New guy, Max IV, hoping for a springer kit

[turtle racer]

This is my story of misery and future redemption, I hope.
I bough a 2003 Max IV 900T about a month ago. It ran and drove, but needed work, the guy I bought it from was up front about what it needed, and I'm the technical/mechanical type and could confirm what he said. The max did not show any signs of abuse on the body and the tires looked new, but it appears the original owner may have driven it in a salt marsh without properly washing and lubing it afterward. There is a lot of rust, I broke half of the bolts, including wheel studs during disassembly. But the worst was having to cut the axles in order to get the frame out of the tub, because shafts, collars, and sprockets were rusted solid together. Before any one ask, I did drill out the set screws first. Presently, every thing is dissembled and ready for blasting and power coat.
From reading some of the post I see that there may be a suspension (springer) kit for the Max IV in the works. The springer Attex and Max II looked great. So I'm going to wait on ordering new parts for my Max IV, I'm going to reassemble what I can, and hope the springer kit will be available soon.
Questions; I need to replace the throttle cable. The Max has the heated throttle cable assembly and I don't want to buy the hole assembly. Can I buy only the cable and insert it into the sleeve myself?
one of the post about the T-20 talked about flushing. What do you use to flush the T-20?
Does anyone know a good replacement (high speed or low cost) variable pitch clutch set for a Max IV?
Thank You

[mightymaxIV]

Originally Posted by turtle racer

This is my story of misery and future redemption, I hope.
I bough a 2003 Max IV 900T about a month ago. It ran and drove, but needed work, the guy I bought it from was up front about what it needed, and I'm the technical/mechanical type and could confirm what he said. The max did not show any signs of abuse on the body and the tires looked new, but it appears the original owner may have driven it in a salt marsh without properly washing and lubing it afterward. There is a lot of rust, I broke half of the bolts, including wheel studs during disassembly. But the worst was having to cut the axles in order to get the frame out of the tub, because shafts, collars, and sprockets were rusted solid together. Before any one ask, I did drill out the set screws first. Presently, every thing is dissembled and ready for blasting and power coat.
From reading some of the post I see that there may be a suspension (springer) kit for the Max IV in the works. The springer Attex and Max II looked great. So I'm going to wait on ordering new parts for my Max IV, I'm going to reassemble what I can, and hope the springer kit will be available soon.
Questions; I need to replace the throttle cable. The Max has the heated throttle cable assembly and I don't want to buy the hole assembly. Can I buy only the cable and insert it into the sleeve myself?
one of the post about the T-20 talked about flushing. What do you use to flush the T-20?
Does anyone know a good replacement (high speed or low cost) variable pitch clutch set for a Max IV?
Thank You

Sorry for all the problems. Whipper is working on a springer kit for the MaxIV now but I don't know how soon it will be available. For clutchs you have a lot of options. There is a high speed clutch for the engine available from route 6x6. For the transmission you should have a standard green spring clutch. You can go with a red spring clutch which will keep the engine in the lower range longer putting more power and torque on the ground in mud etc. A brown spring will keep it lower even longer. I have a red spring clutch in mime and I am very happy with it. I have posted several comments you can check about the red spring clutch! Wish you the best with your improvements. It you decide to go with solid axles contact Whipper who will machine them to the length you want and heat treat them! You'll never have another axle problem. Contact follow site member Jurry Nuss to get an upgaded bearing replacement or talk to whipper, and you should never have to worry about bearings and axles again. Hope this helps!

[MaxRules]

Heated throttle cable - Just buy the one already made up. You can't just 'slide' a new cable in your old since the wire is wrapped tightly around the cable. You'd have to completely disassemble it and re-wrap the heater wire. The difference is $36.50 non heated to $65 heated. You need the aluminum throttle lever (base is aluminum/silver color, lever itself is plastic/black). 2003 was the first year for this so yours might have it. If not, you have to buy it along with the new cable for another $34.15.

[turtle racer]

Thank you for the info. I am sure to have more questions as I go. The Max IV frame and other parts should be back from powder coat in 2 weeks. These buggies are expensive, motorcycle times 3 for parts cost. I think my mistake was to cut the axles, I should have tried to split the sprockets and bearings using a hand grinder with a cut off wheel. It would haven taken a lot longer but I wouldn't have the expense of replacing the axles. I talked to Whipper about the springer kit. I'd love to have one but I can't budget it into this project. Maybe in a year when I start my next 6X6, after I finish up some motorcycle projects that are on hold.

[smokin cigarettes]

Originally Posted by turtle racer

This is my story of misery and future redemption, I hope.
I bough a 2003 Max IV 900T about a month ago. It ran and drove, but needed work, the guy I bought it from was up front about what it needed, and I'm the technical/mechanical type and could confirm what he said. The max did not show any signs of abuse on the body and the tires looked new, but it appears the original owner may have driven it in a salt marsh without properly washing and lubing it afterward. There is a lot of rust, I broke half of the bolts, including wheel studs during disassembly. But the worst was having to cut the axles in order to get the frame out of the tub, because shafts, collars, and sprockets were rusted solid together. Before any one ask, I did drill out the set screws first. Presently, every thing is dissembled and ready for blasting and power coat.

Thank You

Which one did you buy? I was also looking at those. One of them had the 25hp kohler.

[turtle racer]

My Max has the 25hp kohler.