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Old 11-24-2006, 03:25 PM   #1
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Need some help here guys

The sled I am working on is a 2003 ZR 800 EFI Sno Pro.

I am installing my NEW exhaust valve cables and they seem to be to long right out of the box. I am an avid mountain bike rider and wrench so I understand cable adjustment well and this has me stumped! I am thinking my manual has bad numbers. What my manual is telling me is minimum is 1.17, center 1.20, max 1.24. With the adjustment almost all the way out on my cable, my measurement is 1.33. I thought I remembered an old post showing numbers of like 1.51 min and 1.64 max. Numbers like these would make more sense to me based on what I am seeing on my sled. Any help here would be great!

Also, when the servo opens these valves, does it open clockwise as you are looking at it standing in front of the sled?? I am assuming this by the way my old cables cam off and just want to double check this.

THANKS
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Old 11-24-2006, 03:28 PM   #2
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I wish I could help you on the specs, but I'm not sure. I know the Firecats, back in 2003, had a misprint in the owners manual. I'm wondering if you're seeing the same thing with the ZR8? As far as the servo goes - you are correct. It turns clockwise if you're looking at it from the front of the sled.
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Old 11-24-2006, 03:39 PM   #3
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Thanks!!! That might just be what I have here. I see on the Hard Core Sight one of the ZR riders has spec of 1.64 min and 1.72 max. Down a little in that tread the are also posting numbers in the 1.51 to 1.56 range. These all make much more sense.

Do you know if I turn the servo by hand without the cables on it, will it stop in the open position? If so, I can just adjust them to the open position without them being to tight and go that way.
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Old 11-24-2006, 03:55 PM   #4
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Adjust to 1.5 and call it a day.............servo knows where to start n stop.
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Old 11-24-2006, 04:03 PM   #5
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Thanks sled head! You have been a big help with my project! I see that same number on Hard Core so 1.5" it is!
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Old 11-24-2006, 04:38 PM   #6
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Most important part is making em both EXACTLY the same length.

Enjoy
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Old 11-24-2006, 05:10 PM   #7
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http://www.off-road.com/snowmobile/info/ho...haustvalves.htm
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Old 11-24-2006, 05:27 PM   #8
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I like my way of doing them as stated in another post, But if you want to keep changing cables... It's good for the economy

This picture below is out of the 2003 manual


Click below for my way of adjusting the cables

http://www.hardcoresledder.com/forums/inde...p;#entry1957337
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Old 11-24-2006, 06:19 PM   #9
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IMHO ...........the people that see cable issues are those that don't keep the valves clean which causes the cables to bend over backwards (at the servo end / on cold start up) and start kinking, this eventually breaks em. Issue is more common in super cold weather.
Best way to prevent it is to check oil consumption / adjust as required / run quality oil / clean your valves on a regular basis. Easy way to check n see if they cleaning is to pull off the cables at the servo end (engine dead nuts cold) and pull the cable out then release, if it goes backquickly with a noticeable clunk, yer good to go, if no noise and or it goes back in slowly yer overdue to clean them.
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Old 11-24-2006, 09:18 PM   #10
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GREAT INFO. Thanks for the help on this one guys. I finished up my rebuild tonight and lit the 800 and all looks good. The heat exchangers under the seat got warm and the coolant level is now set. Some other small items and I am ready for snow!

Thanks again!!
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