Converting a 2005 EXPEDITION to a low elevation Bush Buggy Summit - REV Chassis - Mountain Sleds - DOOTalk Forums

Jump to content

 






Photo

Converting a 2005 EXPEDITION to a low elevation Bush Buggy Summit


  • Please log in to reply
21 replies to this topic

#1 RAB123

RAB123

    Advanced Member

  • Members
  • PipPipPip
  • 1181 posts
  • Gender:Male
  • Location:Goose Bay ,Labrador
  • Sled:Elan

Posted 30 March 2021 - 05:52 AM

hello , 

 

I just picked up a 550 exp , that I would like to transform into a low alt Summit style sled that I can use in and around the woods , all oriented for off trail , bush , tree kinda riding 

 

I'm thinking the fan exp on diet should be a fun sled at low elevation , not the greatest on gas but thats it lol 

 

I am searching for the following items ; 

 

upper and lower A-arms off a summit 

(names of who may make them , even more narrow than stock if possible )

 

Steering rods (aluminum tubes that attach to the spindle) off a summit 

 

Tachometer off any Rev

 

Steering post that does not use the plate to attach the handle bars

( is there a way to get the post more forward on these original Revs ? )

 

Handle bars that go with the above steering post and the riser block .

 

rear tunnel close off panel at like 10'' long off any summit .

 

names of where I could source a light weight rear tunnel mounted LED tail light 

 

Windshield and attaching hardware or just the attaching hardware

 

TRA clutch in good shape suitable for a 550 fan , I suspect i could any TRA as long as the taper fits , i am willing to be schooled in TRA identification and Classification of intended purposes .

 

Team Rapid secondary splined for BRP would be a nice addition as well 

 

A 550 Aeen pipe and can or either or ,,,,,,,,,,or any reputable can / pipe combo .

 

are there any aftermarket front bumpers to reinforce the front end ?

 

a set of running board braces specific to original REV 

 

How can I stiffen up the infamous Nun bulk head ?

 

Thank you for taking the time to read the list,

 

I appreciate your interest and look forward to your help 

 

Happy trails 

 

 

 

 

 

 



#2 SoloSldr

SoloSldr

    Advanced Member

  • Members
  • PipPipPip
  • 368 posts
  • Sled:None at the moment

Posted 01 April 2021 - 05:55 PM

Had one back then. Often underestimated. I thought it had a 36" front end. Horrendous single rate springs and shocks. By the third corner the Summits and Renes were gone. When we got to the playgrounds it would really shine though. I ordered it with 6.9 Pilots and it just plain worked. If you did 'stick it' volunteers always willing to help because it was so light. Always thought about motor tweaks if I blew it up but it just ran and ran. That vintage of the 550s were nice. Bought that instead of the Summit fan for the 3-up seat for family weekends and 16" track. Rail ext to 144", shim flap, clutch tweaks, measure shocks and look for 'take offs'. You could spend some money building it but it'll be fun.....



#3 RAB123

RAB123

    Advanced Member

  • Members
  • PipPipPip
  • 1181 posts
  • Gender:Male
  • Location:Goose Bay ,Labrador
  • Sled:Elan

Posted 04 April 2021 - 04:26 PM

Solo, 

 

what clutch tweaks did you do, mine has the PB 50 , I removed the ring gear and it has 4 shims plus the slug in each sliding shoe , 

 

Did you ever put a tach on it ? , I scrounged up a brp tach but I cant find the plug in there , I'm now wondering if the 2007 800r which had a tach and speedo in the same gauge would work ? or just get a tiny tach or similar just to Tune it and then remove it.

 

Do you know which of the original summit REVs were the most narrow in the front  , my exp is liken 41 inches wide lol 

 

Thanks for your interest 



#4 broncoformudv

broncoformudv

    Advanced Member

  • Members
  • PipPipPip
  • 559 posts
  • Gender:Male
  • Location:Anchorage, Alaska
  • Interests:sleds, boats, trucks, hunting, fishing
  • Sled:2006 Summit 800 X 154

Posted 06 April 2021 - 01:53 PM

All Summits Revs should be 36" if I remember correctly.

