The World Famous Bull Sessions

Show Us What You Are You Building? => Restorations => Topic started by: cloughrin on January 09, 2018, 08:31:23 pm

Title: 1977 Polaris TX 250
Post by: cloughrin on January 09, 2018, 08:31:23 pm
I am looking at cleaning / restoring my very first sled. I am new to this site and looking for help on different things as I go. The sled is in relatively good shape and ran when I put it away awhile back. I am going to go through the carbs and clean the tank first. I would like to sandblast the motor to give it that clean look. Any tips on doing this. How far does the motor need to be tore down to do this? Can I leave cylinders and heads on?  Some parts I am looking for, is the trim that goes on the edge of the hood around the handle bars along with the small pieces that go on the belly pan by the foot wells. Where can I order this? Anyone have repair / service manual for this sled? The hood needs some fiberglass work from stress cracks etc. (hoping a local shop can help with that) ,Or is there a reproduction hood that would be more cost beneficial? I am really looking for any tips, tricks, and techniques that anyone can suggest. Thanks
Title: Re: 1977 Polaris TX 250
Post by: Gilson435 on January 09, 2018, 08:45:24 pm
Welcome to the site!  8)
I would completely disassemble the engine if you're going to blast it and clean it VERY, VERY, thoroughly afterward. Also, prob wouldn't use sand... glass bead or something not so abrasive. 
Here is a link to a service manual
http://www.vintagesnow.com/Polaris_files/1972-1981_PolarisMasterRepair.pdf (http://www.vintagesnow.com/Polaris_files/1972-1981_PolarisMasterRepair.pdf)
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 09, 2018, 09:50:19 pm
Thank you for the link. I will print off what I need. I will talk with a few people on the glass beads. Anyone use crushed glass. We manufacture this product along with sand abrasives where I work.
Title: Re: 1977 Polaris TX 250
Post by: emrickmn on January 10, 2018, 03:19:03 am
Welcome to the site.
At Vintage Snowmobile Restoration, we kinda specialize in the 76 thru 79 TX sleds and have the parts you wrote about. Also, we have the hoods, pans, seat covers,etc. check our website at www.VintageSnowmobileRestoration.com (http://www.VintageSnowmobileRestoration.com)
Having restored dozens of those sleds, I'm happy to assist our customers with any questions and how to's as well.
P.S.  There are other ways to clean up your motor that are allot less risky than glass beads. Here's a 78 250 we did this summer
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 10, 2018, 06:23:25 pm
Thanks for the post. I will certainly take a look at the website. I have read on some of the other restorations you have completed and they look great. What are some of the other options as far as cleaning the motor goes?
Title: Re: 1977 Polaris TX 250
Post by: chris r on January 10, 2018, 07:05:42 pm
Thank you for the link. I will print off what I need. I will talk with a few people on the glass beads. Anyone use crushed glass. We manufacture this product along with sand abrasives where I work.

Welcome to the site. There are a lot of people who can help with most any project.

I wouldn't use sand on cast aluminum. Sand will rip open the pores and will leave more of a rough surface. I use glass beads on all of my cast aluminum projects. The glass seems to pound the pores shut and you will end up with a surface that will stay looking nice for a longer period of time. I'd image crushed glass would be similar to the beads, but haven't used them myself. Complete disassembly is what I do, wash with soap and water, and a very complete rinse with water.
Title: Re: 1977 Polaris TX 250
Post by: emrickmn on January 10, 2018, 07:55:21 pm
Thanks for the post. I will certainly take a look at the website. I have read on some of the other restorations you have completed and they look great. What are some of the other options as far as cleaning the motor goes?

The motor on the TX above was degreased, then completely disassembled.  All openings were masked off with Gorilla tape.  Then glass bead blasted.  Then rinsed and cleaned in ultra sonic.  Once dried, it was brushed with a wire wheel to get the shine.  During assembly, it was still full of sand / glass. 

As Chris said, rinsing is imperative when blasting with anything but I won't go that route again. 

