Crossfire skid into a 96 ZRT - ArcticChat.com - Arctic Cat Forum
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post #1 of 44 Old 07-03-2011, 12:26 PM Thread Starter
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Sled: 2000 thundercat 1996 ZRT 800 AGLT/136"
10-11 Mileage: 1249
09-10 Mileage: 1200
07-08 Mileage: 650 - 2 thaws
06-07 Mileage: 1100
ATV: Arctic Cat 500/ SuzukiQuadzilla 500-sold
Crossfire skid into a 96 ZRT

Last year I did the AGLT mod on the front suspension. A true 13" of usable travel up front. It truly is what everyone was saying. "Awesome"

This year I thought I would do an 07 Crossfire skid into it and see how this works out.

I would like to give a special thanks to Kev and Leighthomas for answering questions and doing some testing of a 136" Pantera skid and a Crossfire and make some comparisons for me. They took the time for a rough install and test. This sent me in the right direction. Thanks guys.

OK, here is what I did:
First I purchased a skid off E-bay. I disassembled it and repainted everything I could.
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Life is not a bowl of cherries, it's more like a jar of jalapenos, what you do today can burn your ass tomorrow !!!







http://www.arcticchat.com/forum/pinn...to-96-zrt.html
Crossfire skid into a 96 ZRT

http://www.arcticchat.com/forum/z-zl...t=zrt+800+aglt
ZRT 800 AGLT

Last edited by tcat446; 07-03-2011 at 03:44 PM.
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post #2 of 44 Old 07-03-2011, 12:29 PM Thread Starter
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Join Date: Jul 2006
Location: Ripley, New York
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Sled: 2000 thundercat 1996 ZRT 800 AGLT/136"
10-11 Mileage: 1249
09-10 Mileage: 1200
07-08 Mileage: 650 - 2 thaws
06-07 Mileage: 1100
ATV: Arctic Cat 500/ SuzukiQuadzilla 500-sold
Next I sand blasted the skid and painted it with as close to Cat green as I could get.
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Life is not a bowl of cherries, it's more like a jar of jalapenos, what you do today can burn your ass tomorrow !!!







http://www.arcticchat.com/forum/pinn...to-96-zrt.html
Crossfire skid into a 96 ZRT

http://www.arcticchat.com/forum/z-zl...t=zrt+800+aglt
ZRT 800 AGLT
tcat446 is offline  
post #3 of 44 Old 07-03-2011, 12:31 PM Thread Starter
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Join Date: Jul 2006
Location: Ripley, New York
Posts: 8,243
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Thanked 648 Times in 625 Posts
Sled: 2000 thundercat 1996 ZRT 800 AGLT/136"
10-11 Mileage: 1249
09-10 Mileage: 1200
07-08 Mileage: 650 - 2 thaws
06-07 Mileage: 1100
ATV: Arctic Cat 500/ SuzukiQuadzilla 500-sold
I even took the time to add some grease fittings to some of the places that seemed dry when I took everything apart.
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Life is not a bowl of cherries, it's more like a jar of jalapenos, what you do today can burn your ass tomorrow !!!







http://www.arcticchat.com/forum/pinn...to-96-zrt.html
Crossfire skid into a 96 ZRT

http://www.arcticchat.com/forum/z-zl...t=zrt+800+aglt
ZRT 800 AGLT
tcat446 is offline  
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post #4 of 44 Old 07-03-2011, 12:34 PM Thread Starter
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Location: Ripley, New York
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Sled: 2000 thundercat 1996 ZRT 800 AGLT/136"
10-11 Mileage: 1249
09-10 Mileage: 1200
07-08 Mileage: 650 - 2 thaws
06-07 Mileage: 1100
ATV: Arctic Cat 500/ SuzukiQuadzilla 500-sold
I had found out that these skids have had issues in the past with the front arm breaking so I welded some gussets in place. Hard to see in the pic but they are there on both sides. Top side is fully welded and the bottom spot welded. I didn't want too much heat in this area and weaken it.

