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New Tom Cat is Home!

boondocker97

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Some of the shiny stuff under the hood. Oil tank, recoil, frame spars, Intake tubes, intercooler, clutch cover... hours of polishing.

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Something I'm not crazy about with the new aluminum intake tube setup is it's rubbing the steering post. Might have to put a piece of rubber hose over the steering post to cushion them so it doesn't vibrate a hole in the intake eventually.
 

boondocker97

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Oil tank and mounting. Pump bolts in the bottom and oil sensor in the side facing the rear. Mounts too the footwell and one top bolt to the chain case. This sled came with an aluminum top mounting plate, but they have since changed to stainless for better fatigue resistance. I will admit it's not the lightest setup, but it's clean, easy to move if having to do work on this area of the sled, and you can't melt it!
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boondocker97

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Clutch porn. I don't know how much lighter these are than stock, but I might have to take them off at some point and weigh them. You know... for science. Speedwerx did the lightening and balancing. They didn't cut any material off the movable sheave, but you can see they cut the stationary sheave down by about 1/2 the thickness. Both secondary sheaves have been cut. Unfortunately long term durability is unknown on these mods since this is usually only done on the race sleds. Time will tell I guess.

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boondocker97

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And who doesn't get a brand new sled and immediately tear it all apart?! OEM fuel tank with steel pump ring and 1 Tbl spoon of fuel is 15.18lb. Trail Tank with their aluminum pump ring and gasket is 10.82lb for a 4.36lb dry weight savings. Should get me roughly another gallon and a half of fuel. Hopefully that gets me through the short riding days without packing more on the tunnel. Likely still need to get an auxiliary system for the long or really deep days.

BTW the hood comes off this machine very easy with just the two clips above the clutch and exhaust and unplug the one plug on the wiring harness. Nothing else but the side panels and charge tube holding it on. Charge tube on the intake side of the charger doesn't even use a clamp since the side panel pushes it in and holds it in place.

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I didn't like loosing my storage bag behind the tank, and this seat has zero storage. So I think I should be able to make this work with a velcro strip and a couple screws through the bag and into the old seat mounting inserts in the Trail Tank. Looks alright I think.

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IDspud

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I like handle bar bag for quick access items, mine is thin on my side bigger out front so it’s not hitting my coat like some. Have also seen it protect throttle cable and wires from snags. Carry my drinks and food in my bag that replaces the windshield so I don’t have anything to kick or catch snow on my tunnel.
 

boondocker97

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I did run a handlebar bag on my proclimb for a couple seasons and had the thinner side toward me. I liked it for ease of access and holding things like spare gloves that I didn't want wet, but after going to a BCA vest felt like it was too close to my chest at times. I also went to a thin 4" tall sled solutions tunnel bag that was waterproof. Figured out I could put everything I needed in there and it stays dry so I ditched the bar bag altogether. If I find I'm hitting that pouch with my foot I'll get rid of it and everything will have to go in the tunnel bag. I really like the concept of the windshield replacement bag, but also like having vent holes up there to let heat out. Plus the weight of the supercharger setup has me wanting to keep as much weight off the front end as possible. Weight that's high up or out to the sides also takes more effort to throw around throughout the day. So I try to keep it down and centered on the chassis.
 

boondocker97

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Got it on the scales last night. Trail Tank installed, about 1/2 tank of oil (1qt), no spare belts, and no tool kit. First weighed it with 5 gallons of fuel +6oz oil in the fuel tank. Then again with 13 gallons of fuel +15oz oil in the fuel tank. Could still fit another 1/2+ gallon of fuel pretty easy, but that was how much went into the gas cans I brought. 5 gallons in the tank shows exactly 1/2 on my fuel gage so that's nice to know. My fuel + oil mixed in works out to exactly 6lb/gallon so that's nice for future calculation sake.

This sled w/5 gallons of gas = 505 lb
This sled w/13 gallons of gas = 553 lb
Friend's supercharged 165 sled w/ gage flashing low fuel = 508 lb

For comparison sake my old Pro-lite 900 with a full trail tank, oil delete, belt drive, lightweight shafts, 2017 MC tunnel w/D&R, tube boards, Kmod skid w/raptors, 38" 2016+ front end, 162 3" PC track is around 526 lb in the same trim these were weighted at (no spare belts, tools, tunnel bags, muff pot, etc.). So build to build the supercharger is still a fair bit heavier. What I thought was interesting is how balanced these sleds are left to right. Only 4 lb difference on the skis with 5 gallons and dead even with the tank full. This sled full of fuel feels like it takes the same level of effort to rock it side to size as friends sled with only a couple gallons in it. The 45lb fuel difference feeling that similar really has me thinking the front end setups are going to feel different. Excited to see how it feels on the snow!

