The Wolvy new suspenders. Long Read.

[Shoemaker]

Hey TS Gang.

So the little 99 Wolvy the last few years has been in transformation in the last little while. Below is the play by play.
New:
U joints,
CV Boots (preventative),
Bearings all the way around,
Break pads,
Rims and tires,
Winch rebuild with new dial for freespool/engagement and a donated Roller Fairhead (Thanks Yellow Jacket)!

http://www.trackshare.com/forum/show...ighlight=wolvy

10 over Namura Piston,
10 over Namura Rings,
10 over Cylinder,
Replacement exhaust valve (bent),
Airfilters 2 aftermarket ones. 1 K&N with a filter skin, the other a moose 2 stage filter,
Raptor 350 Carb,
Dynojet Jetting Kit,
Airbox and lid,
Starter,
Stator,

http://www.trackshare.com/forum/show...ighlight=wolvy

and now.......
Banshee headlights,
and new suspenders.

Banshee Headlights are new and almost identical to the Wolvy, but are more projector like in thier beam My stock ones are thrashed and melted! Those lights design was garbage! So Banshee lights go on, and bolt and clip right into place! ebay, 100$ for the pair.

Now the suspenders,
The rear puked, and went looking for a replacement. Price from one from Yamaha, ohh, only $292. WTF?! 5 clickers for spring tension, oil filled and almost 300$. Not the way I'm going.
So lots of digging. Elka, Fox, Progressive,Works. All expensive options. Way out of my budget.

Then I found Bronco.

http://www.trackshare.com/forum/show...ghlight=bronco

3 Shocks for the price of 1 OEM rear.

The 2 front were for a 400/350 Yamaha. the Rear off a Honda 420. The fronts bolt right on, the rear need to make the mounting hole go from 10.1mm to 12mm. Some work here coming up!
Awesome! Here are the pics. The new shocks have a 10% stronger spring, have threaded body instead of 5 choices to pick, and are gas filled. I believe they can be rebuildable? (Not sure maybe someone else can chime in).

What was really cool is Bronco North America had a great customer service rep helping me choose shocks for the Wolvy, as none were listed for it! What a great experience tinkering, modifying, fixing, and making better my old little Wolvy.

Back in 99, this was a fairly big machine, but now is Dwarfed by huge 800cc + machines. But this little guy flys through the bush in Belair, and loves it out there!

Having just as much fun riding, as well as fixing and tinkering! Attached is the complete email correspondence.

Never be afraid to ask for help. Never be scared to try something new. Never be afraid to think outside the box!

Shoe Box!

[Shoemaker]

More pictures....

Banshee Headlights on the Wolverine.

A measurement of the ground clearence. Using the winch plate as a reference.

Old and new front shocks.

New shock mounted.

[Shoemaker]

More pictures,

Shock Mounted Side view. Shock mounted front view. Shocks mounted front view.

Measurement after shocks were mounted. Lost 1/8 of an inch. I can live with that with the $$ I have spent.

[Shoemaker]

More pictures,

The new Utility box ($20.00 Lowes special). And about 6$ in hardware to bolt it and make it water resistant. Now I can carry stuff!

Shoe.

[Saskbearcat]

Thanks for the information Shoe, I'm looking at putting new shocks on my 98 arctic cat bearcat 454 and will have to check out the way you did things. Your yammi looks really good.

[Shoemaker]

Rear Shock modifications:

1st picture is old Shock Bushing Top
2nd Pictures is old Shock Bushing Bottom
3rd pic is new shock bushing bottom
4th pic is new shock bushing top

It started with an easy enough plan, then things became complicated! LOL
The idea was to push out the center tubes and bushings from the old shocks and the same on the new, and put the old ones in the new shocks.

Well that didnt go according to plan. We pushed them out with a hydraulic press, but the inner and outer rings were fused to the rubber. arg. so we tried to machine the outside to fit the new shock ring (which is smaller). Nope, it destroyed the outside ring and rubber. So we machined tops and bottoms to the center pin.

On the new shocks we pushed out the top and bottom bushings and drilled out the 10.1mm holes to 12mm holes. Easy for the holes, but shock width is still an issue.

We used the old center pins, cut them, and have now used them as spacers for the new shocks. So 1 free lunch to my Shop friend, and the rear shock will be getting installed the long weekend coming up!

[Saskbearcat]

Those bushings you are using look like the ones used on the old Versitile 400 and 4400 swathers on the knife drive.we sell lots of them and get them from Westward parts.

[Shoemaker]

Final pictures before installation!

A shot of flat back paint, just so the metal wont rust in 15 min.

Not too shabby.....