New Custom Mountain Sled Build

[Maize]

Here are the pics from yesterday. Here is the shot of the bug mess, LOL:





Here is the new SHR840BB motor. It came with carbs, Boyesen Rage Cages, all electrical and rewind. I will be pulling it apart, phasing the crank to make sure it isn't out of synch and checking all crank bearings. I will hone the cylinders and putting new rings after checking all clearances, putting a new base gaskets and O-rings in it.

I am sending the RKT head to Kelsey and having my stock 800 head cut to fit the domes. I want to have a stock looking 800 motor with no clues as to the BB kit in it.

 

[Maize]

I got the head pulled from the new 840 motor. The pistons, domes, cylinders all look good. I am going to pull the motor apart and true the crank. I am also going to putting all new seals in it just to be safe.









I also got my new roller clutch today, I got it torn down, inspected, cleaned and the new parts put in it. It got a fresh purple spring, a new guard, a new swivel abutment and new DJ clutch helix.










I also got the new 800HO Y-Pipe in the mail today. It's like Christmas around here all the time!!! LOL

 

[Maize]

I just sewed up the deal on a BOSS nitrous set up. Just the level I wanted, too. 30HP. Thanks Roos800.

It comes with a 20lb refill station. That should be good for every trip I take.

I pick it up Saturday. I am meeting the guy in Cedar Falls near the UNI campus. EXCELLENT! I little Kick-a-Poo Joy Juice....

 

[Maize]

I picked up my Boss Noss kit today. I met the guys sister on the UNI campus. It beat paying to ship NOS from South Dakota to Iowa.

I was a little skeptical on what all would be included. I was told it would be the complete Boss Noss kit, and a 20lb refilling station for $280. It was all there including the fittings that he did not use. The refill station is completely full.

There was the same kit on Dootalk For Sale section, but he wanted way more money and no refill station. I went with the setup from Roos800 here on SW for $280, and what a deal it turned out to be. I loaded the control module with 8 'AA' batteries, filled the 2lb bottle and hit the 'ON' switch and hit the "GO" button and it released properly.

Just as safety sake, I am going to send the control module to Boss to have them test it properly.

This the stuff at my house, in my garage. This is what all I got. I am so stoked to fire this pig up.......

 

[spook222]

thanks for all the pics and info, It'll be a fun build to watch

 

[kinger9]

Sweet setup! I have a 10lb mother bottle I used to fill my 2.5 tank on my RX1 for sale if you want to carry a bunch of nitrous with you. $150 and looks like I'm fairly close to you. There is 5lbs of nitrous in it as well.

 

[Maize]

OK. I just landed the clear tank I have been looking for.







I also bought a black hood from a Dootalker, but I haven't heard anything more about it since I paid. We will see.....

 

[groth1986]

Hey Maize, Where did you find the clear tank? A friend of mine has been looking all over for one.... How much was it? Thanks

 

[Maize]

Hey Maize, Where did you find the clear tank? A friend of mine has been looking all over for one.... How much was it? Thanks

I got is off ebay for $126.

 

[Maize]

I got the top end of the motor torn down. Very bad news.....hidden damage.....severe damage.

Above the cylinder looks fine....kind of.

Below the cylinder is another story. It looks like this motor was hammered on before it was broken in. It has severe blowby on the rings, and signs of cold sieze on both cylinders. The PTO side is not as severe as the MAG side but started on that side as well.

The PTO side RAVE has signs of being hit by the piston, with indentations and pieces missing.

The transfer bridge on the MAG is cracked all the way through, and the bottom of the sleve has also started to crack. The MAG side piston is toast, and the MAT side cylinder will have to be welded and replated.

The RAVE valves have two different spings in them. One is about a half inch shorter than the other.

I am meeting Big John at Hay Days to drop off the parts to see what can be salvaged and what it is going to cost to fix. I am also sending my stock head to be machined to fit the 840 domes.

I need to head over to the shop tomorrow and pull the pistons off the rods. I am almost afraid to pull the bottom end apart.

I guess this motor wasn't such a smokin' deal for me.

Here are the pictures of the damage:

 

[Maize]

Here are some more pictures of the damage:

Here are some clearer shots of the RAVE damage. It may be OK, but I have another set that I think I will have Big John machine to work. The silver pieces you can see in the pictures are actually chunks missing, they are not just scrape marks. You can't really see the depth of them.





Here is a shot of the RAVE springs that I took out. The caps were turned out all the way. The short spring was in the MAG side, and the long spring in the PTO side. I will be the first to admit that I am not that familiar with 800 motors, but I am pretty sure that this is not a performance thing. I could be wrong, though.



Here is a shot of the carb side of the MAG side piston. NASTINESS!!!



Here is the exhaust side of the same piston. Not bad, but not good either:



Here is the PTO side piston. It has (in my opinion) a lot of blowby past the rings. That leads me to believe this motor was really hammered before the rings had a chance to seat. The top end doesn't have many miles on it, but it was abused to be sure.



You can see (almost) the scoring on the cylinder walls down each side that runs along the edge of each side of the exhaust port. You can drag your fingernale and on the lines......again.....not good.

 

[spook222]

Man, That sucks a**, Maize! Sorry to hear that Well, other than that, the build looks awesome! good luck going forward, keep us posted!

