Help me finish my sled, need some advice

[Ak4life]

Well my sled is still apart but the last of my parts should arive early this week and my case and crank should be ready later this week.

Here is my problem, I got this thing with the motor torn out in a box and a bag full of nuts and bolts. What I need is a procedure for putting this motor in(06' 755). I really need to know the order of installation, wire, cable and line routing. I may also need some hardware identification as I go. I have downloaded the service manual and its great for smaller details but not much help when it comes to the full assembly. Its sorta like putting a puzzle together and all you have is blown up pictures of each piece.

It would be great to have some detailed pictures of some engines in various states of assembly. I will be providing some as I go too.

Thanks,

 

[sled_guy]

Wow. You've picked quite the project to get started with.

Guys spend years gaining the knowledge you are looking for.

Did you tear it apart? Take pictures or notes or anything when you were taking it apart?

sled_guy

 

[Ak4life]

Wow. You've picked quite the project to get started with.

Guys spend years gaining the knowledge you are looking for.

Did you tear it apart? Take pictures or notes or anything when you were taking it apart?

sled_guy

Like I said I got the sled with the motor in a box with a bag of parts. I got a new bottom end for it. The motor will be ready to drop in. I have a ton of experience with building sleds, but this particular sled is a bit different than any other poo motor siting on a set of straps. I have enough experience to know that there is an order that needs to be followed, being that I didnt take the motor out that is the info I am after.

 

[94fordguy]

Hmmm, A complete set of instructions for assembly is something that would be very good to have here. I helped rebuild my buddies 900 this summer with the new crank, so we literally tore it down to almost nothing (oil/water pump cross shaft was the only thing left attached to the cases)


I do have a whole bunch of pics of the motor in various states of assembly if that would help. but I don't have them uploaded

As far as dropping the motor in, it's a little hard to recall all the details, I believe we dropped it in, hooked up all the injector plugs and water lines that run behind the motor, and then worked around to the front. Hard to recall all the specifics tho, luckily pretty much all of the electrical connections are one way, so its pretty hard to get things screwed up as far as that goes... the onlything that jumps out at me is to make sure you get the injector wires on properly, they will be labeled for which position they need to connect to.

I hope that helps a little...

 

[Ak4life]

Hmmm, A complete set of instructions for assembly is something that would be very good to have here. I helped rebuild my buddies 900 this summer with the new crank, so we literally tore it down to almost nothing (oil/water pump cross shaft was the only thing left attached to the cases)


I do have a whole bunch of pics of the motor in various states of assembly if that would help. but I don't have them uploaded

As far as dropping the motor in, it's a little hard to recall all the details, I believe we dropped it in, hooked up all the injector plugs and water lines that run behind the motor, and then worked around to the front. Hard to recall all the specifics tho, luckily pretty much all of the electrical connections are one way, so its pretty hard to get things screwed up as far as that goes... the onlything that jumps out at me is to make sure you get the injector wires on properly, they will be labeled for which position they need to connect to.

I hope that helps a little...

Thanks,

I am pretty good to go as far as assembling the motor, I've got all the torque specs for that.

The "little" details are what I need. I have never even seen a hood lifted on one of these things besides mine. From the few pics I have collected there is usually a air box/intake covering the pto side and the pipe is covering the mag side so the little things are covered up. All those things that you mention are exactly what I am looking for.

Pictures and tips and tricks for dropping these things in is what I am looking for keep it coming.

 

[rmk727]

first things first, take a deep breath and then start cussing next put a pillow or mattress on the shop floor to throw tools at so you don't hurt the tools hope this helps and be sure I really feel for you that job sucks.

 

[snwman77]

I run my own shop and I can help you.
give me a call anytime and I can give you hand when you need it.
303 746 3938
kev

 

[f15ejedi]

Where in Alaska are you? I just finisned putting my 900 together and I'm pulling the handle tomorrow. I was lucky enough to take my own apart so I labled everything in seperate bags so it was much easier to put together after waiting for all the parts. I would hook up the injectors and hoses to the back of the engine first, then set a board across the bottom so the engine isn't sitting on the steering arm. Set it in and start two bolts on the front mount. This way you can pivot the engine forward to hook up all the stuff behind the engine. Have the engine completely put together before you put it in.

 

[Ak4life]

I run my own shop and I can help you.
give me a call anytime and I can give you hand when you need it.
303 746 3938
kev

Thanks man

Where in Alaska are you? I just finisned putting my 900 together and I'm pulling the handle tomorrow. I was lucky enough to take my own apart so I labled everything in seperate bags so it was much easier to put together after waiting for all the parts. I would hook up the injectors and hoses to the back of the engine first, then set a board across the bottom so the engine isn't sitting on the steering arm. Set it in and start two bolts on the front mount. This way you can pivot the engine forward to hook up all the stuff behind the engine. Have the engine completely put together before you put it in.

