Hello all! I just picked up my first 4-wheeler yesterday, and just signed up here a few minutes ago. Here's what $300 got me off of FB marketplace.




It may not look like much at the moment, but it's all there. I've started tearing it apart to fix it. Previous owner(s) took part of it apart after they burnt up the piston and then needed to sell it. I'm getting ready to mail off the cylinder and head to Ritter Cycle Racing and it'll be returned to me with a fresh bore, milled head, and Wiseco piston. I may splurge for the pipe kit after I get everything else all squared away and running. We'll just have to see.

Right now though, I could really use your guys help with the body kit. While the plastic is all there, none of the fasteners are included in the box of bolts that was sent with the 4 wheeler. Does anyone have a list, or an idea of what type of screws are used to hold things like the floorboards or front rack together? I can supply pictures of where I'm missing things if that helps.

 

Just got done putting a rebuilt engine in my 99 300. I had some other items I wanted to work on, so removed most of my plastics. I took some photos of the screws for the fenders, footwell with nuts and front screws for front rack. I would also recommend downloading a parts manual. I found this right on the Polaris website. Not the exact year, but I think 96-99 300s are pretty much the same. Let me know of you have any other questions.

 

Wow, thank you so much for posting that. Yeah, now I'm sure I don't have any of those bolts or screws. Looks like I'll be making a trip to the hardware store in the future. Would you mind letting me know what the size, length, and quantity are of those fasteners? I realize that's an annoying task to do, so I'm willing to paypal you some beer money for your time.

I'm downloading a new manual now too!

 

Sorry for the delay, meant to have my quad back together this weekend but ended up having to replace the petcock and fuel lines, so am a little behind where I thought I'd be. For starters, I can get you going on the mud guards screws. There are 6 screws on each side, these use a common screw used throughout the bike. You have two on yours I can see on your photo holding down the gas tank support, they are part #7512232, holding down part # 5220916-067. Hopefully this gets you started. Once you have the manual, if you want to provide the page #, I can try to provide a photo along with the length and width of the fastener.

 

Based on the information you've given me, I ordered 25 screws and extruded nuts from Amazon that arrived last Saturday. So now I'm good on that front. I've got my manual that I'm slowly going through and I should have page number, or possibly part number, of the remaining screws I'm missing. I really appreciate your help.

My work also has sent us all home for the next 3 weeks thanks to the Corona virus going around. We still have work we have to do via e-mail, but aside from that, if I can get some parts rolling in here, I can get to work on this thing!

 

Okay, so screws that I know I need to figure out next, are the four that hold the footrest down on each side


and the ones that hold my front all together. You can see where they're missing.

 

Sorry, I'm going to blame this one on the pandemic. The foot wells are simple 1 inch by 1/4 screws. My originals were rusted so I used stainless with unlock nuts. I think the originals had larger/flatter heads. The front took two 3/4 by 5/16

Footwell screws/nuts. These were aftermarket, i used stainless as my originals were rusted. 1" x 1/4" with nylock bolts.

Front bumper with original and winch kit bolt installed (partial).

Front bumper 5/16"

Front bumper 3/4" x 5/16"
(I think, caliper showing .29"), see photo. I have a whinch, so the silver bolt was from the whinch kit, tapered, short bolt original.

 

I was looking at the picture and noticed you may have some additional missing bolts along where my winch is mounted. I'd assume same 3/4"x 5/16". I will be in the garage this weekend hopefully finishing up and will be more responsive to your questions. Good luck. Scott.

 

Hey Scott, I really appreciate all the help you've given me. I've also got good news as this arrived from Ritter Cycle Racing yesterday!!!



I've got a few more parts showing up in the mail (hopefully) in the next few days so the goal is to be putting this thing back together this weekend!

 

No problem, glad to see you're back at her. I finally have mine back together so feel free to keep the questions coming as I probably just went through the same procedure. Good luck this weekend. Scott