 

[Maize]

As far as the motor goes. Good news. The cylinders can be fixed. I dropped by the US Chrome booth and showed Scott. He can fix them. The guy I bought the motor from is paying for the pistons, rings, wrist pins, bearings and gaskets. I am paying to fix the cylinders. I am happy with that resolution.

I am going to drop in a rebuilt crank and new PTO and MAG seals.

I just got back into town from Hay Days. It could be just me, but (to me) it didn't seam that as many people were there. There were a lot of people there, it just seamed a little thinner.

Stopped by Majors Friday night and said "Hey" to Jim Phelan and Mark Messinbrink. I also stopped by and said "hey" to Big John and Scott with US Chrome.

I got a bunch of repair parts, but only 4 sets of shocks to sell. I couldn't find any rear shocks for reasonable prices. People were asking more to sell than what I can get out of them AFTER I completely go through them. Most piggy-back shocks were set at $350 for the pair with no springs. C36 race shocks were being set at $250 each.

I did get some nice aluminum bodied, front ski shocks. I also found a bunch of used 90lb single rate springs. We got there at 5am to make sure we got a parking spot close to the exit. We ended up making 4 trips back to the truck to unload the wagon. Here are the shocks and springs I got:



I also got a ton of stuff for the mountain sled. I got the belt guard, the pipe, HPS can, recoil mounting ring, headlight, fender panels, oil tank, coolant tank, rear rack w/tail light, RAVE valves and an almost brand new set of shocks.

I also picked up a nice set of aluminum bodies ski shocks for the wife's 440 fan. I also have a mechanical reverse kit to install and a E-Start to install on that sled before winter.

Here is the stuff I picked up for Spawn:



I took $1500 with me, $220 for the hotel for both nights, $120 to eat at The Melting Pot on Friday, $10 parking downtown, $90 for gas, $30 to get in, $10 event parking, $60 to eat at Red Robin. $30 for food and beer at event.

I got all that stuff in the pictures, and when I got home, I had about $267 left over. I got all the above stuff for about $663. I don't really count the other stuff in as the wife and have been going to to this event for many years. It is a short get away for us. We would be going even I wasn't buying anything. We stopped as several quilt shops for the wife on Friday, had a nice dinner out at a nice restaraunt on Friday night. We don't get to do a bunch of stuff together for a whole weekend, this is one of our get aways. Do I have a great wife, or what?! LOL

The grass drags, the new models, the factory displays, the free-style jumping....open beer......it's all good.

 

[Jut]

SHould be nice, cant wait to see it

 

[wheresthesnow]

Good to hearthe seller of the engine took care of some of the cost. Where was the picture taken in the mtns on that older mod sled you built, that sled look nice.

 

[Maize]

Good to hearthe seller of the engine took care of some of the cost. Where was the picture taken in the mtns on that older mod sled you built, that sled look nice.

He ended up being a pretty stand up guy over the whole deal.

The picture of my other sled was taken 2 years ago at Togwotee. If you have ever been there, it is right under the radio/light tower on the tallest peak.

I love that sled. I just need more power. I am not convinced that the REV is going to be a better sled. If it isn't as good as my other sled, the motor is coming out of the REV and going in that sled, along with the nitrous.

 

[Maize]

Sorry about no updates, still collecting parts and I am just burried in shock work for customers.

Motor update:

US Chrome has the cylinders fixed and complete. They are at Big John's right now. I also sent him a dome to get the correct parts. I am just waiting for his new shipment of pistons to come in. I should have that stuff back in a couple of weeks - tops.

I am waiting on my rebuilt crank to get here from Bombardier.

I have the lower cases cleaned up, a new recoil retianer ring (from ebay) and a new recoil (from ebay).

I need to get the head off to Kelsey to get my stock head cut for the cheater domes.

I will get pictures of all the new stuff I have collected.

I have been swamped with shocks so I haven't had any time to start on anything.

I still have to get my trail sled's tail light figured out, the e-start and reverse in the wife's sled and the finishing touches on the old mountain sled.

 

[Maize]

Here are the pictures to bring everyone current:

I just got the braces from Matt Santwire. He is having me try some more experimental bracing. This is a picture of all the braces, Matt's and Ski-Doo's. These are not only all the 440X braces, but additional, beefier stuff from Matt.









Here is the wiring harness I got from ebay, and the MPEM with DESS I got from here on Dootalk:





These are the two chaincases I have. I will be cutting them in half and having them TIG'd back together to make a longer case:

 

[Maize]

Here are the pictures of the new airbox I got. It is from an 07 Summit. It has the larger opening and the new snorkel:





Here is the new wave brake rotor I got from my Ski-Doo dealer. Someone had ordered it a couple of years ago, and they gave me a smoking deal on it. I also have the Oilite bushings I got from Goodwin Performance. My trail sled also has these on them.



I got the steering stuff from ebay for a little bit of nothing. Everything is nice and tight.



I got a 440X console from the Dootalk picnic:



I already showed the shocks and springs, but here they are complete. I rebuilt and revalved them for my riding.



I decided to not put the controls on the old mountain sled. They work on the sled, I was just going to change them over. This will keep from buying it again.

 

[Maize]

Here is the engine in its current state. I am just waiting on the reman crank from Bombardier. Once that is here, the case will get new PTO and MAG side seals, new ISO grease and the crank trued to 0.001".

Hopefully, within the next couple of weeks, the motor will be complete.