PrayN4snow's Stage build/tuning the AXYS RMK 800

I'm going to document the stage building my personal 2016 AXYS 800 RMK. During this build Ill try to show the good, bad and ugly.
Note: not everyone can afford or needs a turbo or big bore kit. This build is based on the "Average mans budget and skill level". There are many good manufacturers out there (and I've used many) of performance aftermarket parts so please no bashing one over the others, if you like different products start your own build. I chose Bikeman this time for several reasons. #1: I now live in upper Michigan and Bikeman is one of the closest to me at six hours away. #2: They have a reputation for reliable performance parts from long hours of dyno & on-snow research and engineering. #3: They have enough stages to fit mine & most people's needs. I'm going to start out with stage 1 being a baseline (stock) dyno test then installing a Bikeman ceramic coated performance pipe and muffler. I'll be documenting the installation, fit and finish along with real world bang for your buck dyno results of power gains. Also if there are any possible "notable " side effects that Ive had in the past with other companies such as good or bad exhaust temps, plug readings, piston wash, melted plastic panels, real world weights etc. "Starting with" the pipe and can shown here: http://bikemanperformance.com/bmp-axys-800-performance-pipe.html

As you can see I'm expecting to lose some weight and gain some horsepower & torque.

The next stages as my budget allows I will install Bikeman's reliability kit (piston, shims and gaskets) http://bikemanperformance.com/bmp-800-cfi-polaris-durability-kit.html Bikeman's performance billet head, and Bikeman's custom tuned Bully Dog controller http://bikemanperformance.com/snowm...bmp-programmed-bully-dog-gt-for-axys-800.html Down the road maybe they'll have a big bore kit that I can't live without. For now this is the plan, and Id like to complete everything in the next month weather & wallet permitting (Dyno time & traveling).

You might be asking Who am I and why am I doing this?
1st, I'm not paid by Bikeman or have any friends or family that work there (or any another aftermarket companys). Right now they know I'm going to buy some parts and know Im going to write up my every experience (remember the good,bad & ugly). Personally I've been riding every year since 1972 (yes started on Kitty Cat), except for some years in the Gulf war. My Dad rode, built & raced snowmobiles and hot rods (until he passed) and I followed ever since. I used to race some and Im retired military (20 years). Yes, some that know me know I got hurt bad while in, and the VA considers me a disabled Vet, however I do not and Praise God I can still walk, ride and enjoy life unlike my doctors predicted. (my surgeons joke I put their kids through college) I'm now limited in what I can do physically, and monetarily living on my retirement. This is all more than I wanted to share, but this is purposely trying to be an honest thread for us "average Joes".
My riding style is total back country exploring (see "My Favorite Alaska riding areas" in the Alaska section), boon docking and tree hustling. I love climbing and used to live for high marking, but lost to many friends and close calls myself.

Back to the build:
I also wanted to do a port and polish on my cylinder heads cylinder heads but Bikeman talked me out of it, as there wasn't enough performance to warrant spending the extra $275 per cylinder. Many performance companies would have gladly taken my money for this service, however I appreciate Bikeman's honesty and this was the start of building my trust on this build and why I chose them.
The "Good"- they didn't take my money for nothing.
The "Bad" is we as consumers often think we "know"what we want without doing the research. The "Ugly" is I've dealt with other companies that would taken my hard earned money and run while knowing there were no strong performance return for investment.
Note: On other motors I've had fair to huge gains with "good" porting, Ive also had shops ruin cylinders that cost me riding time. No performance is worth missing a blue bird day (or week) and a fresh dump of powder in my book, reliability is key IMO.

I have other plans as well for this sled, I need to update clutching, possibly testing some other belts, suspension and front and rear bumpers, duraflex ice scratchers, ballistic pull start rope etc.
When I raced, I wanted the lightest and fastest everything I could get. Now, after multiple back surgeries, 6 shoulder surgeries, hands & knees surgeries, steel taken out of my eye and a head injury I need the sled to "work", and not "overwork" me. At @50 years old, I can still go most anywhere, and try to do all-most anything guys half my age can. Im not dropping huge cliffs or snow cross racing but I try to push past my limits and encourage some of my riding partners to push their limits each time we ride.
Thats who I am, thats what I'm doing hopefully in this build. If you care to see me succeed or fail stay tuned. Note: please be patient, some parts are not readily available yet, I will build as they come available and weather turns cold enough to Dyno. Thanks.
PrayN4snow

<a data-flickr-embed="true" href="https://www.flickr.com/photos/133877370@N03/21270751541/in/dateposted-public/" title="robert in tree2"><img src="https://farm1.staticflickr.com/749/21270751541_3d4d5ab431_z.jpg" width="480" height="640" alt="robert in tree2"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>
When he says riding past his riding partners limits, he's not joking. I mean, look at how the top ski is on one side of the tree, and the bottom ski is on the other. That takes skill... You guys should of seen the dismount!

