2003 Kodiak I bought new way back when is getting a new life. Was never ridden much but there were certainly some years where it was neglected. So it all started recently when I noticed a torn cv boot and I didn’t like the way it sat at a lean. I’d hit a big rock on the beach back in ‘04 or ‘05 that caused a flat and bent rim and I’ve ridden it that way ever since. Couldn’t detect any issue with the frame but it sagged on that side and now that I’ve gotten older and smarter I figured out there was something wrong with the shock too.

So I needed shocks, axles, wheels and tires and the more I took off the more I found wrong. Horrifyingly I discovered the frame was so rotten it had holes in it. So now this was a giant project but I had to see it through. Everything works on my bike and despite being so old it never had many miles put on it. All the damage is from being parked outside for so many years.

So I found a frame on eBay and for the past couple weeks I’ve painstakingly begun transferring everything from one frame to another. Got the engine, front differential, and front suspension in today. Already had the steering column and wiring from last week. Here’s how she sits as of now.

 

Looking good, great job!

 

Quite a project. Good work!

 

Thanks! I hope to get the rear suspension and arm installed this evening and then start on all the detail work. Routing the wires and hoses properly, getting loose bolts torqued, all the really difficult stuff that will take time and make wrestling that engine in by myself look like fun by comparison.

 

Moving along slowly but surely. Rear suspension in. Rear brake line back in place and connected to the hand lever. Speedometer cable in place alongside the radiator hose and brake cable trying to match all these routings best I can from all the pictures I took to help me get this thing back together as close to original as possible. Rear fender in place and all the wiring out at the rear end in place and ready. Carb jets delivered and waiting on other exhaust parts to hook up the HMF exhaust. 2-3 more days and I may be ready for the coming weekend.

 

All done. Just a few more screws here and there but project finished.