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 Post subject: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Thu Feb 16, 2017 2:48 am 
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Hi guys,

Its been a while since I have been around. Work, weight loss (84lbs or so) kids, family plus other crap has had me away. So I thought I would give you guys a update on my long lost Joylaris project.

Last Jan or so I bought a Polaris Predator 500 motor with a 5 speed and reverse. Once I got it and had a chance to look at it, it had a dropped a valve that massively damaged the head and broke a hole in piston. I ended up buying a used head on eBay and had it shipped to Rick Ritter and had him clean it up, deck it and replaced the valves and guides. I also bought a new piston and had the cylinder honed. So between buying the motor ($400) head and head work ($200 +$275) and the new piston ($275) I now hopefully have fully functional 41+- hp motor.

As most of you know I have no metal fab skills so I have had to hire the work out. Well that has gone badly mostly. But I have good news. A friend of mines kid moved back from CA and together they have been working on it since last Friday. I am attaching some pics. I finally can see some real progress.

I ordered a new rear sprocket from Rebel Gears today. The buggy is a 530 43 tooth and the motor is a 520 so I ordered a 48 tooth and I am using a 13 tooth up front on the motor.

There is still much to do and I also need some help from my friends on here.

1. This Polaris motor has an oil tank. On the bike it was mounted just to the front of the motor. In the buggy the seat is in the way. I was wondering if it could be mounted up high out of the way. Papa Rich on his Joylaris had an oil cooler from his 500HO mounted by the left rear shock. I am thinking of something like that.

2. I need long clutch and throttle cables. Does any one know where they can be found?


Anywhoo take a look and give me your feedback.

Cheers, Bo


Attachments:
File comment: The original cradle was replaced with a large piece of 3/8" steel that the new motors mounts were welded onto.
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File comment: Front Motor Mount
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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Thu Feb 16, 2017 3:10 am 
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a few more...more to come


Attachments:
File comment: Me 80lbs + lighter
20170116_185549.jpg
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File comment: The motor fully mounted
20170215_151845_HDR.jpg
20170215_151845_HDR.jpg [ 746.22 KiB | Viewed 374 times ]

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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Thu Feb 16, 2017 7:33 am 
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Wow would not have recognized you, congrats.

As for throttle cable I got one from Buggyparts NW for my builds. I can't help you on the clutch cable, never built one with that. ( I am too lazy for a clutch according to Ghost) Looks like your friends are doing a nice job on that. You may actually get to ride that thing eventually.

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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Thu Feb 16, 2017 9:49 am 
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I run an ltz motor that's a dry sump with an oil tank and ran into the same issue. rather than change the height of the tank for fear of affecting the running oil level and ability of the pump to return the oil to a higher level, i used barbed brass fittings and some extra braided hydraulic line to lengthen the hose runs. With longer hoses I was able to bring the runs in behind the seat then turn them to mount the tank in the corner next to the seat.

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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Thu Feb 16, 2017 10:06 am 
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Papa Rich wrote:
Wow would not have recognized you, congrats.

As for throttle cable I got one from Buggyparts NW for my builds. I can't help you on the clutch cable, never built one with that. ( I am too lazy for a clutch according to Ghost) Looks like your friends are doing a nice job on that. You may actually get to ride that thing eventually.


Thanks man, It was starting to get tough to find pants and well my umm, umm so I had to do something.

The last time around I bought a slide carb cable from him...I totally forgot he might have a longer one. I will call him today. These guys are doing a really nice job. I have way more pics but will need to resize them to get them to fit on here.

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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Thu Feb 16, 2017 10:35 am 
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xbird wrote:
I run an ltz motor that's a dry sump with an oil tank and ran into the same issue. rather than change the height of the tank for fear of affecting the running oil level and ability of the pump to return the oil to a higher level, i used barbed brass fittings and some extra braided hydraulic line to lengthen the hose runs. With longer hoses I was able to bring the runs in behind the seat then turn them to mount the tank in the corner next to the seat.



I am not sure if I have enough room behind my sea for the oil cooler I have. It is kinda plump down on the bottom behind the seat. I have room up high on the buggy but thats about it.

@PapaRich

The oil cooler for your HO. Does it have 2 or 3 connections. I like how yours is mounted and not sure if I can use one of those. My cooler is plastic and has 2 lower connection and one upper connection. Do you know how much or how far the pump will push the oil.

Thanks gents :D :D :D


Attachments:
File comment: My oil sump
s-l225.jpg
s-l225.jpg [ 7.11 KiB | Viewed 359 times ]

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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Thu Feb 16, 2017 11:15 am 
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The 500 tanks have three connections, delivery, return and a vent hose at the top. I would keep it low if possible. I have had problems with them up high draining back down into the engine.

