Joe, I am sure you already know this but a reminder doesn't hurt. Please be careful when you spill antifreeze because it is deadly to dogs, and we all love Vinny. Bill H from Cranberry Township PA
Nice repair. That wheeler was born in my town! Couple things, never use red loctite on those diff cover bolts. Second, rather than anti-seize, use marine moly grease on those splines. If you drive through water or run in snow, the anti-seize will wash out and they will rust again. The grease stays in much better. If it’s hard shifting at idle you need to replace the primary clutch spring. Finally, either the muffler is burned out or the “donut” seals in the exhaust are blown out. Also could be that the springs at the joints stretched and relaxed over time. Keep up the good work! 27 year Polaris mechanic, former test driver and development tech.👍🏻
I am a retired auto mechanic/engineer and I can't believe how hard it was to get the axle shaft out. The load to install and remove the shaft is due to the clip and the shape/size. That is part of design and i agree 100 percent poor design and or quality. Why such a high force required to remove it? No good reason. I was glad to see Joe was able to cut thru with a Sawxall, a portable bandsaw might have worked better. I bet he went thru lots of blades 😊.@dpl2617
Knocking on that axle just made it become thicker. My opinion would have been to press it out! Your videos are very nicely built as are your projects. Well done!!
Didnt look like you installed a gasket on the dif cases, these also help with ring and pinion backlash. The gears sounded very tight when turned by hand. To adjust backlash it is the copper ring size, and case gasket , some manufacturers use case shims also. If that lash is to tight it wont last for to long. Good luck and keep wrenching.
Love your knowledge and expertise when figuring out these machines and fixing them, please don't take this the wrong way but as a retired mechanic myself my OCD kicks in watching you working on these ATV's when you don't clean the parts thoroughly enough before reassembling them, don't you have solvent tank with a brush? Personally I would always pressure wash everything before disassembly and always clean and even paint the parts like cases etc before putting new parts in them, it looks better and cleaner and they look like new after your done. But like I said thats my OCD kicking in. Plus it makes it easier to see if there are any leaks and just looks better when everything is said and done. Otherwise good job and enjoy watching you diagnose and repair these machines.
I feel your pain. On my 2017 Sportsman 450. Had to do Front diff rebuild (all the seals, new sprag clutch, bearings, rollers, front pin bearing, pinion pin and bushing), front and rear hub bearings, all three brakes, front lower ball joints, front inner and outer tie rod ends. Don't ever try to change driveshaft U-joints on these. Just replace the shaft.
Metal worker here, when cutting metal stock best to use a portable band saw, expensive to buy but you may know someone who owns one. Also sawzall blades just don’t hold up at that speed and I have had no luck with the specialty blades either, but if you are going to use a sawzall recommend the Milwaukee torch metal blades 16TPI.
I just picked up a 2001 can am ds 90 for free guy said he was done trying to get it to run so it sat 4 years went through all the basic steps you show in your videos and she runs like a top..(just needed a carb clean and new fuel lines/filter) score!
this guys a pretty good wrench really, does it the hard way sometimes but gets it done, for xmas have santa bring you a portable impact, portable 3/8ths radial and non radial, you can get in almost anywhere once you have all the attachments and universal adapters.. makes it so much easier, its nice to have one for sockets then one for allens one for screw driver tips so forth, have all sizes on adapters ready to go on either of the 3-4 portables you have, use a small rolling work bench to wheel everything around on, a few magnetic bolt/parts pans, then a mechanics chair, the round seat air/oil rides are nice.. BOOM! let the tools do the heavy lifting you will improve work turnaround times 50% easy, specially when you know every tool you need for the job put em all on the rolling bench and go...
No doubt. The Diablo carbide are what we use to cut the hardened strikers on punch presses at work when the operator crashes them. They are expensive, but for sure the best.
Those gears do not sound happy turning them by hand. If they do go out soon, you'll have to re-thread every one of the bolt holes where you used red loctite into aluminum. Maxima assembly grease would have been a much better choice on those axle splines. It dissolves into petroleum oils where anti-seize has small metal particles in it that will cause premature wear. I'd expect that front diff to whine fairly loud, though. Dont think I've ever seen one without some kind of seal or at least some sealant between the halves. Hope it works out.