 

From what I recall you cannot put a TRA on the 550.

 

You can push the steering shaft forward by drilling one new hole.  If you look at the upper mount you will see how it can be done, I do this on all of mine.

 

The 2006 Summit X models had the flat top style steering shaft and handlebars you want as did all 2007 Summit models and the 2008 Summit 600 model.

 

AAen pipe and can will have to be bought new from the manufacturer, these never come up for sale used.

 

NUN reinforcement plates are sold by a fellow dootalker on here wwracer and are well worth the money and time to install.

 

I wouldn't waste my time with running board braces, they never seem to keep the boards from bending.  Save your money and buy aftermarket boards made of tubing or add a set of boards off a Pro RMK like some others have done.


2018 Expedition SWT 900 ACE

2015 Expedition SE 900 ACE

2015 Summit 800 154

2006 Summit 800X 154

2006 Summit 800X 151

1997 Skandic 500


#5 broncoformudv

broncoformudv

    Advanced Member

  • Members
  • PipPipPip
  • 559 posts
  • Gender:Male
  • Location:Anchorage, Alaska
  • Interests:sleds, boats, trucks, hunting, fishing
  • Sled:2006 Summit 800 X 154

Posted 06 April 2021 - 01:54 PM

https://www.dootalk....ulkhead-braces/


2018 Expedition SWT 900 ACE

2015 Expedition SE 900 ACE

2015 Summit 800 154

2006 Summit 800X 154

2006 Summit 800X 151

1997 Skandic 500


#6 alainm

alainm

    Advanced Member

  • Members
  • PipPipPip
  • 102 posts
  • Gender:Male
  • Location:Montpellier, QC
  • Interests:Ski-Doo 2021 Expedition Sport 900ACE
    Ski-Doo 1988 Safari 377 with SC-4 rear suspension

    Retired sleds
    Ski-Doo 2002 MXZ 380Fan
  • Sled:Expedition Sport 900 ACE

Posted 07 April 2021 - 06:58 AM

Try these guys they have what you are looking for in complete front end A-arms, from watercross 29" to trail 42"

 

https://www.alternat...1-GEN-4_c79.htm



#7 RAB123

RAB123

    Advanced Member

  • Members
  • PipPipPip
  • 1181 posts
  • Gender:Male
  • Location:Goose Bay ,Labrador
  • Sled:Elan

Posted 08 April 2021 - 09:03 AM

what is the difference between a 2006 144 rear skid and a 2012 146 rear skid besides the possibility of the length ? 

 

it looks like the center to center distance is the same .

 

would one transfer more than the other ? 

 

does one have a more compliant ride ? 

 

does one weigh more than the other ? 

 

I have a chance for either or and am trying to decide .

 

thanks to all who have provided input and those who have shown an interest .



#8 broncoformudv

broncoformudv

    Advanced Member

  • Members
  • PipPipPip
  • 559 posts
  • Gender:Male
  • Location:Anchorage, Alaska
  • Interests:sleds, boats, trucks, hunting, fishing
  • Sled:2006 Summit 800 X 154

Posted 08 April 2021 - 10:53 AM

what is the difference between a 2006 144 rear skid and a 2012 146 rear skid besides the possibility of the length ? 

 

it looks like the center to center distance is the same .

 

would one transfer more than the other ? 

 

does one have a more compliant ride ? 

 

does one weigh more than the other ? 

 

I have a chance for either or and am trying to decide .

 

thanks to all who have provided input and those who have shown an interest .

 

 

From what I recall there was no major difference till they went to T-motion and I thought that was in 2015?  All the skids prior to that were very similar with minor geometry changes that didn't actually add any value.


