Help!,
I bought a 97 ZRT600 that someone had apart and did not know how to reassemble. The short aluminum arms that spline to the rear spring arm were not installed matched to each other. I didn't realize it at the time, and just marked them and then took it apart. Now I'm trying to reassemble it, and know that the alignment is not correct. Is there a foolproof way to set the angle with a protractor or something??? Could someone at least send a pic of a rear arm assembled correctly so I can get close?? Any help would really be appreciated as I have the entire suspension rebuilt and just need to install the arms so I will be ready to ride if we get some snow!!!!!!! Thanks

Try brownsleisureworld.com
Might help.

I assume you are talking about the TSL arms at the rear mount. As I remember from mine, when I first got it, there is a notch in the shaft for the bolt. Take the arms off and inspect the shaft for a radiused notch. That should give you your correct and matching angle.

Yes, I am talking about the TSL arms. I originally put it together the same way you recommended. It does seem to look correct and make sense, but I am almost at the end of my track tensioner upon assembly. This is with a brand new track(kimpex). After the track stretches, I'm afraid I won't have enough travel to tension the track properly. I installed new bearings in the front driveshaft and all idlers bearings are good or new. All pivots are in factory locations (checked with factory service manual). The adjuster bolts are not boring through the blocks either. The whole axle is almost at the back of it's travel. Please help, and I'm praying I don't have a faulty track.

there is only one way to put them on.
there is a notch in the shaft that lines up with the 1/4" bolt that passes thru the tsl link to tighten it on the shaft.
The flat side of the tsl link will face outward, with the notched sided inward.
If I remember, I'll post a drawing here tomorrow.

Here's something.
I can get a more detailed closeup tomorrow at home.
You can kinda see how the angle the tsl link sits at, and how the cutout is toward the inside.

Thanks,
I rechecked everything last nite and the TSL arms are installed just like you guys have explained. (same way that I originally put them).
The problem is that I'm out of track adjustment..(almost). The only thing that I changed from factory settings is to put the rear mount in the front mounting hole under the running board. I did not lower the front of the suspension. Do I need to lower the front of the suspension as well, or can I run a 1" track with the suspension mounted in the upper(stock) location? Would this help my track tension problem? I moved it down because the service manual said the upper holes were only good for .850 lug tracks.

I would think that you should be able to run a 1.25 with the suspension in the stock mounting holes. The key factor for track clearance is the space between the driveshaft and the front heat exchanger, so the rear suspension mounts won't effect that in any way. Maybe your new track is sightly too big, but I don't know if manufacturer tolerances can be off that much. When I swapped the TSL skid frame into my old ZR I found I could run the track extremely loose. If your new track is the same size, length wise, as the original one then it should work. Measure the track and exchange it if it is out of spec.

IS IT A brand new track? Maybe it needs to stretch a bit for a few miles.

Originally posted by transam2000@Jan 4 2005, 06:20 AM
Thanks,
* I rechecked everything last nite and the TSL arms are installed just like you guys have explained. (same way that I originally put them).
The problem is that I'm out of track adjustment..(almost). The only thing that I changed from factory settings is to put the rear mount in the front mounting hole under the running board. I did not lower the front of the suspension. Do I need to lower the front of the suspension as well, or can I run a 1" track with the suspension mounted in the upper(stock) location? Would this help my track tension problem? I moved it down because the service manual said the upper holes were only good for .850 lug tracks.
383945


Put the rear mount in the stock location above the running board ! You do not have any clearance problems using the 1 inch track but you will have a very squirrly rear end with the suspension mounted as you do below the running board.
As you bolted the suspension at the front hole in the mount below the boards, you have effectively moved the track return wheels foward making less tension at the top rear of the track and it shows up in your running out of rear axle adjustment.

Green Monster