project 800. (snowmobile)

[95dime]

so i know theres some sled guys on here so this is whats been keeping me from working on my truck. new sled project. its been slow going lately as i race an f7 in grass drags for hebelers, but the season is over for us now so the pace is picking up on this again.

i used to have an '01 zr600 efi le that i loved, but as usual i wanted more horsepower. i also had a TON of aftermarket for the zr chassis that i didnt want to loose out on, and there still isnt a single sled that handles as well as the zr while still being able to put up with my abuse, and the twin spars are just too much money right now.

so i bought an '03 zr800efi snopro with low miles. onto the progress…

the sled the day i brought it home

swapped over my hood, tank, seat, etc. hood will be getting repainted.

swapped in my “speed track” its a camoplast 3/4" full width lug with 240 megabites with plastic square backers. trenches in the deeper stuff but it flat out hooks and rips on the trails and has good top end.

started stripping it down

cleaned up the chassis

polished chaincase cover. will be leaving gearing stock. stock gearing on these 800’s work really well.

picked up some random parts

modified airbox, instead of removing the silencer for more airflow, i simply added a 2" tube to give more air to the tb’s while still keeping velocity up and turbulence down.

airholes in airbox, put these farthest from pipe and right under where hood vents are for cool air

tank and seat permanently mounted

stock can blasted and painted. will be d&d ypipe and pipe with stock can.

bar setup done minus longer throttle cable. running an rsi 7" riser with renthal fatbars in cr bend with fly aluminum hooks under ruffian grips. also have bars filled with foam and rsi high output warmers rsi longer brake line and black powermadd handguards.

more parts. adjustable clutch weights. heavy hitters are the way to go.

went through clutches and did some clutching to get me in the ballpark. ill put my vdo recall tach on when we have snow to fine tune the clutching. i dont buy clutch kits. kits are a compromise.

polished clutch cover

front suspension and randoms powdercoated. opaque black chrome.

rear suspension powdercoated same color.

picture to try and show the color. basically its just a really shiney black

rear skid completely rebuilt and ready to go in with some sneaky performance tweeks.

[KuntryQuestTSi]

03 was the best year for these IMO. No diamond drive BS. I take it your sticking with the 13.5 track? I think I’ve spotted a little something in the rear skid :snky:

[95dime]

@KuntryQuestTSi

03 was the best year for these IMO. No diamond drive BS. I take it your sticking with the 13.5 track? I think I’ve spotted a little something in the rear skid :snky:

is what you see in the skid the clicker front and rear shocks with the bearcat spring on the front shock? plus the limiters set very loose and no coupling blocks. this thing will transfer and ride awesome. lol

firecats were the 13.5, zr is 15"

03 was last year for the 800s, best year for the 900’s.

03 was best year for firecats, lightest, no DD, and best tune(most on the edge mapping/timing. our race sled is an '03. best pass of 5.62 @ 89 with a 1.43 60ft in 500 foot. thats setup with stock track, trail stock class setup. pretty sure its the fastest trail stock f7 anywhere. took us a few years of tuning and racing to get it that fast, next year will be faster. right now were running with the isr sleds already.

this is the race sled. believe it or not, this pig has 7k miles on it

[jay_g]

What’s the hp for these motors? Looking good, I’m a skidoo guy myself but I do have RSI risers on my sled and quad. Real nice products.

[95dime]

@jay_g

What’s the hp for these motors? Looking good, I’m a skidoo guy myself but I do have RSI risers on my sled and quad. Real nice products.

agreed. rsi products are very nice. hp for the zr800 is about 140-143hp. as far as that goes, the airbox mods, reed petals & spacers, d&d ypipe and pipe, and possible cut head(depends on what my squish is at right now for comp.) i should be right at 150hp. that with my clutching and suspension should put me at about 112-114 on radar with getting there pretty quick. not the fastest but still respectable and fun.

eventually in a few years when its time for a rebuild, itll get 900 jugs with spi coated pistons and the 800 heads will be cut for the larger bore.

[jay_g]

I was thinking they were low 130’s, lol shows how much I know about arctic cats. Unless it weighs a ton it will fly.
I ride a mxz 670, it’s old but its snappy. For me its all about getting up to speed quick, its rare to have enough room to get up to 100+. Come out of woods, WFO for 5-10 seconds then jamb the brakes for a more woods and beat my back up lol. Maybe this year we will finally have a nyspeed sled meet.

