295/S Project

[DLDeere]

DA, my goal is to have it at Waconia. I hope to be done before that to get a some riding time on it this winter. Purchased it last October from a guy in Washington state and had it shipped here. Also got a 500 with the deal. Haven't started on that one yet, but it seems pretty clean.

On the 295, the engine rebuild is the last step. It was stuck with the stator rusted to the flywheel, also one piston stuck in the cylinder. Got a Liquifire flywheel and stator from Johnnycyclone. Cylinder honed out OK and piston looks good.

Almost everything else has been painted and is ready for reassembly. Getting into the real fun stuff now! Here's a pic of it from last fall when I got it. It's got slide susp instead of bogie/slide and no race history, but is still a cool sled.

[DLDeere]

Few more pics

[WinnipegStPaul9]

Interesting added "trunk". Looks like you've got a nice project. Looking forward to seeing it soon. DA

[pjr]

Judging by the horizontal rust line on the flywheel and engine cases, it looks as though it was sitting partially under water at some pont for a period of time. Good thing you saved it when you did! Nice project.

[Matt]

I was thinking the same thing, did you find this sled is a pond?

[DLDeere]

I didn't actually see where it was sitting, the guy said his back yard. I think it's strange also. Recoil was also rusted stuck and the spring was in pieces. Water got into it somehow and sat for awhile. Didn't get inside the engine though. Crank is clean and turns smooth.

Any ideas about that luggage rack and tool box? Was that a JD accessory or aftermarket?

[400brian]

The 295S Troy Milely has, had water get into the recoil pretty much like the one shown. Pretty much ruins the flywheel and stator.

[GreenFever]

Same thing happened to the flywheel and stator on my 295/S.

[DLDeere]

Here's an update on my 295/S restoration project. Boy, all of this takes longer than I first thought. Everything has come apart and almost every nut and bolt has been removed. I had the tunnel and hood repainted and the skis and suspension powder coated last summer. Tip: Don't powder coat nuts and bolts! Fortunately, Chem-Clean takes the paint off in just a few minutes! Lots of cleanup, scrubbing parts, repainting and shining up aluminum. Most of the components are done and ready for installation. I've started the assembly process. Of course I don't remember where everything goes. Thank goodness for the parts manual! Here's some pics of the progress. 26 days to Waconia!

Here is the rusted flywheel. You may remember this from a previous post.


I rebuilt the engine with new rings and gaskets.


Replace flywheel and stator with one from a Cyclone


Engine is done, carbs and fuel pump have been cleaned and new gaskets and jets.


Cleaned clutch and secondary, replaced arms in clutch


Here's the repainted tunnel.


Track, suspension, chain case, frame, skis, handlebars and motor are all installed. Gas tanks are next to clean and install. Then the muffler.


Once I have the gas tanks in, the carbs on, and the muffler on I'll be ready for a test start of the engine. Maybe by Thursday. I'll keep you posted.

[JDXspec]

Nice! hope to see it at waconia. I'm hoping I fire my Dator project this week

[ICCSF 108]

Looken good Howard

Kenny

[WinnipegStPaul9]

It looks great!!

DA

[JDT]

Howard your work is fantastic!

[DLDeere]

Thanks Todd. It's amazing what a can of spray paint can do! By the way, I placed my first order at McMaster Carr at your recommendation. Very impressed!

Here's an update.

Making progress with the 295/S. Got it started last week. Link to the video is below. Since then I've had carbs off twice to try and get it to run better. Had to adjust the float lever to the inlet needle a couple times. May need to replace the pilot jets. Don't seem to get enough gas at idle. Still working on that. I'll check timing this weekend and see if it is the problem. Installed the main gas tank, hooked up more electrical and will install bumper, tail light and seat this weekend. Getting closer to done!

By the way...it has hand grip warmers!

Startup Video: http://s261.photobucket.com/albums/ii41 ... ortver.flv

Current state:

[JDT]

Loved the expression of joy.

The thing is come a long way.
Will it be at Waconia?