[2014-2017 CFMoto ZForce Cage Chop Mod]

 

2014-2017 CFMoto ZForce Cage Chop Mod

This mod is basically the same as outlined by Chad (Chuddly) back in 2016 when he was one of the first to do this. I think "Flash" did his about the same time. Anyway, first review Chad's video because this follows his direction.  Here is his video:

https://youtu.be/ym0KtSffjaI

First like he says remove the center bar and grind all welds off. I found my porta-band very helpful during all of this project.
In his video it stated it was important to make straight cuts so I used a hose clamp to help me get a straight line around the tubing. Marked the lower first being the same on both sides then measuring up 5", making a mark, then positioned the clamp, then marking all the way around. Both sides need to be identical as possible:




Now do the same for the one that will be rotated up on top on each side:



Position your cutting device, weather it is a band saw or a saws-all so that you will make straight through cuts. Once cut loosen the front cage bolts so it can move:



Affix something to hold/support the cage while you make minor adjustments. I used a strap to a lift point in the ceiling.
Lower the cage and check the fitment of the pieces. Make any angle corrections to both sides to make the seam straight.




Once this was done, I took the cut-out sections (NOT the center one) and cut 1.5" pieces out, then split them taking about ¼" out so I could roll them smaller to fit into the tubing to help hold the joint straight while welding:



Bevel all ends and clean paint off just in that area. Pay attention to the roof mounting point angles as they need to be the same:



Weld all those joints up and clean-up with grinder:



Now for the center piece. Use the piece you cut out. Know that where the bar will be positioned is likely farther apart then the ends so just sliding it in will require you to spread the bars apart slightly which is easily done with a bar clamp. Make it a bit too long and adjust as needed to fit tight. I was able to rig-up a jig with my drill press to cut the piece. Once in and centered, weld it in.




Clean up the welds, wipe it down with Acetone and paint it. I found just Rustoleum flat black looks pretty close:




OK, now for re-assembly. Before we start this project I would like to point out a few things that no one talks about, Things like:
·        If you have a rear windshield, it will no longer fit without some modification and if that shield is the Polycarbonate with hard surfacing, you will blister it before it gets hot enough to bend and the hard surfacing will show micro-cracks in it after bending so be prepared. If yours is just the plexi-glass, no problem with bending.
·        On the roof some mounts won't line up and will either have to be re-drilled or the mounts moved..or like Chad said, just sandwiched with washers. I re-drilled mine as you will see in the upcoming pics.
·        Depending on if you have snorkels or stacks like mine you may have to trim some of the rear lower roof line as it will stick out farther then it did before.
·        If you had your front light bar mounted through the plastic roof to some bar clamps, expect to modify those as the angles have changed...as well as some front windshield parts and brackets
·        If you have full doors expect to have to either modify the slam latch mount a bit and/or make some adjustments.

OK, onward. Roof and rear window. What a pain PITA. Had to chop-up my SATV rear window and bend it some to fit. Some minor blistering but most is behind bars and roof plastic so it's not too noticeable:






On the roof, I chose to drill two new holes through the window and roof to use as upper mounts and not move the existing cage brackets. I just cut two pieces of flat stock, painted them and covered the old holes with it. Probably repaint later with something closer to the right color:



The stacks needed lowered and the roof lower edge was now in the way so a "little off the bottom please":





On the stacks, I needed to lower them enough so that the top of the Donaldson would be at roof line in prep for the S&B.. so it was closer to a 6" reduction. Took a bit but got it. Looks OK:




Got the rest together and took it outside for a quick photo shoot. Doesn't look so.."Chinese" anymore...lol. Hope all this helps for your decision on whether or not to do a cage mod.

Looks great nice write up

I remember when I had a rzr I did a chop an went a lil to low for me an hit my big head over some big bumps lol harnesses were a must have then hahaha

[2015 Z Force 800 53/Trail EPS]

Looks great nice write up

I remember when I had a rzr I did a chop an went a lil to low for me an hit my big head over some big bumps lol harnesses were a must have then hahaha

I can imagine. I'm only 5'7" and still have over 10"s of room up there so no worries.. for me at least.

[2015 Z Force 800 53/Trail EPS]

All of the above photos and lots more are here if you need them:

https://imgur.com/a/7hsZkGw

Hey guys, many thanks to all that have posted on there cave mods, diced mine up this weekend and it made for a much easier job knowing what you're in for. I just wanted to add one thing that I ran into. For those of you with full doors, check th alignment before welding. My cage went boing when I cut it and the doors dropped quite a bit. Simple enough, I just ran a ratchet strap down to the hitch and cranked the rear of the cage back. Just a quick check could save a big headache later, thanks again, great info here

[2015 Z Force 800 53/Trail EPS]

Very good. Glad it helped. Looks good. I fixed your photos

This right here is awesome!  How hard was it to modify the door latches?  Wondering if my roll up vinyl window could still be utilized?  Makes tires and body look so much larger.  Plus would prolly help on 50" trails that have a lot of tight cornering.

[2015 Z Force 800 53/Trail EPS]

This right here is awesome!  How hard was it to modify the door latches?  Wondering if my roll up vinyl window could still be utilized?  Makes tires and body look so much larger.  Plus would prolly help on 50" trails that have a lot of tight cornering.

My door latches didn't need any modding, just some re-adjusting. Not sure how much it will help the trail's "tippy" but when I ride with my friends with their RzRs and Wildcats, the Z's extra 5-6 inches in heights always got me when having to go under anything they could. This should help.

Excellent work NMK, excellent results and an awesome job of documenting the process.
I am torn about undertaking this or not as I have the overhead bags that are super convenient, but when I sit in the machine and estimate where the swell of the bags reach it appears they might touch helmet/hat on the bumps. More research is needed by me and if I can have both, I'm for it.

[2015 Z Force 800 53/Trail EPS]

Excellent work NMK, excellent results and an awesome job of documenting the process.
I am torn about undertaking this or not as I have the overhead bags that are super convenient, but when I sit in the machine and estimate where the swell of the bags reach it appears they might touch helmet/hat on the bumps. More research is needed by me and if I can have both, I'm for it.

Yeah if I had overhead storage or a sound system up there it probably wouldn't have made sense for me. But I don't have any of that and probably never will...and it seems on every ride with the guys I'm the one that has to break-out the chainsaw to get through..and for only a few inches...it made the decision easier. Still won't make every one but it will be.. a few less stops and chainsaw work-outs...lol

[2015 Z Force 800 53/Trail EPS]

Came across this old photo of mine and one of the Windcats I ride with. I'm still a little taller but...not by much....lol