That front diff is done for. I was cringing when I heard the noise after he got the cases together. Then "They float in oil..." Then when it has oil in it diff the gears sound the same but we will just skip that part. I fix atvs on the side and questioned how he got projects done so quickly compaired to people like me. Thought maybe it was video editing but... I cant aford a customer calling and saying "You know that front diff that you just fixed? Well it locked up!"
@@jerrywilcox9890so true! Joe's finances are his business. Joe has shown he's not only an excellent mechanic, but knows how to wheel and deal as well. These things, along with Vinny get the job done!
For the video it's whatever but I just hope he's still always going over to his parents as much as he did when he went to test out machines. I don't want his momma to miss him
I don’t miss it, but I enjoyed it and it’s what made me sub. I remember thinking this kid really wants to be on TH-cam. I’m so pleasantly surprised that his channel has turned into this. It’s inspiring really.
Excellent! Love your channel man . I was working on a Yamaha badger transmission so I scrolled your list but see that you never done one, need to do a video on that buddy. You’re damn good at what you do man. This is so so valuable for helping folks figure out and fix there toys. Love it
I loved the slightly older 400cc 2t Xplorer and Scrambler's, those things were utterly fantastic looking back. I had a 98 400 Xplorer and me and my 3 friends went to the Hatfield and McCoy trails in WV for a weeks worth of riding....it poured the entire week, everyone there, including my friends on other quads, both 4x4 and rwd, side by sides, dirt bikes.... everyone was slipping, getting stuck in the sloppy azz clay..... I just flew around with absolutely zero problems. I didn't really care for it so much before that, was always into more high performance 2t's (had Banshees and CR and ATC250R's and 500's ECT) and had picked that thing up pretty cheap, never rode it anywhere where it would even potentially get stuck, so I never really understood how great it actually was.... I mean, that seat was so comfortable, the brakes would work all 4 wheels at once, oil injection (trash, but it actually worked lol), didn't have to shift(I like shifting, but it was cool not to), had reverse, and hi and lo AWD.... I really need to find another 😅
that brand of 271 is not bad ... I use it in my motors all the time for stuff like chain guides, transmission arms, cam sprocket bolts, etc. and it breaks free with just a small impact gun ... it's the 272 high heat that might cause a problem ...
With all fixed up again. If you we're to get those plastic side covers for now. It would bring you between $4000.00 to $6000.00 by doing that to cause it looks to be in mint condition to.
Hey Joe....i have a 1999 Yamaha Grizzly 600.I just bought a KFI winch mount and the winch kit.I wish you would do a total new winch istall video and i am just wondering where and how to rout the wire harness....switch and stuff like that.Im sure there are many who also like to see a install on new system.Your vid are great and always good content.Keep doin what you do....Thanks
Big mistake of putting Red Loc-Tite on bolts threading into Aluminum. If you have to take them back out for any reason, you will most likely pull the threads out of the aluminum unless you heat the bolts and the aluminum to atleast 500*F.
Needle nose vise grips, may think about the other style of vise grips. A welder. Weld a nut on to the broken bolt. And remove. A small torch to heat up stubborn bolts aswell. The tool area looks thin. Upgrades in the future. I'll bet. Gotten a night mare for those who run into same type situation for front axle.
I owned a couple of Polaris ATV busting axles or cv joints alll the time finally got. tired of it and bought Yamaha Grizzly ate's no baad axles yet, btw I drive in snow a lot.
Regular maintenance should probably NOT be to disassemble your CV axles every 'couple' of years to replace the anti-seize in them. That's ridiculous if you ask me. WTH.
🎉🎉🎉 Excellent job saving that case on that front diff there Joe Joe 😉😉😉. Told ya it was a lot of work but you got it done and saved you a lot of $$$ in the process 🍻🍻🍻
I know it is overkill, but when I work on atv's I anti-seize all the bolts that do not require a specific torque value. Especially the ones in aluminum.
Great job bring that POS back to life You had me rolling when you vinne is going for a ride first thing I thought was is this jersey and that means it's a one way ride
Could the blade have been set 1mm away from the aluminum gearbox case? Just wondering I could not see but it appears the blade started to cut into the case.
