Apex Backcountry Build

[tkuss]

A little update:


Sled has been coming together real nice up until today. No pictures right now(will try and go tommorow and get high speed, don't want to upload pictures with dial up right now).

Sled is almost all together, just a few miscellaneous parts to wait for and then put on. But like I said earlier today I ran into a bit of a snag. It could be a huge problem and setback or it could not be that big of a deal.

I put the suspension back into the sled, and the problem is either that the track is a bit to short or the rail extensions are a bit to long. I got the suspension in, but now I cannot get the rear axel in because the track is two tight. I have a few ideas to get me a bit more room with the rear axel but not much. So it will be close. Other options would maybe go to a smaller rear axel wheel instead the big 8" wheels that come with it. I need the rear axel to be about 2" closer to the front of the sled so that it fits perfect. I might be able to squeeze the wheel on if I can get the axel and inch closer to the and inch closer to the front.

I am going to take some pictures and send them to AD Boivin tommorow and see what they say. I will also try to update this thread tommorow with pictures.

If my rail extensions are 144" it is almost like my track is a 141" or so. But I don't think any tracks that are 141 are 2.52 pitch.

We will see, I think I can work everything out with out having to rip it all apart again and get a different track. I better be anyway.

 

[Cilius66]

Is the track new? New tracks can be a tight fit...

 

[yamahaboy701]

Old Yamaha Mountain Max's are 141, 2.52. There should be a part number on the track, check it will tracks usa or on here.

I had a similar problem when I extended my expert X on my viper. I was really confused on why my track was so tight even with the 8 tooth drivers which are smaller in size. It did not add up to me, then I read over the Expert X instructions and found out that since I changed the driver size it also changes where I should mount the expert. I remounted it which change the track pitch and then everything lined up correctly.
I would still connect adbovin but also check your instructions on the ZX2.

Like cilius66 said new track are tight and even the used tracks that are rolled up all summer can be tight.

 

[tkuss]

Guess what. Checked track # 679-9788 that I got off the track. It is a 141"

Pretty frustrated right now. Unfortuantly I got the track from a guy on snowest, I will email him and tell him that he sold it as a 144" and it is a 141" and will not fit my sled. I dought I will even hear from him.

I will still send my pictures to AD Boivin and see what they say. But it looks like I will have spend the $ for a new track. Might just wait for Haydays and pick up a track there. But I was hoping to get this sled together before I have to go back to college.

Oh well.

 

[yamahaboy701]

Sorry to hear about the track. I would be ticked off too. Good news is that its a good track for a Mountian Max, if you can't get your money back, post it over on the 2 stroke side and I bet you would have some interest.

 

[tkuss]

Alright got some pictures here.

Once the tunnel extension was on, I put the rear bumper back on and decided to put it on upside down to give it a bit more flair.

I then drained the coolant so I could install the coolant hose splice for the temp gauge into a coolant hose. I realized when I put new coolant back in I would have to bleed the system from the bolt on the coolant crossover tube out back. So I cut a little slice in the protector plate so I could access the bolt with the tunnel extension on.

SNOW IN JULY IN NORTHERN WISCONSIN???

I went for a motorcycle ride and came up on the tail end of a thunderstorm. There was patches of snow for about a 300 foot stretch along the road. Of course it was not real snow, must of just hailed real hard for a period of time and accumulated, then as it warmed up, it all meshed together to make snow. I can say I threw a snowball in mid July though! I was going to trailer the sleds over and get a little rip in.








I then wanted to dye my grey stripe in my seat black.

So I bought some vinyl dye and prep online.

The seat turned out real nice.

Now to my track problem.

I decided to through the rear suspension in a bit early since I had a bit of help around.


It went in really hard but after some time we got it in.

We had to take the rear axel out to get it in, and once we tried to get the axel back in we realized everything was a bit tight. I need another 1.5" of axel adjustabilty to get the axel to fit.


Here is a pic of the wheel with the adjusters up as far as they go.

Here is a pic without the wheel.

I thought I would try flipping that aluminum piece around so that the axel bolt hole would be to the front would give another inch or so of room.

I then tried to get the wheel on and if I really needed to and with a bit of help, I could get it on. But the adjustment bolts that stick out the back of the rails would still be very very close to the track. As in an 1/8 or 1/16" away from the track. And the track would then still be very tight.


I checked the track part# on the internet and found out the track was a 141" not a 144" like I thought it was when I bought it. I just emailed AD Boivin explaining the problem and the guy I bought the track from.