But, on a serious note...PrayN4Snow is a very good guy and I am excited to see what he does with his new sled. I'm also excited to hop on this thing when he's not looking and taking it for a spin. I am very sure all of his reviews and thoughts of products will be down to earth and honest as he is no newcomer to the game of snowmobiling.

Edit: I'm impressed that Bikeman talked you out of porting this thing, that says a lot about a company IMO. I've had a few very positive dealings with them, and I would not hesitate to call them up for assistance or advice in the future!

Thank you for your service!

Sounds like an interesting build! Always nice to see these types of threads.

Great introduction for what your planning to do and taking the time to keep us all informed of the results-

Us in the 50 + age group gotta stick together-and make improvements for the sport we have loved for so many years-

S/C

plugitin said:

When he says riding past his riding partners limits, he's not joking. I mean, look at how the top ski is on one side of the tree, and the bottom ski is on the other. That takes skill... You guys should of seen the dismount!

But, on a serious note...PrayN4Snow is a very good guy and I am excited to see what he does with his new sled. I'm also excited to hop on this thing when he's not looking and taking it for a spin. I am very sure all of his reviews and thoughts of products will be down to earth and honest as he is no newcomer to the game of snowmobiling.

Edit: I'm impressed that Bikeman talked you out of porting this thing, that says a lot about a company IMO. I've had a few very positive dealings with them, and I would not hesitate to call them up for assistance or advice in the future!

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Haha, thanks John. See, times have changed and nothing is sacred anymore with the internet. Not even your worst stuck pics. The stump I side hilled into above that tree faired better than I did lol.

I'm really curious if the BullyDog is needed and how valuable it is. It's a costly piece of the puzzle. I've been told that they don't really provide much detail in terms of interacting with the Polaris motor. I had one on my Silber and they are nearly impossible to see while riding. I do like that you don't need them once you have loaded your map. It looks like that link Prayn4snow provided does not include the BullyDog.

EDIT: I did find the link for the BD on the BMP website. $700! plus you need to pay another $50 for a tune. HERE is the link.

I have the same curiosity on the tuner. Ill know 1st hand if it adds enough benefit for the money. Here are a couple reasons Im going to try it. 1st is the added power if its as claimed. 2nd. The new oil pump can't be manually turned up! You have to have a controller to add more oil and this tune has it! 3rd its the only way to adjust stock fuel curves and RPM limits. For example if the stock motor peaks at 8150 and the mods peak at 8350 your not getting the added power you paid for because the computer stopped you from going past that point. These are good questions and the only way I (we) will find out is someone doing a documented build. Please keep in mind these are only going to be my humble opinion based on my experience of each stage and outcome. Im not a P.H.d in mechanics and computers, I'm only a fellow knuckle dragger wrench bender like many of you.
On a side note. Ive had 5 different controllers on my Duramax. Some worked good, some great and some too good for my use. For example Im running the Banks 6 gun now, its a great controller for most people but it has to much protection and doesn't like all the power I'm making with the 2 stage NOS. It thinks its trying to protect a stock transmission that has been replaced with a sun coast stage 5, so it has to go. Please lets not get side tracked about Diesels Im just using an example.

#2 reason is a good one! I didn't know that. I don't think you are going to get to make modifications to the BD unless you buy that piece that allows it. In my experience, you get the BD controller and whatever map you buy from the vendor (BMP in this case). But I'll wait and see what your experience is.

AndrettiDog said:

#2 reason is a good one! I didn't know that. I don't think you are going to get to make modifications to the BD unless you buy that piece that allows it. In my experience, you get the BD controller and whatever map you buy from the vendor (BMP in this case). But I'll wait and see what your experience is.

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Your right. Thats where the extra $50 fee is for the stage you want. Your basically paying for all the research and development the Dyno guys come up with. Let me tell you that Dyno time for cars is Not cheap. My corvette is getting a custom EFI tune because no one has put a Holley Terminator on a Procharged small block running the power I'm putting through it. That Dyno time is $400 an hour

AndrettiDog said:

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EDIT: plus you need to pay another $50 for a tune. HERE is the link.

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True, but if you were paying for a snowmobile dyno time its $150 an hour with a 4 hour minimum. So your at $600 already. Controllers are expensive I agree. I also don't think everyone needs one, however if people are changing things or adding power this is the best way to make sure everything is compatible IMO.

Loaded up the sled and ready to head out for stage 1 tomorrow. My friends at Leutz sign shop in Marquette Mi just dropped off their prototype "Snowest" avatar windshield sticker to start the build.

Thank you for your service and sharing your experiences.

I'm headed to Wisconsin to Bikeman's today, then on to Haydays! It's interesting how many people are interested in this build after one day and aftermarket parts in general for the Axys. My phone was ringing like crazy yesterday. I'm a long way from done but thanks for the support.

I made it to Bikeman performance this afternoon. Every thing is crazy there because they're getting ready for Haydays. They (rest of the workers there) now know about this build and their surprisingly ok with me talking about my findings. Their parts guy grabbed a random ceramic coated pipe and can for me to start with. They didn't hand pick anything so these will be a good representation of what everyone else will get. I took out the factory pipe and can then I weighed both of them. Im using the same scale to weigh the new pipe and can as well. The reason I did that is have you ever been to the gym and weighed yourself on their scale or the doctors office and it's different than your scale at home? I wanted to compare apples to apples. As expected there is substantial weight savings in the can (muffler). The factory muffler on mine was 19.15lbs. The Bikeman large "Full velocity" muffler was 9.8 making it 9.35lbs less! Remember I said I'd show the good, the bad and the ugly? Well Bikeman's catalog claims this muffler is 7lbs less than stock, they were being very conservative! (thats rare in the aftermarket world, some exaggerate bad). That's "good" for us consumers being another 2.35lbs less than claimed! The smaller Bikeman "Powder Lite" muffler is claimed to be 12lbs less, but it was actually 13.5lbs less! The stock pipe is almost the same as Bikeman's so there is no weight savings in fact it was 0.15 of a pound heavier. That's not a "bad" thing, because there's a substantial quality-control difference. The factory pipe is much thinner and has a poor seal (see other peoples treads on S.W here). Just the little I've been running it (stock pipe) has been spraying oil out all over the belly of my sled so that's "the Ugly ". I compared the fit to the Bikeman pipe and it's much tighter tolerances and the donut seals better even without high temp gasket sealant. The stock pipe has an outside cover and insulation that adds to its weight, the Bikeman pipe doesn't have that but it's thicker making up for the difference in weight. Bikeman's also uses a ceramic hi-temp coating instead of the insulation, the added benefit is that it leaves more clearance for the over structure and hood and doesn't trap moisture under it like the stock insulation and helps hold heat in which is needed. The bosses left for a while so I asked one of the workers for a tour of their facilities. Im not sure if they (bosses) wanted a nosy customer looking at everything but I'm impressed with how organized they are. Each department was well thought out. They definitely have an excellent supply of parts so you're not waiting if you do order something! I met the owner Jimmy quickly and the general manager Mike longer. I'll post more later.

I'm traveling right now so my pics aren't wanting to download so I'll get them up as soon as I can. This is of course the stock pipe and muffler birds eye view. The muffler is so big you can hardly see the battery!

Because my pics aren't loading right now I'll describe their shop. I also got to talk to Mike more and met Joey (dyne guy). The waiting room is full of world championships trophies and signed pics of world class racers thanking Bikeman for their products and services. Some have come back to work here so when you talk to someone like Joey in the tuning/Dyno area your talking to a world record holding racer. Joey went on to U of M for engineering and worked for Ford helping them with problems in their vehicle software. He went on to further study Dyno programming and knows how to properly tune motors for customers. The factory's have some smart guys too, but they have to pass every emission standard and make a tune that fits "everyone for every situation". That leaves a lot on the table. I told him I was having second thoughts on adding a controller and he showed me the inside of the factory tune and compared it to their custom tunes. I'm now sold! I won't give up their trade secrets, but they have some serious time in this Axys computer. An interesting quote from him is that he loves his job and said "try to find a job where you have fun everyday, I do, and I love making thing go fast!). Bikeman's general manager Mike happens to be a gear head as well. He raced quads and loves to ride sleds, side by sides and has his own ramps in his yard for jumping 35' in the air on a 75' gap! How many bosses do you know like that? He's went to school as a motorcycle mechanic and is good at porting, machining and now oversees the whole shop. He's only 27 and has worked there for 7 years. Mikes very motivated so he's set to keep up with the ever changing power sports industry. The interesting thing is that all the employees I talked to enjoy working there and their all addicted to power sports. I found this Interesting.

I figured out that I can't load all the pics I took here because of a weak connection. Im at Haydays so I might have to load all the pics when I get back. Im taking pics of everything including the weights of the parts. Sorry

Pics #1

Pics #1 Inside the warehouse. Sorry their sideways. Im not on my computer to fix them.

Stock pipe & muffler before, fit and finish and weight of muffler pics. Note, some of the exhaust springs are really hard to get to on the bottom of the Y-pipe with the electric start. I bought one of their long spring puller tools because mine wouldn't reach even without the electric start. I might buy a second one for inside my enclosed trailer.