2018 Expedition SWT 900 ACE

2015 Expedition SE 900 ACE

2015 Summit 800 154

2006 Summit 800X 154

2006 Summit 800X 151

1997 Skandic 500


#9 Ski-B

Ski-B

    Advanced Member

  • Members
  • PipPipPip
  • 5890 posts
  • Gender:Male
  • Location:Saskatchewan
  • Sled:2020 Freeride 850

Posted 21 April 2021 - 06:37 PM

Solo, 

 

what clutch tweaks did you do, mine has the PB 50 , I removed the ring gear and it has 4 shims plus the slug in each sliding shoe , 

 

Did you ever put a tach on it ? , I scrounged up a brp tach but I cant find the plug in there , I'm now wondering if the 2007 800r which had a tach and speedo in the same gauge would work ? or just get a tiny tach or similar just to Tune it and then remove it.

 

Do you know which of the original summit REVs were the most narrow in the front  , my exp is liken 41 inches wide lol 

 

Thanks for your interest 

 

Keep the PB-50. It works better than the TRA 550 version.

 

I ran a TSS-04 on our little Rev 550 with the PB-50 was a real nice combo.


2020 Freeride 850. My ride.

2018 XRS 850 Sons sled.

2017 Freeride 860R etec. 860BB. Daughters sled.

2015 Freeride 800R etec. All Stock. Wifes sled.

2015 BCX  800R etec. Trail ported. Spare sled.

2014 BCX 800R etec. All stock. Spare sled.

1998 Formula S 380. She is a keeper.


#10 SoloSldr

SoloSldr

    Advanced Member

  • Members
  • PipPipPip
  • 368 posts
  • Sled:None at the moment

Posted 23 April 2021 - 08:28 AM

RAB123, fuzzy remembering that far back but a friend tweaked the the clutch to compensate for the 1.75 track upgrade. I was a novice at clutching back then. Only slightly better now thanks to Joe and others. Felt the 1.25 and stock engagement RPM was actually a little better but the bigger track had a time and a place. I'm pretty sure??? my front end was 36" but it may have been ordered that way. Funny thing is with the pile of extras I had that thing wasn't even 6 grand new. Your project kinda makes me miss it. The reliability of it was when I really started to head out on my own excursions.....



#11 RAB123

RAB123

    Advanced Member

  • Members
  • PipPipPip
  • 1181 posts
  • Gender:Male
  • Location:Goose Bay ,Labrador
  • Sled:Elan

Posted 23 April 2021 - 05:40 PM

Keep the PB-50. It works better than the TRA 550 version.

 

I ran a TSS-04 on our little Rev 550 with the PB-50 was a real nice combo.

 

I looked up one of those newer TRA 550 clutches and it looked different than the traditional TRA .

 

Which TRA are you referring to ? 

 

what didn't you like about it ?

 

Thanks



#12 Daag44

Daag44

    Advanced Member

  • DOOCrew
  • 27658 posts
  • Gender:Male
  • Location:South Shore, Quebec
  • Interests:1973 Olympic
  • Sled:2007 1000 SDI

Posted 23 April 2021 - 05:59 PM

The key to an awesome clutch setup off-trail (and trail) is the backshift. I don't know of any clutch setups for the 550F, but the principal of the backshift goes a long way. Some of that is in the primary, but there is more to it in the secondary. For this reason it is worth figuring out what affects the backshift. The way that I approach it is to focus on three things affect load on the engine, and the backshift when letting go of the the throttle. I find it makes it easier to follow the discussions found in the archives such as the one below.
 
550 Clutch Tutorial
Started By LRD, Feb 18 2007 01:45 PM

 
For the ski stance I got to try a 34" this past season. It was narrow, but I enjoyed it for low speed riding.
 
The muffler is a big deal with backpressure and heat transfer. With the cowling and active venting from the fan, I am not sure how much of an affect a barker will have on heat transfer to the engine, but heat tape will go a long way. I prefer big mods for short races, and focus on setup for off-trail. For example a skid/track combo with too much drag will rob a good portion of any power adder. A performance tuned-pipe/muffler is easier to install, but it isn't what puts power to the ground. In my opinion, at least ninety percent of the effort is better spent on the skid, track, CVT and how the engine runs long before getting into power adders. Also if the engine isn't up to snuff, power adders will accentuate any problem and accelerate excessive wear. Mods are fun only if the engine runs.


