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I hope not to annoy anyone with this question! I have a 1997 580 EXT EFI 121" track, and am looking to increase it to a 136". I have contacted some dealers and they say it is not available anymore! I find this extreamly upseting, due to the fact that I can still get longtrack kits for older Yamahas. If anyone can help locate a kit for my 580 or ideas it would greatly be appreciated. My 1997 580 EXT only has 500 origional miles on it and I sure don't want to spend &#367,000 for a 136" track! Thanks to all
 

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I just installed a longtrack kit into my 98 ZRT. With the help of a local welding shop I was able to modify the coolers to fit and used 1/2" T6 aluminum round bar 55" long to strengthen the tunnel. (the tunnel did not meet correctly) A set of foot pads cover that area perfectly. Without the ETT it would be easier to have a Machine shop bend a tunnel extension to fit right there for next to nothing.

I bought the Complete Arctic Cat Conversion Kit from someone for 1/2 the price of new. It was for a 99 ZR. I made it fit. You also could go to a salvage yard and scavange the parts to "create" your own kit.
 

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There are a million ways to go on this one. One way which is very cost effective and will let you get things just the way you want is to simply take your measurements for your tunnel extension and go to your local Heating and Airconditioning shop and they should be able to bend one up for you for under 50 bucks out of aluminum. Just make a diagram of what you want, they should be able to roll the edges too.

As far as the rails go, either buy Powder Special rails which will set you back about $100 a piece or get rail extensions. HRP or Holtz should have them. One other thing you can do if you are setting your ZR up for mountain riding is remount your 121" rails back further the tunnel to make up the difference in track length. You will have to relocate or fabricate new suspension mounting plates. I have done this and it is great because you create a much better approach angle for the track in the deep snow. But, thats a whole different story.

Tell us what you are converting your ZR to longtrack for and the route you take will be different depending on the intended purpose. What size lugs are you talking about? 1", 1.25" or what?
 
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