1994 polaris sportsman project

[outlander560]

also new gas cap...oil cap...dash panel..and dash panel bracket

old dash to new one

all together

[Sc0tt]

It is really beginning to come together.

[outlander560]

thanks...it is slowly getting their it should be complete by mid september...

[outlander560]

Update got the new tire on the front, painted the rims and put some stuff on...

JUST RE-UPHOLSTERED THE SEAT AND I THINK I DID PRETTY GOOD FOR MY FIRST TIME.

BEFORE:

AFTER:

[DirtDemon]

The seat looks great, nice job. Looks like the rest is coming together nicely too.

[handyhiker]

As a Polaris fan, I really like your project! Looks really good!!

[outlander560]

thanks guys...it will soon be ready.. just got to wait another 2 weeks cause i just snapped my tie rod..trying to replace the badly worn rod ends and it snapped so looks like my finished date is moved back another month..

[voodoo574]

Hang in there. Good things come to those with patients. And an account on E-bay.:gamer:

[outlander560]

yea it was.. ebay was a life savor for this project...yea i will have to bite the bullet and wait another 2 weeks till i can finally ride it.

[BuckBilly]

Looks good!!!!!!!!!! It will look great when done.

[outlander560]

thanks BB

[outlander560]

Just brought the polaris to the shop...just for a once over and to install the front chain and then i can finally put the plastics on..THEN SHE IS DONE

[DirtDemon]

Excellent, I am sure you will let us know how the first ride goes right?

[outlander560]

of course

[Stoopidbot1]

Cool, can't wait to see the finished product!!!

[outlander560]

well got some bad news....brought the polaris to the dealer. they looked at it, drained the counterbalancer oil and saw it was milky, turns out the pump for the water cooler leaked into the counterbalancer unit and did something to it, he said the engine would need to be taken apart 200 dollars, and then buy 700 dollars worth of parts, and thennnnn put it back together for another 200, sooo my uncle and i are taking it apart ourselves and if there diagnosis is correct we are either rebuilding ourselves or putting a bigger motor in it....so the project is going to be delayed for another couple months

[BuckBilly]

That Sucks!!!!!!!!!!!!!!

[outlander560]

yea tell me about it...now i have to figure out how else to plow our driveway

[DirtDemon]

Good luck man, sorry to hear about the setback, that sucks.

[outlander560]

yea man im just praying the rebuild kit im buying is all i need....if i need to replace the counterbalancer. or any other expensive part im screwed...

[outlander560]

***UPDATE*** got the engine out of the polaris and got the rear swing arm bearings replaced front boot installed, chain installed, put new engine mounts in... hopefully rebuilding the motor:realmad: is the last thing i need to do on this frigging thing. But was able to get some new/used parts off of ebay and craigslist, new clutch cover, a-arms, and a k&n air filter save me a great deal of money:yes:....

here are some pictures...with the motor out i got real into the cleaning...

BY THE WAY, ARE THERE ANY CHEMICALS I CAN USE TO CLEAN UP THE ENGINE A LITTLE BIT. I USED ENGINE DE GREASER, BUT SEEMS LIKE IT IS STAINED WITH DIRT...IF NOT HOW MUCH WOULD IT COST TO GET THE MOTOR BEAD BLASTED??

DIRTY MOTOR

[outlander560]

Update. getting motor rebuilt by Uncle....hope to have it done and put back in atv by the end of December and put all together

[DirtDemon]

Best of luck to you.

[outlander560]

thanks DD...all i can do is hope right now

[outlander560]

FINALLY ITS DONE!!!!!!! pictures will be up shortly

[outlander560]

[BuckBilly]

Tire and ride report please!!!

Looks darn good!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!