Project Apex Crossover - Sled rebuild

[RTYsxv]

Hey all, I've been a member here for quite awhile but posted mostly on the 2 stroke side - I had a 2003 Viper ER but I sold it early this summer. I've always wanted to give the 4 strokes a try, and at the beginning of August this year I met my opportunity. Here's what I picked up for $2500:

It's a 2006 Apex GT with 5200 miles, the previous owner landed on a concrete culvert and then rolled it over once. It's a lot better than it looks, I'd already pulled all the plastic off when this picture was taken. The main hit is in the front of the skid but also wrecked the tunnel, heat exchanger, and the rear bulkhead that the tunnel attaches to - in addition to a whole bunch of small parts.

I'm planning on making a work log thread out of this, I made one on the 2 stroke side for my Viper when I installed a Polaris IQ snocross skid in it. I always like it when others post their projects and it's always an opportunity to learn something new, so I'm sharing my project with you all.

Since I'm going to be rebuilding the rear of the sled, I'm going to stretch it out and make it a crossover sled while I'm at it.

Here's my plan:
- Stretch the sled to 153"
- 2.25" Camoplast Maverick track, 153" off a Nytro MTX
- Extrovert Drivers
- Get rid of the EC Mono skid and drop in the rear suspension from a 144" 2007 Polaris IQ Switchback Crossover sled

 

[Swiss Sledder]

Nice track ... lol. Looking forward to seeing how this sled turns out. Keep us all informed.

 

[sonds]

Not sure you are going to want a maverick unless you are planning on cutting the lugs.

A good solid platform though once you get it straight.

sonds,

 

[kinger]

Thats definitly a challenging rebuild going to take a lot of labor to get at that bulkhead and replace it. Nice thing is if you find the parts used it will be a cheap repair money wise but time wise she'll need some hours. Hopefully the chain case, axle, assembly all comes back in line when your done.

I would love a project like this with a custom tunnel, etc just no time

I'll live vicariously through you

 

[BOUNTYHUNTER]

GOOD LUCK With Youir Project...Looks Like Fun

 

[RTYsxv]

Not sure you are going to want a maverick unless you are planning on cutting the lugs.

A good solid platform though once you get it straight.

sonds,

I picked the 153" 3 pitch Maverick because there are a bunch of them floating around on Snowest for cheap. Since the Nytro MTX comes stock with it, there are quite a few like-new takeoffs for sale. Picked one up with 500 mi on it for $130 shipped

I'm going to try and run it as is, but as cheap as I got it I can always cut it down later.

Also, with a 3 pitch track you can use the 7 tooth Yamaha MTX drivers which are extroverted - if I can find a used set I can save quite a bit of money. I'm college kid so that's key

 

[tkuss]

Are you setting back the 144" skid to get to 153"?

I like how you are just using the stock maverick track everyone is getting rid of. I would just run the track as is and then when it starts breaking apart buy another for 120$. Or like you said just cut it down for trail riding.

 

[yamahaboy701]

The guy who I bought my MTX from cut the maverick down to 1.5. He said it hooks up great now, kinda hard to fold over 1.5" lugs. One other thing is he just did not cut the tops off the lug he also grooved them and took some off the side of the lug to make them bite more on the trails.

 

[RTYsxv]

I ride 99% ditches and offtrail so I'm not afraid of a big lug depth, just as long as I have enough heat exchanger clearance and have a way to keep the hyfax cool (ice scratchers I'm thinking for trails). I've thought about grooving the lugs if I cut it, that might be a good idea. It will all be a matter of trying things and seeing what works, hopefully I can learn a few things out of the deal.

Sorry I wasn't clear, I'm NOT setting the skid back in the tunnel. I'll be using the original Polaris IQ mounting dimensions, then use rail extensions to make it 153".

 

[RTYsxv]

Here are some more pictures of the sled as I got it:

This is where the main hit was. The owner fractured his pelvis by the way!

Here's the track - fully studded Ripsaw in good condition. The sled was sitting in the ditch, and the guys who were supposed to recover it were having a hard time pushing it out, so they said "hey lets just cut the track off!" Needless to say, the owner was NOT happy.