I had some 1" diameter solid rod cut down to 1/2" thick and drilled a hole for the bolts for spacers and added them to the sides. The Crossfire skid is 1" narrower than the older ZRT skids. I also used grade 8 bolts and new nylon lock nuts.

For the back of the skid, without getting crazy and removing the rear bracket and drilling and putting a new one in and making a mess on the tunnel, I decided to make an adapting bracket 7" x 1 1/2" x 1/2" out of aluminum flat stock and drilled the holes that the current mount had and adapt the new brace to it with 2 grade 5 bolts. I then measured and drilled the rear hole 31" from the front existing hole from the upgraded newer torque link skid mounting holes. I never touched the holes for those, just installed it there. I did check and coincidentally it lined right up perfectly.

EDIT: I had problems with the studs just kissing the rear heat exchanger so I had to move the rear mount hole below the boards. You can see in the pic. its almost inline with the other 2 bracket holes. Its not quite even with the other holes but if they were that wouldn't hurt either. I then raised the sled's front end by increasing spring pre load on the front shocks. All seems well. I will run some more and give a ride review. I also added 6 3/8" wheels to the top right next to the torque link in pic 4. This will keep the track from rubbing the top of the aluminum link and the link from putting a mark all the way around the track. Why Cat never put a taller wheel in those Crossfires I will never know. I used some off an old skid. If you want new, the part number is #1604-685.

One thing I did do was to take out (all) the suspension springs. I then reinstalled the shock and skid back in and collapsed the suspension till the front and back were bottomed out so I was sure there would be nothing hitting or rubbing in the tunnel. This is how I achieved the proper hole height on the front and back suspension/tunnel holes. The front has 1/2" clearance with this track/stud combination in the old front holes and the rear has approx. 3" with the rear angled upward slightly. ---- Keep in mind that I used the front holes for the upgraded torque link skid and these holes are the ones I used. Not the original front holes for the 96 non torque link skid.
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Life is not a bowl of cherries, it's more like a jar of jalapenos, what you do today can burn your ass tomorrow !!!







http://www.arcticchat.com/forum/pinn...to-96-zrt.html
Crossfire skid into a 96 ZRT

http://www.arcticchat.com/forum/z-zl...t=zrt+800+aglt
ZRT 800 AGLT

Last edited by tcat446; 02-02-2013 at 04:50 PM.
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post #5 of 44 Old 07-03-2011, 12:36 PM Thread Starter
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Join Date: Jul 2006
Location: Ripley, New York
Posts: 8,243
Thanks: 43
Thanked 648 Times in 625 Posts
Sled: 2000 thundercat 1996 ZRT 800 AGLT/136"
10-11 Mileage: 1249
09-10 Mileage: 1200
07-08 Mileage: 650 - 2 thaws
06-07 Mileage: 1100
ATV: Arctic Cat 500/ SuzukiQuadzilla 500-sold
If anyone is interested I have the paint codes that is just about perfect with Cat's paint. I had gotten this years ago. It works great!!
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Life is not a bowl of cherries, it's more like a jar of jalapenos, what you do today can burn your ass tomorrow !!!







http://www.arcticchat.com/forum/pinn...to-96-zrt.html
Crossfire skid into a 96 ZRT

http://www.arcticchat.com/forum/z-zl...t=zrt+800+aglt
ZRT 800 AGLT

Last edited by tcat446; 07-03-2011 at 02:17 PM.
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post #6 of 44 Old 07-03-2011, 12:38 PM Thread Starter
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Join Date: Jul 2006
Location: Ripley, New York
Posts: 8,243
Thanks: 43
Thanked 648 Times in 625 Posts
Sled: 2000 thundercat 1996 ZRT 800 AGLT/136"
10-11 Mileage: 1249
09-10 Mileage: 1200
07-08 Mileage: 650 - 2 thaws
06-07 Mileage: 1100
ATV: Arctic Cat 500/ SuzukiQuadzilla 500-sold
I knew the type of riding I do that I wanted a 1.25" ripsaw. I also knew that I wanted studs. I went with the fully clipped ripsaw and 189 stud boy studs, 1.375" just down the middle. Never had them just in the middle so I'm gonna see if I like it. Stud boy tells me to run the "V" pattern reversed from the old days. So this is the ginny pig. We will see !!!!