Most of my restos were just degreased with brake cleaner and then wire wheeled.  No sand to screw up the cylinders.  This motor was just cleaned and brushed.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 10, 2018, 10:26:22 pm
What type of wire wheel is used to get inside the fins. When you say wire wheel I am thinking of something I have attached to a grinder and used to get rust or paint off of metal. Is this the type of the wire wheel you are talking about? Do you typically use a softer / fine wire wheel? Thanks
Title: Re: 1977 Polaris TX 250
Post by: emrickmn on January 11, 2018, 02:52:15 am
Yes sir
Fine wire brush on a bench grinder
Title: Re: 1977 Polaris TX 250
Post by: spark1013 on January 11, 2018, 03:23:16 am
Before you do the motor check on piston and rings for it. If it needs pistons about the only thing available is from US Chrome and they are pricey. Rings are next to impossible to find. If it has chrome bore yet you'll have ro see if they have any with cast rings and not moly coated. I learned the hard way.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 11, 2018, 01:30:03 pm
Perfect. Thanks for the information. I am hoping the pistons and rings are good. It ran great when I put it away last. However I never did a compression check at that time. I know its probably best to put new pistons and rings in once its apart, but would rather not if everything checks out.

On another note, this sled is something that I may ride once or twice a year. Once winter is over do and its time to store the sled or display it in the garage, do you normally drain all fuel out of tank and carbs and leave it empty? Just curious as it could be months (maybe a year) before its driven again. My thoughts are drain all fuel, but not sure if that is the right idea either.

Aside from new decals and hood work, the other parts that need attention are the gas tank and plastic shroud for gauges. Paint them? What is best to use as cleaner on them? Other options other than painting? Thanks
Title: Re: 1977 Polaris TX 250
Post by: emrickmn on January 11, 2018, 01:38:55 pm
Perfect. Thanks for the information. I am hoping the pistons and rings are good. It ran great when I put it away last. However I never did a compression check at that time. I know its probably best to put new pistons and rings in once its apart, but would rather not if everything checks out.

On another note, this sled is something that I may ride once or twice a year. Once winter is over do and its time to store the sled or display it in the garage, do you normally drain all fuel out of tank and carbs and leave it empty? Just curious as it could be months (maybe a year) before its driven again. My thoughts are drain all fuel, but not sure if that is the right idea either.

Aside from new decals and hood work, the other parts that need attention are the gas tank and plastic shroud for gauges. Paint them? What is best to use as cleaner on them? Other options other than painting? Thanks


Good questions;
For storage, I'd recommend running some seafoam and stabil through it, fogg the cylinders and the carbs (untill it stalls).  Then get the gas out.  That gas won't be worth saving for the next winter anyway.  You can use the old premixed gas in mowers, trimmers, etc.  Leaving gas in there will harden the lines and gum up the carbs.

For restoring the plastic, there's all sorts of things on this site to try, but basically they don't work as well as scrubbing with soft scrub and re-painting with a plastic compatible paint.
Title: Re: 1977 Polaris TX 250
Post by: chris r on January 11, 2018, 01:47:54 pm
On painting plastic, I use a product called Bull Dog. It's a adhesion promoter that comes in a spray can. They also make one for metals so if you check into it, make sure you get the correct one.

