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SKI-DOO Power steering install 850

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:

  1. 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.
  2. 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.
  3. 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.
  4. Reassemble lower portion of the shaft:

    • Install washers and a plastic carrier onto the shaft.
    • Attach the new adjustable dog bone to the sled.
  5. 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.
  6. 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.
  7. 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.
  8. 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.