2004 zr 900 Efi sno pro - HCS Snowmobile Forums

ZR/ZL forum This is a brand-specific forum. Posts on this forum are assumed to be questions aimed at similar model owners, and are not looking for comments of a sarcastic or "bashing" nature. Please be aware that if you violate this policy you are in danger of losing your posting privileges on this website.The calling out or posting of another members personal information IE phone number or address is prohibited.

Like Tree3Likes
Reply
 
LinkBack Thread Tools
Old 02-14-2020, 12:18 AM   #1 (permalink)
Newbie
 
Mike-arctic-cat's Avatar
 
Join Date: Feb 2020
Posts: 2
Default

Hello all, I have a 04 zr 900 that seems like the track or something is slipping. I had the diamond drive checked out and was in good shape. I replaced the belly pan so snow wouldn't pile in. Belt is brand new. This is the second season with this sled and it has slipped since day one. Sled runs like a top till I get in powder. I do hear a noise coming from or around the secondary clutch. Clutches was cleaned and was told there in good shape. The sound I hear almost sounds like grinding or a belt getting chewed up. I'm checking the track tension and the drive cogs tomorrow. I will let ya'll know what I find. I can't figure it out and it's bothering the heck out of me. Thanks for any advice

Last edited by Mike-arctic-cat; 02-14-2020 at 12:30 AM.
Mike-arctic-cat is offline   Reply With Quote
Sponsored Links
Advertisement
 
Old 02-14-2020, 09:28 AM   #2 (permalink)
Super Advanced Member
 
Join Date: Mar 2003
Posts: 19,871
Current Sled(s): "Agri-vator"
Default

Well.....04 was the first year for those and I find it hard to believe that one of them is still out there that Hasn't had the drive shaft to diamond drive coupler system updated (to the design that came out in late '04 and was used in all sleds after that), but, I'd say that's what you have going on and it's going to completely fail on you at some point, leaving you unable to move. Was your diamond drive Remived from the sled when it inspected? It needs to be. I think they maybe just removed the cover and looked in at the gears. Anybody familiar with a Cat of that era should have been able to see the issue, but I can't see it from here. Just saying....that was a big thing back in 04. You need to jack it up, get under the sled, back the track tension all the way off, look up at the back of the diamond drive inside of the tunnel and try to wiggle the axle. Turn the tack by hand. Look for signs of movement, rust that looks like it's disturbed, etc. Google 2004 ZR 900 drive shaft update. A few years ago parts were available still, they should be still around. Black diamond extreme had a kit. I doubt it's cheap anymore. But walking isn't fun. Welcome to the forum
stronger800 is offline   Reply With Quote
Old 02-14-2020, 10:33 AM   #3 (permalink)
Newbie
 
Mike-arctic-cat's Avatar
 
Join Date: Feb 2020
Posts: 2
Default

Thanks for the advice on that diamond drive update. I will be checking that out for sure. The guy I had check it out only looked at the gears. Hopefully I can find that upgrade for th diamond drive.
Mike-arctic-cat is offline   Reply With Quote
 
Old 02-14-2020, 10:47 AM   #4 (permalink)
Super Advanced Member
 
mnstang's Avatar
 
Join Date: Aug 2007
Posts: 7,865
Current Sled(s): 8000 high country, SnoPro 500, zr900
Previous Sled(s): many cats
Location: Independence, MN
Favorite Riding Area: Northern MN
Age: 37
Default

The update is a new driveshaft and new lower gear for the diamond drive. Actually none of the zr9's got it from cat (stock). Black diamond extreme is the company who made the diamond drive for cat and will hook you up, best to just call them. You'll have to do a little Jerry rigging to get the speedo to work with that setup. Usually when those shafts go, they go. Without looking at it it's hard to say for sure but there isn't much else to that system besides the gear case and the driveshaft. You'll have to take the gear case apart anyway to install the new lower gear so you'll see if there's an issue. There is a planetary gear that could have broke off teeth and that could be an issue too. Best to replace all the bearings in there at the same time, again black diamond extreme should have all that stuff

Last edited by mnstang; 02-14-2020 at 10:51 AM.
mnstang is offline   Reply With Quote
Old 02-14-2020, 02:55 PM   #5 (permalink)
Super Advanced Member
 
Join Date: Mar 2003
Posts: 19,871
Current Sled(s): "Agri-vator"
Default

Mnstang, was that an update to the update then? Because I only had an 04 in early 04 and my dealer swapped out the entire gear case and the shaft (complete)..... I looked right at the old parts complete, on his table, when he had a few other customers have issues and he didn't want me having problems. I sold the sled not long after though. I thought I had the updated stuff like the 05-06's had, but maybe not.
stronger800 is offline   Reply With Quote
Old 02-14-2020, 04:11 PM   #6 (permalink)
Super Advanced Member
 
mnstang's Avatar
 
Join Date: Aug 2007
Posts: 7,865
Current Sled(s): 8000 high country, SnoPro 500, zr900
Previous Sled(s): many cats
Location: Independence, MN
Favorite Riding Area: Northern MN
Age: 37
Default

