2003 Max IV resurection

  1. Welcome to 6x6 World.

    You are currently viewing our boards as a guest which gives you limited access to view most discussions and access our other features. By joining our free community you will have access to post topics, communicate privately with other members (PM), respond to polls, upload content and access many other special features. Registration is fast, simple and absolutely free so please, join our community today!

    If you have any problems with the registration process or your account login, please contact us. Looking forward to seeing you in the forums and talking about AATVs!
+ Reply to Thread
Page 1 of 4 1 2 3 ... LastLast
Results 1 to 10 of 33

Thread: 2003 Max IV resurection

  1. #1
    Join Date
    Mar 2015
    Location
    Pickering, Ontario
    Posts
    633

    2003 Max IV resurection

    Hi, I figured I would start a thread on the reassembly and repair to my new to me Max IV. I just purchased this unit from another forum member and I can't call this a restoration as the Max is in overall excellent condition, it just requires a few minor repairs and some assembly that I will document here and look forward to your input and criticism.

    My new to me Max IV



    1st order of business is to repair the T20 mount holes that have started to oblong.



    I decided to go with 1/4" plate as that is what I had on hand, I will install slightly longer mounting bolts as well.

    plates cut, drilled and test fitted


    a few bolts and nuts to keep everything aligned while I weld it up


    All welded in and painted



    dropped the T20 back in to make sure all is well, looks good.



    On to chains, a tensioner, motor mounts tomorrow. If I keep this pace up I should be out for a test ride this weekend.
    Last edited by Canadian_Zuk; 10-27-2015 at 04:19 PM.

  2. #2
    Join Date
    Aug 2011
    Location
    Kotzebue, Alaska
    Posts
    1,209
    Thanks for sharing. The pictures do help with understanding what is being done.
    Stand for the Flag. Kneel for the Cross.

  3. #3
    Join Date
    May 2007
    Location
    Kings Mountain, NC
    Posts
    7,788
    Nice work. The T20 shouldn't go anywhere now.

  4. #4
    Join Date
    Mar 2015
    Location
    Pickering, Ontario
    Posts
    633
    Well, progress is being made. I had a minor setback on my first test drive out in the woods, a magnet came off the inside of the flywheel and rearranged the rest of the magnets and the stator lol. The stator parts were cheap enough, but the magnets are not available individually, I would have had to buy a new flywheel.




    Upgrading to an external alternator was the most frugal solution. I found a 37amp 10SI style alternator for $80 from my local re-builder and cobbled an adjustable mount together. I'm still waiting on my Ebay PTO shaft to arrive so I can permanently bolt this down to the engine stand. It's not pretty but it will be effective and only took a few minutes lol.



    The motor ran when installed, but not well. I removed and cleaned the carb 3 times in a heated ultrasonic cleaner, it improved greatly but still had a rough idle and ran lean. I kept looking for(expecting to find) a small bit of dirt or something clogging the main jet as all the rubber appeared to be in good condition upon disassembly and only the needle was a little sticky at the first cleaning. After 3 stabs at it I broke down and ordered a Kohler carburator repair kit, man oh man, $110 sure doesn't get you much from these guys (couple of O rings and screws) lol, not even a float or jet for that price! Regardless, it was money well spent as the 25HP motor is purring like a kitten now. During the rebuild, most of the rubber that appeared good at first inspection broke or cracked during removal to install the fresh O-rings.



    I picked up 9 24" Argo tires from Kijiji last week as well and have them installed now, having 3 full size spares kicking around isn't so bad either.



    Tracks are also all ready to go, just waiting on the axle extensions I ordered from Adair Argo to arrive.



    Ugh, back to watching tracking number now, I need more parts to arrive
    Last edited by Canadian_Zuk; 11-11-2015 at 08:59 AM.

  5. #5
    Join Date
    Mar 2015
    Location
    Pickering, Ontario
    Posts
    633
    PTO shaft arrived.


    I got.my alternator installed tonight



    And goodies arrived from Adair, tracks on next week

  6. #6
    Join Date
    Apr 2013
    Location
    Crestview Florida
    Posts
    550
    Could you not mount the alternator straight to the PTO shaft and eliminate a lot of extra work or would it not spin up fast enough?

  7. #7
    Join Date
    Mar 2015
    Location
    Pickering, Ontario
    Posts
    633
    Quote Originally Posted by Dozerlarry View Post
    Could you not mount the alternator straight to the PTO shaft and eliminate a lot of extra work or would it not spin up fast enough?
    Yes, the alternator wouldn't spin fast enough and it would probably be harder to fab a mount that kept the alt perfectly true to the PTO. The Pulley and V-belt setup is more forgiving with minor misalignments and also allows me to adjust the Alt speed. I was originally going to use a regular slotteed automotive adjusting bracket too but went with the threaded rod jacking setup instead. I did this so I could use a wide range of belt sizes, that way I have a better chance of finding replacements in a pinch.

  8. #8
    Join Date
    Apr 2013
    Location
    Crestview Florida
    Posts
    550
    10-4, kinda' figured that. You did a great job on fabbing the alternator mount!

  9. #9
    Join Date
    Mar 2015
    Location
    Pickering, Ontario
    Posts
    633
    I took the family for a short ride in the Max today and got a chance to get it wet for the first time in a local pond. It swims faster than I expected.


  10. #10
    Join Date
    Oct 2007
    Location
    Texas
    Posts
    2,158
    Nice build. Yes those Argo tires are awesome swimmers. I have a set on a Max2 and am always amazed how well they swim.

+ Reply to Thread

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts