CMX
Crazy Mtn Motorsports INC
PO Box 162 ~ 312 1st Ave No
Clyde Park, MT 59018 ~ USA
Ph 406-686-4921 ~ FAX 406-686-4222
www.crazymtn.com
Thank you for purchasing the Crazy Mountain Xtreme Drive System (CMXDS). When installed properly, the CMXDS will provide greater horsepower efficiency to the track and many miles of trouble free operation.
CMXDS Installation Instructions.
Note: These instructions will be for Polaris RMK application. Installation in other applications will be similar, but will vary from sled to sled. This is a general guide, not detailed for all sleds. Please read instructions completely before beginning installation of CMXDS!
On existing sled with OEM drive system and rear suspension removed:
1.) Fit drive side plate to bulkhead (BH) with top shaft in stock location. Belly pan and footrest area will need to be trimmed for dropped and rolled CMX drive system. Remove all rivets that keep the plate from setting flat against the BH. There are 3/16” holes in the CMX drive plate that align with rivet holes in the BH. Use 3/16” drill bits to align plate on BH, (Polaris Only) clamp CMX plate to BH and match drill 5/16” mount holes and cut bottom shaft hole and also cut out area for backer plate to recess through BH then slot through bottom of BH to match CMX plate. (Option: you can cut a smaller hole for the bottom shaft the same size as the inside of the backer plate and remove the backer plate and use the BH for the bearing backer.) Note: make sure sliding nut for idler/tensioner sprocket is in the slot on backside of CMX drive plate. Permanently install CMX drive plate.
2.) Install clutch side plate. Remove rivets that keep plate from setting flat against the BH. Trim bottom of footrest mount as needed. Use alignment holes in BH to locate plate. Note: The top shaft on the clutch side drops 1/32” from stock location. (This is to maintain belt alignment.) Temporarily install top shaft. You can use drill bits as a gauge to confirm offset. Simply place the proper size drill bit between jackshaft and BH from side to side. As close to the side as possible, the drill bit on the drive side should be 1/32” larger than the one on the clutch side. Cut and drill new holes in BH to match plate, top and bottom. Permanently install clutch side plate. Other than Polaris: You can find a common reference on both sides of the BH to locate the bottom shaft. Remember the offset.
3.) Install top shaft and bearings. Make sure drive side bearing is fully seated in plate. Tighten 5mm socket head pinch bolt at top of plate. (Caution: do not over tighten pinch bolt, or premature bearing failure will occur). Do not tighten locking collar on clutch side bearing at this time. Note: You will use red loctite and tighten clutch side set screws, top shaft and bottom shaft after the rear suspension is installed.
4.) Install track shaft. Be sure to set track in position first. To install track shaft, remove 5mm socket head pinch bolt and window retainer. The window in the bottom of the plate will drop out. Note: be sure clutch side bearing and flangettes are on drive shaft (loose) with locking collar side toward drivers. The clutch side bearing will bolt up on the inside to the BH. Install the drive shaft by sliding the flats on the shaft in the slot on the CMX drive plate and then slide shaft toward clutch side. You may have to tap the shaft to seat the drive side bearing in the plate. Bolt up the clutch side flangetts. Lift clutch side of track shaft to top of hole and then tighten bolts. Confirm the drive side bearing is seated and install the window and pinch bolt. Tighten the pinch bolt. Do not tighten locking collar on clutch side bearing at this time. Note: You will use red loctite and tighten clutch side set screws, top shaft and bottom shaft after the rear suspension is installed.
5.) Install bottom sprocket. Make sure brake disc is on sprocket prior to installation. Install and tighten aluminum nuts that retain bottom sprocket.
6.) Install CMX billet machined, 4-piston brake caliper. Make sure brake pad is in caliper prior to installation. Install Titanium mount bolts. Route steel braided brake line against CMX drive plate and retain brake line to plate with clamp and screw. Install Wilwood master cylinder and connect brake line. Use Dot 4 brake fluid and bleed brake.
7.) Install idler and top sprockets. Place belt on bottom sprocket prior to installing idler and top sprockets. With belt in place, install top sprocket to hub with 6ea. Titanium socket head cap screws. Now, install idler sprocket, before tightening idler retaining bolt, tension the belt by hand, push on the idler spindle and then tighten the retaining bolt. This belt runs fairly Loose. Use your judgment when tightening the belt.
8.) Install protector cup. Note: it is better to bolt cup on, so it can be removed easily for maintenance.
9.) The footrest on the drive side needs to be blocked off so that snow and ice cannot get in to drive system. This can be done by what ever means is the easiest, such as thin aluminum or plastic.
10.) Install rear suspension. Note: if your track shaft moved down 1 ½” and back 1½”, then your rear suspension will need to move down and back the same distance. After the rear suspension is installed you will need to loctite and tighten the setscrews on the jackshaft bearing and the track shaft bearing.
Now that the CMXDS is installed you need to look to see that everything functions properly. Check to see that the exhaust system has enough clearance to the drive system, and if not you can add a heat shield as required. You may need to add a reinforcement to the drive side footrest. You can attach a brace from the outboard footrest, trailing arm attach area forward to the BH in front of the CMXDS. This will add strength to that area for impacts on the ski.
We welcome feedback from you on your installation and use of the CMXDS. We have tried to make this as comprehensive as possible.
A lot of time and money went into the development of the CRAZY MOUNTAIN XTREME DRIVE SYSTEM and we are very proud of our accomplishment. Every effort has been made to insure reliability and performance. We will legally protect the intellectual property and all rights to our methods and design. If you have any questions please give us a call Thank you, Mark Hoffman @ CMX