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Operation ZX: preserving a memory


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#1 Columbo

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Posted 30 September 2020 - 06:47 PM

Back in 2005 I bought my first “adult” sled, a 2002 Skidoo MXZ 700 trail. I had worked a lot as a 19 year old to purchase it and bought it sight unseen over eBay. Although I sold it three years later, that sled remains one of my favorites to this day. Modern sleds have come so far in comfort, power and conveniences but I still love the classic styling of the ZX chassis. I still attribute my loyalty to Skidoo to this sled.

Fast forward to today, I have the need for a project. A few weeks perusing Craigslist and Facebook and I found a 2002 Skidoo 600 Renegade for a reasonable price in acceptable condition. My plan is to slowly work through this sled and “restore” it to a reliable, clean example of the ZX chassis to preserve for years to come.

I’ve never done a build thread before but I’d like to have one place to document this project and ask questions as I go along. I’m very familiar with the newer machines but back when I owned my first ZX I was mainly concerned about keeping the gas and oil tanks full lol. Feel free to chime in with your tips, comments and suggestions!

#2 Columbo

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Posted 30 September 2020 - 06:49 PM

Here she is when I brought her home. I had a few hours after work to get started by removing the exhaust, air box, secondary, etc. I’m planning to clean both carbs, leak down test the engine and rebuild the clutches. Everything else in the under the hood will get a good cleaning!

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#3 REV-O-LUTION

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Posted 30 September 2020 - 07:11 PM

   good looking sled !!!  nice buy...       :righton  :righton


       * LETS GET READY TO   RRRUMBLLLLLE !! *


#4 Ditchbangr zx

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Posted 30 September 2020 - 07:18 PM

Looks like a clean sled to start from. Sounds like your on the right track with a leak down test on the motor and doing the general maintenance.
What’s your plans, keeping it stock and original?
I’ve had my 99 ZX 600 since 2004 and it still runs strong! I stretched it to a 136 like a Gade, but also put the narrower Summit front end on it cause I was using it more for ditchbanging and off trail riding........still love this sled as well!! I do love my 05 Rev Summit, but still love the look of the ZX 😎

Good luck with your project and can’t wait to follow what you do.

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#5 Columbo

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Posted 30 September 2020 - 07:40 PM

Thanks guys! Yeah I’ll be keeping it as close to original as possible, I’ll update a few things here and there but nothing too crazy. It’s gonna need new skis for sure, one of the loops is damaged and I was never all that fond of the precision ski anyway. I have a set of pilot 6.9 I could use but I’m open to other suggestions too.

If anyone has a shop manual (printed or pdf) that they would sell please PM me.

#6 Columbo

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Posted 30 September 2020 - 07:41 PM

Ditchbanger, that’s a really nice looking ride!

#7 800_XRS

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Posted 30 September 2020 - 07:48 PM

Please private message me

Edited by 800_XRS, 30 September 2020 - 09:44 PM.

03 x 600ho
12 xrs 800 etec
15 x 800
16 xrs 800 etec

#8 Ditchbangr zx

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Posted 01 October 2020 - 02:28 PM

Ditchbanger, that’s a really nice looking ride!


Thanks!

I still have her, it’s been a great sled.

#9 pma1123

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Posted 01 October 2020 - 02:54 PM

Had that EXACT same 02 Gade and loved it!!!   It would skip water for miles!!!

Tuned in for updates and looking forward to seeing your project come together.  B)  

 

ZX's are now "classics" and should have the brake fluid serviced and also suggest refinishing the pipe before it develops rust pinholes and blows rusty fiberglass dust everywhere. 

You'll find out that the pipes are year/model specific, and the oil reservoirs have become one of the more valuable parts on those sleds; usually one of the first parts sold during a part-out. 


Fleet of Doo triples, couple twins too.


#10 Columbo

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Posted 01 October 2020 - 09:29 PM

First off, thanks to those that pm’d me, much appreciated! I got a little more time in the garage tonight and have her stripped done to the point that I can complete the leak-down test. Fortunately no big surprises so far other than a small rodent nest (no damaged wires thankfully) and a snapped bolt on the chaincase cover (a little heat and the stub backed right out). Pictures of today’s progress are below.

Pma1123 read my mind, since I have the exhaust out I’d like to have it cleaned up and coated. I’ve never had an exhaust with a ceramic coating before, there’s a shop near me that does cerakote is that a good option? The quoted me $180 to clean the rust off the pipe and coat it, does this sound reasonable?

Also, a few other questions that came up. First, both clutches look to be in good shape but I’ll disassemble them for cleaning and maintenance. Does anyone know if one of the current primary service packs from BRP work on this old of a clutch?

Second, has anyone found a source for the course foam that covers the intakes? The foam on this sled is starting to degrade and I’d like to replace it before it pulls pieces into the motor.

Finally, the hood is marked “carb update completed” and what looks like a date in 2011. Anybody recall what that was about or have a copy of the tsb? I’m going to pull both carbs apart (they’re filthy) and see what’s in them for jets before I order new ones.

Anyway, that’s it for today. Thanks all for the support and help with this project.

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Edited by Columbo, 01 October 2020 - 09:30 PM.


#11 Columbo

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Posted 01 October 2020 - 09:32 PM

Also, I dug up a pic of the sled that started it all, my first 2002 MXZ 700.

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#12 turbopete

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Posted 01 October 2020 - 10:32 PM

Cool story. We often discuss this on the vintage forum, how we all want the sleds that we had or remember from our past. It’s all about nostalgia, and it’s neat how it evolves and different sleds do it for different generations.  Those last models before the rider forward change were good sleds, fun to ride and are still enjoyable to ride now in my opinion. 



#13 pma1123

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Posted 02 October 2020 - 08:50 AM

For clutch service, I'd replace the primary spring and get some new O-rings for the slider shoes, and just clean everything else up.  The bushing in the moveable sheave tends to get hammered over time and if there was ever rust on the shaft of the fixed sheave, that'll tear up the moveable sheave bushing as well.  At that point, it is worth replacing that press-in bushing since it'll prevent the primary from shifting out all the way.  

The secondary, if RER style, I'd clean it up and replace the slider shoes as necessary; reassemble.  

Biggest thing is getting in there and knowing what you have; addressing any surprises before they ruin a great weekend of sledding.  B)

 

You're on top of things with the leakdown test, thumbs up! 

Take a look at your carb boots, especially underneath for dry rotting and cracking.   Replacement boots are pretty cheap (amazon) for SPI brand on a 600 carb if you need em. 

I'm unsure what the update on 600 carbs was for 2002's.    

 

Intake foam....somebody on the vintage side of things pointed out that Shop Vac filters use the same style of foam, the factory piece is discontinued as you've probably found. 


Fleet of Doo triples, couple twins too.


#14 Greg63

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Posted 02 October 2020 - 09:20 AM

Shop Vac filter, as well as a drum style humidifier pad, both work well as replacement air intake filters.

#15 Rhubarb

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Posted 02 October 2020 - 08:00 PM

Foam for hood filters google below if you want it pre-cut bunch of results come up

SPI, SM-07555, Intake Air Box Foam Filter 

Michael M
RIP LOKI you were the best Puppy ever and best friend I could have ever asked for. Your life was to short buddy Nov 06 2003 - February 23 2011.

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