Edited by Daag44, 23 April 2021 - 06:01 PM.

Air/Fuel Ratio for two and four strokes
Air/Fuel Ratio for 1200 with boost
Air/Fuel Ratio is measured through emissions
Wideband and EGT
Wideband readings of Air/Fuel Ratio on a two stroke
600 SDI MY2004 Lean/Hot spot running 6900-7000 rpm @ 40-45% Throttle Opening
800R Cranking Compression
800R Oil Injection / Premix combo
800R P-TEK Electrical Troubleshooting #1 and #2 
800R Turbo
850 Center Oil line for coolant pump melted
850 Main Oil line caught fire #1 and #2
900 ACE Turbo - muffler turning red hot
1200 4-TEC Mapping
1200 4-TEC MY 2009 to 2011 Fuel Line issues that could cause a fire
Batteries
Belt Blowers: Overview of UPMICHIGANDER's and Ronn's experience
BUDS 3.3.0 won't connect to SDI
BUDS not connecting to HO or SDI - Try a CanDoo
Crankshaft runout - maximum allowable specs 
CVT efficiency - BlueMax
Deep snow intake for XP chassis
Electrical - ECM drivers for Ignition Coils and E-TEC injectors 
Electrical - Diagnoses of a failed ECM
Electrical - 30A Battery Charging Fuse Socket Diagnoses and Relay
Electrical - Relay Coil Wine
Electrical - Relay Testing
Electrical - Battery Charging Relay Diagnostic 
Electrical - Troubleshooting with BRP video 
Electrical - Solder vs Crimp
Electrical - Diagram for Fanners on page 3
Engine Break-In 
Engine Weight 
E-TEC 600HO Clutching
E-TEC Oil Pump
E-TEC Dial-A-Jet
E-TEC Electric Start troubleshooting
E-TEC Engine Management
E-TEC eRAVE position code recurring
E-TEC Stator fault codes P1562 or P1563
E-TEC Capacitor Charge Hold Test and Residual Voltage Test
E-TEC Voltage Rectifier Regulator troubleshooting
E-TEC Power Fades are not normal and can be fixed
Fuel Issues: Could new Ester type oxygenated additives be deteriorating the Fuel Sender Grommet?
Fuel pump and regulator replacement for ACE, E-TEC and SDI
Gasoline quality and storage
Bad Gas for a Two Stroke - Is it a Myth ?
GNR CVT Alignment for the G4
Grip N Rip Clutch Alignment testing
G4 Clutch Alignment, Engine Movement, Sheave Runout and Clutching
G4 850 Throttle Jerkiness solved with clutching
G4 850 Snappy throttle/clutch engagement
G4 850 pDrive tech - A question of Engineering
G4 Steering
G4 850 Tuned Pipe @ 12.6 lbs and Muffler @ 15.4 lbs vs 800R and 800RE muffler weight
Longevity - 800R E-TEC 
Mikuni o-ring for carb float assembly - Arctic Cat part# 6505-875 or from Amazon and eBay
Muffler Red Hot
Off-trail riding for flatlanders
Oil versus Fuel consumption
Pictures - How to resize and upload to DooTalk
Pictures - How to post with the correct orientation
Pipe Pressure testing on a dyno
Pipe Pressure testing from LRD (#1) and (#2)
Pipe Pressure testing results from BRP
Power Loss - How to diagnose in the field
Power at the Crankshaft vs Track - BlueMax
Power Curves: 600 HOE (E-TEC)
Power Curves: 600 vs 800 vs 850 vs 1000 vs 1200
Power Curves: 1000 vs 800 vs 600
Power curves: 800RE 2010.5 to 2016 vs 2016.5 850
Quebec/NY State border crossing
REV Gen1 Gauge Display stuck on "SCALE"
REV Gen1 Volt and Temp Gauge install
REV Gen1 electrical connectors for sensors and MPEM (Multi Purpose Engine Module)
Seafoam for E-TEC injectors
Shortblock or Rebuild?
Ski-Doo Snowmobile Tech Training
Spark Plugs cracked
Squish - The limit
Squish - A discussion on head design
Stator and Relay Diagnostic 
Stator testing for E-TEC using a T harness/Bridge
Stator testing for 1200 4-TEC
Stator Removal on page 3
Stator replacement for a 1200 4-TEC
Suspension Adjustment
Triples - Coolant Pump Assembly
Y-Pipe bolts loosening fix


