Yamalaris build

[zx4ever]

Well the steering is finally done. That was the most painful part of this conversion so far. I weighed the air boxes and like I figured the viper air box is 2 lbs heavier. It weighed in at 5 lbs 10 oz if weight was a factor I would go with k and N’s but I will try it out. I had to cut the air box side so the steering will work, hopefully that will not affect airflow.

 

[zx4ever]

Getting really close to firing this thing up. I got all the rad hoses connected and radiator installed. I made a battery box and mounted it below the air box and I wrapped all the wiring to protect it from rubbing and such. Next is the wiring and fuel tank and filling all fluids. And then cross my fingers this baby will start.

 

[kinger]

Getting real now! I always dreamed of electronic steering on a sled, where the bars turn a switch and then an electric motor moves the skis, just be hard to ever trust that as fast as I ride and no way to formally engineer such a system, I don't need to die LOL. Good job so far! Be fun to get it running!

 

[zx4ever]

Well after what seems like forever. The yamalaris is alive. I have a big list of things to finish up, but it is now running.

 

[zx4ever]

With some video help from mr sled. Here it is running. The yoshi exhaust sounds so sweet, I can’t wait to crack it open out in the snow. If everything goes as planned this week, I will be testing this weekend.

 

[MrSled]

With some video help from mr sled. Here it is running. The yoshi exhaust sounds so sweet, I can’t wait to crack it open out in the snow. If everything goes as planned this week, I will be testing this weekend.

looking great!! Nice work.

 

[zx4ever]

Well very little has gotten done on the build. I have been riding and fixing my turbo tank for the last few weekends . I have got a battery box made and installed under the air box. And I also made a relay holder above the ecu.

I also am working on the brake caliper holder, making it fit with my exhaust.

 

[kinger]

Great work!! What is the diameter of that yoshi? I had one too and it was awesome but when I used a silencer with it to ride a more quiet area, it blew the muffler out of the top on my 250hp apex. Just a FYI. Great relief its running!!

 

[zx4ever]

Mine is a 2” in and out. I bought it used and cut it down. It has no silencer insert so I hope it will be good. Thanks.

 

[zx4ever]

Man I was suppose to have this thing done before the snow flies. It is now sledding season and I don’t have as much time to finish this. But I will keep plugging away. First re engineering to be done is the reverse system. It was not strong enough to push down on the lever to engage reverse. So I changed it to the nytro system and it seems to be stronger, and now I have a place for the fuse box. I also know after some garage testing my upper steering system will need some changes. But I will try it on the snow first.

 

[zx4ever]

Well I tried it out last weekend. I could not get a feel of how it will truly handle due to lack of snow. But it was really good, and has some major potential. I put on 4 km from my house, I didn’t want to get to far in case I had to walk home Lol. I have a few issues to fix like the stupid hand warmer code. And a small coolant leak. But the major issue was the upper steering post was a bad design. I am now making it more like the pro upper steering post with 2 mounting locations. I could not even see where my revs were at due to the stupid code 81 flashing. I forgot what stock nytro power felt like after riding a turbo for so many years. Wow. Hopefully with some clutching and a power commander it will wake up. Who know I could have been revving way low.

 

[zx4ever]

Well the weather finally broke it got up to a balmy - 20 c. I put on 40 km in the last 2 days. I am very happy with this sled it handles so much better than my nytro. It feels stable I can do donuts in the fields and not have to worry about getting past the no return tipping point like the nytro. I got the hand warmer short fixed so I can now see my revs. As I had figured they were low, so I adjusted my supertips and now it finally pulls like it should. Goes to 9200 and settles at 88-9000 in the deep snow. I could add a bit to the heel to make it bang on. The one thing I like is the tipped up rails on the skid. It works really well on a stock sled and makes the 163 track seem very playful. Jury is still out on the stock Polaris track it seems to spin lots compared to my powerclaw. The steering is better now but it still needs some work, and change a few angles to get less steering effort. I also will adjust the front track shock to help with this. All in all I really like this sled and so far I think it is a success here is some final pics.

 

[kinger]

Great job!!! That was a massive job! Its rewarding when they turn out like you hoped!

 

[zx4ever]

Well after a bunch of rides and 400 km later I will give a update. I really like this sled it handles way better than the nytro, I had a few mishaps, and have made a few changes. First the future afr bolt came undone and melted some stuff, which I fixed by tack welding it back in. Then the steering system that I was going to change this summer, sheered off the lower mounting point and I had to redesign the whole system. I am happy with it now, I bought a small u joint and went under the air box like the vipers do.

then I had to reroute the coolant hose and a few other things. It is much cleaner looking under the hood


The sled pulls hard for a stocker and I think I got the clutching dialed in as the clutches are cool to touch. Here is a pic from last weekend in the mountains.

 

[Snowman871]

I would be so confused if I saw this pull up sounding like a Nytro! Sweet build!!