Title: Re: 1977 Polaris TX 250
Post by: lbet29 on January 11, 2018, 04:55:22 pm
Pistons and rings are available from Never Enough TX's on this site.  Yes a little expensive.  If you still have 120# of compression run it.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 11, 2018, 05:06:33 pm
Sounds great. Thanks again for all the info. I am looking forward to starting this project. Will try to post some pictures once I get it pulled out and on the stand. Thanks again. I am really enjoying the site.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 13, 2018, 01:37:32 pm
Here is the only picture I have of the sled right now.
Title: Re: 1977 Polaris TX 250
Post by: LitrBox on January 13, 2018, 04:21:14 pm
Good looking sled as is. Should help restoration to have a straight and complete start
Title: Re: 1977 Polaris TX 250
Post by: RustedHistory on January 14, 2018, 03:20:54 am
Great looking original condition sled, good luck to you on the project!
Title: Re: 1977 Polaris TX 250
Post by: RMK800 on January 14, 2018, 04:42:17 am
Hello cloughrin. To clarify about blasting the engine. I abrasive water blast my engines with fine sand or crushed glass to remove all dirt and grime buildup. I then water blast with glass beads to smooth out the aluminum surface and creates a satin shine. I do not tear the engine apart to do this unless I am doing a tear down anyway. But then one must make covers for the intakes and exhaust ports and seal off any other openings and protect the PTO shaft and seal. I make simple 20 gage steel or aluminum covers and use silicone gasket maker for 100 % sealing and this works perfect. The blasting media will get in anywhere that you do not 100% seal up real good. See my restore project 75 440 Sno Twister.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 14, 2018, 11:48:26 pm
Thank you for the replies. That motor looks great. Now I just have to find someone with a set up to help me out with this.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 16, 2018, 08:50:10 pm
A few more pics as I got it to the front of the shed. Hoping to get it into the shop this weekend. Pictures make it look better than what it is. The lighting is not great but I had belly pan redone when I first got it along with the seat. Belly pan was spray bombed with Polaris midnight blue paint. ( Will probably regret that).Not decided how far I am going to go with this thing yet....
Title: Re: 1977 Polaris TX 250
Post by: ShaunB_827 on January 17, 2018, 05:42:18 am
Looks like a nice shape original as it is! Your plastics pieces (dash, tank, trunk lid, etc) are not faded or broken looking so thats a HUGE bonus and a good start to a resto! Looking forward to seeing more.  8)
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 17, 2018, 12:44:13 pm
Thank you. Trunk lid is excellent. Tank and dash are faded and need some work hard to tell in pictures. I got the sled moved to the shop last night so hopefully take some pictures in good light and start with a basic cleaning and put a plan together from there.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 19, 2018, 02:27:35 pm
Anyone have suggestions for rebuilding the master brake cylinder? I noticed it is very soft and low on fluid. Is there a seal kit for these available? I have never had one apart before.  Thanks
Title: Re: 1977 Polaris TX 250
Post by: acrneon on January 19, 2018, 03:21:33 pm
I don't what level of restoration you are doing, all correct or just a rider. The newer style master cylinder from the mid 90s makes things easier as you can remove it from the handle bar quickly. Parts are available from many sources.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 19, 2018, 04:58:05 pm
Not a professional restore by any means... But Iwould like to rebuild the existing brake cylinder if at all possible.
Title: Re: 1977 Polaris TX 250
Post by: Drift Buster on January 19, 2018, 06:17:41 pm
Nice TX 250, I have bought rebuild kits from the Polaris dealer that worked, they were for a late 80's early 90's ATV's.  Have them show you the diagram and look for the same looking brake cylinder and it should be good.  Basically all you need is the cup and O ring anyway. Also I use Dot 5 silicone brake fluid in mine, if you spill some it will not eat the paint and it does not attract moisture. Don't mix the two types, flush the Dot 3 out and refill with Dot 5. 
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 19, 2018, 09:45:49 pm
Drift Buster: I will look into that this weekend. Thanks. Does anyone know what the center to center measurement should be from primary to secondary. Or crankshaft to jackshaft?
Title: Re: 1977 Polaris TX 250
Post by: acrneon on January 20, 2018, 02:54:21 am
Center distance is 12". Free download of service and parts manual at vintagesnow.com
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 20, 2018, 03:38:18 am
Thanks ACRNEON. I did download and print everything I thought I needed. Must have missed that.

Long story short this is what I came up with tonight as I started taking things apart. Engine number and model number. The way I read this the chassis is for a 250 and the motor is a 340? What would you guys do.. Change decals to match the engine? Find a 250?
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 20, 2018, 03:41:16 am
Here is model number 0770523
Couldnt get picture to load.
Title: Re: 1977 Polaris TX 250
Post by: emrickmn on January 20, 2018, 10:57:34 am
Cody
You have the correct 250 motor.
Polaris used 340 bottom ends for both the 250 and 340 motors.
If you still have the tag on the front, PTO side of the crankcase go by that ( the earlier tags were printed and could get scrubbed back to just aluminum). As well as the cylinder cast number.