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boondocker97

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Only been out on the sled two times so far this year, but it's a hoot! Here are some things I've noticed so far.

The good:
I'm happy to report the light feeling on the shop floor translated to the snow. Light steering and quick handling. I've been pleasantly surprised that the heavier front end feel I was expecting with the supercharger has not shown its face. I don't know if it's the Kmod skid, the spindle setup, or both. I just know it's good. Definitely need some more time to adjust to how fast the sled comes around. Several times I didn't get to the other side quick enough or pulled it around too hard and dumped me and the sled on our side. Also washed the back end around on a couple hillsides. The fact that I'm still rusty this season isn't helping either!

A few times I found the front end lifting more than I wanted. Then I remembered... I have a coupling skid! Quick change on the coupler block and much more manageable. Setting 1 for trails and low angle terrain, setting 2 for general boondocking, and setting 3 for steeper lines seemed to be the ticket. Just like what I run in my other twin rail Kmod. Ended up on position 2 on the QS clicker on the rear shock to be able to handle G-outs and creek crossings when boondocking. QS set to 1 all the way around for the trail ride in and out with small to medium sized bumps. Skid ride on the trail is good so far.

The power is really strong right off the bottom and excellent in the midrange. Not quite as much as I was expecting on the top end, but still plenty. The ability to jump creeks and hop obstacles on this thing is insane! Bank gaps that would have been tough on my 900BB were just a thumb squeeze away on this. Also did a double log hop at the top of a hill that was out of my normal comfort zone. The extra boost lift coming into it made it possible. Also popped itself out of a few holes where I thought it was stuck for sure.

Clutching was spot on for me. Very smooth and spinning 8400rpm which is at the top of where it should be (8250-8400).

Overall little snow and ice buildup on the sled. I thought there would be some in the front bumper, but it did well in that regard. Also handled a small tree hit when I let the sled go on it's own.

Working on this sled is really easy with how quick the hood and panels come off.

Muff pot barely fits with the way the recoil is spaced out, but it fits!

Not quite as hard on fuel as I thought it was going to be... maybe? Or maybe not as noticeable with the bigger tank. I think I can leave the spare jug at the truck though for most of our rides.

Sled sounds really good when it's on the gas going through the trees! Buddy took a short video of me climbing through the trees so I got to see what it sounds like.

What could be improved:
The throttle pull feels stiff like a carb sled. I'm not sure what is added when the supercharger is installed to cause this, but my buddy's supercharged sled is the same way.

The accessory seat vinyl is slick, and I did hit a foot on it once trying to jump across through the middle of it. I'll probably live with it this season since I don't sit a lot, but before next year I'll probably trim it down 1" to 1-1/2" and have it reupholstered.

Powdercoat on the handlebar riser clamp surfaces is not good. Bars rotated on me even after tightening the bolts some more. Going to have to file it off before next trip.

Handlebar warmer codes. Didn't realize this was such an issue with Ctec Cats. Hit reverse and back forward has been working to clear them. The adjustable heater levels are nice when they work.

Snow and ice builds up in the footwells. This isn't an issue on my other sled with full tube boards where that area is cut out more in the bottom.

Front bumper could have better grab points.

Front shocks are a little harsh. I'm going to try to get some Evol chambers installed so I can get the pressures dialed in for a bit more initial comfort.

It runs warm down the trail. Even with the scratchers down and ducking off to the edges once in a while the temp light flashed quite a few times. The Kmod scratchers aren't the greatest either and one snapped off in the trailer on the way home when it was clipped on the rail. Kevin at Kmod actually recommends running ski scratchers instead of the rail ones he sends with the kit. Can't do that with the Powder Pro skis so I'm going to try retrofitting a stock set of Alpha scratchers somehow.

