I've done some fabrication work for a French engineering company... talk about ridiculous. Their American office actually said how terrible their projects were.
You have my sympathies. The French mechanics I work with would agree with you.
I've done some fabrication work for a French engineering company... talk about ridiculous. Their American office actually said how terrible their projects were.
In comparison to a Yamaha, the Polaris' suck to work on. But we've had many Sportsman 500's and they are good machines.
I considered going Japanese but don't know anyone with a Yamaha, and only know people with Suzuki's which I absolutely hate riding. The King Quad's I've been on have driven absolutely atrocious. I enjoy how the Polaris ride ridiculously smooth. The 99-03 500 Sportsman's are supposed to be up there in reliability with most of the best.
Kawasaki drove us to Polaris, parts were too expensive. My Yamaha's are go fast type being a Banshee and a Raptor 700R.
I made some progress on my Dodge 3500 tow rig‘s AAM 11.5 rear end.
From this:
View attachment 481434
To this (one ton truck axles are massive and heavy compared to TJ axles):
View attachment 481435
New ring and pinion with an ARB going in. This is the 1st test fit with the new pinion races in and set up bearings with the factory shim stack (0.054”). I set the pinion pre-load at 25 in.lbs. and then the backlash by feel. That‘s all for today. If I can after work, I’ll get the dial gauge out tomorrow to get the back lash in spec and run the first pattern.
This is an intimidating project but I’m starting to think I can do it
Alright here is the first pattern on the AAM 11.5 set up. 0.054” pinion shims (OEM spec and this is an OEM R&P). Pinion preload in spec @ 25 in.lb. Back lash 0.006” (spec is 5-7). Seems damn close for attempt number one. A local friend with a shop that does a lot of gears said “run it”. Thoughts? @hosejockey61 ? @Blackjack ? others?
Drive
View attachment 481705
Coast
View attachment 481706
Have to love those crappy two cut gear patterns. That being said I think your friend is correct in letting that one run. You could try if you want to go a couple thou deeper but I think your coast side pattern might go south on you.
I concur with Blackjack
Got the two bolts installed and tightened down. The connector is hooked up.
Waiting for my fingers to thaw out and then I'll connect my scanner and try starting it.
Love it. You've got 2 other big projects in your Jeep and RV and then the daily acts up
I'm having a similar time lately. Hang in there.
In comparison to a Yamaha, the Polaris' suck to work on. But we've had many Sportsman 500's and they are good machines.
I had a ripped CV boot, turns out I have almost brand new OEM axles on the shelves from past endeavors, cool. Also have almost brand new OEM control arms and bushings, awesome.
Notice the shock bushings are shot, go to remove the shock, sure as shit if the exhaust was 1/8” farther away it’d come out…. Well guess who gets to remove the muffler .
Maybe they are a bit of a pain….
I remember lots of different sized fasteners.
9/16” will remove almost the entire rear suspension….