Exhaust valve cable adjustment, APV's - ArcticChat.com - Arctic Cat Forum

Reply
 
LinkBack Thread Tools Display Modes
post #1 of 18 Old 11-24-2006, 03:25 PM Thread Starter
Senior Member
 
spatchin's Avatar
 
Senior Member
Join Date: Oct 2006
Location: Michigan
Posts: 438
Thanks: 0
Thanked 0 Times in 0 Posts
Sled: 2003 Arctic Cat ZR800 Sno Pro
07-08 Mileage: Yet to come!!
06-07 Mileage: 1000
ATV: none
2007 Mileage: NA
2006 Mileage: NA
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
spatchin is offline  
Sponsored Links
Advertisement
 
post #2 of 18 Old 11-24-2006, 03:28 PM
Team ArcticChat
Team ArcticChat
 
Team ArcticChat
Join Date: Oct 2003
Location: Minnesota
Posts: 3,920
Thanks: 0
Thanked 0 Times in 0 Posts
Sled: 2012 Polaris Switchback 800 Pro-R
10-11 Mileage: 1400+
09-10 Mileage: 1613
08-09 Mileage: 1226
07-08 Mileage: 846
06-07 Mileage: 1139
ATV: No ATV (yet)
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.

Join the Team-Click here---------->




1981 John Deere Trailfire
1987 Panther 440
1995 EXT 580
1996 EXT 580 Deluxe
2000 ZR500 EFI
2003 F7 Standard
2007 F8 Standard
2009 Polaris Dragon 800
2011 Polaris Pro-R 800
Bontz is offline  
post #3 of 18 Old 11-24-2006, 03:39 PM Thread Starter
Senior Member
 
spatchin's Avatar
 
Senior Member
Join Date: Oct 2006
Location: Michigan
Posts: 438
Thanks: 0
Thanked 0 Times in 0 Posts
Sled: 2003 Arctic Cat ZR800 Sno Pro
07-08 Mileage: Yet to come!!
06-07 Mileage: 1000
ATV: none
2007 Mileage: NA
2006 Mileage: NA
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.
spatchin is offline  
Sponsored Links
Advertisement
 
post #4 of 18 Old 11-24-2006, 03:55 PM
Senior Member
 
Senior Member
Join Date: Oct 2003
Location: Earch
Posts: 4,157
Thanks: 21
Thanked 317 Times in 298 Posts
Adjust to 1.5 and call it a day.............servo knows where to start n stop.
zr sled head is offline  
post #5 of 18 Old 11-24-2006, 04:03 PM Thread Starter
Senior Member
 
spatchin's Avatar
 
Senior Member
Join Date: Oct 2006
Location: Michigan
Posts: 438
Thanks: 0
Thanked 0 Times in 0 Posts
Sled: 2003 Arctic Cat ZR800 Sno Pro
07-08 Mileage: Yet to come!!
06-07 Mileage: 1000
ATV: none
2007 Mileage: NA
2006 Mileage: NA
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!
spatchin is offline  
post #6 of 18 Old 11-24-2006, 04:38 PM
Senior Member
 
Senior Member
Join Date: Oct 2003
Location: Earch
Posts: 4,157
Thanks: 21
Thanked 317 Times in 298 Posts
Most important part is making em both EXACTLY the same length.

Enjoy
zr sled head is offline  
post #7 of 18 Old 11-24-2006, 05:10 PM
Banned
 
Banned
Join Date: Mar 2004
Location: ELMHURST,IL
Posts: 1,162
Thanks: 0
Thanked 0 Times in 0 Posts
Sled: ZR///RX///CF
06-07 Mileage: 1310
ATV: 05 RAPTOR 660
2007 Mileage: 110
2006 Mileage: 545
MELR0SEMAFlA is offline  
post #8 of 18 Old 11-24-2006, 05:27 PM
Team ArcticChat
 
snow800's Avatar
Team ArcticChat
 
Team ArcticChat
Join Date: Jun 2005
Location: Metro Detroit
Posts: 2,123
Thanks: 12
Thanked 86 Times in 76 Posts
Sled: 14 xf 9000 ltd 07 xfire 1000
07-08 Mileage: 1500
06-07 Mileage: 2000
ATV: Honda 70 fourtrax
2007 Mileage: 25
2006 Mileage: 2
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


If it looks stock..... It must be ??????

Last edited by snow800; 10-18-2013 at 09:16 PM.
snow800 is offline  
post #9 of 18 Old 11-24-2006, 06:19 PM
Senior Member
 
Senior Member
Join Date: Oct 2003
Location: Earch
Posts: 4,157
Thanks: 21
Thanked 317 Times in 298 Posts
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.
zr sled head is offline  
post #10 of 18 Old 11-24-2006, 09:18 PM Thread Starter
Senior Member
 
spatchin's Avatar
 
Senior Member
Join Date: Oct 2006
Location: Michigan
Posts: 438
Thanks: 0
Thanked 0 Times in 0 Posts
Sled: 2003 Arctic Cat ZR800 Sno Pro
07-08 Mileage: Yet to come!!
06-07 Mileage: 1000
ATV: none
2007 Mileage: NA
2006 Mileage: NA
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!!
spatchin is offline  
Reply

  Lower Navigation
Go Back   ArcticChat.com - Arctic Cat Forum > Snowmobiles > Arctic Cat Snowmobiles > Z/ZL/ZR/ZRT/Tcat/EXT/jag/cougar

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the ArcticChat.com - Arctic Cat Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome