New Project - SPAWN

[Maize]

Well, I got the engine dropped in the chassis today.

It dropped right in place, no issues. I also got all the coolant lines & hoses hooked up. I also got all the electrical harnesses put in place, and the starter on it.

Tomorrow I have to stop by Menard's and pick up some stainless bolts for the Boyesen's. I still need to go through both carbs and rebuild them and make sure they jetted properly.

I spoke with Big John today to see what the starting point should be for jetting. Big John is awesome. Taking customer on a Saturday is above and beyond.

[Maize]

I got the oil pump hooked up (what a PIA THAT was!). I got the fuel lines on, the oil hoses connected, the Boyesens on and the carbs rejetted and the correct needles put in. I also rebuilt both carbs and synched them. I also made sure the air box fit and that I had the room put the Boss Noss controller between the gas tank and the air box.

This is also the improved flow airbox from the 07 SummitR.









I also got the controls put on, the handle bar wiring done, the new brake switch put in, the handwarmers on, the J-Hooks in place, the master cylinder put in and the billet stuff from Brian at Tricked Toys installed.







I am still waiting on some parts. I am off work tomorrow, I will doing some polishing tomorrow and getting the exhaust finished up. I need to take the y-pipe off my other mountain sled (it the EGT bungs welded in) and change it out with this one.

The rest of the day I need to regroup in the garage. Now that things are getting hung on the sled, I need to clean.

[Maize]

I ran into a setback yesterday.

The steering riser harness won't work with the 03 harness I have. The kill switch won't work. I did some wire tracing and one side of the ground goes to an open spot on the main harness connection.

I don't if just wiring in a spot to ground will work. I am going to tray that today.

I also hooked up the used tach to my 04 trail sled and the tach won't move. The high beam light comes on when you use the switch, but the brake light will not come on either.

Does anyone know if you have do anything different to get the SummitX style tach/speedo to work, or is this unit just toast?

[Maize]

OK. I figured out the Tach. Had to switch a pin around to get it to work properly.

Unfortunately, I also got the kill switch to work by tying it into another ground wire. However, the 03 harness is missing some of the wires to make it work with the newer Tach/Speedo.

I ordered a new wiring harness so I will have to wait until that comes in to fire it up.

[Maize]

I got a big SkiDoo order in today.

I put the new brake line on (the other was too short), I put the brake pads in, put the gears and chain in (21 top 45 bottom w/74 link chain), put the hand guards on, put the mountain strap on, the chaincase cover went on and the battery tray went in place.

The handle bars are now finished.

I got the new extensions from Wild Child today. I test fit those and tightened the track. They are prefect length, now. I then dropped them off at Cool Concepts to be powder coated.

I got everything squared away with Joey last night. The new kit was sent today so I can put the other roller clutch on my old mountain sled.

Yesterday I got the RPM Composites one-off stuff. I will get some pictures of that tomrrow.

I also got everything to set up my primary clutch. I got a used Thunder Shift kit with oversized rollers to used on this one.

Here are some shots of tonights progress. I am hoping the harness is here tomorrow.

[Maize]

Not many pictures from the weekend as everything looks pretty much the same.

I had to tear the plastic back off the sled, the gas tank, the seat and rear seat cover off.

I got the old wiring harness out, and the new harness put in place.

I also got the primary clutch set up with the new 415 ramps, a new primary spring and the Thundershift arms set up were I want to start with them.

Joey's new helix should be here this week so I can get that set up. I have new internal parts on that, too. I did tear down all the rollers and cleaned them all up.

I just need to drop the swing down a bit, get the Y-Pipe off the old sled and get it added to the new sled and add the exhaust.

Next is just put gas and oil in her and she will be ready to fire up.

I am also going to change the top gear per Big John's suggestion.

[Maize]

OK....I ordered the last of the stuff I need to finish the sled. Some gaskets for the exhaust, the quick clickers, and floating secondary but and the sway bar disconnect.

I picked up the WildChild extenstions from Cool Concepts tonight, and dropped the rear suspension to relocate the front arm down about an 1".

I also got some shots of the stuff Raffi (from RPM Composites) whipped up for me. Thursday those will get put on. I had weddings over the weekend, and Mother's Day so not much got done over the weekend.

Here are some quick shots of the stuff.

This should give pretty good coverage for "float" on the front end.

[PAULARIS600]

make sure that cotter pin is secure in that top gear. no trail mishaps.
lol
looking good lynn. nice color picked.

[Maize]

Thanks, Paul. But remember, the key (all 10 pieces of it) was attached to the magnet. I just won't be using Harbor Freight keys anymore. LOL

I got the new 19 tooth gear in the mail today, so that will be changed out this weekend.

I got the new holes drilled for the front arm. The skid is back under it. WildChild's rail extensions are in, and the track tension set.

The skid sits perfectly now. The back tips up like it is supposed to, and the front of the skid is level.

Tomorrow I can pick up DJ's helix. It should be finished up this weekend. Just waiting on the wrap from Casey and the windshield. They sent the yellow one instead of the smoke one I wanted.

[Maize]

I got Raffi's Kevlar/Carbon Fibre skid plates on tonight. Tomorrow, I will put the A-Arm protectors on.

I also got the snowflap on.

I Dynamo Joe's new helix in the mail and got the secondary done up.

I will be getting the rear rack and bumper permanantly mounted, along with the rear wiring and wire cover plates on.

I need to switch out y-pipes with my old sled as it has the EGT's in it. I thought I might fire it up this weekend, but I don't have the Y-Pipe bolts, Nordlocks or either of the donut gaskets. So I will have to wait until next weekend when my order comes in.

I need to order new fuel jets for the Boss Noss. So I can get that all plumbed in. I think I will wait to get the engine running then install the Boss Noss and Digitron on the same weekend.

I will have more shots (with better lighting), and some good shots of RPM Composites stuff. When I have the A-Arm protectors on, I will get it up in the air for complete shots.



With Raffi's skid plates, and Matt Santwire's bracing, it makes a VERY rugged chassis. I lawn darted my trail sled with this same setup, and just sheered off some skid plate bolts. Without them, I would have been replacing a NUN.

Here are some complete shots of the sled with better lighting.





Here is a better shot of the rear skid with lighting: