 Let me show you what this bad boy can do. Hey guys, welcome back to the titanium man garage and I finally got to the point where I got this 6x6 Polaris Projects all done. I got the bugs all worked out and let me tell you there was a lot of them. Actually I'm so excited right now, I must have spent like anywhere from 10 to 15 hours bleeding the brakes then. I'm gonna crack a beer. I'm not excited right now but yeah there was some major issues, the shifter was bad. There was a couple springs in here, actually there's two of them, they're still laying down here. They weren't in the right spot, this thing was filled with water. So that was telling me probably in the wintertime it probably froze and the guy probably couldn't shift it. I'm jamming on the transmission, the shifter, carburetor was bad. So I just replaced the carb with a brand new carb, both master cylinders were bad. This was all rusted tight so I replaced the master cylinder and the handbrake, got it off of Ebay, the other side I robbed from another four wheeler. The calipers were seized, well this rear caliper was a pain in my butt, it had a bunch of rust around it. I thought it was rusted tight, I ended up taking it off and using a seat clamp pushing the piston back, managed to get everything loose. The normal guy when I took this thing and parted it out, it got so bad that I had to take a guitar wire and shove it through the brake lines because there was so much crap stuck in there that it was plugging up the lines. So yeah, let me do a little walkthrough, show you everything I did. The first thing I did when I bought this thing was I threw a brand new battery in it, wanted to test the starter, tried to kick it over and I got nothing. The starter, the solenoid, was all rusty and corroded, I ended up having to replace it. I didn't have one on hand at the time so I ended up trying to pull-starting it. Well, I took the pull-start, pulled-started it, it fired right up, I'm like, sweet! I put an auxiliary gas tank on because I didn't trust the gas that was in there, it was all brown and nasty smelling, so just hung an auxiliary tank to the carburetor, I'm like, great, I got this thing running. Well, didn't end up the way I wanted it to. So I drove it around a little bit, it started spitting, sputtering and bugging out, so I thought it was the carb at first and the carb was kind of nasty looking and needed to get replaced so I replaced the carb through an HO carb on there, that's what was supposed to be on there. I think the guy had replaced the carb at one point and put a non-HO carb on it or he replaced the plastics, I don't know, it's just 500 HO sportsman, 6x6. So I could still drive it, low RPMs, it would roll fine, but if I tried to give her gas she would spit and sputter, so I'm like, alright, maybe it needs a carb clean and squeezed the hand lever, I noticed the brakes, there were no brakes and then when I shifted from forward to reverse, I noticed the shifter was really wonky. So I took the shifter, I hope you guys can see that, I had a pull in the part, you guys seen this taken apart before, there's a couple springs in here, actually there's two of them, they're still laying down here, they weren't in the right spot, this thing was filled with water, so that was telling me probably in the wintertime it probably froze and the guy probably couldn't shift it, it was probably like a slurpee, you know, all that slushy, frozen crap in there from jamming on the transmission, it wrecked the shifter and it also made the shifter lever on the transmission a little sloppy, so I replaced the shifter, got the correct one, I got that working good, she shifts like she should. So then I got my starter relay hooked up, got all my wires cleaned, fired it up and all of a sudden I hear grain, grain, grain, turns out it was the bendex gear for the starter that was right behind here, I know a lot of people they hear grinding noises, it's not necessarily the engine, a lot of times it could be the clutch rattling, other times it would be the bendex gear, the bendex gear I had, poof there it is, the bendex gear I had, the gears were all ground, this would not go back in, spring is shot, so lucky for me I had a couple bendex gears laying around through that end and noise went away, I'm like great, took her for a drive and it died, I'm like okay what's going on here, so I pulled the wires off of the run stop kill switch and they were pretty green and corroded so I ended up cutting and splicing or rewiring them and also replaced the run stop kill switch and that solved a lot of my problems, started running smooth and then I got a one spark no spark issue, so immediately I pulled the black wire on the CDI, most guys would have took one look at this thing and probably parted it out, but I'm the type of guy where I'm gonna take this thing apart, bit by bit and put it all back together, get it running good, bring another one back to life, I believe this is number 60 for me, so what I got going on is I got a one spark no spark issue and I've been going through the wires, if you've seen my previous video, I had to splice these wires in, they were green, I cleaned the wires coming to here and now I'm working on the grounds, so as you can see this is all rusted and corroded, this is where the grounds go, I should really replace this thing, but I'm gonna try to clean it up, whoever had this thing must have left it outside because it's getting kind of rusty, so I just got to go through all the wires, the terminals, the grounds, I did get it to pop and fire, now I have a one spark no spark issue and I'll show you what I mean by that, okay so I got the grounds loose, pulling out the coil, the spark plug, I should really replace this, I mean this is all pretty rusty, it still does