For your brakes, remove the hand lever, pull out the piston and clean everything with a Q-tip. Make sure both the big and very small holes are clear. Get the jelly out, refill and make sure to bleed it well. You'll probably be fine then.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 20, 2018, 03:24:07 pm
The tag number on the PTO side is 600418.. I did not look at cylinders. I will check those out today.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 22, 2018, 12:02:07 am
Some disassembly and cleaning today.
Title: Re: 1977 Polaris TX 250
Post by: acrneon on January 22, 2018, 01:27:35 am
That one is in nice shape. I have the same sled. Make sure to service the clutches. You will be surprised of the performance of the 250.
Good luck and enjoy!
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 22, 2018, 09:28:41 pm
Thanks ACRNEON
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 25, 2018, 01:03:23 pm
Worked on the sled last night for few hours. Got both primary and secondary clutches removed for service. Took the brake apart and started clean up. Talk about nasty old sludge. Anybody have a line on the gasket that goes on the cover of the master cylinder? How about original hand grips? I want to remove the cylinder from the bars to clean up the black peeling paint. In trying to do this, I could not get the old grip to come loose. I may have to cut it off.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 25, 2018, 01:18:28 pm
One thing I forgot to ask, what is the best way to drain the chain case oil before removing the cover? I didn't notice a drain plug anywhere. Any trick for this with out getting oil on everything? thanks
Title: Re: 1977 Polaris TX 250
Post by: emrickmn on January 25, 2018, 01:30:03 pm
Cody
Try to save the hand grips. Those on the 77 are very hard to find. It's kind of difficult to do, but a long screw driver, some WD-40 and an air compressor almost always works.
Give me a call tonight and I can walk you through it. Our number is on our website:  www.VintageSnowmobileRestoration.com (http://www.VintageSnowmobileRestoration.com)

For the chaincase, just pull the cover and wipe up the mess. There's only 4 oz of oil at most in it.
Title: Re: 1977 Polaris TX 250
Post by: chris r on January 25, 2018, 01:31:33 pm
Worked on the sled last night for few hours. Got both primary and secondary clutches removed for service. Took the brake apart and started clean up. Talk about nasty old sludge. Anybody have a line on the gasket that goes on the cover of the master cylinder? How about original hand grips? I want to remove the cylinder from the bars to clean up the black peeling paint. In trying to do this, I could not get the old grip to come loose. I may have to cut it off.

I'd check with Mario who has a lot of Polaris parts for the gasket.

On the grips, I use a long thin skewer type too and carefully slide it between the bars and grip, then I stick the tube on the WD-40 in and give it a quick shot. Sometimes I do it in two or three different locations and then I just twist with my hand to try and loosen it up. I try to stay away from the heat gun (though it might work) because I don't want to take a chance on melting the plastic, and I also don't want to use any type of channel locks or pliers. Even with a rag or something to soften the contact point, I worry that I might damage the grip.

 :)
Title: Re: 1977 Polaris TX 250
Post by: chris r on January 25, 2018, 01:32:26 pm
 ;D

We posted the same thing at the same time.

Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 25, 2018, 03:15:22 pm
Thanks for the responses. I did try the air hose trick last night but did not use WD - 40, I will try that next. Probably mess around again on Saturday.
Title: Re: 1977 Polaris TX 250
Post by: chris r on January 25, 2018, 04:00:16 pm
Thanks for the responses. I did try the air hose trick last night but did not use WD - 40, I will try that next. Probably mess around again on Saturday.

Use something narrow enough to just slip the tube on the WD between the grip and bar. I would be cautious as far as prying on it too much.