You have far more patience (not to mention knowledge) than I would have. Good going, although I think this will be a continual tinker 😱Vinny says "get me off of this death trap, I don't have a helmet"
Good job brother I forgot that maybe you might have forgot about the bolt but anyhow do you want to sell that thing let me know I don't need no snow plow on it
Nice work as always buddy, all this could have been avoided if Polaris just put seals around those ends to stop water ingress and eventually rust siezing the ends in...32:05 Brake checking Vin, nearly resulted in a tail ender 🤣
Fixing other people stuff always fun especially when they throw it a side and leave it sit n sit for years when you get it you got spent thousand bucks in to it to make it run or functional
Do you ever sleep! Dudes been cranking out an amazing amount of videos. I love it! Keep up the great work!
Joe, I am sure you already know this but a reminder doesn't hurt. Please be careful when you spill antifreeze because it is deadly to dogs, and we all love Vinny. Bill H from Cranberry Township PA
Nice repair. That wheeler was born in my town! Couple things, never use red loctite on those diff cover bolts. Second, rather than anti-seize, use marine moly grease on those splines. If you drive through water or run in snow, the anti-seize will wash out and they will rust again. The grease stays in much better. If it’s hard shifting at idle you need to replace the primary clutch spring. Finally, either the muffler is burned out or the “donut” seals in the exhaust are blown out. Also could be that the springs at the joints stretched and relaxed over time. Keep up the good work! 27 year Polaris mechanic, former test driver and development tech.👍🏻
Why would anyone buy a Polaris quad. After seeing him revive many. The quality and engineering is piss poor. What a nightmare!
I am a retired auto mechanic/engineer and I can't believe how hard it was to get the axle shaft out. The load to install and remove the shaft is due to the clip and the shape/size. That is part of design and i agree 100 percent poor design and or quality. Why such a high force required to remove it? No good reason.
I was glad to see Joe was able to cut thru with a Sawxall, a portable bandsaw might have worked better. I bet he went thru lots of blades 😊.@dpl2617
Had to laugh when you pulled that tiny tree out with the ATV. 🤣
im surprised you never heated it up before trying to knock the shaft out!
Glad it wasn't just me sitting here thinking, why didn't he just heat the diff up with a blow torch and knock it out with a lump hammer?
Knocking on that axle just made it become thicker. My opinion would have been to press it out! Your videos are very nicely built as are your projects. Well done!!
You need to get some brass drifts to keep from mushrooming what you are hammering on.
Didnt look like you installed a gasket on the dif cases, these also help with ring and pinion backlash. The gears sounded very tight when turned by hand. To adjust backlash it is the copper ring size, and case gasket , some manufacturers use case shims also. If that lash is to tight it wont last for to long. Good luck and keep wrenching.
It looked like there was a o ring around one of the case halves
More and more great stuff. Just had my hip replacement done. I have time now to go back and watch from the start.
Love your knowledge and expertise when figuring out these machines and fixing them, please don't take this the wrong way but as a retired mechanic myself my OCD kicks in watching you working on these ATV's when you don't clean the parts thoroughly enough before reassembling them, don't you have solvent tank with a brush? Personally I would always pressure wash everything before disassembly and always clean and even paint the parts like cases etc before putting new parts in them, it looks better and cleaner and they look like new after your done. But like I said thats my OCD kicking in. Plus it makes it easier to see if there are any leaks and just looks better when everything is said and done. Otherwise good job and enjoy watching you diagnose and repair these machines.
Yeah, bothers me too. I am anal retentive when I do jobs like this. I usually soda blast cases and zinc plate all the bolts again.
I feel your pain. On my 2017 Sportsman 450. Had to do Front diff rebuild (all the seals, new sprag clutch, bearings, rollers, front pin bearing, pinion pin and bushing), front and rear hub bearings, all three brakes, front lower ball joints, front inner and outer tie rod ends. Don't ever try to change driveshaft U-joints on these. Just replace the shaft.
Joe, can you explain to us why you refuse to or don't use heat when you have a sticky bolt? Thanks for the great content.
I don't think he knows how! After watching tons of his videos he could have saved hours of time if he just used heat!