work, when you get a one spark no spark issue the coil is working, so I'm gonna just try to clean it up, get all the rust off of here and so it gives it a good contact for ground, clean this up, most of my terminals are kind of crusty and corroded, usually when you get a one spark no spark issue, usually it has to do with the CDI or the run stop kill switch, well I rewired everything up to the run stop kill switch and I put a new switch in, now down to the coil, this wire down here is pretty corroded, I'm gonna clean that up, I think it's just a lot of corrosion going on and as I'm cleaning things up I'm trying to start this thing, other things are popping because you know it's kind of like chasing gremlins, you know I get one thing fixed and it's groaning out up here and it's working like it should and it's power going through it like it should and then all of a sudden well this is corroded, well that's not working right so just kind of going through cleaning everything up, I'm banking that CDI is probably bad and I'll show you how I figured that out, now if you guys don't know what the CDI box is I'm gonna try to get you in here, it was right here, it's black box, it has a black wire going up to this plug right here and that goes to your kill switch, run stop kill switch, you also have everything else, you got your ground, you got power going everything else, I'm not gonna go in detail with this whole thing does but basically this was all corroded and that goes to the kill switch so I'm thinking that could be part of my problem and I'll show you why, alright so I'll show you what I mean by a no spark issue, so one spark, no spark is usually something has to do with your CDI so I pull the spark plug out, put it back in the boot and see, got the key turned on, now that's a spark plug, probably not a spark once, you got to put it out of your own, if you saw that, put somewhere where you can see it, only a spark once now when you come over here is your CDI, it's your black wire coming up, you're gonna unplug that, I need two hands to do that so there you go, black wire is unplugged, okay so now unplug the black wire and we're gonna try this one more time and I got the fan height hot wire that's what you're hearing, if that's just somewhere, I should get spark, so I got constant spark, that tells me there's an issue with the CDI, I figured that out first while I was checking my ground wires, I just cleaned the ground wires, I pulled the plug, got a no spark issue, cleaned my grounds, put it back together, so that tells me that that is not the spark plug coil, it means that's still good because once I disconnected the black wire it kept sparking, so the CDI kind of tells the spark plug wouldn't spark, I'm gonna have to replace that but for now I can leave it unplugged and if you're lucky sometimes it'll run and shut off with that black wire unplugged, sometimes you have to plug the black wire back in to shut it off so it acts like a kill switch, so I guess I'll find out if I need to do that. Alright guys let me show you what this thing can do, I got it rewired, I got the new carb on, I end up buying an aftermarket carb, you can hear this bad boy fire up and I got the shifter working good, shift sling it should, I got to test that out, the gas tank was hooked up a little auxiliary tank, it's going straight into the carb, bypasses any tank or fuel pump issues so I know it's not that, so if I do hook up the fuel pump later on in a fuel tank I'll know what it is, they hooked up the black wire, acted like a kill switch and shut it down, now the CDI is down here it controls your spark, there's a black wire right here going up to the kill switch, a lot of times if you unplug that and you got the one spark no spark issue, if you unplug that it disables the kill switch and you'll get spark constantly, so I did that, got spark constantly, fired it up, she ran good, I came up with a little trick I want to show you guys, so for my subscribers across the world, Australia, Germany, all you guys that can't get parts I'm gonna show you a quick fix that I came up with if you got a bad CDI, so your box is down here, a black box, so black wire running up, let me disconnect it, so a lot of times if you disconnect this it'll start and run but you won't be able to shut it off, the only way to shut the four-wheeler off is to plug this black wire from the CDI back to the switch, if you watch my channel you know me I like to come up with interesting ways to fix problems, what I ended up doing was I took a toggle switch and you got your terminals here, I hooked up the lead, the terminal, I hooked this side to here and this side to the kill switch, so now when I want to start it, I'll hit on, I'll turn the key, hit the start button, she'll fire up, when I want to turn off, I turn the key off it'll still stay running and it'll flip the switch and that'll kill the motor, it's kind of like an auxiliary kill switch, what I did I did this to one other six-wheeler, I could not get it to work right and I even replaced the CDI, I had another issue, so when I went to sell it I said it was a anti-theft device, nobody knows how to start it, you turn the key it won't start, flip the on, she starts, so I worked out pretty slick but so I had hooked this up and in the process I ended up cleaning all of the the terminals by doing it, this was kind of rusty and corroded in here, I thought it was gone, I thought it was a goner, I couldn't clean it up, all of a sudden I go plug the black wire to the CDI to the kill switch and what do you know what, all of a sudden she starts up and she stops, so sometimes it's just a little corrosion on your terminals and your connections and sometimes that's all it takes, this thing must have been sitting for a while because