Im out in Wasilla, good to hear you are about to get yours running. When I disassembled the motor I put everything in ziplocks and labeled it. Im covered on all the stuff I took apart. Your advice is exactly what I was looking for. Nice little trick only putting two of the bolts on so you can move it forward.

Any advice on installing the oil tank and the heat shield(s) like where the oil line should or making sure that some of the electronic plugs should be so the wires dont get pinched or chafed?

 

[f15ejedi]

couple of pictures that might help

 

[donbrown]

Thanks man



Im out in Wasilla, good to hear you are about to get yours running. When I disassembled the motor I put everything in ziplocks and labeled it. Im covered on all the stuff I took apart. Your advice is exactly what I was looking for. Nice little trick only putting two of the bolts on so you can move it forward.

Any advice on installing the oil tank and the heat shield(s) like where the oil line should or making sure that some of the electronic plugs should be so the wires dont get pinched or chafed?

The oil line goes between the cylinders and is a very tight fit. I think it is better to run it over the head but for stock it is between the cylinders.

 

[duece1]

Here is a pic of the rear of the 755 showing the injectors and oil supply line running between the jugs. I just put mine back togeather this last weekend and it was not very hard. As the others have said put everything on the motor prior to dropping it in. Oil pump and lines (install lines before tb's), reeds, tb's, y-pipe, injectors, and denotation sensor. When the fuel tank is removed the wires plug into the ecu rather easily and are marked. Little bit of a cluster f**k of wires around the ecu but it all fits. Dont forget to hook up the rear coolant line when installing the motor or you will struggle later. The tb wiring runs along the right hand side along with the headlight harness and cooling hoses. Throtle cable was over the top and to the left.

Couple tips. Leave the two bottom recoil housing bolts out. If they are left in you really struggle changing a rope with out pulling the motor again. Double check your engine mounts to ensure they are not torn. Replace the 6 engine mounting bolts with grade 8 bolts. Balance your primary clutch- this was the issue that wrecked my crank.

First ride of the year this next weekend so time will tell. The 755 has been a pretty good motor for me. Well for a 2stroke anyways!

 

[SLDHVN]

basically, everyone here has way more info than they want to type, and i dont blame them. Unfortunately I have taken these motors in and out a few times(like frikken 20 or 30) so if you need any help feel free to call.
406-261-2232

 

[guidoxpress]

basically, everyone here has way more info than they want to type, and i dont blame them. Unfortunately I have taken these motors in and out a few times(like frikken 20 or 30) so if you need any help feel free to call.
406-261-2232

Ski is exactly right...we are all more then willing to help..but its pretty time consuming and detailed to get a good write up on such a broad subject..

but like ski said..give him a call..or send me a pm and i will give you my number and you can call me as well..i have somewhat of a clue on what to do

 

[Ak4life]

Here is a pic of the rear of the 755 showing the injectors and oil supply line running between the jugs. I just put mine back togeather this last weekend and it was not very hard. As the others have said put everything on the motor prior to dropping it in. Oil pump and lines (install lines before tb's), reeds, tb's, y-pipe, injectors, and denotation sensor. When the fuel tank is removed the wires plug into the ecu rather easily and are marked. Little bit of a cluster f**k of wires around the ecu but it all fits. Dont forget to hook up the rear coolant line when installing the motor or you will struggle later. The tb wiring runs along the right hand side along with the headlight harness and cooling hoses. Throtle cable was over the top and to the left.

Couple tips. Leave the two bottom recoil housing bolts out. If they are left in you really struggle changing a rope with out pulling the motor again. Double check your engine mounts to ensure they are not torn. Replace the 6 engine mounting bolts with grade 8 bolts. Balance your primary clutch- this was the issue that wrecked my crank.

First ride of the year this next weekend so time will tell. The 755 has been a pretty good motor for me. Well for a 2stroke anyways!

Thanks man this is what I am looking for. Thanks for the picture a well, just what I need is more photos like that one. Thanks for the the suggestions on hose and cable routing that was my main concern.

I got a call from HPAK and said my case will be done tommorow so expect some pictures from me in this thread and a bunch of questions.LOL


Thanks again to all those who offered advice and a huge thanks to those who left thier Phone#. This seems like a great crew of guys in the 900 forum.

Thought I would drop a before and after picture of my project, its getting there...slowly but its getting there.


Before

Now

Just got my F&I shock tower vents today gonna install those tonight....

 

[guidoxpress]

AK..

what did you end up doing with the control housing from your bars..more pics..

 

[Ak4life]

AK..

what did you end up doing with the control housing from your bars..more pics..

I am mounting it to my Fly pivot adapter between the risers. I havnt finished it yet, I still neet to make the bracket that will hold it down. I did the same thing on my 02', its super easy. Will have pics soon as its done...