Or a service manual.
@@Dono743670777Heat wouldn't get those axle shafts out of the differential. I would be curious what service manual said about this ....
Metal worker here, when cutting metal stock best to use a portable band saw, expensive to buy but you may know someone who owns one. Also sawzall blades just don’t hold up at that speed and I have had no luck with the specialty blades either, but if you are going to use a sawzall recommend the Milwaukee torch metal blades 16TPI.
I doubt he cares lol, he doesn’t listen much to others, but this is excellent advice that I myself will be taking for the future!
Harbor Freight has a great one for a decent price
I just picked up a 2001 can am ds 90 for free guy said he was done trying to get it to run so it sat 4 years went through all the basic steps you show in your videos and she runs like a top..(just needed a carb clean and new fuel lines/filter) score!
Many hours working on it equals to many hours viewed hopefully the views paid for it all.👍👍👍😁
22:53 That noise will tell us that the gear is not happy. Seems that the are shims missing. This definitely won't last long.
Looks like Vinnie is your new "branch manager"! Great video, glad you got this rig fixed! Thanks Joe!
You have more patience than me, my friend. That would have become a 2-wheel drive trail machine, or parts machine long ago if it were mine. Well done.
Ok I have to ask !what happens to the ones you don't get fixed we never see the final fix .Like the gold wing and many others?
I’ve often thought the same
How many are kept/ sold etc
Just out of curiosity of course 🙏🏻😀
That was a friggin battle dude. Well done, wish I had your troubleshooting skills.
Good job Joe.
this guys a pretty good wrench really, does it the hard way sometimes but gets it done, for xmas have santa bring you a portable impact, portable 3/8ths radial and non radial, you can get in almost anywhere once you have all the attachments and universal adapters.. makes it so much easier, its nice to have one for sockets then one for allens one for screw driver tips so forth, have all sizes on adapters ready to go on either of the 3-4 portables you have, use a small rolling work bench to wheel everything around on, a few magnetic bolt/parts pans, then a mechanics chair, the round seat air/oil rides are nice.. BOOM! let the tools do the heavy lifting you will improve work turnaround times 50% easy, specially when you know every tool you need for the job put em all on the rolling bench and go...
Look into diablo saw blades. I prefer them personally they seem to cut throw most anything and at a fairly quick rate
No doubt. The Diablo carbide are what we use to cut the hardened strikers on punch presses at work when the operator crashes them. They are expensive, but for sure the best.
They’re my go to.
This guy is ace at fixing things mist would just walk away from
Vinny says, "im fast AF boyee" 😂😂
Vinny just loves that quad!! Nice job!!
Those gears do not sound happy turning them by hand. If they do go out soon, you'll have to re-thread every one of the bolt holes where you used red loctite into aluminum. Maxima assembly grease would have been a much better choice on those axle splines. It dissolves into petroleum oils where anti-seize has small metal particles in it that will cause premature wear. I'd expect that front diff to whine fairly loud, though. Dont think I've ever seen one without some kind of seal or at least some sealant between the halves. Hope it works out.
That front diff is done for. I was cringing when I heard the noise after he got the cases together. Then "They float in oil..." Then when it has oil in it diff the gears sound the same but we will just skip that part. I fix atvs on the side and questioned how he got projects done so quickly compaired to people like me. Thought maybe it was video editing but... I cant aford a customer calling and saying "You know that front diff that you just fixed? Well it locked up!"
I’d be interested in what machines you sell and keep it would add a new component to your videos Joe
Know one's business really.
@@jerrywilcox9890so true! Joe's finances are his business.
Joe has shown he's not only an excellent mechanic, but knows how to wheel and deal as well.
These things, along with Vinny get the job done!
I’m surprised Vinny hangs around the garage @6:47 my dog Ringo hates when I make loud noises in the garage, good work on the Polaris so far!
I miss the days of the old speed runs at the parents house ! 😂
Same, miss a little tinkering and his brother Charlie wearing flip-flops popping wheelies
For the video it's whatever but I just hope he's still always going over to his parents as much as he did when he went to test out machines. I don't want his momma to miss him
I don’t miss it, but I enjoyed it and it’s what made me sub. I remember thinking this kid really wants to be on TH-cam. I’m so pleasantly surprised that his channel has turned into this. It’s inspiring really.
