Going to be a SRV440

[SS440-80]

My best friends son Johan got his SS440 1981 many years ago, and it has been (ab)used a lot. Most of it aint on photo, but some moments are captured






The hood has been open more than closed, always repairing something





And many odd repaires it has been, both on the outside and the inside of the sled.



But the motorn has ALWAYS worked



So when we got a SRV very cheap, we decided that we would build a SRV440.



It's a 1982 SRV:n with a 1981 cut up hood. Sled has a bad seat, worse skid and broken track and everything is dirty as hell.



The reason that the hood is cut open, is because the previous owner had mounted a Enticer 340 motor. But now it's gonna be a SS440-engine instead

[SS440-80]

Started to get the ET-engine out.



Found a odd thing... the motor mounting plate was not bolted in the front



Motorn out!



Sad to see that the previous owner has made it easy for him self, cutting out the side wall on the PTO-side

[SS440-80]

Stripping









Going to be another track and skid on the sled. And when the drive shaft is out I'm gonna mount new bearings.











Skis in good shape, but the skins are not But the plan is to get modern plastic skis. är i bra skick.



Wheels mounted to make it easy to wove the chassi around....



Cleaning





New side wall welded and the mounts for the ET-motor is grinded away.

[SS440-80]

Now the SS has to donate some parts to the project

First the engine





Skid and track





The Polaris skid has worked very well on the SS, so the plan was to use it on the SRV too



But it needs welding, and we have no good welder for aluminum around here...





So we decided to use a Phazer skid instead. Bought new shocks and the skid is ready for mounting.

[SS440-80]

With the motor on the bench, I took it apart and put new oil seals on the crankshaft and new piston wrist pin bearings.



A little oily behind the stator plate



Bottom is off



The oil pump gearing taken off. It won't be mounted again...
Could not guess that the pump and gear could weigh almost 0,7 kilo.



New oil seals



and new needle bearings



With the motor back together, I started to make a new left front motor mount



I think it will work...

[SS440-80]

Took the TSS apart to check the condition on shocks and springs. Everything was in good shape.









Then I mounted grease fittings on the TSS-arms

[SS440-80]

When I put the chaincase back together I used the smaller upper sprocket from the SS, and the bigger lower sprocket from the SRV. Giving me a lower gearing that will be good on our narrow curvy trails.

The carb and airbox back on



Then it was time for the gas tank, but I got a wiered feeling that I should check the fuel filter...
And there was no filter left in the cage



But I took a fuel pickup that was over from a John Deere and mounted in to the cage, and then back in the tank




Next to be put back on was the plastic. But it was so bleached from sun, that I just had to do something...
A hot air gun usually works well to bring back the black in plastic, but this time I almost gave up. But I kept on warming and finally it turned more black

[SS440-80]

A 121" track in better condition than the old 116" track



The Phazer skid will work fine





The exhaust was modified to fit the ET340 engine, but with som cutting and welding it fits the SS440 engine



Sprayed with Hot Paint



Looks good, hope it will hold

[SS440-80]

The hood had holes in it to fit the ET340-engine, so some repairs had to be done. I'm not doing a perfect repair, but good enough to work this winter.



I reinforced with some aluminium profile and rivets



Then used plastic weld



Sprayed with black paint



Made a cover for the big hole above the secondary clutch. Used plastic from a black oil can



Hood waxed and the wind shield mounted.
First start, and it runs well