 :)
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 28, 2018, 01:21:35 am
A little more work in the shop today. Got brake all cleaned up and reassembled. Need to bleed the system yet. Also got chain case removed and started cleaning up. Going to replace bearings right away while its apart.
Title: Re: 1977 Polaris TX 250
Post by: ShaunB_827 on January 28, 2018, 04:19:27 am
Looking nice and clean!! I'm curious, has anybody on here ever experimented with "rit dye" for restoring faded plastics??? These TX plastic pieces are getting hard to find.. It's available pretty cheap, and I've seen it used on motocross plastic parts with great results...
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 28, 2018, 11:53:48 pm
Some more work and clean up today. Go some work to do on the jackshaft as one bearing was none existent. At least the bearing housing wasn't damaged. Next on the list is to get bearings pressed out and find replacements. Have you guys had a hard time finding the correct bearings for these sleds?
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 28, 2018, 11:56:30 pm
More pictures
Title: Re: 1977 Polaris TX 250
Post by: svnuccadoc on January 29, 2018, 03:43:39 am
Looking good.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 29, 2018, 08:32:56 pm
Anyone have information on the bearing for PTO side of jackshaft. There is nothing left of mine so I have nothing to go off of. Any part number or anything would be helpful. Thanks
Title: Re: 1977 Polaris TX 250
Post by: Gilson435 on January 30, 2018, 01:47:34 pm
Here is the parts manual if that helps... looks to be part# 3514501.

http://www.vintagesnow.com/Polaris_files/1977_TX.pdf (http://www.vintagesnow.com/Polaris_files/1977_TX.pdf)

This one says it replaces Polaris# 3514501.

https://www.denniskirk.com/parts-unlimited/front-axle-bearing-1242-0006.p123989.prd/123989.sku (https://www.denniskirk.com/parts-unlimited/front-axle-bearing-1242-0006.p123989.prd/123989.sku)
Title: Re: 1977 Polaris TX 250
Post by: acrneon on January 30, 2018, 02:18:07 pm
Wahl's sells high quality NTN bearings as205-100 for this application.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 30, 2018, 02:26:49 pm
Thanks for the information ACRNEON and GILSON435
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 30, 2018, 09:10:39 pm
If I was to redo the bulk head and tunnel, would you suggest paint or powder coat? Does anyone have paint codes to share for this. I have done some searching but hard to find out what is most common as not one has been the same.  As I stated not sure I will do this yet but looking for opinions and different options. Thanks
Title: Re: 1977 Polaris TX 250
Post by: emrickmn on January 30, 2018, 11:41:50 pm
If I was to redo the bulk head and tunnel, would you suggest paint or powder coat? Does anyone have paint codes to share for this. I have done some searching but hard to find out what is most common as not one has been the same.  As I stated not sure I will do this yet but looking for opinions and different options. Thanks

I haven't painted a chassis in years. All of our restos are now powder coated. It's simply a better way to go and gives a better result for about the same costs.
Title: Re: 1977 Polaris TX 250
Post by: olpolaris on January 31, 2018, 12:53:30 pm
AXALTA (Dupont) formula # F3701 seems to look nice. Formula can be mixed in all the popular paints (urethane, water, vinyl).
Title: Re: 1977 Polaris TX 250
Post by: chris r on January 31, 2018, 01:12:17 pm
If I was to redo the bulk head and tunnel, would you suggest paint or powder coat? Does anyone have paint codes to share for this. I have done some searching but hard to find out what is most common as not one has been the same.  As I stated not sure I will do this yet but looking for opinions and different options. Thanks

I haven't painted a chassis in years. All of our restos are now powder coated. It's simply a better way to go and gives a better result for about the same costs.

And I'll add that it's a lot less work for the person doing the restoration. Also a huge time saver considering the time it takes to de-grease, sand, etc. Drop it off, and pick it up.

But, you must have a straight chassis to start with or the end result won't be as satisfying. You can't do any body filler with powdercoating. I tried the All Metal body fillers as an experiment once and it swelled up like a big boil on Grandma's neck. I think it was due to the fact that the hardener added to the filler is clear and there's no way to be 100% positive that it's completely mixed since you can't see it like with a cream hardener in normal body fillers.

