Project Razr

Was going to go ride the RZR in the rain Thursday one last time before getting it ready to install all the new suspension parts that were coming friday ( i have thurs, fri and sat off ) when I noticed the right lower balljoint looked funny .. Further inspection revealed it had pulled out of the socket , the weight of the machine was the only thing keeping it in place ....  
Time to install all the front Bushings, 4 Ball Joints & 2 Hub bearings the brown truck dropped off Friday ..

Front hub bearing snap rings were bamboozling me at first, using an inferior tool , but now I got em figured out , lol after some tool grinding - and with a new set of snap ring pliers on order   Took me a few to figure out how to separate the seized hubs from the carrier . Wiggling back and forth with 2 pry bars did the trick.
Bearings are actually pretty easy to change without a press. Just got to hit em in the right places ( Big Hammer. I also cheat and use an air chisel but a hammer will suffice ) & use the right technique so you don't screw them up . Just like a VW Passat/Jetta front hub set-up..
Also All new front a-arm bushings & 4 new ball joints , front sway bar bushings & some modifications & fabricating lower shock mounts & spacers , I didnt order them thinking hey were ok but found they were shot , too .
I made shock mounts & spacers out of the old upper a arm bushings & spacers by cutting the bushings to size and reusing the un-worn center section of the metal inserts - just like my Sportsman fabrication .
Ready for some more WV pounding now  


Finished about 10pm

Jeff where did you find snap ring pliers to fit? What bearing did you use? VW OEM Or after market?

I bought some cheap snap ring pliers at autozone that barely spread open far enough & I ground the tips thinner to fit the snap ring . Crude , but very frustrating & it barely gets the job done .
Going to overpay for a nice pair of pliers from snap-on tool man when he comes back Wednesday .
I ordered OEM bearings from World Of Powersports . Use 10-OFF coupon code .
They were as cheap as buying aftermarket bearings within a couple dollars .
All the listings for front aftermarket bearings for the Diahatsu charade car or whatever car they fit were back ordered and needed special ordered anyway so I just went with OEM.
Note - got 4 balljoints from super Atv for just under $100
Both lowers bad , uppers still good but they are easy to change so I did all 4 & have 2 good used for roadside emergency kit now .

Brown Truck had a few more deliveries scheduled here .
First one arrived yesterday

At least I'm not the only one dropping a dollar!

Lee wrote:

At least I'm not the only one dropping a dollar!

Done some wheelin-n-Dealin , made another trip to west ohio and ended up with a set of like new 27 inch Maxxis Mudzillas on Chrome sportsman wheels along with 2 front wheel spacers .
Wheels have crappy flat black paint which I will be removing here soon .
27x9x12 front
27x12x12 rear
Getting ready for another snowy/muddy Nobember-March riding season



It's hard to pass up a good deal -all tires , wheels and 2 spacers for $275
They cleaned up quite nice !


Most came off 1st application , soaking on the second application

Nice and shiny chrome now

Picked up some seats last week in Western Ohio, too . $75 each

Tires are not my thing but, I really like the seats

Mr.Ed wrote:

Tires are not my thing but, I really like the seats

I agree with you about the tires , your former neighbor , now he would like them

This is my project RZR



The axle end splines are new.

The hub in the Diff. is on back order until the Oct. 17.

Reason for replacement, to much movement and a lot rattle. Eventually the splines woyld strip and then there would be no 4X4.

How many miles are on your heated RZR Mr Ed?

3,800. It has been bad for a while just got to the point of to much rattle which drove me crazy

It will be a better job when it is back together,

Internal parts of the Diff. are interesting.

Installed wheels , tires and seats



Install $49 Harbor Freight 2500lb Winch with remote control


Spent about 3 hours upgrading the wiring from another old winch kit , replacing several shitty butt connectors & soldering them to the cable ends , disassembling the remote box , soldering all connections , waterproofing the box , adding heat shrink and wire loom & running the wiring , mounted the box under the dash inside .

Installing the re-incarnated Krusty ;D

New parts are installed, ready to take it for a test run down the road

Too bad it wasn't together yesterday

Took it down the road for a test run, everything seemed great until I hit a couple of bumps and the rattle was back. Hoisted back up looked around and of all things found a rubber bushing missing where the sway arm goes through the tube to the other side. I think that was most of my rattle all along.

Replacing the axle parts sure did tighten things up though.


Hope to be ready to ride next weekend

Glad to hear ed, ol krusty rocks!

Sounds like a ride next weekend! Let me know,

Sounds like a plan at this time

Was out shopping for a new box yesterday am
( the Contico box leaks and I was tired of cleaning wet crap out of it after every ride )
Saw this for $68 - only $10 more than the one I was looking at that was 1/2 the size
It should hold all kinds of rain gear ( And extra Polaris parts  : ) no problemo



Infringing on Krusty's space a little bit

Put the windshield in , Rain x on both sides
Forgot all about having it and that I was going to order a marine wiper motor ,
Now it's too late to get one before the ride .
Still have the squeegee and washer solvent spray bottle

If I can find enough plastic line and a switch I may install this washer pump & tank I have
( I volunteered to work tomorrow so time is short )



And I peeled off that hideous dewalt sticker and installed the correct one on the left side .
There is room for a QCR sticker on the right side

Windshield looks familiar. I think that box might be big enough. Curious as to how you hold it in. Where you going to mount the washer container?

Mr.Ed wrote:

Windshield looks familiar. I think that box might be big enough. Curious as to how you hold it in.  Where you going to mount the washer container?

Box is ratchet strapped in on lower part .
It is way big but for extra $10 why not . It comes out easily ..
Going to be wet this coming week so I want to have a nice dry jacket & sweat shirt to change into if need be ..
Washer bottle can go anywhere , has flexible fill pipe so I can bury it , maybe behind drivers seat or rf pass side footwell area ..
Could you post / send me pic of your wiper set-up ?

Been thinking about this wiper setup
Company located in Lancaster Pa
Schmitt Ongaro 31014
With 14 inch arm and blade
And heavy duty 3 position rocker switch- fits right in dash slot

That's the motor Sportsman Are I are using, but single speed with auto park. Ill get a pic. and tx to you

Don't have your # for tx. but I put mine on the top !7" over and 3" down from the top looking at it from front to rear