Trail Mods to our Pred-90 - pulling it together... - Off-Road Forums & Discussion Groups
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post #1 of (permalink) Old 03-18-2005, 07:30 PM Thread Starter
 
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Trail Mods to our Pred-90 - pulling it together...

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For our '03 Polaris Predator 90, here's my Improvement / Modification List, associated "lessons learned" and future planned "wish list" items:


Completed

a - Installed front light for "daytime driving lights" and the rare time we get caught on the trails at sun down in our dark bush trails. I'd perform this mod again.

For pictures, surf: http://community.webshots.com/album/283371980xEWfck


b - Performed proactive Brake Fix. If wondering, the factory 45 degreee steel bracket for the plastic rear guard "can stop" the back brake arm from moving forward. A little welding resolved this safety risk.

For pictures, surf: http://community.webshots.com/album/284408738FRgcEq


c - Installed back push bar. I'd perform this mode again. This is an excellent mod to help push my son's quad out of the mud and load/unload from our trailer.

For pictures, surf: http://community.webshots.com/album/284404321yqauIv


d - Installed HPD Spring loaded Chain tensioner. I'd perform this mode again. Due to our positive success with this mod, I'd recommend ALL Pred-90s (and other mini-quad brands) have a Spring loaded Chain Tensioner.

For pictures, surf: http://community.webshots.com/album/108721500mjHKZk


e - Installed 3/4" length aluminum skid plate for $45.00. I'd perform this mode again. For our unique bush, rocks, ice, etc. riding, this was another excellent mod.

For pictures, surf: http://community.webshots.com/album/284493780TASOxK


f - Removed Oil Injection system, installed single gas throttle cable (run with 32:1 premix). I'd do this mod again. Should have done this mod within the 1st month we purchased our Pred-90. Instant 50% reduction of tension on the thumb control. No more sore thumb for my young rider!!!!

For pictures, surf: http://community.webshots.com/album/130997005nxNiAA


g - Installed WRH Racing Performance Reeds (reed upgrade). This gave our Pred-90 more throttle control and smotther higher RPMs. I'd do this mod again. Note: Many thanks to Billy Holt at WRH Racing for helping us out with this mod.

For pictures, surf: http://community.webshots.com/photo/...90462994zZEkdY


h - Installed shock covers. For our mud, ice and water riding, this was another excellent mod.

For details, surf: http://www.shockpros.com/main.html


i - Installed grease zerk within its Swing Arm. An excellant mod to reduce Swing Arm bushing wear. I'd do this mod as well.

For pictures, surf: http://community.webshots.com/album/284538349PdZJcL


j - Installed foot guard rails. I'd perform this mod again except the next time, I'd do it a little different. A little more professional looking. If wondering, this was a great safety improvement mod for my son.

For pictures, surf: http://community.webshots.com/album/284377392himalK


k - Modified our factory air box's snorkel to be less restrictive. Due to our deep mud / water riding, this was the best solution for us.

For pictures, surf: http://community.webshots.com/album/283726905AgWkij


l - Installed univeral mirror mount and driving mirror on left side of handle bars. This was an excellent safety increase mod I'd do again as well. If wondering, this cost me: $6.95 for bracket & $12.95 for plastic mirror.


m - We use 4.5 - 5 lbs (instead of factory recommended 3.5 lbs ) of air in all tires. This made our unit less mushy on the corners and ride uptop on the deep mud much better. Also makes our unit SLIDE into the corners instead of digging in - and possible rolling.


n - Installed 1.5" "machine engineered" wheel spacers on each tire. To me, widening a mini is a MUST with trails with sharp corners. I'd do this mod again.

For pictures, surf: http://community.webshots.com/album/209852103mosGcm


o - Completed our Customized foot brake. My son can now stop his Pred-90 with very little muscle effort. I'd definately do this mod again. Should have done it the 1st week we bought our '03 Pred-90.

For pictures, suf: http://community.webshots.com/album/242848150eXxxII


p - Replaced 35T with 39T rear sprocket. Also replaced 19T with 18T front sprocket (from '01 Scrambler-50). This lowered its top speed from 30ish down to 24mph. However, it dramatically shifted its power band to lower ground speeds. Thus giving it more spin in our "less then" 20 MPH trails. I'd do this mod again. Note: Many thanks to Billy Holt at WRH Racing for helping us with this one. This one was well worth it!!!!

For pictures, surf: http://community.webshots.com/album/284402100NAfkOS


q - Installed grease zerk in rear axle assembly area. This will make its axle bearings last much longer. Not too sure if I would do this mod again.

For pictures, surf: http://community.webshots.com/album/284538349PdZJcL


r - Eliminated the gap at the bottom of our plastic engine case. I'll know in 6-8 months when I inspect / clean our stator area if this was a good improvement.

For pictures, surf: http://community.webshots.com/album/288567422ndcBWR


s - Replaced our blown stator within a used one. Also installed larger gasket at the back of the stator assembly. Note: Many thanks to Billy Holt at WRH Racing for helping us with this one.

For pictures, surf: http://community.webshots.com/album/262582347LVsyKh


t - Installed an extra "thick" ground wire from battery to frame ground. I've been told by a few that a better ground will reduce the risk of stator, Ijnition coil and/or CDI burn-out problems. Easy mod to do in order to reduce the risk of future electrical problems.