I'll say I've had things powdercoated for over 20 years and have used a couple different shops. For the most part I've always been satisfied.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 31, 2018, 01:43:29 pm
Thanks for the info. For the most part, as far as I know the chasis is straight. I have one spot where a cleat hit the tunnel that I will weld and clean up. Talked with a local powder guy last night who is going to look into the custom color and see what he can come up with. From there, hopefully get a quote on what that will cost and make a decision.
Title: Re: 1977 Polaris TX 250
Post by: acrneon on January 31, 2018, 01:46:45 pm
I have restored the same sled, to a LOCAL show level. I used a $15. spray gun from harbor freight and paint from the paint guy on this website. Will my sled win a national show? Absolutely not. It all depends on what you are going to do with the sled.  There is a military term for where you are at right now it is called " mission creep". Make your plan now for best results that fit your needs.
Good luck and enjoy your sled
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 31, 2018, 03:55:36 pm
I would agree with the "Mission Creep". My ultimate goal is to clean up and make it rideable again. Maybe a local show. More a less a conversation piece in the shop with the guys. But with that, I don't want to look back after I have it all cleaned up and wish I would have threw a coat of paint on it.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on February 12, 2018, 02:54:10 pm
Anyone out there have a remedy for fixing the lower PTO jack shaft bearing speedo cable?. Or parts for this? As you can see in one of the pictures, the cable is broke that goes into the jack shaft. My bearings showed up and looking to fix this right away if possible. Thanks
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on February 16, 2018, 12:52:16 pm
I was able to reuse my angle drive and found new speedo key. Not much happening in the last two weeks after being on vacation. Hope to get back at it this weekend cleaning up more parts.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on February 16, 2018, 01:53:30 pm
Anyone ever use "Dry Ice Blasting" for cleaning an engine? If so, please explain the good and bad. THanks
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on February 22, 2018, 02:04:19 pm
I finally found a local guy that will be able to help with bead blasting my motor. Long story short I will be in need of some head gaskets, base gaskets and crank seals. Anyone have any ideas where I can get these? I tried local shop and they could not find anything on their end based off original part numbers I gave them. Thanks
Title: Re: 1977 Polaris TX 250
Post by: acrneon on February 22, 2018, 02:29:26 pm
Mfg supply in Wisc. I have used the gaskets and seals they sell, good quality.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on February 22, 2018, 03:39:14 pm
Perfect. Thanks
Title: Re: 1977 Polaris TX 250
Post by: Mario on February 22, 2018, 05:57:58 pm
I have them all on hand as well. Pretty sure I even have some in NOS Polaris.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on March 01, 2018, 01:02:19 pm
Little more work completed. New bearings all around.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on May 03, 2018, 12:03:25 pm
Finally got back on the sled a little bit. One question, can anyone verify if the picture I have attached is showing the correct upper spacer for the back side of the top gear in chain case? It fits loose and doesn't seem correct. If it is the correct one I am assuming the smaller shoulder part goes towards the bearing? Thanks for the help. 
Title: Re: 1977 Polaris TX 250
Post by: emrickmn on May 04, 2018, 12:27:02 pm
That's the correct spacer and yes, small side goes in
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on May 09, 2018, 03:06:20 pm
Anyone have a line on (2) of these?
Title: Re: 1977 Polaris TX 250
Post by: Mario on May 09, 2018, 07:10:37 pm
I have them in NOS. Shoot me a PM if interested
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on May 10, 2018, 05:44:55 pm
PM Sent
Title: Re: 1977 Polaris TX 250
Post by: AllenJ on June 07, 2018, 01:06:34 am
That's the correct spacer and yes, small side goes in
I am pretty sure the small side goes out and provides clearance for the drive chain when running a 15 tooth driver.
Title: Re: 1977 Polaris TX 250
Post by: Mario on June 07, 2018, 10:48:54 am
That's the correct spacer and yes, small side goes in
I am pretty sure the small side goes out and provides clearance for the drive chain when running a 15 tooth driver.
.

