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Discussion Starter · #1 ·
It's been a long time coming, but I finally finished my AGLT front end, as well as the final touches on the new rear skid. I was able to ride it some today, and like everyone else that has posted their experiences after this mod, the thing is plain awesome. It feels like a completely new sled. In addition to the suspension mods, I also did the steering post mod and added a 3.5" Ole's riser (thanks for the track and riser Scooter). At 6'3" I can comfortably stand and ride now, which is something I still need to get used to. Oh yes, in the pics you will see that the throttle block is turned 180 degrees. That lasted about 750 ft. before it got ugly, and it got ugly quick. What happened was, as I drove through a small ditch to get into a field I lost my balance just a bit, falling backward. Well as you can imagine with the throttle on the opposite side of the bars with me falling just slightly back it meant instant full throttle and I got thrown off the sled. I saw it tip on one side but it ended up back upright somehow, don't know if it rolled or not but everything on the sled was fine. I also broke a swaybar arm, so after that it would really roll in the turns, but the thing soaks up every bump that I hit. One the rear skid I added some fat boy springs and a rear arm clicker shock out of an '02 ZR 800 CCE. Here are some pics of the before and after.

Before


Another before


After


After front


Here are some pics of the steering post/Ole's riser mod







As everyone else that has done these mods, I too would strongly suggest these to anybody with an AWS 4 sled. A year ago I wanted to put the old girl to rest for good, but now I wouldn't trade my sled for anything. In fact I would love to find a '94 or '95 ZR 700 to do the exact same mods, as my wife loved her Wildcat, and I can only imagine how much she would love that motor attached to a killer riding suspension!

I want to thank everyone that helped me along the way. AG obviously for coming up with the idea as well as answering my questions. KevinS for the swaybar and a very good post with all the pics. Also thanks to Scooter for the track and riser deal....and I still think that retro ZRT of yours is the best looking I have seen, so good that as bad as I want to do it to mine I won't....that deserves to be a one of a kind thing, even though it isn't.
 

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I broke one of those swaybar arms shortly after doing the mod as well. I wasn't riding it just moving it around the garage and I noticed that it was very wobbly on the front. When I got new arms I got the plastic ones. I though they might hold up better than the white metal ones. Part number was 0603-917.
 

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Greg, Great Job! Not worthy:

Before you had a chance to ride it... Did you ever think it was going be that good?

When I was ride-testing different configurations, the first few test rides out on the lake... I didn't even know how good it was until I had that first chance of riding it on the rough trails. I was surprised at the difference!

It's gotta be a tough thing for a lot of folks who read about the mod, many probably don't think it's worth it. They just don't realize what it can do.

Only those who were brave enough to venture into this mod will find out. I can understand that though, ripping apart a front end isn't for everyone.

About the Ole's 3.5" riser... I bought one from KevinS. I used a PowerMadd throttle cable extension kit to lengthen the throttle cable. The stocker could have worked but was a tight fit.

If your throttle cable is a little bit on the tight side, get yourself the throttle extension kit from PowerMadd.

:chug:
 

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:cooool: mine is all set and rebuilding has begun .AND I CAN"T WAITE !!!
I did mine with the bellypan off and it's amazing that it took someone so long to figure this out .
anyways great job :thumbsup:
 

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<div class='quotetop'>QUOTE (crofty @ Jan 30 2007, 07:19 PM) <{POST_SNAPBACK}></div>
...it's amazing that it took someone so long to figure this out.[/b]
So long?

As soon as the 43" AWS5 sleds were on the showroom floor at the dealer for the first time ever, I was there with a tape measure taking measurements. They weren't even on the snow yet!

The thing that took the longest was finding the donor parts sled for the right price.

Mr. dealer probably thought I must've been nuts when I mentioned what I had planned.

:chug:
 

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<div class='quotetop'>QUOTE (crofty @ Jan 30 2007, 07:46 PM) <{POST_SNAPBACK}></div>
<div class='quotetop'>QUOTE (A G @ Jan 30 2007, 07:39 PM) <{POST_SNAPBACK}>
Mr. dealer probably thought I must've been nuts when I mentioned what I had planned[/b]
you mean your NOT ;) :rofl:
[/b][/quote]

Yes, that's my story... And I'm sticking to it! :tongue_nana:

Unfortunately, Mr. Dealer probably guessed correctly. :lol:
 

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by the way Greg ,what are those handle bars off from ??
 

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Discussion Starter · #9 ·
<div class='quotetop'>QUOTE (A G @ Jan 30 2007, 07:39 PM) <{POST_SNAPBACK}></div>
Mr. dealer probably thought I must've been nuts when I mentioned what I had planned.

:chug:[/b]
Funny you say that, as I have gotten the same type of reaction when mentioning what I was doing to my sled too.