Leaking coolant from the damaged heat exchanger. This became very annoying after awhile, because it seems like you never get it all out. You move the sled around a little and all the sudden a puddle is forming on the floor - there are little piles of Floor-dry all over the shop

 

[RTYsxv]

Here are some disassembly pictures.

The parts came apart relatively easily - until I got to taking the tunnel apart. There are rivets everywhere, and 90% of them spin when you try to drill them out! It was also a challenge removing them where the tunnel was severely bent. The right hand foot support and floorboard were a mangled mess, which means no drill access to the rivets you need to remove

After defeating the tunnel rivets in a long battle, I made the discovery that the rivets holding the front of the tunnel protectors were behind the engine and completely hidden. I also knew that the aluminum pieces ahead of the tunnel were bent, so at this point I decided to do the best job I needed to pull the motor out.

Out she comes..

The removal process was not difficult, pretty straightforward. I think one of the keys to doing this is paying attention to everything and how it comes apart - hopefully you will remember a few more things when it's time to re-assemble. I also tried to thread bolts back in their holes after removing parts, it really helps when re-assembling if you don't have a pile of bolts to organize. I really love how you can get this thing out of the frame without taking the primary clutch off, way to go Yamaha

I was running through the computer checking the diagnostic codes at the time I took the pictures. I didn't find any fault codes, other than the ones for all the sensors I unplugged in the removal (see Apex/Attak FAQ for info on how to do this)

And here's the tunnel, finally on the ground by itself! I don't think a normal tunnel swap would be a big deal, mine was just severely bent on the right side. I don't have a picture of the footrest and support, but they are little more than a twisted ball of aluminum.

 

[RTYsxv]

Here's what's left of my sled...it's real easy to move around the shop now

Notice how the aluminum is bent out at the left rear.

Meanwhile, I decided to do some polishing on the top frame support. I might add that the Deere 8420T tracked tractor makes an excellent workbench when it's not out in the field

BEFORE:

AFTER:

I also polished and then clear coated the the steering tierods, spindle brackets, and the handlebar riser.

 

[RTYsxv]

Parts showing up...by now the UPS guy probably knows everything about this project!

Tunnel, foot supports, and rear bulkhead:

Here is my resident expert in the areas of ripping and shredding...

The paint isn't the best and many of the rivets are rusty. For now I'm focusing on getting the sled together and functional, then comes the looks. I have a few plans in the back of my head...more to come on that

Next came the suspension - 144" skid out of a 2007 Polaris IQ Switchback with tipped up rails and fresh Fox Zero Pro shocks. I also got my Tracks USA rail extensions to make it 153", and had them installed for the pictures. I flipped the wheels to show the black side instead of the gray Polaris swirl design. This skid is in pristine condition, even better then expected

Rear shock - piggyback reservoir with clicker adjustment:

Tracks USA rail extensions:

Here's a look at the tipped up rails:

Then came the track - 153"x15"x2.25" lug, 3.00" pitch Camoplast Maverick off a Nytro MTX. 500 mi on it, for $130 shipped

I stuck the suspension inside it and applied some tension with 2x4's. I really like the black skid wheels:

I set the stock 121" rail next to it for a comparison of length - it doesn't look that long until you see them side by side. Also note the shallower approach angle of the Polaris rails - the curve is less abrupt and steep than the Yamaha mono rail.

I don't have pictures, but I also received my Muffinworks tunnel extension (powdercoated gloss black ) and a set of used Nytro MTX drivers. These drivers are factory-installed extroverts, 7 tooth 3.00" pitch to fit the Maverick track. It was a way cheaper route than spending $75 or more apiece for aftermarket extroverts, and I get to run 4 drivers instead of just 2 - better in my opinion.

I'm excited to see how this all comes together

 

[fergdog93]

Wow, you mean bussiness on this one. Your on the move with this project, don't lose steam. By the way, isn't it awsome to see the UPS truck pulling up the drive 2-3 times a week? Its like Christmas all thru the summer! Keep up the good work!

 

[Super Sled]

I'm watching this project very intently -- this sled is going to rock!!!!