#13 Ski-B

Ski-B

    Advanced Member

  • Members
  • PipPipPip
  • 5890 posts
  • Gender:Male
  • Location:Saskatchewan
  • Sled:2020 Freeride 850

Posted 23 April 2021 - 07:09 PM

I looked up one of those newer TRA 550 clutches and it looked different than the traditional TRA .

 

Which TRA are you referring to ? 

 

what didn't you like about it ?

 

Thanks

 

The TRA i am referring to is the 2010 and newer XP chassis 550F primary clutch. It is heavy as hell and the motor has a lazy feel trying to spin up the weight.

 

The PW-50 is a better clutch. Super light and the engine will spool up way faster than a 2010 550 with the TRA. The PW-50 is easy to tune and just works well on the 550F. I retained the ring gear just for the convenience of starting for younger riders. 


2020 Freeride 850. My ride.

2018 XRS 850 Sons sled.

2017 Freeride 860R etec. 860BB. Daughters sled.

2015 Freeride 800R etec. All Stock. Wifes sled.

2015 BCX  800R etec. Trail ported. Spare sled.

2014 BCX 800R etec. All stock. Spare sled.

1998 Formula S 380. She is a keeper.


#14 Daag44

Daag44

    Advanced Member

  • DOOCrew
  • 27658 posts
  • Gender:Male
  • Location:South Shore, Quebec
  • Interests:1973 Olympic
  • Sled:2007 1000 SDI

Posted 24 April 2021 - 06:52 PM

Smaller engines need less mass in the primary than larger engines.


