So...I sold my wife's Mountain Cat 800 last fall and bought her an M8...PROBLEMS!!!!!
- Thread starter borderstaff
- Start date
borderstaff
New member
Rebuilding a sled is really just a matter of memorizing where everything that you took off goes when you put it all back together. It looks intimidating but after this project, I can honestly say that its not rocket science. You just have to use common sense and try to group sections of the sled together. I tried to keep the front suspension, rear suspension, plastic, steering components etc in separate piles in the garage and it made reassembly much easier.
Anyhow, I buttoned up the bottom of the sled tonight and tomorrow I will have it running. Its coming out so clean we could eat off of it. And we will!!! I already reinstalled the "Muff Pot" on my wife's sled and I also have another "Muff Pot" on my M8 - 2 course meals are in our future!
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mjkaliszak
New member
QUOTE " Rebuilding a sled is really just a matter of memorizing where everything that you took off goes when you put it all back together".
Delrin would be my plastic of choice. It is very stable and does not shrink & deform over time. Does not become brittle, is not cheap as far as materials go. Actually the price is staggering. It's good stuff & used in many industrial applications .
I just replaced the S & E module on my SD, not a small project either, when I looked at the micro fiche the fasteners alone were overwhelming. I took pictures then labeled & grouped my parts together during disassembly.
Borderstaff: You might want to check your harness for wires rubbing during final assemby, I had some issues with my F6 harness and eventually had to individually tape connector terminal wires & rewrap the convolute of the harness. Wires rubbing and/or getting pinched will send some CCU errs. Kind of drive you crazy or at least it did me. Just something to look out for as you go.
Just a suggestion, ( don't take this the wrong way ) but you should do something with those torsion springs It doesn't look right with the rust , AND your front shock springs ???? Maybe white would be a good contrast, many years ago I "rattle can" painted my skid & front shocks, it kind of held up well. OR... You could do a black fade to orange like you slydog ski's ???? I guess at this point .... I would bar no expense, you could get some custom decals made ( right / left good ones ) for your tunnel that say( BS Engineering or something) ! I mean that in a " GOOD " way. Something small to put your " seal " of craftsmanship " on it .
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borderstaff
New member
mjkaliszak, I appreciate any and all advice. I did double check as many potential wire rub areas as I could. As far as more cosmetic improvements, time constraints are my biggest problem now. I need to have the sled running tonight so I can break the motor in. Then, exactly a week from me writing this we'll be rolling into the parking lot outside of Cooke City for 4 days of riding in Montana. So, although I'd like to do a few more things to add to the eye candy, it will have to wait until after the riding season is over because I haven't yet had a chance to go over my M8 and prepare it for the trip also.
where did you fit your muff pot I riveted it to the can.it fit no place else I have a D&D pipe and I think the tail is taller than stock where it goes in to can not enough for a muff pot.almost thought about a timbersled intake to get rid of the under hood duct work but thought that was just a tad extreme just to accommodate a muff pot
borderstaff
New member
I don't have a pic of the Muff Pot right now...but I installed it at the front edge of the main pipe about 4"inches after the y-pipe. I had to move it back and forth a few times to clear the hood ducting but it does fit.
borderstaff
New member
WELL ITS FINALLY DONE!!!!!!!!!!!!!
Indy was the first to ask about the skis. I sold the stock M8 skis and bought a set of Slydog Powder Hound skis. I was sold on the orange flames molded into the black background. They are wider than the stock skis by about an inch and it was a toss-up between these and Simmons Gen 3's. I went this route to save $100 (the skis cost $245 shipped).
Here's the left side. I bought the hood at the Rum River Grass Drag and swap for $20 and put a little time into zip-tying it into shape. I put the stock hood away so when my wife rolls the sled down a hill or two and wrecks the hood I won't care as much. Now, thats not saying that she's an unskilled rider...but this sled isn't going to spend much time on the trails and it won't be babied so a roll here and there are going to happen.
Here's the right side.
And, finally, the happy owner!!! Merry Christmas honey!!!
Indy was the first to ask about the skis. I sold the stock M8 skis and bought a set of Slydog Powder Hound skis. I was sold on the orange flames molded into the black background. They are wider than the stock skis by about an inch and it was a toss-up between these and Simmons Gen 3's. I went this route to save $100 (the skis cost $245 shipped).
Here's the left side. I bought the hood at the Rum River Grass Drag and swap for $20 and put a little time into zip-tying it into shape. I put the stock hood away so when my wife rolls the sled down a hill or two and wrecks the hood I won't care as much. Now, thats not saying that she's an unskilled rider...but this sled isn't going to spend much time on the trails and it won't be babied so a roll here and there are going to happen.
Here's the right side.
And, finally, the happy owner!!! Merry Christmas honey!!!
borderstaff
New member
Just so everyone doesn't have to scroll to the bottom of page 2 here's the finished product:
There's still a few tiny things to address like the nose vent covers and putting the gas tank on the back, but all in all its ready to go and I did run it for about 10 seconds tonight. Tomorrow I'll run it through a few heat cycles to break the motor in and then hopefully the new reg. numbers I ordered will be here Friday so I can take it out for a few miles before the big trip.
THANKS EVERYONE FOR THE GREAT COMMENTS...ITS BEEN A FUN BUILD AND I ENJOYED READING WHAT EVERYONE HAD TO SAY ABOUT THE SLED!!!
There's still a few tiny things to address like the nose vent covers and putting the gas tank on the back, but all in all its ready to go and I did run it for about 10 seconds tonight. Tomorrow I'll run it through a few heat cycles to break the motor in and then hopefully the new reg. numbers I ordered will be here Friday so I can take it out for a few miles before the big trip.
THANKS EVERYONE FOR THE GREAT COMMENTS...ITS BEEN A FUN BUILD AND I ENJOYED READING WHAT EVERYONE HAD TO SAY ABOUT THE SLED!!!
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techsledder
Member
That sir is one job well done! Very nice!
That sir is one job well done! Very nice!
What he said!
borderstaff
New member
Yes, I'd do it all over again. This is the second sled I've done this to. The other one that I replaced a tunnel/bulkhead on was a 2002 ZR 600 that I did about 6 years ago - although on that sled I didn't bother with any mods. I just wanted a sled to ride for the winter. I'm sure in the future I'll find a reason to do another one. But, the next one will be for me will probably include adding a turbo. Until then I have a lot of other projects to do...namely a new driveway, rebuilding the 77 Ford that I have and my wife wants a new kitchen...oh, the projects never end.
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vic_junior
Member
Looks good Chad, now you and your wife can tear it up in Montana. Have fun on your trip!!!
