Polaris Repair Log

1/5/2008 - Lost boogie on 4th Lake, picked up by brothers firtherr and p-dog
1/5/2008 - Ran out of gas on way to Tea House, only 90 miles after fill up, towed by brother firtherr
1/9/2008 - After further review, additional boggies in bad shape and sliders burn thru. Decided to replace all boogie wheels.
1/13/2008 - Rear suspension removed from sled, thanks brother firtherr. Parts ordered.
1/22/2008 - All parts arrive, assembly begins. Rear inner boogies froze. Need 2 additional boogies. thanks brother firtherr
1/23/2008 - Purchase additional boogies and bushings at Filers. All boogies installed and new slides installed. thanks brother firtherr and scotty.
1/24/2008 - Brother Scotty helped install rear suspension in Polaris. Here is how we did it. First we rolled the sled on its side, then maneuvered the suspension into the track. While still on its side we aliened and installed the front 2 bolts (hand tight). Next we rolled the sled back up right. To install the bolts connected to the shock, we compressed the suspension with a strap clamp. Scotty pushed down on the suspension and I tightened the clamp. After a couple trys we were able to alien the bolts and hand tighten them as well. On the Xtra 12 (133") suspension there are also a set of boggies in the back, upper that needed to be installed. We musseled these in (also using a rubber mallet when needed). All bolts where then tightened to according to spec. Lastly we aligned the track.... Not knowing the proper track tension, we inspected the Pantera which was professionally adjusted. (Note, with new boogie wheels and sliders, the track was tighter so the back idler wheels are now moved in as compared to their original position). While tested the track, brother Scotty noticed a rather loud noise. After further review, we discovered the front of the sliders were hitting the track. Brother firtherr arrived and it was decided to let the track naturally round these off (any thoughts mr. nappi?).

Since the gas mileage was poor (see 1/5/08 ran out of gas) it was decided the spark plugs should be changed. The right plug was arching inside the spark plug cap. (this is when brothers scotty and firtherr left). After inspecting the inside of the cap, I noticed the metal sparkplug connector could be removed. I replaced the metal connector with one from a spare CDI. The connection is now tight and the sled ran fine. Lastly a few missing body bolts were replaced and I called it a day.

Moral of the story... If you want to find something wrong with your sled look a little closer... If you don't, just jump on and ride...