John Deere Sprintfire 1983. Long time project....

[skoalmint]

Does solder really melt before plastic ? I must really be stupid ! I was refering to to the elec conn in the sensor itself as heat was applied to solder new connectors.

[SS440-80]

New bearings for the drive shaft and some nice paint on the bearing holders...

[SS440-80]

The bearing+locking ring on the clutch side was 6mm to wide, so I had to give the drive shaft a spin in the lathe... took 9mm just to be sure it will be no problem to centre the drive shaft in the tunnel. (And now I noticed that I have the 7 tooth drive koggs)








Before putting the track back in the tunnel I had to make it look a bit better.

Brushed the steel free from loose rust



The edge of track was full of white nylon threads, but a gas torch will fix that



Before



After



And then I did something worthless, I painted the cleats with black paint. I know it will wear of after a few meters in the snow, but it look good on the sled until then




Drive shaft and track back on the sled.

[SS440-80]

With the drive and track back, the skid can be mounted. The skid has been ready for a long time now...




Halv way there



Done




Track tension is perfect.
And a new rear grab bar. I don't like the round original so much, so I made my own model.



The old one was not worth saving



So after some measuring, cutting and welding I had a new bar







Painted and with dome nuts it looks real nice

[sledhead16]

Skid looks great!

[SS440-80]

Skid looks great!

Thanks! But without the this thread made by acesillini06 about a fitting gas shock the skid wouldn't look so good
http://www.jdsleds.com/community/viewto ... 14/url/url


Now the snow flap is cleaned and mounted. I have also painted the trailer hitch (?) and made a new bolt for it.



And I also mounted a tiny rubber puck with a stainless rivet so that the hitch won't eat more of the D and stop the rattling sound.

[SS440-80]

After mounting new bearings on the crank shaft, I had to wait for a delivery of crank seals, needle bearings and a o-ring for the center crank bearing...





Was a bit nervous to stretch the o-ring over the crankshaft and rods, but it was good quality






Some old but good Permatex gasket seals the crank case



Before I mount the cylinder, it must be honed...





Pictures before





and after






Pistons cleaned and new needle bearings



I'm glad that the pistons is in good condition after being loose in a box full of engine parts for several years

[SS440-80]

Pistons in place.



And cylinder





Cylinder head

[SS440-80]

Dirty stator plate and ignition coil, no spark plug caps and the wiring is cut... So if these parts work I do not know






After a quick inspection I found something really bad, the stator plate has a long crack and is bent, but I hope that I can repair it



First some cleaning








I cannot weld in aluminium, but I can solder aluminium with zinc. It makes a seam almost as strong as when welded.

After straightening the plate I grind the crack so I get a good surface to solder on



I use flakes of zinc that I place in the crack.



Then I heat the zinc until it melts and keep on heating and at the same time I scratch in the crack trough the zinc with a stainless cable tie, so that the aluminum oxide scrapes off and the melted zinc bites to the clean aluminium.



Maybe not beautiful, but strong and straight




Stator plate mounted. The cables going to the ignition coil is repaired of course.




Flywheel mounted and it does not scratch against the stator, so that's good

[SS440-80]

Starter cup mounted.




The flywheel cover is really dirty...








But after some cleaning the cover is back on the motor and the CDI-unit mounted




Water pump belt and cover there.
New pulse line for the fuel pump and a oil line with a oil filter from a Yamaha.






Starter recoil needs some service



Cleaned and new starter rope

[sledhead16]

Very interesting process on the stator! She's closer to firing!

[SS440-80]

Very interesting process on the stator! She's closer to firing!

Did some good tunnel repairs on the Yamaha SRV that I shrank and rebuilt for my 7 year old daughter, it was plenty of cracks in that tunnel so I got lot of practice with the zinc and gas burner

[sledhead16]

Now there's a custom!

[SS440-80]

Now there's a custom!

Yeah, it was a fun project and my daughter loves her sled. It's not a 540cc engine in there, I replaced it with a Enticer340 engine and geared the transmission down from 29-17 to 33-15.

I made a thread about the rebuild on the SRV-board. If anyone would like to see the project from start to finish, I could make a thread it in the category OTHER BRANDS... ?

[SS440-80]

The Y-pipe was of course rusty, like all exhaust parts on old sleds...




The steel brush took away most of the rust




Some aluminium based heat paint makes it look alright again. Will be interesting to see how long it will hold




Engine mounting bracket mounted




And the engine is ready to put back in the sled