Keeping Sane in Texas Rebuilding a Polaris ATV

[JoeRainville]

Hi Guys,

Since taking an aerospace job in Texas, you can say I've been a bit bored when I am not traveling for work or home to see Cari. With my off time, I've been running and working out, and wrenching to keep my hands dirty. I brought down my old Polaris 98 Sport 400L quad, and a few Liquifire Kawi motors for my I-500 sleds.

Here is the starting point: I purchased a work bench at Sears, some Craftsman tool, and an ATV lift:



I started tearing it down, not expecting to find too much damage, but I knew she needed a starter motor and recoil rope, rear swing arm pivots and front struts, but I found a lot more "fun" than that. Shown below is the start of the tear down:

[JoeRainville]

As the work progressed, I figured I better find a parts source because lots small parts are bent, loose or missing. Turns out there are about 4 Polaris dealerships in the greater Fort Worth, TX area including this one called "4 Wheels of Texas":



So I can order my parts on line, and pick them up at a place about 15 minutes from were I work. As the tear down progressed, the parts list grew:

[JoeRainville]

It seemed like the more I took apart, the more trouble I found. I wasn't planning to go to the bare frame, but it seemed more likely when I found the coolant hoses were drying out, the handle bars were bent, the stearing shaft and it's lower bushing was trashed, tie rods were loose, etc...



So to the bare frame she went. This was taken right after I degreased and power washed it at a local car wash. Note a previous repair job in the front of the frame were a friend hit a tree with it:

[JoeRainville]

The strip down resulted in my trailer, a vintage John Deere snowmobile trailer, being pressed into service for parts storage and sorting:



And parts needed to be cleaned, so I made good use of the tools at hand:



Since Cari is only here once in a while, the dishwasher was upgraded to a parts washer. Luckily I did go this far with the tear down, as the rear swing arm was craked all the way through on one side, and starting on the other, just in front of the rear axle. The next few jumps were going to have a rough landing!

[JoeRainville]

Cari Deerest came down for Labor Day weekend. She was glad to see the Polaris getting rebuilt so I can get some use out of it down here. They have ATV parks not far from here, so it should see more use than in NY.



The parts total so far is up to $550, but I will need to spend about $1,300 to $1,500 total as I haven't purchased the new $350 updated swing arm kit, the front struts, a bearing plate, front skid plate, coolant hoses and such yet. Darn things is starting to feel like a restoration compared to a rebuild, LOL!

Later Liquidator,
-Rainville

[JDT]

Joe I forwarded the pictures of your parts washer to your landlord.

How that is going to be a problem.

[JoeRainville]

No problem at Todd. But your insubordination will be reflected on your next NOS parts invoice.:>)

Picked up another $75 in parts today. This thing is starting to feel like a snowmobile, LOL!

-Rainville

[JDT]

Nothing ever turns out to be as cheap of a fix as you first think.

I figured I was pretty sauve last spring when I bought a $400 car for my daughter.
A $1000 would get her going nicely... that was the plan.
But the bad tranny took it way over the top.
Ended up with $4000 into it but it is good to go now.

Best aproach is doing it right the first time then you know what you got.
She is looking good Joe.