Woo hoo! I'm about ready to try and fire this thing up! Unfortunately, I also have a few extra parts. Can anyone tell where these go? Do they even belong to this 4 wheeler? They're the only parts I have left that i can't figure out where they should go.


Aside from that though, everything is looking pretty good.If you guys wouldn't mind, take a look at the photos and see if you can find anything out of place. I had to guess on a few of the springs and bolts. I think I've got everything in the right spot, but the manual didn't always have the best pictures of diagrams.




Looks like I'm missing a bolt here towards the bottom. Is that true? What goes there?


These parts (tube and hanger in background) I didn't know where they go, or how they were supposed to be routed. Help would be appreciated.

 

Possible location of extra screw and washer?

Missing bolt and two washers, I think these are shown in your photo on the white towel? This is essential to keep the cover from rubbing on the belt. Dont want melt your clutch cover.

Possible extra screw washer location?

Hard to see, look at the tip of the screwdriver, the temp sensor shown on one of your photos gets attached to the rear engine mount. Based on advice I received from OPT, I removed my wiring and just put in a switch so I could contril the fan manually. I installed a trail tech computer to get RPM, speed, and engine temp, that way I can turn on the fan as needed.

Foam seals part numbers 5810444 and 5810441.

Silencer assembly. While you cant see it, you are missing the seal between the silencer and air box. Part number 5410506.

 

Also, wanted to add the tubing in your photo should be routed toward the front of the bike (should be a grove in the tank), then up into steering post. Should also be a vent from the oil tucked up there.
Everything else was looking pretty good.

 

Dude, you are amazing. Seriously, I'm going to send you some beer money after this is all over with.

I've fired this thing up and it sounds great. I've been able to put the body all back together and am only waiting on a pair of new front brake calipers to arrive before I can start test driving this around my place!

 

Glad to here your project is almost complete. I cant wait to ride mi e after the rebuild.

 

So, it's been a few days since my last update. The issue was waiting on two new front calipers to come in (the old ones were seized and I damaged them trying to get both of them apart), and then bleeding the damn brake lines. Holy cow what a pain.

Pro tip: Use plastic syringes and tubing to force the fluid in through each bleeder and out the master cylinder instead of the traditional way. Spent two days trying the traditional way, couldn't get it. Fifteen minutes after using syringes, I was all done.

I've done a 5 and a 10 minute session as break in just going around the yard. It's got power, but I think I need to adjust the shifting linkage slightly, as well as the carburetor. It's got a high idle right now.

Front bumper and rack are off currently because I just haven't gotten there yet.

But she's running!

 

Well, great. I went through a tank of gas and that's been it. Fiance' rode it a few days ago, said when she parked it that it was "steaming". I couldn't get it to restart. I go through the normal checklist; it's got fuel, air, and spark. So I put my finger over the spark plug hole, hit the starter, and I've got next to no compression. It can't even blow my finger off the hole.

So great. Now I get to tear it all down and try and figure out what went wrong.

 

Great work

 

Okay, so I tore into this motor, and found out the oil injection system isn't working. So my new motor never stood a chance. I now believe that's what killed the original motor as well. I have the cylinder at a shop getting bored and a new piston fitted for it, and then I'll get this back together. I won't bother trying to fix the oil injection system as I'd rather just keep mixing the gas knowing that it's getting lubricated rather than hoping it keeps working and doesn't take out another motor.

 

Well, I decided to pull the block out so that I could more easily get to the 6mm drain bolt at the bottom of the crank case that decided to snap off on me the last time I was installing it. Very frustrating. And while I had the block out, I thought this would be a good time to pull the oil injection system off and at least take a look and see what failed.

I have a later '96 model because I have the steel drive gear instead of the plastic ones, so that eliminated that as an issue. It wasn't long before I figured out where the issue was.

Check valve.

She was locked tight. I couldn't blow or suck through it at all. Not sure what would have caused it to seize up like that, but that's what was keeping oil from getting up to the carb.

I'll see if I can even find the part first. That might make the decision to pre-mix even easier.