Air/Fuel Ratio for two and four strokes
Air/Fuel Ratio for 1200 with boost
Air/Fuel Ratio is measured through emissions
Wideband and EGT
Wideband readings of Air/Fuel Ratio on a two stroke
600 SDI MY2004 Lean/Hot spot running 6900-7000 rpm @ 40-45% Throttle Opening
800R Cranking Compression
800R Oil Injection / Premix combo
800R P-TEK Electrical Troubleshooting #1 and #2 
800R Turbo
850 Center Oil line for coolant pump melted
850 Main Oil line caught fire #1 and #2
900 ACE Turbo - muffler turning red hot
1200 4-TEC Mapping
1200 4-TEC MY 2009 to 2011 Fuel Line issues that could cause a fire
Batteries
Belt Blowers: Overview of UPMICHIGANDER's and Ronn's experience
BUDS 3.3.0 won't connect to SDI
BUDS not connecting to HO or SDI - Try a CanDoo
Crankshaft runout - maximum allowable specs 
CVT efficiency - BlueMax
Deep snow intake for XP chassis
Electrical - ECM drivers for Ignition Coils and E-TEC injectors 
Electrical - Diagnoses of a failed ECM
Electrical - 30A Battery Charging Fuse Socket Diagnoses and Relay
Electrical - Relay Coil Wine
Electrical - Relay Testing
Electrical - Battery Charging Relay Diagnostic 
Electrical - Troubleshooting with BRP video 
Electrical - Solder vs Crimp
Electrical - Diagram for Fanners on page 3
Engine Break-In 
Engine Weight 
E-TEC 600HO Clutching
E-TEC Oil Pump
E-TEC Dial-A-Jet
E-TEC Electric Start troubleshooting
E-TEC Engine Management
E-TEC eRAVE position code recurring
E-TEC Stator fault codes P1562 or P1563
E-TEC Capacitor Charge Hold Test and Residual Voltage Test
E-TEC Voltage Rectifier Regulator troubleshooting
E-TEC Power Fades are not normal and can be fixed
Fuel Issues: Could new Ester type oxygenated additives be deteriorating the Fuel Sender Grommet?
Fuel pump and regulator replacement for ACE, E-TEC and SDI
Gasoline quality and storage
Bad Gas for a Two Stroke - Is it a Myth ?
GNR CVT Alignment for the G4
Grip N Rip Clutch Alignment testing
G4 Clutch Alignment, Engine Movement, Sheave Runout and Clutching
G4 850 Throttle Jerkiness solved with clutching
G4 850 Snappy throttle/clutch engagement
G4 850 pDrive tech - A question of Engineering
G4 Steering
G4 850 Tuned Pipe @ 12.6 lbs and Muffler @ 15.4 lbs vs 800R and 800RE muffler weight
Longevity - 800R E-TEC 
Mikuni o-ring for carb float assembly - Arctic Cat part# 6505-875 or from Amazon and eBay
Muffler Red Hot
Off-trail riding for flatlanders
Oil versus Fuel consumption
Pictures - How to resize and upload to DooTalk
Pictures - How to post with the correct orientation
Pipe Pressure testing on a dyno
Pipe Pressure testing from LRD (#1) and (#2)
Pipe Pressure testing results from BRP
Power Loss - How to diagnose in the field
Power at the Crankshaft vs Track - BlueMax
Power Curves: 600 HOE (E-TEC)
Power Curves: 600 vs 800 vs 850 vs 1000 vs 1200
Power Curves: 1000 vs 800 vs 600
Power curves: 800RE 2010.5 to 2016 vs 2016.5 850
Quebec/NY State border crossing
REV Gen1 Gauge Display stuck on "SCALE"
REV Gen1 Volt and Temp Gauge install
REV Gen1 electrical connectors for sensors and MPEM (Multi Purpose Engine Module)
Seafoam for E-TEC injectors
Shortblock or Rebuild?
Ski-Doo Snowmobile Tech Training
Spark Plugs cracked
Squish - The limit
Squish - A discussion on head design
Stator and Relay Diagnostic 
Stator testing for E-TEC using a T harness/Bridge
Stator testing for 1200 4-TEC
Stator Removal on page 3
Stator replacement for a 1200 4-TEC
Suspension Adjustment
Triples - Coolant Pump Assembly
Y-Pipe bolts loosening fix


#15 RAB123

RAB123

    Advanced Member

  • Members
  • PipPipPip
  • 1181 posts
  • Gender:Male
  • Location:Goose Bay ,Labrador
  • Sled:Elan

Posted 25 April 2021 - 03:14 PM

Ski-B ,Daag44 

 

thanks for showing interest in my build ,

 

ref the clutching , and thanks for the tutorial , I'll read it later , hopefully I don't have to retract the up comming paragraph 

 

I wanted to try the new TRA for its ability to change the profile, as you know the PB-50 is linear with those three slug holders and the helix is 44* , so there is not as much to influence the shift characteristics , well not as much as with a compound helix and different ramps . 

I have never seen that new 2010 + 550 fan TRA ,, I thought it may be lighter not heavier , I removed the electrictric start system along with the ring gear .

 

I would love to try 34'' stance , are those custom arms or from someone like the link above ? 

 

The motor is tired and will need attention , but not yet lol , when I start thinking about engine and power mods I end up going down the fan cooled HP rabbit hole, I'm going to punish this engine first , thereby figuring out what it can and can't do , much like the experimental stage lol 

 

I seem to be leaning towards extending the season by changing/modifying the operating envelope to include , bush roads , marshes and sandy beaches . Have either of you guys ever installed wheels similar to Sand-X in the UAE or something similar ? either locally or sourced through available parts already in production ?

 

Overall my goal is to have a competent low altitude summit style sled , that will see lots of trees , alders and creak beds with the occasional trip to the mountains  3500 '. ish , plus the summer envelope lol  

 

thanks for your interest 






0 user(s) are reading this topic

0 members, 0 guests, 0 anonymous users