For picture, surf: http://community.webshots.com/photo/...89612822mtEmFB


u - Installed new rear brake pads with groved pads. Also, re-adjusted the front cables so they have better cable alignment.

For pictures, surf: http://community.webshots.com/album/284413681CLEjQH


v - Replaced factory rear light with greater viewing surfact, thinner / wider profile tail light and wired in both brake and front light wires. This thinner rear light also allows me to use our rear 6" frame loop without hurting the back of my knuckles. I'd do this mod again. To me, this should be future factory design. For pictures, surf:

http://community.webshots.com/photo/...93612273nAlTyF
http://community.webshots.com/album/283371980xEWfck/1


---------------------------


My "under construction / under investigation" future improvements are:


A - When our engine needs a re-build, I'll increase its PSI to 145/150 and use Squash (poor man's port job). For pictures of parts waiting to be installed, surf:

http://community.webshots.com/photo/...84809125bCLdfB


B - Extend its Swing Arm and install an Adult sized shock. This method is much less expensive then a Works Performance rear shock. Due to our hill climbing trails, a longer Swing Arm would reduce its risk of front/back flips.
* If you are interested in helping me investigate this low cost upgrade, please send me a PM. I'm looking for someone who has access to Dinli & Yamaha Blaster parts.


Note: If unable to find an inexpensive "used" Blaster front shock, I might simply add a spring spacer in the rear shock. For a picture, surf:

http://community.webshots.com/photo/...89519332KjSwml


C - Install 45 degree braces on its frame. If wondering, the frame around the top shock mount will break when doing rough / extreme riding conditions. Especially if a heavy kid rides the Pred-90. This inexpensive brace adds more support to the frame. Biscuit (a user from another forum) did an excellent frame re-inforcement job on his Pred-90. For a visual, surf top 3 pictures within:

http://community.webshots.com/album/113532491VkQbLi


D - Install Handle Bars with a padded cross member. To me, ALL minis should come with a padded cross member. Depending upon the padded cross bar location, I may need to relocate its ingition swith & Tether switch.


E - Replace the plastic bushing within its steering column. Unknown to many, its bracket on the top of its steering column is "very cheezy". This bracket did pass Polaris Engineering Stress tests but due to its thin contact surface, its plastic bracket wears out every 2 years. A design improvement that Polaris needs to fix in their future years.


For our unique mud, water, snow/ice trail riding and our limited dollars, these are the maximum "wish list" mods we can perform.


Hope this info & online pictures helps others...

.
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post #2 of (permalink) Old 05-03-2005, 06:48 PM
lumpyk
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Re: Trail Mods to our Pred-90 - pulling it together...

Can you provide the specific manufacturer for the throttle { (f) in your post }?

Is that modification the addition of a twist throttle, or still using the thumb throttle?

Did the modification eliminate the rev limiter?

Did the modification include a new CDI with out a rev limiter?

Also, if I go to this throttle modification, do I have to remove the oil injection?

Finally, what is the advantage to removing the oil injection and pre-mixing?

Thanks for all your help! Love the pics of your modifications, makes alot more easy to understand! Hope my questions aren't too dumb, but I'm a newbie
post #3 of (permalink) Old 05-14-2005, 12:05 AM Thread Starter
 
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Re: Trail Mods to our Pred-90 - pulling it together...

[ QUOTE ]
Can you provide the specific manufacturer for the throttle { (f) in your post }?

Is that modification the addition of a twist throttle, or still using the thumb throttle?

Did the modification eliminate the rev limiter?

Did the modification include a new CDI with out a rev limiter?

Also, if I go to this throttle modification, do I have to remove the oil injection?

Finally, what is the advantage to removing the oil injection and pre-mixing?

Thanks for all your help! Love the pics of your modifications, makes alot more easy to understand! Hope my questions aren't too dumb, but I'm a newbie

[/ QUOTE ]


Sorry... I don't go into this forum on a regular basis.

To answer your questions....

Still a Thumb throttle control system. With Oil Injection system removed, the tension on the thumb was instantly reduced by 50% less (IMO).

We are running the factory CDI with its Jumper Removed. If we want to go above the fixed RPM, I need to replace the factory CDI with a High Performance CDI. These are available at many mini-quad performance shops.

If you want to reduce 50% tension on the thumb control, you need to remove the factory OI system and replace the factory "Y" cable with a single gas throttle cable. These cables are available from Billy Holt @ WRH Racing or terrycable

There are advantages and disadvantages of removing the factory OI system. Advantages are: 1 - when the engine is getting gas, you know it's getting oil. 2 - 50% pressure reduction in the thumb control. To me, this is a major safety increase. My kid is better focused, instead of him trying to reposition his hand / thumb - in order to reduce the pain from its too strong of OI Pump Spring. Disadvantages areas: 1 - you have to premix your gas at 32:1 (depending on the brand of oil) and it has to be exact ratio each time. 2 - you can no longer pull up to any gas station and say "fill her up - please".

If you do remove the Oil Injection system and go with pre-mix, you "may" have to re-jet the carb as well. Our Pred-90 was running "factory rich" before and didn't have to rejet after OI Removal. As soon as we changed another part, we had to rejet. Don't worry, performing "minor" carb rejetting isn't has bad as it sounds. Jets are around $10/each and you'll may only need 2. Minor Carb Re-Jetting takes around 30 minutes of engine running time.


To learn more about removing OI system, surf:

http://www.off-road.com/atv/kidskorn...n_removal.html


Hope this helps as well...

.
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