Excellent! Love your channel man . I was working on a Yamaha badger transmission so I scrolled your list but see that you never done one, need to do a video on that buddy. You’re damn good at what you do man. This is so so valuable for helping folks figure out and fix there toys. Love it
If he ever buys one that needs the transmission done he probably will.
Enjoy all your videos. Really. Cup of coffee and learn so much. Very happy for you when you win!
Great video, not sure if you noticed though but the speedo wasn't working.
Kudos to those Milwaukee blades, but you should have used a cutoff blade on an angle grinder, it would have been way way faster and easier.
I loved the slightly older 400cc 2t Xplorer and Scrambler's, those things were utterly fantastic looking back. I had a 98 400 Xplorer and me and my 3 friends went to the Hatfield and McCoy trails in WV for a weeks worth of riding....it poured the entire week, everyone there, including my friends on other quads, both 4x4 and rwd, side by sides, dirt bikes.... everyone was slipping, getting stuck in the sloppy azz clay..... I just flew around with absolutely zero problems. I didn't really care for it so much before that, was always into more high performance 2t's (had Banshees and CR and ATC250R's and 500's ECT) and had picked that thing up pretty cheap, never rode it anywhere where it would even potentially get stuck, so I never really understood how great it actually was.... I mean, that seat was so comfortable, the brakes would work all 4 wheels at once, oil injection (trash, but it actually worked lol), didn't have to shift(I like shifting, but it was cool not to), had reverse, and hi and lo AWD.... I really need to find another 😅
hey Joe. it would be nice to see a video from you on what to look for when buying a quad.
Man that blade has paid for itself twice over lol awesome video man! As usual
you need to invest in a torch heat works wonders on taking things apart
Great job, would a metabo with cutting disc have worked other than the Sawzall?
Fun watch but 271 on bolts? Yikes! Will be extra fun to break down next time!😁
that brand of 271 is not bad ... I use it in my motors all the time for stuff like chain guides, transmission arms, cam sprocket bolts, etc. and it breaks free with just a small impact gun ... it's the 272 high heat that might cause a problem ...
With all fixed up again. If you we're to get those plastic side covers for now. It would bring you between $4000.00 to $6000.00 by doing that to cause it looks to be in mint condition to.
Vinny is hilarious! Nice work on that work horse.
Man that’s the perfect piece to weld a nut on the bolt and turn it out once you put a lil heat to it
You did it Joe !! 🎊🎊. But please don't baja around with the plow.
Joe you continue to be the man inspiring all of us. Always enjoy the videos... keep up the great work!
Invest in a table vice will help hold things while you need to pound on them. just bit of advice wish I had a table and vice lol
I don’t think a 2vintage video is complete without a piano keys text alert
Agree! 👍
And atleast one Facebook messenger *”ding”*
True that
That's just jade messaging him what she wants him to make her for supper when she gets home from work 😂
Hey Joe....i have a 1999 Yamaha Grizzly 600.I just bought a KFI winch mount and the winch kit.I wish you would do a total new winch istall video and i am just wondering where and how to rout the wire harness....switch and stuff like that.Im sure there are many who also like to see a install on new system.Your vid are great and always good content.Keep doin what you do....Thanks
Big mistake of putting Red Loc-Tite on bolts threading into Aluminum. If you have to take them back out for any reason, you will most likely pull the threads out of the aluminum unless you heat the bolts and the aluminum to atleast 500*F.
When I watched Joe use 271!😮 242 would work just fine!
Yo Joe 32.38 in see the Christmas tree sorted ? Vinnie's a live wire hey well done on the refit
Glad its done for u. Someone will enjoy it I’m sure if not u will
Dry ice works great too.
Use never seize on spline shafts liberally for future removal also. On inside.of spline shaft tube.
. Good luck.
Joe is so persistent that he usually succeeds in the end. 👍 Now he just needs some snow to plow, and for Vinnie to run around in :-)
Needle nose vise grips, may think about the other style of vise grips. A welder. Weld a nut on to the broken bolt. And remove. A small torch to heat up stubborn bolts aswell. The tool area looks thin. Upgrades in the future. I'll bet. Gotten a night mare for those who run into same type situation for front axle.