Riding down a rough trail at the end of the day with instant boost sucks. Forget the slow ruh, ruh, ruh, ruh, ruh through the woops because it's a killer. Pretty much have to commit to holding a constant throttle and blitzing everything.

Hardweld runners on skis aren't for me. I'll be going back to carbides.

Tried to throw a fresh belt on and discovered the threaded holes in the outer secondary sheave were in tough shape. One was stripped and the other was almost stripped. Going Heli-coil both of them. You may notice that I said "both of them." The secondary on this sled has the normal belt tool hole and the hole for the old deflection adjuster. So... it's an older secondary that must have been sent in to be reworked and lightened.

Found a loose front shock bolt so I'll be keeping an eye on the bolts with aluminum nuts. The little idler wheels (not anti-stab ones) toward the front of the skid were also loose on the rails. I've heard the stock alpha skid can be hard on these as well.

Snapped the limiter strap in the skid. Repost from Kmod thread:
Was where it was set when I got the sled. I like the handling as it's setup so I probably won't change it. Overall the strap was in tough shape end to end, but it snapped right where it goes under the washer on the lower attachment point. Washer has a bit of a sharp edge so I'm not too surprised it broke there. Going to radius that washer and sandwich an extra piece from the old limiter there as a sacrificial item going forward. Ordered a new one from Kevin yesterday and a spare to have on hand. We field fixed it but broke again within 1/2 mile.

FYI when the limiter breaks it both loosens the track and pushes it away from the drivers. You'd think the skid pushing out on the track would tighten it more, but it doesn't. Lets the track ratchet pretty easy and ends the riding day.

We encountered the shrader valve issue on a friend's skinny he just installed. If you bottom out the rear shock, the main air chamber cap gets down close to the inside of the track. Then if something pushes the track up at the same time the drive nubs can hit the cap and try to rip it off along with the valve. Sounds like the fix for now is to swap that cap with the one that is on the bottom of the nitrogen reservoir. It's more rounded and lower profile so less chance of it getting ripped off.

Overall pleased with the sled! Just needs a few tweaks here and there to make it perfect.

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sno*jet

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nice! nothing is exploding yet with the lightened primary and a supercharger. You could even take it a step further with Ti hardware... But do you notice any extra vibes over a stock clutch yet? Im still in the lighter is better camp but notice some folks saying the opposite here on the internets.

whats the deal with the carbon fiber flap? i seen it in the catalog and cant wrap my head around why that would be a good idea if it is stiff..?
 

boondocker97

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As far as I can tell Speedwerx left the movable sheave alone (aside from having the lighter cover attached) when cutting material off. Since that is what seems to have issues most of the time I don't think the chances of exploding would be any worse than a stock clutch. It was balanced after the work was done so no vibrations yet. Seems to run pretty smooth. There's already some extra drag on the crank spinning the supercharger so I don't think adding a little weight to the clutch in an effort to reduce vibration is going to help anything in this case. IMO cutting weight off increases responsiveness (performance) at the cost of lost flywheel effect (reduced consistency and less vibration damping). So you have to decide if you're looking for all out performance or ease of use and longevity. They don't put heavy flywheels on motocross bikes, but they do on trail machines. Different users and end goals.

Jason said they experienced some stretching issues with Ti bolts on race sleds in the past so he doesn't really use it. From everything I've seen the best grade of Ti you can get is 6AL-4V. Which is equivalent to about a grade 5 bolt (8.8 metric). So any bolt on the sled that has a 10.9 or 12.9 stamped on the head that is replaced with Ti is going to be weaker. That being said I did a front end suspension Ti bolt kit on my other sled and haven't seen any issues yet. I personally won't use it on anything that has dynamic loads in tension. So I'm a no on clutches and engine bolts. Even replacing relative large lower steel a-arm bolts it only saved 1lb total. So there's not going to be a lot of weight loss in a few small bolts and pins in a clutch.