Quote:
Originally Posted by stronger800 View Post
Mnstang, was that an update to the update then? Because I only had an 04 in early 04 and my dealer swapped out the entire gear case and the shaft (complete)..... I looked right at the old parts complete, on his table, when he had a few other customers have issues and he didn't want me having problems. I sold the sled not long after though. I thought I had the updated stuff like the 05-06's had, but maybe not.
I'm not sure about the 04 updates. I know there was a clutching update for them to get heavier weights. And I know the 04 was a little different in that it had a vent hose, while the 05/06 vented through the top gear shaft of the secondary clutch. But cat never put the bolted connection setup on any of the zr9's stock. I don't remember there being an update through cat for that but I'm sure some dealers were doing it with bdx parts. I have read some of the later units came with the bottom gear being threaded for the bolt so you didn't have to update that, although my 05 wasn't threaded so I'm not sure on that. Kinda weird that coupler connection, I don't think the firecats ever used that I think it was zr9 only. I never had a problem with mine until I went to do the update and the little set screw rounded out. It could be easy not to get that coupler fully tight or the set screw to not hold and loosen up the coupler and then strip the splines I'm sure that happened alot.
mnstang is offline   Reply With Quote
Old 02-14-2020, 09:45 PM   #7 (permalink)
Super Advanced Member
 
Join Date: Mar 2003
Posts: 19,871
Current Sled(s): "Agri-vator"
Default

I actually changed the track out on mine, put a studded one off an 800 that I had on it, (my oldest daughter then learned to ride on the 900 that year, think I sold it a year or two later to a member here) and now that you mention it, I remember the coupler. I called Krom while tightening it to make sure I had it locked. No, firecat's never had that crappy setup. They had the lonnnnng bolt, not sure if the last ones ever had the short bolt like all of the later sleds had or not, but I don't think so.
My 04 was the blk/red one. Great looking sled.
mnstang likes this.
stronger800 is offline   Reply With Quote
Old 02-15-2020, 02:14 AM   #8 (permalink)
Super Advanced Member
 
mnstang's Avatar
 
Join Date: Aug 2007
Posts: 7,865
Current Sled(s): 8000 high country, SnoPro 500, zr900
Previous Sled(s): many cats
Location: Independence, MN
Favorite Riding Area: Northern MN
Age: 37
Default

As much crap as the diamond drive got, I think it was unwarranted, I never had a problem that wasn't self inflicted. I think I'd take the diamond drive over the procross drive system
Litre1000 likes this.
mnstang is offline   Reply With Quote
Old 02-15-2020, 07:42 PM   #9 (permalink)
Super Advanced Member
 
snochopper's Avatar
 
Join Date: Mar 2004
Posts: 5,069
Current Sled(s): 2017 ZR9000 Limited
Previous Sled(s): 77 ElTigre 500 FA
Location: Upstate NY
Favorite Riding Area: Up North
Age: 60
Riding Since: 1972
Default

Quote:
Originally Posted by mnstang View Post
As much crap as the diamond drive got, I think it was unwarranted, I never had a problem that wasn't self inflicted. I think I'd take the diamond drive over the procross drive system
Yamaha Turbo with a latest greatest Diamond Drive and you'd have a hell of a machine.....
mnstang likes this.
snochopper is offline   Reply With Quote
Old 02-15-2020, 11:07 PM   #10 (permalink)
Super Advanced Member
 
Join Date: Mar 2003
Posts: 19,871
Current Sled(s): "Agri-vator"
Default

Did 140 miles today riding/racing along side my buddys F1000. Like 6500 miles on it. He hasn't replaced a part on the sled that I'm aware of.
stronger800 is offline   Reply With Quote
Sponsored Links
Advertisement
 
Reply

Thread Tools

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On



All times are GMT -4. The time now is 10:02 AM.



Powered by vBulletin® Copyright ©2000 - 2020, Jelsoft Enterprises Ltd.
Search Engine Friendly URLs by vBSEO 3.6.0
vBulletin Security provided by vBSecurity v2.2.2 (Pro) - vBulletin Mods & Addons Copyright © 2020 DragonByte Technologies Ltd.
User Alert System provided by Advanced User Tagging (Pro) - vBulletin Mods & Addons Copyright © 2020 DragonByte Technologies Ltd.