Update:

Update:
Took it up last weekend so I could at least test it out and make sure all was in working order. Worked really well. I was really happy with the "feel" of the sled. Made riding around, climbing, maneuvering, etc, seem not only easier, but way more fun. I havenít fabricated the hood to work with the new setup, so I didnt ride it long since it was snowing like a mother and I didnít want to get a bunch of snow in and around the clutches, engine, carb etc. I still have the stock skid and track, but I picked up a Mountain Max skid, 136x2 track and drives for $100 (SCORE!) so Im wanting to get that put on and running well before I go up again, also want to get stock hood modified to fit back on again.

Changes to the sled so far:
- Adjusted the steering to almost a vertical stance (Lot more involved than it sounds)

- Drilled the stock foot rest out and moved them back about 4-6 inches.

- Reinforced the running boards with metal shelfing "L" brackets from
Lowes. Riveted them in and its almost commical how well it works.

- Lowered the rear of the skid about 2 inches

- Fabricated the rear skid wheels to just two on the inside. Works great.

- Took off stock seat, I donít like the one in the pics so im going to fab my stock M7 seat to fit, I was checking it out and it should work really well.

I think thats about it so far. Changing the steering to where it is now was much more involved than I thought it would be. I had the entire engine out and had to cut the steering bolts down so they were flush and wouldnt rub the engine mount. ( You'd have to see it to know what I mean) Also had to cut/file some of the crank case so the steering wouldnt rub. Sounds like a dumb move, but it wasnt a big deal either.

Next:
-Now that I know I like the position of the steering column Im going to remove the temporary supports that go over the engine, and weld in some clean metal supports.

-Also, and Iím really excited about this=, I purchase a 150cc Quad frame with the entire front end. A-arms, shocks, steering, spindle, etc. And Im going to work with a buddy to fabricate the front end onto the sled. Should be really really cool. Imagine this thing with some A-arm suspension up front!

-Lastly I want to get that Mountain Max skid and Track mounted up. I honestly have a hard time believing how heavy that stupid ass skid is. Feels like its made out of freak lead lol. This summer Iíll have to look into fabrication my own simple efficient and light skid suspention, but for now this moon rock will have to do. The key will be reducing the rolling resistance as much as possible. Thinking about getting a 8 or 10 inch big wheel kit, as well as possibly porting the track a little. Weíll see.

Anyways, hopefully Ill have some new pics and possibly a video up soon. Just been crazy busy with work, school, house, band, etc.

PS, made a little edit from that day of riding, only I was on my M7

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Old 01-23-2013, 11:18 AM   #9 (permalink)
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As for the "ski-Spreader" kit, Im going the exact opposite. Im wanting to bing them in as much as I can. I wide stance might be good for a "Track" sled. But Im going for more of a nimble/flickable geo. Look at Polaris's new Pro. Arguably the best snowmobile ever made period and I believe the skis are about 35-36 inches apart. Older mountain sleds are more around the 40-45 inch stance I believe. Making them much much much more difficult to throw side to side and flick about. Ill be limited as to how narrow I can go because of the A-arm suspension Ill be putting on, but looking to be around 30-33
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Old 01-23-2013, 01:15 PM   #10 (permalink)
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Stock Steering Position


New Steering Position


Temporary setup to test the new riding position.


**** I wish I could get an exhaust that would turn a smooth "U" turn to the right, enabling me to cut about a foot off the nose of the sled.******

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Old 01-24-2013, 07:00 AM   #11 (permalink)
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The width of the A arms might be a pain up in the mountains!
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Old 01-24-2013, 12:34 PM   #12 (permalink)
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A-arms

The A-arms came off a small chinese quad so they arent very big. The width of the arms will be the exact same as the stock width, give or take an inch or two. My goal will definitely be to keep them as narrow as possible.

The reall issue Im going to have is that I want the skis mounted as far back as I can get them, but the engine/exhaust/clutch setup are going to make that a whee bit tricky, but I think Ill be able to pull it off pretty cleanly. Just want to try to add as little weight as possible to the sled.
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Old 01-24-2013, 08:59 PM   #13 (permalink)
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This thing is cool. Nice job on the rider forward steering!
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Old 01-25-2013, 08:30 PM   #14 (permalink)
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Thanks Wildcat, its really really fun to ride. Found out today we are on mandatory OT for Saturday and Sunday which sucks because I wanted to get a video up for you guys this weekend. Might be able to get a short day in on Sunday, we'll see.
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