The snow flap is purely for looks. Jason and I are both of the opinion sleds look better with something back there. It does have some flex, but not a lot. Probably similar to a PDP plastic flap, but weighs next to nothing. I might end up having to angle it down a little more to help out with cooling on the trail.
 

boondocker97

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I did end up fully clipping the track on the sled with one of these tools and a small cordless impact gun: https://www.atwindustries.com/product/snowmobile-track-clip-tool-for-up-to-3-1-lug-paddle/
Hoping it reduces heat buildup on the trail to extend the track life a little and help keep the track centered between the hyfax. For those that are worried about rotating weight: a pack of 10 alpha clips weighs right at 0.75lb. So adding 23 clips added 1.7lb to the 165 track.
 

sno*jet

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i agree with you and jason on the flap!
i havent had any clutch troubles with Ti bolts. the stretch factor is interesting... maybe its a good thing for an exploding clutch lol. Yours is undoubtedly light with the steel ring removed anyway, probably wouldnt notice much diff with the bolts.
I added a touch more weight to my cutler flyweights after the full Ti bolt kit. So Im a fan. Id love to build a motor with full Ti like one of buradnts builds. i need to retire someday tho lol
 

boondocker97

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Here's a good article on Ti fasteners: https://www.vitalmx.com/features/Everything-You-Wanted-To-Know-About-Titanium,6432

Looks like it really comes down to how the fastener was manufactured. So as expensive as Ti is already get it from a reputable place. Even if it is manufactured correctly there's still a stretch factor because of the low modulus of elasticity. I've heard from a good source of engines with Ti bolts having trouble keeping things together correctly over the long haul. Lots of factors going into that though. Full race engine that's torn down frequently and re-torqued back together there's probably not much downside.
 

sno*jet

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good read, thank you. i didnt get anything from that to suggest not using it where i have it. at one point he says go ahead and use it for brake calipers and motor mounts, even inside the motor. the biggest issue i read about in my research was galling. which should not be an issue if you use loctite like on the clutch bolts. i think galling occurs between aluminum and steel also. i would think the aluminum threads would fail before the torqued bolts stretched. Actually the cover would probably fail first. Im with ya on anything bolted down tight with a nut though. clutch pins, i dont see an issue with. im no expert obviously tho. Side note, I did a quick trim down off the tip of my diamond S Ti can. Or so I thought it would be quick... I decided to just do it with my cutoff wheel while it was still on sled. Bad idea! That stuff does not cut as easy as steel!
 

boondocker97

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Got the Evol kit in for the front shocks and test fit one side last night. Lots of loctite holding the caps to the shafts. Had to pull the o-rings and shrader valve out and use quite a bit of heat to get it to break loose.

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Upon fitting it the air cap would just hit the spindle with the ski off the ground at full lock.

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Tried spinning the bottom of the shock 180 and could get it to touch the tie rod with the ski off the ground and a little pressure applied to the ski.

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The spindle has a notch on the inside of it a bit lower for clearance to something (maybe a shock spring retainer). If I replicate the size and shape of that notch right where the cap is hitting It should clear no problem. So looks like the die grinder will be coming out!

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Oh, and the plastic bushings Cat uses on the eyelets of these shocks suck! There's a ton of play in these already that let the ski pop up and down probably 3/16". I'll be ordering a new set and a spare set to have around. Change them the same time I change ski dampers in the future.
 
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boondocker97

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Was able to flip the shocks upside down with plenty of clearance all around. If the snow starts turning the QS adjusters I might have to go with my original thought and clearance the spindle to run them right side up.
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bgraff1

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i dont think i would be running those shocks with the QS chamber forward outside of the a arms. one tap of a tree and those will be smashed off
 

IDspud

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Did you change upper a arms when going to riot spindle?

I have that same shock and spindle with lots of clearance and it looks like you need the riot upper a arm.
 

boondocker97

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Did you change upper a arms when going to riot spindle?

I have that same shock and spindle with lots of clearance and it looks like you need the riot upper a arm.
Yeah it has the TKI upper arms to match with the spindles. Got a picture of your setup?

i dont think i would be running those shocks with the QS chamber forward outside of the a arms. one tap of a tree and those will be smashed off
I definitely thought about that. I'm going to run it for a ride and see if I can get the shocks to do what I'm looking for with the Evol chambers then evaluate. Just have to be easy on the tree bashing for now.
 

bgraff1

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Yeah it has the TKI upper arms to match with the spindles. Got a picture of your setup?


I definitely thought about that. I'm going to run it for a ride and see if I can get the shocks to do what I'm looking for with the Evol chambers then evaluate. Just have to be easy on the tree bashing for now.
yeah ive said that before and 100% tapped some trees. nothing that did damage but i dont think it would take much to ruin your day and cost more money
 
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