1992 Polaris Trailboss Rebuild

[gillies_robert]

Good evening just like to share my current project, which is #8 in my fleet of Polaris.

 

[gillies_robert]

it came pre-disassembled so this should go fairly quickly...

took 4 pumps of grease and off it popped, its a can am puller the thinner tipped one. it bottomed in clutch before crank so the grease hydralic locked and off it came!

never dealt much with these power bloc clutches. a few on older ski doo thats it.

 

[gillies_robert]

after a couple hours of cleanup, there was alot of aluminum transfer and is already at .40 over. im gonna run it as is with those couple scores. i ended up taking the die grinder through the exhaust a bit just because of the carbon and melted piston

 

[gillies_robert]

started stripping the bottom end didn't find anything too surprising.

 

 

[gillies_robert]

cases split without issue and after a good cleanup the bearings felt like new.

couple more pics of the aftermarket add ons. think i dreamed about everything on this bike when i had my 94 trailblazer

 

[gillies_robert]

Reviving my old thread here, gonna try posting a few picture and videos of this beast all completed 😎

[green53]

What rear tires do you have on that bike?

[SashaGraves21]

How did you hook up your carb?

[SashaGraves21]

You inspired me to keep trying because my little girl will be old enough to rip around too and I want her to have a mellow little bike to play on.

[gillies_robert]

On 3/28/2021 at 1:15 PM, green53 said:

What rear tires do you have on that bike?

It came with pure sports bandits, very popular in the 90s 😎 I added a set of ams sand snakes that were all folded up from shipping for ten years. They cracked terribly but I added a little slime and they sealed right up 👍🏻

On 5/25/2021 at 7:30 PM, SashaGraves21 said:

How did you hook up your carb?

I ordered a aftermarket replacement intake manifold, and used the original air box and boot 👍🏻 It needed a throttle cable so I replaced with aftermarket, be sure to set and double check your oil pump setting when changing cables, choke cable is factory, and all fuel lines and oil lines are new as well. If you have a project like this pick up a copy of the service manual, I have both the clymer and the factory Polaris. They will be a big help 😎👍🏻

[SashaGraves21]

I’ve figured out it’s not my engine it’s my transmission 😞 idk what to do at that level.

[Sycoholic]

Nice wheeler. I've fixed up a couple old Polaris's recently. This one is my wife's. Next is my son's 350L. Just got the cylinder back from Rick Ritter. Long wait, but worth the quality.