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Discussion Starter #1 (Edited)
Just bought this used and abused road legal predator 500 so I'm going to do a full restoration on it and bring it back to life !
It came with these upgrades :
560cc big bore kit with ported and gas flowed head
Dynojet kit
Pure polaris exhaust
Fox shocks all round
Steering dampener
Douglas alloys
Nerfs
Xlarge enduro tank





The quad in action doing 2nd gear donuts :)

 

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Discussion Starter #3
Got it all blasted now and I've found some small hairline cracks in the front engine mount so I've decided to cut the plates out and put thicker 3mm plates in place.

















Now ready to be powdercoated orange :)
 

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Wow.... you've been busy! Looking good & keep us posted.
 

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Discussion Starter #5
Back from being powdercoated :)





Started to fully strip every single part so it can be aqua blasted.







Got everything back from the aqua blaster a today and well impressed with the results, everything looks brand new again :)













Got the rear axle and front hub guards powdercoated black too



Bought a load of a4 marine grade stainless steel nuts, bolts and washers to reassemble the quad.
Just started to put it all back together again.
I've literally bought every single bearing, steering joint, steering bearings and balljoints there is now infact here's the list of brand new parts I've bought for the quad :

Trackrods
Front wheel bearings
Rear wheel bearings
All upper lower balljoints
Wishbone bushes
Steering dampener
Fuel tap
Stainless steel Steering bearing
Inner steering tie rods
All brake pads
Steering top bush
Full plastics
Front bullbar
Handlebars
Nerf bars
Oil filter
Spark plug
Starter clutch bearing
Casing gaskets
Rear brake lever bushes
Choke cable
Rear brake switch
Rear brake switch bracket
Front brake switch
Rad switch
Swingarm bearings
Rear brake disc
Front brake discs
Rear caliper bracket
Rear hub
Seat cover
Rear brake light
Exhaust gaskets
Exhaust downpipes
Chain rollers
Chain and sprockets
Chain swingarm rubber
Clutch lever
Sprocket hub
Rear caliper bracket alloy
Rear caliper bracket pin
Manual
Flywheel puller
Rear brake lever
Headlight bracket
Clutch cable
Throttle cable
Rear axle o rings
2 rubber bungs in chassis
X4 alloy arm steering bearings
Oil tank bottom rubber
K+n filter
Complete airbox
All fairing metal brackets
Handlebars
Shock socks
Fuel pump bracket

I've currently spent £1700 on it so far !

Here's some receipts for some of these parts.

 

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Awesome work so far...can't wait to see it finished.
 

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Discussion Starter #8
Starting to put it back together now







m

New steering bearing installed





New rubber grommets installed

























All brand new a4 stainless steel bolts too











Stripped and cleaned the carb out



New steering track rods fitted



New rear wheel bearings fitted















Got the oil lines fitted

 

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Discussion Starter #9
Put the front calipers back together







Got the front arms fitted with new bushes and balljoints



















That's all for now lol hope u like it !
 

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Discussion Starter #10
Oh and while I'm busy fitting the rest of the parts here's some of my other toys u might like !

My road legal honda cbr900rrx fireblade buggy











My yamaha r1 rossi replica





My rare yamaha tzr250 3ma 2stroke



 

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Quite a collection you have there...I bet that little buggy is down right nasty
 

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Discussion Starter #13
Some more progress for you chaps.

Brand new airbox.








Stainless steel fixings.








Front springs have been powdercoated.


New k+n filter.


New red hoses fitted.












 

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Discussion Starter #14


You wouldof thought after spending £130 on a new airbox it'll come with new clips but did it......did it fuck ! So had my old ones powdercoated black.




New rad hoses




Had the carb metal plates powdercoated silver and fitted all new stainless bolts.


























Got all 4 wheels back on her !










New clutch lever.




















 

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looks amazing! I cant wait to see it when it is done! I wish we could make atv's street legal here in Minnesota USA
 

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Definately a project well done! I learned something looking at your teardown pictures too: I saw the two into one exhaust and went "Huh?". Didn't realize the 500 Predator had two exhaust ports. Definately says "hot rod".!
 

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My thoughts were crushed.....

Well, I guess I can stop thinking about using Predator parts to "hot rod" my Sportsman. Bore: bigger on the Predator. Stroke: longer on the Sportsman. Nothing is interchangeable. Fooey!! lol. Back to the drawing board!! Sure do like the twin overhead cam setup on the Predator.. The piston in the Predator looks like a "flat top" while the one in the Sportsman looks dished. 10.81 vs. 10.2 compression. I seriously doubt the Sportsman cylinder can be bored out to 3.91 from 3.62. Sigh...Good thought while it lasted....
 

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Discussion Starter #19
Cheers chaps.
I've just ordered a full yoshi exhaust system, new plastics, new elka stage 4 shocks, new alba full wrap around nerfs and alba front bumper.
It'll be looking mint again soon :)
 
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