1996 Polaris Scrambler 400 4x4

Discussion in 'Other Vehicle Builds' started by letitsnow, Sep 26, 2020.

  1. letitsnow

    letitsnow I'm Awesome

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    The 1st heat cycle is complete! It is always good to hear a motor run after having it apart!!

    I started it up at 7 am. Some people like to hang out with their neighbors. Me, I try to keep them just upset enough with me to leave me alone. It's all about balance...

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  2. thegawd

    thegawd I'm More Awesome!

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    what a neat set up! iv been following along, I have no idea about this machine but it's pretty cool how its built!
     
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  3. letitsnow

    letitsnow I'm Awesome

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    I went for a short test ride yesterday. Everything went well. I now have to take it back apart and check stuff over/start adjusting.

    The rear suspension worked great. The front worked well, but the rebound is too slow. The clutching seems to work nicely. For the motor being stock inside, it scoots pretty good. All in all, a success.

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  4. 454cid

    454cid Sooper Pooper

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    Okay now we need video :D
     
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  5. letitsnow

    letitsnow I'm Awesome

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    I'll have my wife take video at the races. That probably won't be until summer 2022 though...
     
  6. letitsnow

    letitsnow I'm Awesome

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    This afternoon I did some work on the front fenders. There were 3 things that I wanted to address.

    1. The front was riveted together. This made it tough to remove them.

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    I drilled the rivets out and will use zip ties to hold them together. The zip ties allow for flex while racing. If it was just a trail machine, I would have replaced the rivets with bolts.

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    2. When lifting the fender up (to remove) it would bind under the handlebar mounts and the gas filler neck. I cut a small part away so that there is more room.

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    This is what it looked like stock. You can see where it had been scratched up by the handlebar clamp over the years.

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    This part of the plastic is sandwiched by 2 plastic pieces that hold the ignition and choke, so it will still be plenty strong.

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  7. letitsnow

    letitsnow I'm Awesome

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    3. The machine came with a clear plastic gas tank, but you couldn't see the tank to check the fuel level. You had to remove the gas cap and look inside the tank. That works, but it is nice/faster to be able to see the level.

    I drilled 3/8" holes, 1" apart, so that you can see the level. I did this towards the front of the tank, trying not to mess with the plastic in the are that your knee/boot will be rubbing against. It looks like it will work nicely.

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  8. letitsnow

    letitsnow I'm Awesome

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    Last night I added some handlebars, clamp on grips, tether, and added a different start button. The oem start/headlight/rev override switch assembly was too bulky to allow for the width of bar that I like.

    I used a starter button that was in my misc wiring pile. No idea what it was from, but it seems like a quality piece.

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