1994 polaris sportsman project

[outlander560]

hey guys u most likely have seen my threads asking questions about this atv..and now i would like to show u wat im working with..ill put more pictures up over time..cause i have done a lot to it but for now i will show u the beginning and will post more tomorrow[/img] sorry for the crappy picture phone was broke wen i first got it

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and here is a day after i got it

[outlander560]

more work put about 10 hours into it prob more i dont know for sure but here is it all torn down and outside for a power wash to get 15 years worth of dirt and grease off

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next is the rear fender half painted to show the new color and the old plastic.. i know painting plastic has a lot of problems but i found this new paint called "plastic dip" the stuff is like spray on rubber it is very flexible and is pretty good with adhering to the plastic plus its very tough paint

here it is entirely painted

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here is the exhaust i painted used to be a nice rust color took me a while to get it prepared for paint but i finally finished it...i used rust-o-leum outside grill paint made for high heat

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and finally this is me just putting in some detail

Edited July 18, 2009 by outlander560

[DirtDemon]

I moved this thread to the project room.

Where did you get that paint you used, I am very interested in hearing how it works out for you.

[outlander560]

thank u... i got the paint at home depot, i will keep u updated on how it holds up outside

[Stoopidbot1]

Looking good, can't wait to see the final project.

[outlander560]

thanks bot cant wait either..DirtDemon that paint is just like spray on rubber it is extremely flexible i tried peeling some off with my finger nail and it didnt work so i used a flat head screw driver i got a little off and the paint is like a rubber band its pretty stretchy i would definalty put 2 or more coats of paint on though one is just not enough.. and for colors it says that there are various colors to choose from but all i have found were yellow and flat black, so idk how big their color choices are

Edited July 19, 2009 by outlander560

[DirtDemon]

Thanks for the info, that sounds like some decent stuff, I might give it a try. The Krylon Fusion that I used on my R just isn't cutting it.

[Sc0tt]

I can't wait to see it when you finish. I would like to have one just a little newer.

[outlander560]

yea i agree a late 90's polaris would be a lot easier to work with because you wouldnt have to deal with 2 strokes and the amount of work it needs is not going to be as labor intensive..another reason i say this is because of all the people mine has been through... 1 person had a zip-tie rave and everything was zip-tied even the muffler.. another had a tape fase..another had a hose clamp fase.its been through so many people i forgot how many guys i was told owned it before me

[Sc0tt]

No I want a two stroke 400cc. I think my friend has a 1998 it rocks.

[outlander560]

o thats cool wat model 98 is it?

[Sc0tt]

It is a Sportsman.

[outlander560]

i didnt know they made 2 strokes for the sportsman that late in the 90's..learned something new

[Sc0tt]

I may be wrong about that. It looks like they made them until 2003 though. You can buy a piston from ATV parts for up to a 2003.

I don't know if this is right though AAEN performance says 93-97.

Edited July 20, 2009 by Sc0tt
update

[outlander560]

beats me u might be right though i think they stopped the 2 stroke sportsman in early 2000

[outlander560]

***UPDATE*** Just ordered a bunch of parts..mounted the exhaust on..funny story about that broken bolt on the manifold i brought up in another forum..we bought drill bits and got the e-z out bits, they where working out well until my dad hit the e-z out just one to many times and on the 3rd hit it broke inside the bolt..and because the metal is so hard we tried getting it out but between frustration and anger, we just drilled a new hole right next to the broken bolt and now the exhaust is on...im currently redoing the front suspension. and im rebuilding the shocks i will post pics tomorrow of the before and after..everything that i ordered should be here in the next couple weeks so i can finally get this project going..MAN DO I LOVE EBAY..

o yea and im going to repaint the frame in the next few days

Edited August 11, 2009 by outlander560

[Stoopidbot1]

Nice, sounds like a fun project.

[Sc0tt]

Can't wait to see the new pix. Isn't mechanic work fun...

[outlander560]

yea it is fun..but fixing something that has been outside for a year is ruff... every single bolt that i took off broke or is stripped and nothing was really taken care of on this bike...it was in such bad shape, im surprised all the electrical works..

[outlander560]

finally got around to posting some pictures..hope you enjoy

before paint..i just stripped the frame down as much as possible[/img]

this is the frame after 2 coats of high gloss black..

here are the new(black) and old(red) springs i just got in the mail today

close up of what the front struts looked like with the old springs

and finally, the front after the new springs, frame being painted and the spring spacers put on

Edited August 19, 2009 by outlander560

[Stoopidbot1]

Looking great! You should be proud of yourself.

[outlander560]

thanks bot..its getting their

[outlander560]

i need everyone's opinion on what color i should paint the rims... the first rim i painted silver but i dont know if it goes well with the black and red plastic and racks on the polaris..my other two atvs have black rims so should i do something different by painting them silver..

well here are two pictures of the rim painted silver.. tell me what you think. and what should i do..\

[BuckBilly]

I say leave the Silver. I think it will make the Red and Black combo stand out better.

[outlander560]

yea i see how it all looks when it is put together.. that will probably be the deciding factor

[BuckBilly]

By the way , this project is looking good!!!!!!!!!!!!!!!!!!

[outlander560]

thanks BB...it will be done in the next month or 2...only a few more parts left to order

[BuckBilly]

:fact::bow2::ola::bouncen::moon:

[outlander560]

just bought 3 new chains for the price of 1, and 2 front and rear break pads for the price of one pair off of ebay..I LOVE EBAY

[outlander560]

NEW PHOTOS....just got a small order today...also a lot of work has been done to it

FRONT STRUTS:BEFORE

STRIPPED

PAINTED

REAR BRAKE I REBUILT IT. THEN STRIPPED THEN REPAINTED.

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ALL PUT TOGETHER AND PUT ON ATV

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FRONT BRAKES STRIPPED BOTH BRACKET AND CALIPER THEN PAINTED RED AND BRACKET IS PAINTED BLACK

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STRIPPED

PAINTED

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