I got the best deal on stud boy studs from a place in Lafayette Indiana called Ultimate Sports Inc. (USI). I found them on the web and called for pricing. They also sell on E-bay. They are a ton cheaper than anyone else hands down. Very accommodating too.
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Life is not a bowl of cherries, it's more like a jar of jalapenos, what you do today can burn your ass tomorrow !!!







http://www.arcticchat.com/forum/pinn...to-96-zrt.html
Crossfire skid into a 96 ZRT

http://www.arcticchat.com/forum/z-zl...t=zrt+800+aglt
ZRT 800 AGLT

Last edited by tcat446; 07-03-2011 at 02:18 PM.
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post #7 of 44 Old 07-03-2011, 12:42 PM Thread Starter
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Join Date: Jul 2006
Location: Ripley, New York
Posts: 8,243
Thanks: 43
Thanked 648 Times in 625 Posts
Sled: 2000 thundercat 1996 ZRT 800 AGLT/136"
10-11 Mileage: 1249
09-10 Mileage: 1200
07-08 Mileage: 650 - 2 thaws
06-07 Mileage: 1100
ATV: Arctic Cat 500/ SuzukiQuadzilla 500-sold
On my 96 zrt I knew I didn't have a ton of clearance with the studs to front heat exchanger (about 1/2" to 5/8") with the stock track and studs so I had to change the front drivers from 9 tooth to 8 tooth if I wanted to get the 1.25" Ripsaw with studs in it. Auggie recommended me to have the drivers chucked up in a lathe and turn them down for even contact on all. I think I took off around .030-.045 thousands is all. Auggie helped me through some stuff over the years and is a wealth of knowledge. Thanks Auggie! I then bought a 26 tooth top gear and a 74 pitch chain to get the gearing as close to stock as possible since changing to an 8 tooth from the 9 tooth. Only because I had a very nice clutching set up and didn't want to ruin that after all my hard work. One last thing was to take out the auto adjuster and put in a manual adjust. This holds the chain better for the longer 74 pitch chain.

EDIT UPDATE:
After riding the sled and doing lots and lots of research I discovered I could not use the 8 tooth drivers mentioned above. I had to get Wahl 8 tooth anti-ratchet drivers. Reason being that with this type of track (1602-865A) it is the quiet track ripsaw Cat installed on the 06 Crossfires. When you go to the anti-ratchets they recommend 2 wheels and no need for all 4. The track has nubs molded into it, and in combination with the 1.25" lugs and studs of the track this sled hooks so hard I could not keep it from ratcheting so I had to go with the anti-ratchet drivers. I got to 1/2" sag with a 20lb weight hanging and it still did it. Suppose to be around 1 3/4" sag. I think if you used any other track you would be fine with the standard drivers from all that I have researched. You can see what I had and what I put in in the pic below.

One other thing to add is the speedo will be off when you go to the 8 tooth drivers from the 9 tooths. This will make the speedo show you are going faster than you really are and really rack up the miles on the speedo!! You will have to buy another speedo drive adapter part #0620-031. This is for an 8 tooth. Got mine off ebay. Part #9 in the third pic.
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Life is not a bowl of cherries, it's more like a jar of jalapenos, what you do today can burn your ass tomorrow !!!







