2003.5 rev sway bar removal??

[montanass]

really wanting to remove my sway bar, but dont see an easy way to do so aside from cutting the bar on one end... looking for a little advise on removal. my machine is a 03.5 (should be the same as 04) 800 144.

thanks,

Cody

 

[Wyorever]

really wanting to remove my sway bar, but dont see an easy way to do so aside from cutting the bar on one end... looking for a little advise on removal. my machine is a 03.5 (should be the same as 04) 800 144.

thanks,

Cody

When I took mine off I cut it, but I heard afterwards if you drill the rivets that hold the plastic connection pieces to the actual sway bar you can get it out without cutting the bar. Not sure if it works but that's what I've heard. Good luck.

 

[snowcap]

cut it out. after a day of boodocking you won't ever put it back in. but if your a trail rider you will hate it..

 

[mastertech]

Dont be a hacker..

Unbolt it at both ends and the bracket on the belly. tip your sled on the side. takes about 2 mins to wiggle it out..

 

[highmark00700]

Yup just take the plastic bushing in the bulkhead off, also if you have a skidplate you will have to drill some rivits out of it for enough clearance to fish it out.

 

[wildcard28]

If you like it out like about over 90percent who already have, you will like mentioned before never put it back in, also lighten up the front shocks if they are X package and loosen the limiter strap in the front skid shock and have fun.

Wildcard

 

[montanass]

how loose should i go with the limiter strap?

i attempted to fish the bar out last night without cutting, the skid plate was in the way, so instead of drilling the rivets i just cut the bar

i tightened up the front shocks a hair, they were on 1.5 and i bumped them to 2. gonna give them a shot and see, if i dont like i can just tip it and loosen them up in about a minute.

 

[gman086]

Yup just take the plastic bushing in the bulkhead off, also if you have a skidplate you will have to drill some rivits out of it for enough clearance to fish it out.

This! It is a hassle on the '03-'04 BECAUSE it is larger in diameter than the later model years that some here are telling you to just wiggle out. I suggest cutting it out - if you don't like it you can pick up a link style stabilizer bar for a song as many of us have them laying around and ZBros makes a mount for your old-style a-arms for them. The link-style are much better in that they do allow a small amount of independent ski action.

Also do NOT soften up the front ski shock springs afterwards; you need to STIFFEN them up. This is because the opposing shock was "borrowing" force from the other shock when connected by the stabilizer bar so you need to compensate by STIFFENING the front springs! And no need to let out straps unless your sled wasn't set up properly by your dealer. The "X" springs were NO different than stock in '04; in fact I suggest getting even stiffer springs from your dealer.

Have FUN!

G MAN

 

[mastertech]

This! It is a hassle on the '03-'04 BECAUSE it is larger in diameter than the later model years that some here are telling you to just wiggle out. I suggest cutting it out - if you don't like it you can pick up a link style stabilizer bar for a song as many of us have them laying around and ZBros makes a mount for your old-style a-arms for them. The link-style are much better in that they do allow a small amount of independent ski action.

Also do NOT soften up the front ski shock springs afterwards; you need to STIFFEN them up. This is because the opposing shock was "borrowing" force from the other shock when connected by the stabilizer bar so you need to compensate by STIFFENING the front springs! And no need to let out straps unless your sled wasn't set up properly by your dealer. The "X" springs were NO different than stock in '04; in fact I suggest getting even stiffer springs from your dealer.

Have FUN!

G MAN

The man always says it right!!

 

[mil81]

This! It is a hassle on the '03-'04 BECAUSE it is larger in diameter than the later model years that some here are telling you to just wiggle out. I suggest cutting it out - if you don't like it you can pick up a link style stabilizer bar for a song as many of us have them laying around and ZBros makes a mount for your old-style a-arms for them. The link-style are much better in that they do allow a small amount of independent ski action.

Also do NOT soften up the front ski shock springs afterwards; you need to STIFFEN them up. This is because the opposing shock was "borrowing" force from the other shock when connected by the stabilizer bar so you need to compensate by STIFFENING the front springs! And no need to let out straps unless your sled wasn't set up properly by your dealer. The "X" springs were NO different than stock in '04; in fact I suggest getting even stiffer springs from your dealer.

Have FUN!

G MAN

The 03.5 had the "x" style adjusters where they were the screw style. The adrenalines in '04 and '05 had the click style whick didn't allow enough tension for guys pushing 220 when the sway bar was pulled

But g man is right. Tighten the heck out of those spring. I'm right around 200 and have my front springs cranked tight

 

[wildcard28]

Man the 03 must be stiffer and different than the 04 or newer cause this actually the complete oposite of any boondocking set up I have heard or read before, stiffer doesn`t seem to be easier to pull over any sled I have been on that has been cranked up or has a stiff front end you can hardly even get them to tip over with out Yanking!! on the bars , but a softer front end the sled leans over its self as the side you are leaning towards the suspension compresses and tips easier, Maybe I`m wrong but the feel of what my sled was stock to how it is now is a complete difference.

when I softened up the front shocks on my older S chassis 670 Summit X and removed the swaybar and loosened the limiter strap up enough not to make it push on the throttle in the corners and would turn at slow speed turn arounds it performed really well and sidehilled and layed over much better than stock. actually the limiter strap and no swaybar was the most noticeable differences

Good Luck, Wildcard

 

[mil81]

Man the 03 must be stiffer and different than the 04 or newer cause this actually the complete oposite of any boondocking set up I have heard or read before, stiffer doesn`t seem to be easier to pull over any sled I have been on that has been cranked up or has a stiff front end you can hardly even get them to tip over with out Yanking!! on the bars , but a softer front end the sled leans over its self as the side you are leaning towards the suspension compresses and tips easier, Maybe I`m wrong but the feel of what my sled was stock to how it is now is a complete difference.

when I softened up the front shocks on my older S chassis 670 Summit X and removed the swaybar and loosened the limiter strap up enough not to make it push on the throttle in the corners and would turn at slow speed turn arounds it performed really well and sidehilled and layed over much better than stock. actually the limiter strap and no swaybar was the most noticeable differences

Good Luck, Wildcard

If you read g man's post it should make sense to you. When you pull the sway bar the two springs are no longer sharing the load, meaning there is more weight on one spring at a time. So with no sway bar, when you turn a corner the outside spring just sinks. The sled gets scary tippy on the trails. Same thing when you lean it over to carve. Even though you have the spring cranked way tighter, it actually feels softer than stock, and is easier to carve.