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02-08-2012, 07:38 AM
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ATV Enthusiast
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Member #22943
Join Date: Feb 2012
Location: Houston
Posts: 59
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This is an awesome rebuild story. Glad things are starting to come together.
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2012 Sportsman 400 H.O. Boardwalk Blue Stock.
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02-08-2012, 08:30 AM
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Polaris ATV Junkie!
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Member #18006
Join Date: Aug 2011
Location: Chaumont NY
Posts: 1,031
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Keeping my fingers crossed that the fenders come in this time. Still haven't come across any in my travels.
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2004.5 Sportsman 700 EFI
2007 Sportsman 700 EFI
"Signature abridged by popular demand"
  
"Watch out for the Gander Mtn buckets"
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02-08-2012, 08:53 AM
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Extreme ATV Enthusiast
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Member #20465
Join Date: Nov 2011
Location: North East Pennsylvania
Posts: 128
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I have tracking numbers this time. They are supposed to arrive tomorrow. I never would have imagined that ordering plastic would be the hardest part of this project.
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02-09-2012, 05:54 AM
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Extreme ATV Enthusiast
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Member #22851
Join Date: Jan 2012
Location: Northeast Ohio
Posts: 132
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Great story and effort bzerk1!! Looking forward to seeing the completion.
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2012 Polaris 500 HO Yellow
2500# Warn Winch
Synthetic Rope
60" Moose Plow
Hand Warmers
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02-10-2012, 06:19 AM
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Extreme ATV Enthusiast
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Member #20465
Join Date: Nov 2011
Location: North East Pennsylvania
Posts: 128
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I rushed home yesterday and was greeted to two large boxes on my porch. I flung open the door and started dragging boxes inside. My hands surged with energy as I tore through the cardboard. When the dust cleared, I gasped for air and sat amazed at the sight before me. This must be what it feels like to climb Everest, or walk on the moon I thought. It was just as logistically challenging. Before me sat front and rear sagebrush green fenders for a 2011 Polaris Sportsman 500 HO. They are harder to find than the element Astatine. I double stepped up to my shop like a NFL running back. I bolted on the fronts. They fit perfect. I had to leave for work #2 so I did not get time to mount up the backs. Thank you Motosport.com.
I'm still waiting on the driven clutch buttons. Once they are replaced I can assemble the sheave, put the clutch cover on and mount the back fenders. Does anyone have any idea what would wear those buttons out so quickly? Is it normal for them to wear? Pictures to follow.
Now listening to: Nothing.
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02-10-2012, 06:30 AM
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Extreme ATV Enthusiast
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Member #3330
Join Date: Feb 2010
Posts: 122
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Craig and Paula
OP KS\Truman Lake MO
97 400 Sport (Hornet)
87 250 Trailboss (Devil)
03 Kaw 250 Bayou (Tonka)
86 Suzuki lt230ge (Blacky)
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02-10-2012, 06:47 AM
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Polaris ATV Junkie!
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Member #11247
Join Date: Jan 2011
Location: Michigan
Posts: 1,032
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I haven't heard of them wearing like that, but who knows what the previous owner did. He did burn the machine to the ground after all. Maybe he modded it incorrect, maybe he tried to drive it after it started on fire. Who knows. It doesn't seem to be a common problem though.
Sent from my SCH-I510 using Tapatalk
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2011 Sportsman 500 H.O. - Guru brush guard, 26" original Big Horns, gutted muffler, Polaris 2500 w/synthetic line/hawse/winch saver, Polaris HD springs, Polaris heated grips, Glacier III 60" plow, Quadovator reverse mod, 3 headlight mod, Polaris rear rack extender, rear L&R cargo box, HIDs
2011 Trail Boss - HIDs SOLD
Last edited by antoniodef; 02-11-2012 at 02:55 PM.
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02-10-2012, 09:40 AM
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Polaris ATV Junkie!
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Member #11494
Join Date: Jan 2011
Location: Rhode Island
Posts: 1,263
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Quote:
Originally Posted by bezerk1
I Does anyone have any idea what would wear those buttons out so quickly? Is it normal for them to wear? Pictures to follow.
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Maybe heat from the fire messed them up somehow where they visably looked fine, but as soon as they were put under load they cracked? They certainly don't normally wear that fast.
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2010 Sportsman 500 H.O.
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02-10-2012, 10:11 AM
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Extreme ATV Enthusiast
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Member #20465
Join Date: Nov 2011
Location: North East Pennsylvania
Posts: 128
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It could not have been heat because there was virtually no heat damage below the fuel tank except for the wiring harness. In fact I am still using the original clutch cover. The original belt looks to be in pristine condition. It sounds like a case of abuse to me. I don't have much experience with these clutches so I really do not know what to look for. All I know is that the clutching action is no where near as good as my trusty 87 Cyclone, which I rode until last fall.
Now Listening to: Nothing.
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02-10-2012, 10:22 AM
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ATV Enthusiast
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Member #18190
Join Date: Aug 2011
Location: Kingston
Posts: 33
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Now Listening to  rink in My Hand-Eric Church
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