[ryanbgb22]

@jay_g

Maybe this year we will finally have a nyspeed sled meet.

Yea, we need to work on this. Prettymuch everyone I use to ride with bailed out.

[95dime]

jay_g, the zr weighs 515 lbs, but with the lighter boss seat, c&a skis, and pipe, i should be around 500 even. so not too bad for being an older sled. but yea, defineatly not low 130’s lol. i wouldnt have bought it if they were only that. and i hear ya on point a to b speed, thats how i like em, but when you clutch em yourself you get that and the top end because the clutching is spot on instead of just being “good enough” that all the aftermarket clutch kits are. my zr600 i had before was dead nuts even with a clutched and studded f6 and it lifted the skis til about 65 and just floated after that. clutching and suspension can make a sled feel entirely different.

ryanbgb, i agree. not too many people i know that still ride other then the guys i race with. i would be up for an nyspeed ride could ride out to the log cabin or something.

more pictures tonight.

[Spam16v]

Used to work for Tim Bender back in the Cup Lite racecar days. After i melted down my engine, Tim helped me re-“build” it. '88 Indy 400. Got radar’d on Redhouse Lake @ 108 with a tall windshield 2up in the mid 90’s. Spent a good many days massaging those transfer ports. Open the hood and it looked 100% stock though… complete with rusty stock pipe… shhhhh

[ryanbgb22]

@Spam16v

Used to work for Tim Bender back in the Cup Lite racecar days. After i melted down my engine, Tim helped me re-“build” it. '88 Indy 400. Got radar’d on Redhouse Lake @ 108 with a tall windshield 2up in the mid 90’s. Spent a good many days massaging those transfer ports. Open the hood and it looked 100% stock though… complete with rusty stock pipe… shhhhh

Wow, 107 out of that 400, stock besides porting? I had a 93 440 that would struggle to go 70.

[95dime]

never heard of a 400cc running 107 radar especially just with motor work and no pipe…glare ice and geared way up? hard to believe lol

anywho, update for tonight. its finally coming together and i dont have parts scattered all over. tomorrow will be some more progress most likely.

front suspension and bumper bolted on

rear suspension back in

[Spam16v]

cylinder head might have said 400… snky snky, it was glare ice, with a bunch of toying with the clutch. they were geared pretty tall to begin with.

[jay_g]

boss seat is tits, jealous

[93dx_hatch]

nice progress, you are inspiring me to get my sled in the garage so I can put a track on it.

+1 for the nyspeed sled meet. Maybe Chautauqua lake so we can get some top end runs

[boardjnky4]

ugh, trails in chautauqua county are awesome

[95dime]

jay, if you ever even think about getting a boss seat, just do it lol. hebelers can order them if you want to go local. i got mine for like 300 bucks. the fitment needed work and it still isnt perfect(the new generation of boss seats dont have as good of quality) but the ergonomics and feel of the sled after having it is awesome. i love mine it has better ergonomics then the “rider forward” chassis sleds. chataqua county trails are considered as good or better then trails in OF and the hill, theyre some of the nicest trails ive ever been on and dont get the traffic that old forge does. ive only been on the lake there once, snow was fairly deep though but it was coming down good when i was out there. does it clear off a bit so its more packed? i could get ahold of a radar gun if anyone wanted to go out there.

should have more progress pics tonight.

[95dime]

alright tonight i wired in a heated shield hookup(even though i wear a snoxhelmet with smith vented goggles, might get a fullface with heated shield for the icecold/snowy nights lol), got the rear idler wheels on, couple random brackets. nothing worth taking pictures of til more progress. also picked up some heat tape and got the metal i needed to make a new stand since i donated my last one to our race team as a backup.

[95dime]

update…

silencer trim piece in and new heat tape in and trimmed

silencer in…i think next year im gonna modify this thing so its a little lighter while still being quiet.

couldnt find black 5 spoke idler wheels, so i did what i had on my old 600. went with the same setup the snopros run

tunnel has been consuming alot of time but is finally paying off. one side done

its pretty shiney. now to finish the other side then clean up the rest of the sled

[93dx_hatch]

Did you do the tunnel by hand? Process?

[KuntryQuestTSi]

@93dx--hatch

Did you do the tunnel by hand? Process?

Look at the pictures. There is a rag and some mothers polish. Do this with a power ball to speed up the process in large area’s. and bust knuckles the rest