xtx star suspension with broken limiter straps

[sgilbert]

over 6000 mi with limiters still good cond. did the star kit. couple hundred miles and very pleased. wanted to have some limiters on hand incase. didn't get them. and ofcourse, snapped both like butter. the kit uses less travel on the front shock. so the limiters suck it up like an inch on the shock. I'm up north now. noticed the machine had wicked ski lift under power. looked and sure are anything, limiters were broke. I actually love it. I just remember them saying it can cause damage somehow. maybe because it tops the shock out? any input would be good, have a few days of riding left and no choice but run it.

 

[yox185]

Can you use two to make one, bolt it together? Maybe make it a bit longer so it doesn't break, but will protect the shock.

 

[sgilbert]

maybe, or go to the cat dealer here and get something and make it work, my fault for not having some. would rather let it go and deal with it in my shop. just seems to me I remember someone saying something about damage happening to the front shock. I've seen rails stab tracks, but we held this in the air and its far from stabbing. the limiters are an inch gap, so the kit obviously lets the rails drop lower than stock. I love the ski lift. hoping I can atleast put longer limiters in. I emailed star, we'll see what the say. I have rebuilt and seen inside shocks, just not real sure about what a shock is designed to take topping out. seems to me the rear tops out and isn't limited

 

[upei93]

 

[Beenba]

It might have been me you saw talking about damage last year around this time.

When the limiters broke, it allows the front and middle portion of the skid to drop down excessively allowing the rear shock to invert at its front linkage. Once the invert happens it locks up the rear suspension, which then completely destroyed the 2 tie rods along the rear shock...and then my rear shock itself the line got cut going to the reservoir and all the fluid drained out.

To continue on sled trip (we were stranded with my sled broke), We removed the rear shock and linkages all together, but then the torsion springs were able to pop out of the holders on bumps and stab my track, so I ended up using rope to compress the skid up against the tunnel to prevent this from happening. Quite an ordeal. Took us 2 hours to go 30mins of normal riding.

This was with the OEM rear suspension. I now have the star kit also,and although it looks like it prevents it, I still wouldn't trust it. Let us know how u make out.

IMO Tread carefully....

Here is the link with my pictures and damage for you....
http://www.ty4stroke.com/viewtopic.php? ... highlight=

 

[Andyfreeze]

over 6000 mi with limiters still good cond. did the star kit. couple hundred miles and very pleased. wanted to have some limiters on hand incase. didn't get them. and ofcourse, snapped both like butter. the kit uses less travel on the front shock. so the limiters suck it up like an inch on the shock. I'm up north now. noticed the machine had wicked ski lift under power. looked and sure are anything, limiters were broke. I actually love it. I just remember them saying it can cause damage somehow. maybe because it tops the shock out? any input would be good, have a few days of riding left and no choice but run it.

Thats a bummer Scott. Hope ya can get something cobbed up so ya can keep riding. If not

 

[jp111]

sgilbert, did you have the limiter straps set per the instructions of star kit?
I just installed this kit and will be heading to Maine next week. I do carry a spare set of limiter straps but really don't want to deal with changing them on the trail.
While I was installing the kit I was a little perplexed with the "calibrate" the shock for the kit, does this mean to set the spring up as suggested OR have the shock re valved by star? I had my shocks done last year for the stock suspension. What was everyone else thought on the "calibrate" portion of the instructions?

 

[cjjeeper]

sgilbert, did you have the limiter straps set per the instructions of star kit?
I just installed this kit and will be heading to Maine next week. I do carry a spare set of limiter straps but really don't want to deal with changing them on the trail.
While I was installing the kit I was a little perplexed with the "calibrate" the shock for the kit, does this mean to set the spring up as suggested OR have the shock re valved by star? I had my shocks done last year for the stock suspension. What was everyone else thought on the "calibrate" portion of the instructions?

If you Re-read the instructions, the center shock with max preload is the "calibration". I believe this this an attempt to minimize the strap flex while just supporting your weight. When the front compresses the straps bow out and can come in contact with the track in motion. There is a thread here where many members report success with the kit.

I replaced my center shock....

