If it has major problems, I wouldn't look at it as a "paper weight" but an investment.
1. kids can help you work on it and learn. Time spent together is priceless
2. you can sell parts off of it and make more money than the $250+ you put into it. - the boys would already have a return on their investment.

 

We've been slowing taking it apart. Some of the nuts and bolts are rounded off making everything take longer then it should. Still need to find a repair manual for this. That would be a huge help with determining what parts are missing.

 

Looks like a 325. I have found the 325s to be good machines and I know a guy that as an older 425 which goes to the trail regularly. $250 for it is a great price and your boys will learn skills that they will use for the rest of their lives. I have said it before that there is no feeling like the first time it fires up and runs on its own....The 325s and other early machines are fairly simple to diagnose and repair. I have not found a specific manual for the 325 or 425 for that matter, just a generic Polaris ATV manual which covers it. From Haynes, covers 1998 thru 2007 I think. I rebuilt the engine in my first one following that manual.

If you search for your machine on Ebay, you will find both paper and electronic versions of a manual. I prefer paper myself, but the electronic version on a CD may be more specific to the machine.

bikebandit.com is another resource. They have the exploded parts views that can sometimes give you an idea what is missing or how it needs to come apart.

Good luck with the project!

 

Awesome, I have started a similar project and can confirm this forum is an excellent resource.

I also found a seller on eBay who is parting out a machine identical to mine and have saved a lot of coin buying used axles and anything I cannot repair or glue back together!

When you cannot find used parts, make a list of those OEM parts you need and buy online from a site that offers free shipping once your list is expensive enough to meet the free shipping minimum. That will keep your boys costs down on new parts. Be prepared to wait a little longer on shipping as they normally don't stock the items we need.

I would encourage the support of forum members who sell parts you need. I may be able to find a better deal on the web, but if I need a clutch or parts I will contact Ridinagain and if I need bushings I'm going to contact jccapri. I've heard a lot about their great customer service!

Keep us posted on progress, maybe even start a build thread if you have the time. Yall have fun!

 

that is an excellent machine. the 325 is a great motor, i had one in my trailboss and i couldnt kill it. sunk it, and WOT 95% of its life. i will be following your progress and it will be a great bonding experience for you and your boys. and by the way you stole the machine at only $250.

 

So far we've only done a few things. The first thing we did and I thought it was going to be easy was take the wheels off and sand and paint the rims. Well, three of the wheels came off pretty easy, but the fourth has all four lug nuts stripped/rounded off. We'll need to figure that one out later. Second, we replaced the broken throttle cable. That was pretty easy. Third and last, we bought a new air box and attached it to the carb. just to find out that the rubber adapter that attaches the carb. to the cylinder is broken.

I think the previous owner used every nut and bolt that he could find around his shop to replace the ones he lost. I've never seen so many self tappers.

 

just to find out that the rubber adapter that attaches the carb. to the cylinder is broken.

Saw someone on here keep it cheap by scouring the plumbing section of the hardware store for a straight rubber connector.

 

This is the part I need to order. The one on the atv was cracked and fixed with silicone.

 

 

We are super pumped. We got the engine to turn over and it idled pretty good. Kids are so excited. Looking for an oil line. Let me know if you got one. Thanks.