Edge 500 Transformation

[Vinnee]

Before everyone starts yelling "USE THE SEARCH FEATURE", let me assure you that I have searched old threads to get me to this point.

So with that said.... I need help understanding some details of a build I would like to do for my son.

I just picked up a 2002 Edge 121 with low miles. My goal is to extend the tunnel and convert the sled to a 144".

(This is when allot of you Edge guys start nodding your head, knowing what's coming next.....)

Of course I want to put a two inch paddle track on the sled! But you already knew that, didn't you?

In researching threads, I have learned that the full length tunnel coolers (potentially) get in the way of this being possible? So the options seem to be, notch the track, install a U cooler, Install a single cooler in the back of the tunnel similar to the Vertical Edge....? So, I get the track notching... pretty straight forward, but I hate to notch a new 144"! But as far as the U cooler goes, is this a full length cooler you install in the tunnel? What makes it different than the factory coolers? Is it evidently thinner than the factory cooler? How much room do I need?

What would you do if it was yours?

Went to the Snow Show last week and picked up 144" rails as well as a tunnel extension. Now all I need is a track!

Any suggestions you have would be most appreciated!

 

[Ryanlilly]

I may have a possible solution. I modded my 144, so I have my 144 rear extension, front and rear coolers, and the 144 foot rest coolers. If your interested let me know.

 

[X2Freeride]

Any U cooler is going to be thinner than the stock strip coolers in the tunnel. So by installing the "U" cooler you will have enough clearance for a 1.75 for sure. A 2" should be fine too, but I'll be honest I dont think I would put a 2" track on a 500 CC sled at that length at elevation with a 144. You dont have a lot of power at the track, even geared down spinning that big of a lug at that length is going to put quite the strain on that engine. Ever consider going to a 1.5 track? then you can use the stock coolers and just gear down for the length. The engine should still have enough power to spin that.

 

[Goinboardin]

Your son looks stoked!!
I'd run a 2" paddle without thinking twice about power, won't win any races or top over any big mountains, but it will work more than fine. I had a 1990 500 motor spin a 136x2 and I'm alot heavier than your son.
Couple guys out here put a 151 on a gen II 500 and said they loved it for skiing access.
I may be wrong, but don't you only have to notch the track if you run the stock coolers?

 

[treemagnet03]

Pretty sure camoplast sells a prenotched track. They used to anyway. Kimpex did and I installed that without much trouble several years ago. I will say though that a 1.75 will be a pretty good bet as you will essentially be rubbing on the front cooler at 2in. Better for snow clearance too. And fighting to put that 2in in is an absolute pain in the...well...

Having done this same thing myself, I will note that he is going to hate sidehilling this thing without some adjustments to the shocks/deletion of the sway bar. Also a ski with less outer edge (like the sidehiller skis) will make it easier. This sled is designed to stay flat and does so quite well...

One more thing is to get some better boards (or similar) on there so it doesn't pack in the snow and send him slip slidin' all over.

Tell him to have a blast on this sled! That 500 is a classic sleeper for its size. Now thinking about it, a Holtzman ATACC system would keep this thing crisper powerwise if you get around to it...the list of a dreamer here...

 

[Vinnee]

Thank you all for some very solid suggestions! I really appreciate your feed-back, ideas and expertise!

My son is absolutely stoked for sure!

Tree- ya, I recognize this thing is designed to keep the skis on the ground. Do you have experience or reccomendations on suspension set-up? I did already determine that the swaybar needs to go!

My son is seven and just 65lbs so he should have plenty of power. I would like for him to get a couple years on this before putting him on a 600 155" IQ.

Thank you again! Project starts tomorrow!

 

[treemagnet03]

Yeah-

The front suspenders I set pretty soft at first and brought them back up as I weight about 190 with gear on. I have the same shocks as that sled I believe (you are lucky to get the X). Which is good because if you can adjust the compression of the rear such that it is softer. Moving the front and rear arms forward helps with the attack angle and squat. And set the rear blocks to the soft setting. Should be a good place to start.

You might even want to invest in a set of softer torsion springs (cheap if you look in the midwest). Though keep the stiffer ones for him as he grows up.

That motor should be great, just watch the o-ring on the head...I've seen 3 leak.

Hope this helps and have a great winter!