Polaris 90 project from hell! | cvetitula.ru
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post #1 of 8 (permalink) Old 05-01-2013, 03:36 PM Thread Starter
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Polaris 90 project from hell!

We found a 2007 Polaris 90 Sportsman on Craigslist for $1300, and paid $1100. Lets just say it needs some work! No front brakes, a rattle behind the clutch cover, no power and a rough idle, kick start would bounce back, the starter spun freely, and the rear tires were even on backwards. However, the machine cosmetically was in great shape!

I have since rebuilt and cleaned out the carb, replaced the spark plug, drained and replaced the fluids, and ran SeaFoam. The engine now has its life back for under $50!!! We noticed that the starter sounded like it wasn’t engaging. Figured that it might have some stripped gears, or something. Took the clutch cover off and saw that the gears spinning as they should, however the variator was failing to spin. I noticed that there were two screw heads have sheared off laying at the bottom of the clutch case. After removing the variator assembly, I saw the part with the sheared screw heads sheared off of (Polaris exploded view) 0454642 Asm., Wheel Starter, Kick. After doing some research, it seems they did a revision of the part. Wheel starter “one way clutch” is in two parts now, thus causing the starter gears just to spin w\o engaging the variator. I ordered the following after noticing some wear, wheel starter (failed), roller weights, kick pinion, clutch one way, and clutch gasket.

New parts arrived! I first cleaned all the starter, and kick start gears. Then used a lighter lube "Liquid Wrench Chain Lube" for all the components. I tackled putting the kick stater assembly back together, let me say it flat out sucks!!! That spring is under a lot of tension, it took me a good 20min to wind the spring back. With the kick start cleaned, lubed and put back together. I then proceeded to primary assembly. I cleaned out the variator and replaced all the weights, facing the same direction. Then proceeded to install everything back in order, and torqued down to 29.ftlbs. I tested the starter before putting the clutch cover back on. Works great!!! Put the clutch cover back on with a new gasket. Tested out the kick starter, PERFECT!!!!

Feeling good, quad is running, not perfect put running. I go and look at the back end and the swing arm where the mono-shock attaches has a broken weld! ARGH!!! One thing after another. I can weld, but out of argon gas. I called a local place on Friday and they said to only bring in the swing arm Saturday morning. So I proceeded to take apart the whole rear end. Every bolt and screw was a pain to remove. Something is just not right. The atv was also missing it's chain guard that I had already ordered. I only had two bolts to go, the bolts go through the drum brake and into the axel housing, they are beefy bolts. Just so happens these bolts would not come out, and one broke. This atv had to of been in a wreck, all the welds were rusty on the swing arm. I took the rear end assembly to my local welder and he could not remove the broken bolt and said everything was rewelded. That sums up everything. This thing was rolled, or something. I found a rear end on EBay assembly for $275 with a 30 day guarantee. The assembly would have cost me over $600 new. Also ordered a new carburetor, ignition coil, and front and rear brake shoes. My daughter has seen me paint mufflers\exhausts before and wanted her’s blue! So while I waiting on parts I prepped and painted it. She also wants other parts painted, we will see. Should have all the parts in before the weekend. If I head north of $1500 for the atv plus parts, it is a bad deal. Right now I am hovering at $1475.

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Two 2013 Rancher AT's 420 IRS 4WD for me and the wife
**Viper 3000 winches w\synthetic rope, future upgrades rear cargo box**
Daughter has a 2003 Recon 250
**Viper 2500 winch, Vapor Speedo**
Youngest Daughter has a 2007 Polaris Sportsman 90
**Polaris 1500 winch, Vapor Speedo**


= PHANTOM_PAIN
= DA BEARS
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post #2 of 8 (permalink) Old 05-02-2013, 04:14 PM
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Sorry man...I've bought two lemons in my lifetime...Make that lemonade the best ever !!! good luck !
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post #3 of 8 (permalink) Old 05-03-2013, 07:54 AM
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location: League City, Texas
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I can relate with my Yamaha Big Bear project bike, although I picked it up for only $100 and I'm currently around $700. All those "little" things that are broken/missing/screwed up can really add up quickly. Hang in there - you'll have a good bike soon.

Greg
League City, Texas
1994 Fourtrax 300 4X4
2006 Yamaha Grizzly 660 Special Edition
1991 Yamaha Big Bear 350
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post #4 of 8 (permalink) Old 05-03-2013, 10:46 AM
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No wonder it's causing so much grief....it's a popo stupidman...lol

-'96 sportsman 500 "HO" build...
-'97 trx300 4x4
-'93 trx300 4x4
-'91 trx300 4x4
-'85 trx250
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post #5 of 8 (permalink) Old 05-06-2013, 11:08 AM Thread Starter
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Yeah, on Saturday I replaced the whole backend, put the upper and lower chain guards on, swapped out the carb and ignition coil. The quad started on the first kickstart (5yr battery is dead). Have to send the brake shoes back, they didn't fit. Now the wife is concerned about the front, the left front tire has a lot of camber on it, leaning in on the top. So, I found some used A-arms on Ebay for $44 w\free shipping. Hope that will be the last of parts. I will get the A-arms replaced this weekend, and hoping to get going on the hydrographics.

Two 2013 Rancher AT's 420 IRS 4WD for me and the wife
**Viper 3000 winches w\synthetic rope, future upgrades rear cargo box**
Daughter has a 2003 Recon 250
**Viper 2500 winch, Vapor Speedo**
Youngest Daughter has a 2007 Polaris Sportsman 90
**Polaris 1500 winch, Vapor Speedo**


= PHANTOM_PAIN
= DA BEARS
Tripod is offline
post #6 of 8 (permalink) Old 05-15-2013, 08:26 AM
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location: Qtown PA
Posts: 39
I purchased a MINT 2004 Polaris 90 on clist for 1200 bucks. That ATV is fast as hell Never had a problem with it but a Battery. I have bought some Lemons in my day and when it becomes man against machine get ready to open your wallet and spend your hard earned cash. Good Luck

2002 Rancher 350 4WD
2002 Honda 400 EX
2000 Kawasaki Lakota 300
2004 Polaris 90 2stroke
1986 Honda TRX200SX
1984 Honda ATC 200X
Honda CRF50
HONDA XR70
1975 Yamaha DT125E
1979 Yamaha DT175
1980 Yamaha DT125
Yamaha PW 50
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post #7 of 8 (permalink) Old 05-15-2013, 10:12 AM
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Re: Polaris 90 project from hell!

We just picked up a Dale Earnhardt Jr addition Polaris 90 for a grand total of 300 bucks it does not run but has good compression . I have not had a chance to start on it yet I pray I don't have as many problems as you have had

2013 Rubicon 28-10-12" mud witches on hd3 wheels

gone but never forgotten E.T. (90 fourtrax300fw)

94 sportster with andrews n4 cams hc pistons p&p heads drag pipes under drive pulleys

2010 Colorado 4 door 2wd

2013 recon es 23-8.50-12 front and 23-10.5-12deestone suretrack on hd3 wheels (her bike)
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post #8 of 8 (permalink) Old 05-15-2013, 12:14 PM
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Quote:
Originally Posted by rlfoulch View Post
We just picked up a Dale Earnhardt Jr addition Polaris 90
What the heck Richard - you starting a quad farm there? You are gonna need a new barn to house all these new bikes in!

Greg
League City, Texas
1994 Fourtrax 300 4X4
2006 Yamaha Grizzly 660 Special Edition
1991 Yamaha Big Bear 350
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