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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Thu Feb 16, 2017 8:19 pm 
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I have a firewall on my Joyner, maybe you can build one and mount the oil sump on the left behind the driver.

Greg

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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Thu Feb 16, 2017 8:44 pm 
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GMANLV wrote:
I have a firewall on my Joyner, maybe you can build one and mount the oil sump on the left behind the driver.

Greg

Yeah that will likely work. We are looking to put it in the back somewhere and running hoses up to it. We just needed to be sure if it was higher than the current location on the quad the pump would be able to push the oil up to. Certainly do not want to starve it for oil.

We are still looking for a solution for the clutch tho. I spent about and 1.5 hrs at a motorcycle salvage place here in town and no luck finding a match or a near match. Ugh...still looking though.

Thanks guys. I will post more pics once I figure out how to shrink them.

Cheers, Bo

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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Thu Feb 16, 2017 9:17 pm 
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Does the motor have the oem clutch cable? On my motors I use the oem cable and couple it to my input. The Joyner has an hydraulic pedal, with a cable connection from the slave cylinder to the clutch actuator arm and the single seat is all mechanical, consisting of 2 cables.

Greg

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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Fri Feb 17, 2017 1:17 am 
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GMANLV wrote:
Does the motor have the oem clutch cable? On my motors I use the oem cable and couple it to my input. The Joyner has an hydraulic pedal, with a cable connection from the slave cylinder to the clutch actuator arm and the single seat is all mechanical, consisting of 2 cables.

Greg



So the motor did not come with a clutch cable. The existing one was cut so off to eBay I go to buy a stock one only to find out its not the correct one. I will buy another but the issue is its about 6" short.

How did you connect the 2 together. I am attaching the some pics.


Attachments:
IMG_12871.jpg
IMG_12871.jpg [ 167.79 KiB | Viewed 301 times ]
IMG_12901.jpg
IMG_12901.jpg [ 145.98 KiB | Viewed 301 times ]

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Joyner Sand Viper - Joylaris wish...Maybe someday trying another swap.
Roketa GK-13b (work in progress)
06 Rhino- Machined Sheave, Trail Port/Polish Head and Progressive Rear Shocks (The Green Machine)
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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Fri Feb 17, 2017 2:30 am 
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I think the easiest would be to use the barrel type cable stops. You can find those at auto zone. It would require you to cut off the lead end. You could also drill a hole in a 3/8" or 1/2" bolt. I can post some example pics tomorrow.

Greg

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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Fri Feb 17, 2017 4:19 pm 
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GMANLV wrote:
I think the easiest would be to use the barrel type cable stops. You can find those at auto zone. It would require you to cut off the lead end. You could also drill a hole in a 3/8" or 1/2" bolt. I can post some example pics tomorrow.

Greg

please do...Thanks bud

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Joyner Sand Viper - Joylaris wish...Maybe someday trying another swap.
Roketa GK-13b (work in progress)
06 Rhino- Machined Sheave, Trail Port/Polish Head and Progressive Rear Shocks (The Green Machine)


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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Sat Feb 18, 2017 2:05 pm 
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Here are pictures of the shift linkage clutch cables and throttle using a barrel connector


Attachments:
IMG_0478.JPG
IMG_0478.JPG [ 1.98 MiB | Viewed 249 times ]
IMG_0500.JPG
IMG_0500.JPG [ 2.08 MiB | Viewed 249 times ]
IMG_0508.JPG
IMG_0508.JPG [ 1.51 MiB | Viewed 249 times ]

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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Sun Feb 19, 2017 3:20 pm 
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Hi Ac,the bracket and the lead tube on the end of the cable,looks like it came off an old Harley i use to own.You might try the Harley shop.Ghost

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 Post subject: Re: Phoenix Rising From The Ashes out In Mesa AZ
PostPosted: Sun Feb 19, 2017 3:45 pm 
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Ghosthunter wrote:
Hi Ac,the bracket and the lead tube on the end of the cable,looks like it came off an old Harley i use to own.You might try the Harley shop.Ghost

I thought the same thing. I have an older cable from my Sportster but it will not work.

I found a cable I think will work. I will post some pics later. Thx everybody.

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Joyner Sand Viper - Joylaris wish...Maybe someday trying another swap.
Roketa GK-13b (work in progress)
06 Rhino- Machined Sheave, Trail Port/Polish Head and Progressive Rear Shocks (The Green Machine)


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