Rebuilding my beloved 2011 Sporty 800 - Polaris ATV Forum
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post #1 of 57 (permalink) Old 08-10-2019, 05:11 PM Thread Starter
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Rebuilding my beloved 2011 Sporty 800

Well gentlemen I have alluded to it in some of my posts but now it's official!!! A damn near complete rebuild of the 800. Every major component has been sent out and rebuilt. I purchased a new frame. Almost everything is being upgraded. From new suspension bushings all the way to adding electric power steering!!!

I guess I'll be adding to the whole story here and there but I'll try and give the parts that got me to this point now. I could go back a few years when in New Hampshire after loading the wheeler on top of my Diamond Back carrier I noticed the diff and tranny seals were sweating and thought well those will be needing new seals and potentially bearings. The real culprit that started this undertaking or shall I say the straw that broke the camel's back was literally breaking the frame. So here are a few pics of the carnage. This happened nearly two years ago on a ride in upstate New York.
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Corbett1973 and jjuelmen like this.

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
bp405 is online now  
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post #2 of 57 (permalink) Old 08-11-2019, 04:45 AM Thread Starter
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So a little over a year ago it was coming down to the wire as our annual Hatfield & McCoy trip was approaching in September. I needed to start wrenching on the 800, ASAP!!!! In the first pic here you'll noticed a removed the plastics on the 800 and had a new set of Big Horn 2.0's shipped. Figured a little added incentive couldn't hurt. Plus I needed new rubber. Funny thing is at this point I didn't know I'd be putting those new 2.0's on a new 570-T. But as I soon discovered in the tear down of the wheeler I had more damage to the frame then previously anticipated!!!
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Corbett1973 and jjuelmen like this.

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)

Last edited by bp405; 08-11-2019 at 08:29 AM.
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post #3 of 57 (permalink) Old 08-11-2019, 03:58 PM Thread Starter
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Well I haven't been doing anything Earth shattering on the reBUILD. Just putsing around cleaning suspension components and installing the rest of the Garage Products bushings. Well I ran out of things to do as far as the suspension is concerned and moved onto getting the engine in the frame. Wasn't able to get that completed either as I compiled a list of parts I need. But I did unpackage the engine that has been sitting in my garage for 11 months. Here it is in all its glory. What we have here is a fully rebuilt engine from nFlow. I had the HO package installed in lew of having it rebuilt with essentially the same parts.
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Corbett1973, nFLOW and jjuelmen like this.

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
bp405 is online now  
Sponsored Links
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post #4 of 57 (permalink) Old 08-11-2019, 05:14 PM Thread Starter
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Looks like I forgot to mention and post a pic of the new frame I bought. I wasn't going chance repairs on the original frame. There was the original break at the right rear lower a-arm tab. Then the vertical member that had heat and abrasion damage. Also the upper strut support crack. Fast forwarding when I removed the transaxle I noticed numerous fractures via rust stains in the welds. So let's rewind to the original incedent. I was at a crossroads, do I call insurance and put in a claim and have it totalled out, have what was visibly wrong welded and ride it or sell it, or bite the bullet and dive in and let the chips fall where they may. So obviously #3 the hard way is what I chose and is typical of my daily choices, lol. So here's the frame I'll be bolting everything to.
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Corbett1973 and jjuelmen like this.

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
bp405 is online now  
post #5 of 57 (permalink) Old 08-12-2019, 09:02 AM Thread Starter
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Location: New York
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Like I said I'll be jumping back and forth from present day real time work on the 800 to the tear down and rebuild of parts and components. Although I'll be jumping I'm going to try and keep chronological order of the process. So here are some pics of my ATV Guru front brush guard. Since the wheeler was on IR I figured it was time to call John and have a permanent bracket installed for my Rigid Industries light bar. You'll see what I had done in the photos. What you can't see is the broken sections of expanded metal where it ties into the square tubing. Believe me when I say this machine and I went to war against practically every trail we hit, haha.
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Corbett1973 likes this.

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
bp405 is online now  
post #6 of 57 (permalink) Old 08-12-2019, 04:33 PM Thread Starter
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Well best laid plans of mice and men, coming up doughnuts here fellas!!! After failed attempts at the front suspension, then the motor, now SuperATVs EPS. Same story different day, "waiting on parts"!!! But I was able to get the frame rigged up on some dunnage, front diff is in, and I opened a familiarized myself with the EPS install.
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Corbett1973 likes this.

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)

Last edited by bp405; 08-12-2019 at 04:37 PM.
bp405 is online now  
post #7 of 57 (permalink) Old 08-12-2019, 05:21 PM
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It will be “Better-Faster-Stronger”. For a little less than 6 Million. Lookin’ good Bp.
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post #8 of 57 (permalink) Old 08-13-2019, 02:18 AM Thread Starter
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Quote:
Originally Posted by Sprotsman View Post
It will be “Better-Faster-Stronger”. For a little less than 6 Million. Lookin’ good Bp.
Thank you sir!!!! Yes that's my anticipation, "Better-Faster-Stronger". That's the thing $$$$$, it's a cool project and all but I wonder HOW pound foolish this may be. Bottom line is I'm having fun with it, the kids come out to hang and check out the progress, the wife thinks I'm some sorta mechanical genius, and the fellas think it's pretty damn cool what I'm doing. AND I get to share it with you gents!!!

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
bp405 is online now  
post #9 of 57 (permalink) Old 08-13-2019, 05:55 AM
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Posts: 358
It’s all about the journey! For sure I’d like to have a bike assembled/built by myself knowing everything about it. You have total “quality control”.
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post #10 of 57 (permalink) Old 08-13-2019, 08:31 AM Thread Starter
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Quote:
Originally Posted by Sprotsman View Post
It’s all about the journey! For sure I’d like to have a bike assembled/built by myself knowing everything about it. You have total “quality control”.
This is very true!!!
Corbett1973 likes this.

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
bp405 is online now  
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