<div class='quotetop'>QUOTE </div>
by the way Greg ,what are those handle bars off from ??[/b]
They are ZR Sno Pro bars from '96 if I remember right.

One question I have about the rear skid.....when mounting a clicker shock on the rear arm of the skid, should the reservoir be up or down?
 

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<div class='quotetop'>QUOTE (Greg_H @ Jan 30 2007, 10:08 PM) <{POST_SNAPBACK}></div>
<div class='quotetop'>QUOTE (A G @ Jan 30 2007, 07:39 PM) <{POST_SNAPBACK}>
Mr. dealer probably thought I must've been nuts when I mentioned what I had planned.

:chug:[/b]
Funny you say that, as I have gotten the same type of reaction when mentioning what I was doing to my sled too.

<div class='quotetop'>QUOTE </div>
by the way Greg ,what are those handle bars off from ??[/b]
They are ZR Sno Pro bars from '96 if I remember right.

One question I have about the rear skid.....when mounting a clicker shock on the rear arm of the skid, should the reservoir be up or down?[/b][/quote]

Resevoir down
 

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I have a buddy with a 98 ZR 500 converted from black magic to a 1000 tripple. I told him about the mod and he is very interested. Roughly what does this all cost to do this total. Just trying to see if it is a next summer project or if we should do it this year.
 

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<div class='quotetop'>QUOTE (snoman820 @ Jan 31 2007, 08:10 AM) <{POST_SNAPBACK}></div>
I have a buddy with a 98 ZR 500 converted from black magic to a 1000 tripple. I told him about the mod and he is very interested. Roughly what does this all cost to do this total. Just trying to see if it is a next summer project or if we should do it this year.[/b]

Sorry... It won't work, the 98 ZR5 has an AWS5 chassis. Gotta start with the AWS4 chassis.
 

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The '98 ZR 500s is not AWS4? My friends ZR only has a 41" ski stance and the spindles look like the old AWS4s. If the AGLT mod will not work there must be some factory parts out there to at least get it to later 43"ski stance.
 

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<div class='quotetop'>QUOTE (Martin @ Jan 31 2007, 11:05 AM) <{POST_SNAPBACK}></div>
The '98 ZR 500s is not AWS4? My friends ZR only has a 41" ski stance and the spindles look like the old AWS4s. If the AGLT mod will not work there must be some factory parts out there to at least get it to later 43"ski stance.[/b]
AWS V went to 43" in 2000. In 98 & 99 it was 41". I'm not sure how much of an upgrade 2" would be. You wouldn't have to go thru getting A-Arm spacers and your spindles cut. You should just be able to bolt on the 2000+ parts and go.

Kevin
 

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<div class='quotetop'>QUOTE (KevinS @ Jan 31 2007, 12:45 PM) <{POST_SNAPBACK}></div>
<div class='quotetop'>QUOTE (Martin @ Jan 31 2007, 11:05 AM) <{POST_SNAPBACK}>
The '98 ZR 500s is not AWS4? My friends ZR only has a 41" ski stance and the spindles look like the old AWS4s. If the AGLT mod will not work there must be some factory parts out there to at least get it to later 43"ski stance.[/b]
AWS V went to 43" in 2000. In 98 & 99 it was 41". I'm not sure how much of an upgrade 2" would be. You wouldn't have to go thru getting A-Arm spacers and your spindles cut. You should just be able to bolt on the 2000+ parts and go.

Kevin
[/b][/quote]

Kevin's right... Straight swap-out bolt-on of A-arms & tie-rods.

It might be worth an extra 2" if the price is right.

Either way, 43" is going to be better than 41.

:chug:
 

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So for 98, just swap out the a arms and tie rods? What about sway bar. My buddy just spent a lot on his motor and doesn't plan on selling the sled anytime soon so I think he will probably do what ever he can. I told him about it and he's pretty stoked.
 

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Discussion Starter · #18 ·
<div class='quotetop'>QUOTE (snoman820 @ Jan 31 2007, 06:18 PM) <{POST_SNAPBACK}></div>
So for 98, just swap out the a arms and tie rods? What about sway bar. My buddy just spent a lot on his motor and doesn't plan on selling the sled anytime soon so I think he will probably do what ever he can. I told him about it and he's pretty stoked.[/b]
Doing that will only change his stance to 43", not sure how much more travel he will get. I checked Brown's and the part numbers for the '98 swaybar and the '01 swaybar are the same, so he won't have to change the swaybar. He will not get the travel we are getting out of putting those parts on our AWS 4 sleds, but hey, even just 2" wider is gonna be more stable if he can get the new parts at a decent price.
 

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I have a 97 ZRT 600. It sits in the corner and never gets ridden. Rough estimate, what is the cost to do this mod? Worst case senario.
 
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