Thatís the way I always figured it as well. Otherwise it would be the same all the way across. But in reality it doesnít matter unless you are using a 15
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on June 13, 2018, 06:42:25 pm
I am using stock drivers.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on July 12, 2018, 11:57:50 am
Finally got back at the sled after a few weeks. Did a compression check and had 125 # across both cylinders (That made me happy). Removed engine to start cleaning. Got the belly pan removed. Not sure what route to go with that yet as stress cracks are more noticeable than I thought, and had rivets pulled through in more than places than I thought... Next step, start the cleaning / degreasing process.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on July 12, 2018, 11:59:02 am
Belly Pan Removed
Title: Re: 1977 Polaris TX 250
Post by: emrickmn on July 12, 2018, 12:17:27 pm
Cody,
If you need a new pan, we've got them with the OEM midnight blue gel, "natural" interior color and the cloth reinforcements -just like the factory.
It would match the dash and tank we're already doing for ya
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on July 12, 2018, 01:28:42 pm
Aj, I have been thinking hard on this ha!
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on October 18, 2018, 08:53:27 pm
Not a lot happening on the sled this summer. Got tunnel decals removed and started clean up on the motor. A couple more baths and I think it will be to my liking. After motor is cleaned up. I plan to get the pipe and muffler cleaned up and repainted.
Title: Re: 1977 Polaris TX 250
Post by: ShaunB_827 on November 20, 2018, 06:45:23 pm
Looking good! What is your method on cleaning the motors and getting deep in the fins?
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on November 20, 2018, 07:28:47 pm
I used mostly brake cleaner and "the works" cleaner. I would not suggest the works cleaner as I noticed after sitting for a few days it started to get a white residue. Maybe I didn't rinse it enough after cleaning it, but not positive. As far as getting in the fins, I found using a small bristle brush such as that used for cleaning the barrel of a gun worked well getting to the bottom of the fins. I am going to try and degrease again this weekend to see if that gets ride of the residue. If not then I will be going to the wire wheel option.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on December 03, 2018, 07:42:34 pm
Got back on the sled this weekend. Decided to stick with the original belly plan. Sanded, cleaned it up, and got it primed. Pictures make it look way better than what it is, but over all, it will look decent. Trying to figure out what color I want to keep the inside. was thinking black, but also don't mind the grey. Got all suspension parts , y pipe and pipe sandblasted and will hopefully be powder coated next week. Forgot to take pictures of suspension.
Title: Re: 1977 Polaris TX 250
Post by: ShaunB_827 on December 09, 2018, 01:42:01 pm
Looking good! Keep us posted with the updates  8)
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on December 20, 2018, 12:46:55 pm
Little paint work last night. Need about 3 more coats on the belly pan if I had to guess. Still waiting to get the suspension back from powder coat so I can start assembling that. I also plan to repaint the skis when I am done with belly pan and then should be able to get this thing upright after that. I am looking for (2) rubber saddles for the skis, if anyone has a line on them.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on December 27, 2018, 01:52:01 pm
More time in the shop last night. Wasn't happy with the way the motor cleaned up so I decided to tear it down. Hoping to have it cleaned up by the weekend. I am looking for a few parts yet. In need of (2) ski saddle rubbers.
Title: Re: 1977 Polaris TX 250
Post by: Mario on December 28, 2018, 11:56:42 pm
Looking good!

I do have the NOS spindle rubbers, but I didn't get to looking for the suspension shaft yet. Just getting moving around again, after squashing my big toe two weeks ago,,,,,
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 02, 2019, 01:46:44 pm
Sounds great. Keep me posted.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on March 21, 2019, 12:11:36 pm
Not much happening on the sled for the past few months. We actually had some snow to ride this year! Got a little time on it last night working on rear suspension. Hoping to get a few hours of shop time each week now to piece this thing back together. Very happy with how the skid turned out.
Title: Re: 1977 Polaris TX 250
Post by: Vics stuff on April 04, 2019, 03:02:31 pm
looking good. Keep the pics coming.
 Vic
Title: Re: 1977 Polaris TX 250
Post by: Brokenleg on April 16, 2019, 11:43:41 pm
Coming along nice. Amazing how many hours you can spend rebuilding a sled isn't it.