If I really wanted I think I could come up with a solution to make this track work. But I want it to be right, so I will see what AD Boivin says. But it looks like I will have to get a different track and take this thing all apart again.


On a bright side the sled looks pretty nice with the skid in it.


Also i got the my graphics today and they look pretty good. However once I left and got the road a bit I realized they put them on upside down. Will have to email them tonight and see what they want me to do.


Luck is just not on my side today.

 

[yamahaboy701]

That thing looks sick!!!! The bar riser looks twice the size without a hood or windshield on. Very Nice job so far.

 

[kinger]

Whats with the gas tank cover around the fill cap?

Looks nice man, but seriously you have my luck when it comes to stuff, thought you had a 144 but ended up with a 141, that is straight out of the kinger diaries....

Perserverance pays off my friend....

 

[subaru2006]

Ha this is kinda funny, I thought I had some bad luck. You have me topped. Best of luck with the rest of the install.
Looking good tho, keep it up...
Subaru2006

 

[tkuss]

A track is on the way as off today.

It is the 1.75" Backcountry, fully clippped.

Should have it in a few days. Got a good deal on it, I decided on the Backcountry because I won't have to cut it down once I get back from outwest. The paddles are a bit stiffer so they should hold up better. Might not do quite as well in the deep pow, but it should be a better all around track for me.


I plan on starting to rip the chaincase apart again later on today.

 

[tkuss]

A little update with no pictures.


New track is in and the suspension is under the sled and it fits this time!!!


Sled is close to all together, I started it up today and it ran. Working on installing the temp gauge. When I ran it today it works, I just need to take some time and wire it so that all the wires are able to disconnect quickly so when I take the headlight off the gauge disconnect easily as well. (The guage is mounted on the headlight pod). I hate wiring, I don't have much experience with it, and I don't have the proper tools to do it.

Also I drained all the coolant out earlier and now refilling the coolant and bleeding the system with the tunnel extension on and doing it by myself is a pain. So I will wait for somebody to help me with that.

Also both clutches had new springs put in as well as a few bushings here and there.

Sled should be all together except for a few parts such as ice scratchers, and tunnel supports which I will put on once the sled is all set and ready to ride.

Pictures will come within the next 1-2 weeks.

 

[MotoPsycho]

The Horns await your arrival. There is supposed to be a lodge open on the south end this year too... I'm just a bit excited to see this feat of modern engineering with my own eyes!

HURRY UP, WILL YA?

 

[yamahaboy701]

Post some pics when you get a chance. I also want to see those "backflip" stickers you got!!

 

[stopdropanroll]

A little update with no pictures.


New track is in and the suspension is under the sled and it fits this time!!!


Sled is close to all together, I started it up today and it ran. Working on installing the temp gauge. When I ran it today it works, I just need to take some time and wire it so that all the wires are able to disconnect quickly so when I take the headlight off the gauge disconnect easily as well. (The guage is mounted on the headlight pod). I hate wiring, I don't have much experience with it, and I don't have the proper tools to do it.

Also I drained all the coolant out earlier and now refilling the coolant and bleeding the system with the tunnel extension on and doing it by myself is a pain. So I will wait for somebody to help me with that.

Also both clutches had new springs put in as well as a few bushings here and there.

Sled should be all together except for a few parts such as ice scratchers, and tunnel supports which I will put on once the sled is all set and ready to ride.

Pictures will come within the next 1-2 weeks.

If you need a hand with some nice weather pack plugs I stock a few types, easy disconnect with a water tight conection. I have been in the 12volt business for all of my life. No "super special" crimper needed, can find one at Sears.

 

[tkuss]

Post some pics when you get a chance. I also want to see those "backflip" stickers you got!!

I have pictures of those upside graphics set to go. I don't think I told that full story here yet. Like I said earlier, the graphics were put on upside down. Also the color was a shade off on the red. If they were put on the right way I wouldn't of minded the color difference that much. I went in to get things straightened out, and the lady told me I would have to pay full price again (70$) because they would have to be redesigned.

I was already pissed about the track being the wrong one at the time, so I just was quite and left and told her I would think about it for a few days. I would also think she would do them again but for free or cheaper, since she designed them up side down. But She says that I never told her what way was up or down. Anyway there are no graphics on my sidepanels now, and I really like the look of it that way. We will see what happens.

Here are some pics of the upside down graphics with colors a shade off what they should be.

Also I would have pics of everything set to go right now, its just I am dealing with dial-up and it takes literally 3-4 hours for 6-7 pictures or to load up so I go find wifi to do that. Pictures will be coming though sooner or later.

Off to work on the sled and hopefully finish up that wiring.