 

[sgilbert]

folded over the rear hinge. rear shock snapped and its a huge mess now. my own worst enemy. alleast made it back without a tow or track damage. in the back of the truck it goes. still get to ride the apex....this should be super duper expensive

 

[Beenba]

folded over the rear hinge. rear shock snapped and its a huge mess now. my own worst enemy. alleast made it back without a tow or track damage. in the back of the truck it goes. still get to ride the apex....this should be super duper expensive

Dammit man!!!! I hate to say it (and not trying to be an a jerk), but I did warn ya.. I feel bad for ya..

Guess this confirms that the star kit doesn't prevent the issue. I was REALLY hoping it did (1/2 the reason I bought it). I'm glad I made my safety tether now.

It just makes me mad Yamaha designed a fault like this. I'm surprised we haven't seen more cases like this...

 

[sorenson1610]

Ouch that sucks, only good thing is you can now upgrade your skid shocks!

 

[Andyfreeze]

folded over the rear hinge. rear shock snapped and its a huge mess now. my own worst enemy. alleast made it back without a tow or track damage. in the back of the truck it goes. still get to ride the apex....this should be super duper expensive

That sucks alot... But at least you got the apex at camp too. I'll try and stop in sunday if your home by then.

 

[yam429]

Same thing happened to me last year, limiter straps broke and caused the linkage to pivot the wrong way preventing the rear suspension from working thus destroying my rear shock. I reinforced the limiter straps by doubling them up using bailer belt from Fleet Farm per another TY member. I now have the Star kit and limiters are holding up well. Problem solved.

 

[sgilbert]

folded over the rear hinge. rear shock snapped and its a huge mess now. my own worst enemy. alleast made it back without a tow or track damage. in the back of the truck it goes. still get to ride the apex....this should be super duper expensive

Dammit man!!!! I hate to say it (and not trying to be an a jerk), but I did warn ya.. I feel bad for ya..

Guess this confirms that the star kit doesn't prevent the issue. I was REALLY hoping it did (1/2 the reason I bought it). I'm glad I made my safety tether now.

It just makes me mad Yamaha designed a fault like this. I'm surprised we haven't seen more cases like this...

ya, except I was up north near canuk ville with no service unless at the pub. read it too late. was exactly what I needed to know though.
Now home with it in my shop. shock is junk. thinking of going with 300 fox zero from schmitts.
I will say this. after working on 7000 miles now, when those straps broke, the machine was unbeleivable. the ski pressure was consistant and smooth. could go over anything with 1/2 throttle, both skis up, even on a down hill. I had never touched the straps before and didn't have wear issues either. the incredible preload this kit gives you, sucking the straps over an inch at the stock hole. it snapped those like butter, right in the middle. That is why they recommend you send shock in to shorten stroke and run super tight track. both of which I did not do. anyways. this new added inch of forward skid travel is exactly what I want, so I am setting up longer straps and reconfiguring rear to not hinge over. revalve all you want, nothing comes close to reconfiguring. this thing was an animal. I will make it do it or it goes in the dumpster. I can easily see why people drop the front end. I am going to go this way though. leaves alot of travel to use, high up and heavy it will be.loved it. I would never have known, so the damage doesn't hurt as bad. this is easily solvable, it's just that it had 20 pounds of ice so I couldn't mind melt with it and I had several beers in me too. first part I have had to buy yet.

 

[sgilbert]

heres what I came up with. after the star front shock mount is installed, with limiters in stock location, there is like 1 1/2 holes preload as opposed to stock shock mount gives you 1/2 hole preload. so when the straps break it lets it down over an inch further. when that happens, the rear shock tops out, the hinge flops over, bends the rods, snaps off the shock and so on. I want to set this up with 2 inch limiters and have them with very little preload. that requires extending the pull rods 1/2 inch and using a 1 inch longer shock. I swept it through and should all clear nice. dug through some books and found a switchback ryde fx 8602 is 18 long, 12 inch closed and happens to have 10 mm eyes. stock is 17 long and 11 closed, 10 mm mounts. all seems like it was meant to be. will update this week when I get some parts.
If you are doing the star kit, without a doubt the front shock should be shortened an inch. limiters will never take it. instant disaster