http://www.arcticchat.com/forum/pinn...to-96-zrt.html
Crossfire skid into a 96 ZRT

http://www.arcticchat.com/forum/z-zl...t=zrt+800+aglt
ZRT 800 AGLT

Last edited by tcat446; 05-12-2013 at 08:39 PM. Reason: More info.
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post #8 of 44 Old 07-03-2011, 12:49 PM Thread Starter
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Join Date: Jul 2006
Location: Ripley, New York
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Thanked 648 Times in 625 Posts
Sled: 2000 thundercat 1996 ZRT 800 AGLT/136"
10-11 Mileage: 1249
09-10 Mileage: 1200
07-08 Mileage: 650 - 2 thaws
06-07 Mileage: 1100
ATV: Arctic Cat 500/ SuzukiQuadzilla 500-sold
I have read numerous things on the cooling of triples the last few years. Although I don't think this is totally necessary, I do a lot of hard pack riding and sometimes cooling does become an issue. I think if anyone does the cooling mod they should look everything over first and proceed with caution. Measure twice and cut once so to speak. And yes, I did cut off the pretruding screws so the track doesn't hit them.
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Life is not a bowl of cherries, it's more like a jar of jalapenos, what you do today can burn your ass tomorrow !!!







http://www.arcticchat.com/forum/pinn...to-96-zrt.html
Crossfire skid into a 96 ZRT

http://www.arcticchat.com/forum/z-zl...t=zrt+800+aglt
ZRT 800 AGLT
tcat446 is offline  
post #9 of 44 Old 07-03-2011, 12:59 PM Thread Starter
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Join Date: Jul 2006
Location: Ripley, New York
Posts: 8,243
Thanks: 43
Thanked 648 Times in 625 Posts
Sled: 2000 thundercat 1996 ZRT 800 AGLT/136"
10-11 Mileage: 1249
09-10 Mileage: 1200
07-08 Mileage: 650 - 2 thaws
06-07 Mileage: 1100
ATV: Arctic Cat 500/ SuzukiQuadzilla 500-sold
I would recommend that if anyone does this mod they can use the plastic barbed elbows with 1" rubber tubing I purchased at the local NAPA store. I used copper tubing fittings because its what I had and this is kinda a test bed thing.

I cut a section of tubing I had from the aluminum supply lines (since I would have to add rubber hose) and cut them at a 45 degree angle and tig welded them together to make the 90 degree elbows needed for the project. I bought the heat exchanger off E-bay and had it sent to my door for $30.00. The reason the white lines are on the exchanger are for the alignment of the elbow to be welded.
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Life is not a bowl of cherries, it's more like a jar of jalapenos, what you do today can burn your ass tomorrow !!!







http://www.arcticchat.com/forum/pinn...to-96-zrt.html
Crossfire skid into a 96 ZRT

http://www.arcticchat.com/forum/z-zl...t=zrt+800+aglt
ZRT 800 AGLT
tcat446 is offline  
post #10 of 44 Old 07-03-2011, 01:22 PM Thread Starter
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Join Date: Jul 2006
Location: Ripley, New York
Posts: 8,243
Thanks: 43
Thanked 648 Times in 625 Posts
Sled: 2000 thundercat 1996 ZRT 800 AGLT/136"
10-11 Mileage: 1249
09-10 Mileage: 1200
07-08 Mileage: 650 - 2 thaws
06-07 Mileage: 1100
ATV: Arctic Cat 500/ SuzukiQuadzilla 500-sold
If you do this mod you will have to cut the seat. Do not install the coolant lines toward the front of the sled. If you do you will have them position under the gas tank. They need to face the rear of the sled as pictured.
I modded the seat with a Dremel tool. I had to supply clearance for the tubing and exchanger to fit into the seat bottom. Sorry guys. No measurements were taken. I just lifted the seat bottom and did my measuring that way.
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Life is not a bowl of cherries, it's more like a jar of jalapenos, what you do today can burn your ass tomorrow !!!







http://www.arcticchat.com/forum/pinn...to-96-zrt.html
Crossfire skid into a 96 ZRT

http://www.arcticchat.com/forum/z-zl...t=zrt+800+aglt
ZRT 800 AGLT
tcat446 is offline  
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