Nice Work! Really enjoy watching your videos. Have you ever used Diablo blades. I have found they cut much better.
been lolking forward to this one, enjoyed the outcome, tip on removing studs and snapped bolts, mig a nut on top heat helps turn it out
I owned a couple of Polaris ATV busting axles or cv joints alll the time finally got. tired of it and bought Yamaha Grizzly ate's no baad axles yet, btw I drive in snow a lot.
Regular maintenance should probably NOT be to disassemble your CV axles every 'couple' of years to replace the anti-seize in them. That's ridiculous if you ask me. WTH.
Must have been in water and road saly. I think next time you should slow down the saw and use a cutting fluid. Might have saved a blade. Great job.
🎉🎉🎉 Excellent job saving that case on that front diff there Joe Joe 😉😉😉. Told ya it was a lot of work but you got it done and saved you a lot of $$$ in the process 🍻🍻🍻
I know it is overkill, but when I work on atv's I anti-seize all the bolts that do not require a specific torque value. Especially the ones in aluminum.
That's not over kill. That'll save you ALOT of time in the future
Excellent content Joe, but got to love Vinnie helping you out.
Great job bring that POS back to life
You had me rolling when you vinne is going for a ride first thing I thought was is this jersey and that means it's a one way ride
Good job dude. Way to hang in there. 😊❤
Tie rod tool might be the best way to pry it out.
Could the blade have been set 1mm away from the aluminum gearbox case? Just wondering I could not see but it appears the blade started to cut into the case.
Great job joe!!🇺🇸
big job mate well done.
Man I've never seen anyone struggle with those as much as you have 😅
You have far more patience (not to mention knowledge) than I would have. Good going, although I think this will be a continual tinker
😱Vinny says "get me off of this death trap, I don't have a helmet"
Worth the effort !! Winter's coming.👍
Good job brother I forgot that maybe you might have forgot about the bolt but anyhow do you want to sell that thing let me know I don't need no snow plow on it
I was wondering if you forgot to grease the splines or if you dont usually do that?
Nice work as always buddy, all this could have been avoided if Polaris just put seals around those ends to stop water ingress and eventually rust siezing the ends in...32:05 Brake checking Vin, nearly resulted in a tail ender 🤣
Nice! This one was a journey.
27:35.. No anti-seize for the outer splines, then?
Okay Joe I have to ask why you have a trail through your yard and then the pieces that are not cut😊 is it like that for a reason
Vinnie must run on battery's. He had a work out in the test run.
He runs on a healthy dose of adhd 😂
You should do a video on sleds this winter
Thanks for the video, save my Friday👍👍
Is that a diff or a hammermill for grinding animal feed ?
Man a heat wrench woll do it .i use it on heavy corroded marine stuff all the time .
The sawzall and the claw hammer to the diff 😂😂
I know it may sound crazy but if you cut at a slower RPM it will cut faster and not burn the blade
I’ve use a ball joint separator for this before
you should get some muscle sleds this winter
Just one more reason for me to resist ever buying a Polaris, that was ridiculous!
You need a couple of Ball Pean Hammers !
Vinny loves testing the bikes.
Fixing other people stuff always fun especially when they throw it a side and leave it sit n sit for years when you get it you got spent thousand bucks in to it to make it run or functional
The part of the video where you're hitting the axle with a hammer reminding me of the monkey with the tambourines
Damn Vinnie I have said it before I am terrified that dog is gonna get ran over. Thank God he is alright.
From watching this channel it seems to me that working on Polaris machines is a huge pain in the ass.
That’s exactly what I was going to say.
Next time you have to cut a axle try a grinder with a cut off wheel or you can invest in a band saw. FYI
What gear oil/transmission fluid do you use for Polaris sxs’s?
is it me, or does it sound growly when he is moving the input shaft by hand?
I love these old quads. These, the old Hondas etc.
I would not have paid that much for it but nice project.
Well done my friend 👍👍
Would have been nice of you to reroute the winch cables, but good video.
Well done, the hours you put in is worth it, plus we love it 👍👏🏻👏🏻👏🏻👏🏻