This is where I am going to post pictures as I work on my 1982 Excel 540!
I will post some in a bit, and will also have some questions that need answering!
I will post some in a bit, and will also have some questions that need answering!
Look what kind of mess I am dealing with!
ws6transam
New member
Hey, that looks familiar! I just finished doing the same thing to my 1980 Excel V. However it looks as if you've got some more work to do on the wiring harness than what I did. Pay immense attention to the ground wires, as you can't make them too good. Good grounds will go a long way to making it reliable.
Also, check out the end links on the steering linkage. I found that mine were loose from vibration, and when I tightened them up it make a huge difference in the handling. Now's the time to do it while the engine is out.
I also found that a commercial degreaser and a black bristle brush is a great way to clear out the black sludge that was stuck to the bottom of the floorpan. Used liberally, scrub it out good, then hose it out. Then do it again with Engine brite! Mine had half an inch of grime and old seed pods that were left by the rat/squirrel/mouse which nearly totalled the sled.
Lastly, I also took the time to remove the seat, tank, and airbox in order to switch out the old fuel lines. I also had to clean the airbox of old foam and seed pods. When I was done, I partially filled the side baffles of the airbox with mothballs. It didn't seem to harm the performance any, and you can occasionally get a whiff of naptha when you remove the snowmobile cover. I figure that it'll keep bugs and mice out of the airbox.
Also, check out the end links on the steering linkage. I found that mine were loose from vibration, and when I tightened them up it make a huge difference in the handling. Now's the time to do it while the engine is out.
I also found that a commercial degreaser and a black bristle brush is a great way to clear out the black sludge that was stuck to the bottom of the floorpan. Used liberally, scrub it out good, then hose it out. Then do it again with Engine brite! Mine had half an inch of grime and old seed pods that were left by the rat/squirrel/mouse which nearly totalled the sled.
Lastly, I also took the time to remove the seat, tank, and airbox in order to switch out the old fuel lines. I also had to clean the airbox of old foam and seed pods. When I was done, I partially filled the side baffles of the airbox with mothballs. It didn't seem to harm the performance any, and you can occasionally get a whiff of naptha when you remove the snowmobile cover. I figure that it'll keep bugs and mice out of the airbox.
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ws6transam said:
I actually dotn know if I will have it running again now, all the wires from the harness and from my engine are too faded to match up, and I didn't mark them before I pulled them, so unless I can figure something out to match up the wires right again I am shit out of luck!
How many KM is on your excel? Mine is sitting right at about 12k, which is good for the year of it considering I put on about 4k this winter.
ws6transam
New member
Mine's got a little over 4000 KM on it. It spent a lot of time in the previous owner's garage sitting around with a mouse nest in the intake manifold.
As for the wires, it can't be too bad as the electrical system is pretty simple. I'll look in my Excel service manual and see if there's a wiring diagram. If there is, I'll scan it.
As for the wires, it can't be too bad as the electrical system is pretty simple. I'll look in my Excel service manual and see if there's a wiring diagram. If there is, I'll scan it.
Thanks alot! I know everything on the sleds is the same as far as engine and what not, pretty sure the seat is the only difference.
With the wires though, I cant tell whats what coming from the engine, CDI, or harness
With the wires though, I cant tell whats what coming from the engine, CDI, or harness