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Polaris Sportsman 110cc rear end damage

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I have a 2018 Polaris Sportsman 110cc that my son rides.  We are active riding in the Colorado mountains.  My son struggles to navigate trails with rocks.  He follows my line and occasionally hits the rear end.  Well the pictures show the damage well.  After a weekend of riding almost 60 miles, he hit one rock and nearly ripped the rear axle off.  There was about 1/2" of metal still attached on one of the tubes.  Luckily I have a neighbor that is a big fabricator as his help will be needed on this one. 




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My neighbor helped me out.  A main plate was added to stiffen up the component and new rails added to help "jump" over the rocks instead of hitting them head on.  This will be tested next month on another ATV trip, see what breaks next.



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  • 5 weeks later...

Definitely not great photos.  I got new bearings and seals, everything put back together and the ATV ready to ride again.  I feel pretty good about everything.  We are going out this weekend so will see how it holds up.  These youth quads are definitely not built for rough Colorado mountain trails. 

The OEM welds on these units are also not great quality.  Some welds just ran off into space, cold welds and other issues.  This repair is of much higher quality and added a bunch of steel to this rear end. 

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