the carb was pretty caked up, couldn't get a cleaned up decent, saw my issue with the the jet not being able to come out, so I got brand new carb, so I've got a lot of questions about this, you know and people ask you know why will my four-wheeler bog out or why won't it start, a couple issues are your fuel lines, when they're about 20 years old they get really soft, well this is a vacuum operated carb with a vacuum operated fuel pump, when it's vacuum operated it's sucking in gas and pushing it out and your lines could collapse, well these are pretty soft so I'm not going to take a brand new carb and use old fuel lines because to me that's just like you know pouring dirt right into your carb, you know they get soft and this one's actually really brittle, you could get little pieces of hose, dirt, old gas, I even contemplating replacing that fuel pump only because I ended up having to clean out the gas tank and that thing was nasty, I got it sitting over here, I had drained all the old gas out it was actually brawl when it poured out and what I ended up doing was I took the fittings off the bottom, I just got this on here temporarily just for cleaning purposes and I cleaned out the tank, what I ended up using was, you know what did I use, I used a heavy-duty degreaser, it's actually used for pressure washer, I poured that in the tank, switched it around let it soak for a little bit, poured it out, did it about three or four times and then that does kind of leave like a soapy bubbly residue so I ended up taking some old gas that's not not the brawl and stuff but some older gas from another four wheel I just threw back in the tank, switched it around, cleaned everything out, I took my fittings off the bottom here because there are screens in here and I blew them all out, they were all full of crap, I could only imagine what my fuel lines look like, I got myself some brand new fuel line, I went with the high pressure, it was a little more expensive only because I wanted it to last so this is about nine feet and I paid about 40 bucks for it so I'm gonna go ahead and replace those fuel lines, I'm gonna try to blow air through the pulse pump, make sure it pulses and make sure everything works correctly, put the clean gas tank on, gonna check that fuel filter because sometimes those get plugged as well, also keep in mind too where are they here, I got them laying here, I don't even know why they put this filter on here because that gets plugged up and if that gets plugged up it's gonna make your four wheeler run rough, so like I said I'm kind of going through everything I'm gonna just replace the hoses, do everything right and I want to make sure this thing runs good for a long time, I got a nice clean carb, let's put all brand new fuel lines in, what's that? I don't see anything, there's nothing there, well I'll finish showing you the rest of what I did and last but least like I said I had the brake issues, this was all rusted tight so I replaced the master cylinder and the handbrake, got it off of eBay, the other side I robbed from another four wheeler, I went to bleed the brakes and they were still pretty soft and like I said earlier in the beginning the lines were all plugged up with crap and sometimes they do get water in the lines and they rust so I ran a guitar string through them so the reason it took longer like I said to bleed the brakes is because you got your front handbrake, your left that goes into the front brakes and also goes into the rear caliper and then you also have an independent right rear brake that goes straight to the caliper, well the issues I was having as I was getting the front brakes tight and then after it's sitting for a while the the brakes would feel all mushy. Well the rear caliper was a pain in my butt, it had a bunch of rust around it, I thought it was rusted tight, I ended up taking it off and using a seat clamp pushing the piston back, managed to get everything loose and I thought I was gonna break the bleeder screws because it was pretty rusty but I managed to crack them open and I got all the old fluid out of there, crank the bleeder tight, there's one up here and there's one down here, this is for the independent handbrake, this goes from the front brakes and to the rear as well so when you squeeze the left side it breaks both front and back at the same time so I managed to get that all out and then I was trying to get this one to work and I got real tight and it wasn't squeezing tight at all on the caliper so I ended up taking this line off thinking maybe there's some corrosion in there and nothing came out. The steel line that comes up here ended up to be having some crap stuck in it so I ran a guitar string through there got it unplugged and boom I got fluid out everywhere it was beautiful, all of a sudden they cracked the bleeder screws, blood the back caliper and the front's tightened up real good and when I squeeze when I squeeze the right hand independent brake that got really tight too so I'm like all right beautiful. I managed to get that blood, it was a pain in the butt because they bled the front brakes a couple times and I figured this back wasn't going to move at all so I did monkey with it but after I couldn't get the front brakes tight I'm like all right I gotta tackle this thing so I did clean it all up got it working and now sure works good so it is October and Halloween is coming up so I'd like to wish you guys a happy Halloween so here you go folks, total time invested probably somewhere around 50 hours said more labor than anything else so you just chalk it up as the labor of love make some cash off of it move on hope you enjoyed the video thanks for watching hope you liked the little Halloween trick my son played on me and like always till next time