Brokenleg
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on April 18, 2019, 09:25:36 pm
Brokenleg, you are not a kidding. Each week I wish I could put more hours in. Its a slow process but its going in the right direction. Finished up the rear skid last night. Next step put belly pan and skis on so I can flip this thing over.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on May 30, 2019, 05:33:44 pm
Finally got motor cleaned up. This is the only picture I have for now. What is the trick for cleaning up all hardware (nuts / bolts / washers) to make it look new? Or does anyone have a parts list or a hardware kit put together for this? Thanks
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on November 21, 2019, 04:06:18 pm
Have not posted for awhile. Finally got belly pan, skis, and steering components installed. Was able to flip the beast over for the first time in over a year. Been a long time coming, and its finally starting to look like a sled again. Next I plan to clean up and polish front bumper. Not sure if old decals are good enough to leave alone or if I will remove and replace. After that, I will get dash, tank, and seat installed. Will post pictures as soon as I can get them resized.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on November 21, 2019, 04:13:06 pm
Hopefully the pictures show up this time.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on November 21, 2019, 04:13:52 pm
Another
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on November 21, 2019, 04:14:21 pm
Another
Title: Re: 1977 Polaris TX 250
Post by: MERC x3 on November 21, 2019, 09:38:25 pm
Very nice work . Taking your time is paying off . Looks like a trophy sled .
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 06, 2020, 12:46:01 pm
Little more work completed this weekend. Tank, dash, and seat installed. 
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 06, 2020, 12:54:42 pm
Another
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 06, 2020, 12:55:06 pm
Another
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 06, 2020, 12:55:32 pm
Another
Title: Re: 1977 Polaris TX 250
Post by: emrickmn on January 06, 2020, 04:15:18 pm
I was wondering how you liked the tank and if it matched the dash.  I used a different method for painting the tank.
Coming along nice but you should have gotten one of our seat covers.  That one will fit better over time.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on January 07, 2020, 12:47:13 pm
Yes it matched real well. I've been meaning to send you an email. Thanks again for taking care of this. And agree with the new seat cover but for now this will one is in good shape and will work. Once I get my motor back together and installed, I need to come up with a plan for my hood as that is my weakest link to the whole project I feel.
Title: Re: 1977 Polaris TX 250
Post by: emrickmn on January 07, 2020, 02:16:52 pm
Yes it matched real well. I've been meaning to send you an email. Thanks again for taking care of this. And agree with the new seat cover but for now this will one is in good shape and will work. Once I get my motor back together and installed, I need to come up with a plan for my hood as that is my weakest link to the whole project I feel.

Let me know when ready.  Our hoods are as close to OEM as you can get.  Both midnight blue and white gelcoat means no need for a costly paint job (making ours actually less expensive than the others).  Thicker fiberglass will hold its shape better and remain crack free longer, Natural color inside means the hood looks like a factory hood when opened and reinforcement cloth panels are a VSR exclusive.  We've found some nice shipping options too. 

Ironically, I have a 77 hood boxed and will be shipping to PA today.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on March 26, 2020, 01:29:31 pm
Some progress. Motor is going back together.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on April 23, 2020, 06:53:47 pm
Little update. Getting closer to finishing the project.
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on December 07, 2020, 07:04:16 pm
It is finally ready for snow!!! Keeping the original hood for now. Hope we get some snow soon!
Title: Re: 1977 Polaris TX 250
Post by: cloughrin on December 07, 2020, 07:05:06 pm
Few More Pictures
Title: Re: 1977 Polaris TX 250
Post by: chris r on December 08, 2020, 11:43:19 am
 :)
Title: Re: 1977 Polaris TX 250
Post by: Lumpy59 on December 08, 2020, 06:27:08 pm
Great job! I like the hood , I graduated from high school in 1977 and I have some scratches as well its just the journey of life . Enjoy your TX !