This video provides a guide on installing an electric power steering assistance kit on a Snowmobile Gen 4 or Gen 5 850 (possibly compatible with 600 as well).
Before you start:
- Purchase the kit with either pre-modified muffler and steering post or prepare to modify them yourself.
- Disconnect the battery (especially important for smart shock sleds).
Steps:
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Remove hood, handlebars, and exhaust:
- Detach the five screws and two plugs under the dash.
- Follow instructions to remove the dash cover.
- Unscrew the chrome hood screws and loosen the air intake hose clamp.
- Take off the exhaust springs and loosen the muffler.
- Carefully remove the muffler heat guard to avoid damaging it.
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Disassemble steering post:
- Ensure the steering post is in the most forward position.
- Disconnect the dog bone from the rack and pinion using an Allen wrench.
- Remove the steering post by taking out the bolts and nuts at the rack and pinion.
- Detach the dog bone using an Allen wrench and impact wrench.
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Modify steering shaft (cutting and welding):
- Cut the shaft according to specified measurements to fit the electric motor.
- Attach the couplers to the designated spots on the shaft.
- Mark and weld the couplers onto the shaft at specific distances based on measurements provided.
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Reassemble lower portion of the shaft:
- Install washers and a plastic carrier onto the shaft.
- Attach the new adjustable dog bone to the sled.
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Install the motor:
- Slide the motor onto the shaft and tighten the Allen screw.
- Install the brace to prevent the motor from twisting.
- Loosen all bolts except the Allen screws holding the motor for easier alignment.
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Attach handlebar brackets and upper bracket:
- Install the bicycle brackets onto the handlebar.
- Assemble the upper bracket and ensure it doesn’t interfere with the redundancy bolt.
- Position and tighten the upper bracket and handlebar clamps.
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Final assembly and wiring:
- Install the carriage bolt to secure the airbox.
- Attach the safety clamp to prevent the handlebars from separating from the sled.
- Mount the ECU with the provided bracket and connect the wires according to instructions.
- Check if the power valve clears the motor by manually moving it.
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Wiring:
- Connect the white activation wire to a power source that works with the ignition but not the headlights.
- Secure the ECU in a safe location.
- Locate the main power wires and connect them to the battery and ground.
- Reconnect the battery after aligning the front end with the shocks at full extension (important for smart shock sleds).
Additional notes:
- Use caution when modifying the muffler and steering shaft.
- The adjustable dog bone helps to align the handlebars.
- For smart shock sleds, avoid adjusting tie rods for handlebar alignment.
- Consult a dealer if alignment issues persist.