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My RZR rebuild project

4.7K views 19 replies 6 participants last post by  Heapsofprojects  
#1 ·
My previous thread got deleted and I got banned for spamming which never was my intention but it got resolved thanks to admin. As I don´t have a copy of it I will just write again

So...I saw a FB ad where a guy was selling two RZR570, one was supposed to be running and the other one not. As I didn´t wanna spend much I ended up buying the non runner and took it as a fun project. The old owner didn´t really remember what was wrong with it exactly as it had been sitting for few years. We forklifted it on the trailer and I took it home:

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It was a bit rough, had been at least on its side and the seats were chewed by a dog or maybe mice. I don´t think it got much love at all during its 500 hours.
Firstly, I bought a new battery to see what is the problem with it. Put it on, turned it over for few seconds and it started up! I wasn´t prepared for it as I hadn´t even checked the fluids. Turned it off and discovered that there was not much oil left in the engine. Topped it up and took it for a spin. Everything seemed to work so I went and got the oil filter and oils for the diffs and replaced them all. Did few small laps around the farm and one weekend took it into the dunes:

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I don´t have many pictures of that but I do have a video on Youtube. I am afraid to post the link as that might trigger me as a spammer again :D but if you search for my user name you will find it.

I did notice there that the prop shaft was wobbly and there was a strange noise - turned out to be a bad universal and worn slip yoke splines so I turned the front wheel drive off to save it as much as I could (but still have some fun).
 
#2 ·
So a few days later I decided to pull the prop shaft off and see what is the problem there. It was not as easy as I thought it would be and one thing led to another...


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And I just couldn´t stop myself pulling the bits off :D

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I got to this point as I was just waiting for some parts for it from USA and thought I might as well give it a fresh coat of paint. I ordered new universals, slip yoke, wishbone bushes, ball joints, tie rods, and wheel bearings. The parts are slowly turning up so I will be busy soon.

I didn´t want to spray the paint over the rust so I got out the sandblaster and had about 3 hours of fun with it:

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I took about 200kg of sand and I got it fairly clean.
 

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#3 ·
As it was a nice day I just kept on going with the project:

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I didn´t really wanna paint it black again so I thought I´ll choose something more interesting. I know most of it will be covered by the plastics anyway but hey, I know itś there :D

The wishbones and other frame bits will be painted black again as I don´t want it to look too KTM.

The rear tub (or box) is broken beyond repair so I am looking for a second-hand one. New is about 900 Australian dollars which is bit too much for me. If I can´t find one I might look into building one myself as I am planning to build the doors anyway.
There is a video of the sandblasting and painting on youtube and again, I don´t wanna add the link but if you search my username you will find it.
Next steps will be painting all the bits and pieces and then start putting it back together :)
 
#8 ·
I am not too familiar with the 570 but there is a lot of good info on this Forum good luck!
 
#10 ·
As the seats were beyond repair in my RZR I was looking for second-hand ones. There was I guy on the other side of Australia who was willing to sell his for 100 bucks but the freight would have cost 600... So I ended up buying these together with the harness:
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I just don´t know how well they would fit in there and how easy will be getting in and out.
 
#11 ·
It's already been few weeks since the last post. I have been busy with some other things but still managed to get little bit done.
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Cleaning and painting the wishbones took sooo long. Wish I had sandblasted them but I just didn't feel like setting the blaster up again so I just kept on going.
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I had to repair the broken engine mount and put new bushings in the wishbones and I could finally start the puzzle.

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Now it is getting more interesting again as it is not far from being a roller again.

As before, moving picture is here:

 
#16 ·
Not too much to talk about really but little bit still:

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This is the passenger seat bracket I made. I was gonna use the base of the original seat but I found some cracks there so decided not to use it.

It is looking like something again. As you can see the passenger seat is just a bit lower because of the different brackets.

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And that's pretty well done, there will be some additions to it still which I will talk about when I get there :)
And the video of the last bit (with some skids and jumps):