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Old 08-26-2017, 09:22 PM   #1
Kneil
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Default Ezgo polaris sportsman build

Hi everyone, I used to be a member here but can't remember my info so I am starting a new account, I have my 1991 ez go with a yamaha 433 cc sled motor. It's been built for almost 10 years. And has been setting for the last 6 or so in its prime it was fun but never had reverse, I always wanted to build this cart but never got around to it I've had ninja zx6r motor and even a single cylinder yanmar I wanted to swap but never started any of them. I recently got a 2009 Polaris sportsman 300 to fix and make some money but it is just way to far gone,every bushing,bearing is gone. Needs stator. Axles etc... so here I am cutting it up.i want to use the front and rear on the cart with a Polaris trailboss 325 motor powering it all. My trailboss I got new in 99 but it needs a lot as well so it's donating the motor to this project. Here are some pics so far,I just started today and it will take some time but I'll try to document the whole thing here,let me no what you guys think. Good or bad
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Old 08-27-2017, 12:34 AM   #2
old_yamaha
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Default Re: Ezgo polaris sportsman build

nice! Looks like a hell of a good idea to me.
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Old 08-27-2017, 03:48 AM   #3
ironmonkey17
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Default Re: Ezgo polaris sportsman build

Nice 2 donor carts, are you planning on hooking the 4x4 up in the front, it will make one hell of a snow plow, that's if you get much snow in your area..
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Old 08-27-2017, 12:23 PM   #4
Kneil
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Default Re: Ezgo polaris sportsman build

Yes it is going to be push button 4x4. I get enough snow to need the plow but the way the weathers been the last few years I may not. I'm in Pennsylvania
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Old 08-27-2017, 01:52 PM   #5
Minnesota_Duane
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Default Re: Ezgo polaris sportsman build

My unfinished ATV front swap
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Old 08-27-2017, 04:53 PM   #6
Kneil
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Default Re: Ezgo polaris sportsman build

Made some progress today along way to go yet but I have every evening to work on it wile I have long days of light left
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Old 08-27-2017, 07:15 PM   #7
ironmonkey17
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Default Re: Ezgo polaris sportsman build

get as much done before the cold hits, I did my original swap in the winter, froze my a$$ off
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Old 08-28-2017, 08:58 PM   #8
Kneil
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Default Re: Ezgo polaris sportsman build

I'm back to square one already. Lol my original plan to mount the front end to the cart was an ok design but I came up with something better. I'll get some pictures as soon as it's welded up,I want to plow snow with the cart this winter and use it for hunting and just weekend play toy I have trails close to house to play on so it will get used once a day at least even if it's just to run to the store up the street,I live in a very small town lol
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Old 08-29-2017, 08:32 AM   #9
Unforgiven
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Default Re: Ezgo polaris sportsman build

Are you using the Polaris independent rear suspension?

I've had a lot of problems out of my Honda 350 rear with looseing left rear bearings. Thinking about rear IS out of a Rhino.
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Old 01-16-2019, 03:46 PM   #10
Drgyver
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Default Re: Ezgo polaris sportsman build

Kneil did u ever finish this build? I just came across a Sportsman 500 rolling chassis and was thinking of using the front end to give my Ezgo Workhorse 4wd Mostly wondering how you did the front driveshaft? Jackshaft to get power to other side? I want to keep my rear end and HF motor. Thanks..
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