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1996 Jag Project

13K views 79 replies 7 participants last post by  Skier76 
#1 ·
I picked up another sled last night! 1996 Jag 440 fan, single carb. It's got a new hood, studded track and seems to be in good shape; although it could use a good cleaning. It doesn't run right now. The seller thinks it's fuel lines. So that's first order of business. It does have spark.

One of the previous owners changed over the bars, used an aftermarket brake handle and flipped the throttle. The wiring is a little questionable. I'm leaning towards finding a set of OEM bars with all the wiring and cables and installing those. It will also need a seat cover.

It came with another seat pan/tank, foam and cover. However, I think that's for a 1997. It has a back rest, but I'm not sure if that'll fit based on my trying to test mount it. And a set of old skins; they attach with straps!

I got everything for $200.

A couple of pics:

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#6 ·
I'll probably try to sell this and use the money to fix the sled up. Same goes for the tank/foam/seat cover. I'm thinking those are for a 1997 and up and won't work with my AWS1 chassis.

I'm gonna run a compression test soon...fingers crossed!
 
#7 ·
Great news on the compression test! 120psi on both cylinders. I attached a pic.

A couple of shots now that it's out of the trailer. Does the rear seem to sit high or is that normal?

I noticed two missing bolts on the rear tunnel. Any idea what they are for? (One on each side)

Two bolt holes on the front of the tunnel...again, not sure what the other is for. I felt around and it seems the other hole is blocked by a plate on the inside of the tunnel.


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Rear bolt hole:

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Front bolt hole:

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#9 ·
Thanks KC. It's hard to say what was done. Behind that hole on the rear of the tunnel is the bracket that supports one of the wheels the track rides on. I can't tell if the wheel was moved or not. I'll try and get a pic of it. I checked alphasports.com and it doesn't seem to have a good diagram of how that area is assembled.
 
#10 ·
I think I figured it out. Looks like he moved the mount from the side of the tunnel to the drop bracket. That raised the rear suspension up a bit. I did a little research and it appears others have done this as well. Doesn't seem to have any ill effects...let me know if anyone has any insight.
 
#12 ·
Looks like someone dropped the front of the skid. It appears that I have to bolt hopes on the front of the tunnel. The lower one is used currently.

I thought I read something on here regarding the positioning of the rear shock mount on the rails and how it effects traction...I'll post a pic of where mine is lunged currently.
 
#15 ·
KC, yep, I need to hit the swaps! I know there's one close to the VT/Mass line in the fall. That's a good start.

RJ,
Excellent. Thanks for confirming. I'll get some better pics soon. I just got it up on my new dollies last night. I need to hit the track area and belly pan with a shop vac to get all the debris out of there...and it needs a good scrubbing down.
 
#16 ·
The ski bolts were a real bear to remove! The throttle side took a lot of PB Blaster and Liquid Wrench. I ended up using a jack to lift the front of the sled so I could rock the ski back and forth. I then used a ratchet and a breaker bar to gently move the bolt to free it from the bushing. I'll put in new bolts and a healthy amount of grease!

I'm looking for an OEM handlebar setup that includes all the grips, levers, wiring and cables. I've seen a few on e-bay. It looks like the earlier, pre AWS sleds have the exact same bars. Can anyone confirm?
 
#18 · (Edited)
Excellent! Thanks RJ!

That seat/tank combo I have looks like it's from a 1997 and up Jag/Puma. I don't believe it will fit my sled due to where the tank filler is located. However, would the cover work on my sled? If so, I'll use that vs. sourcing another one.

Edit:
Which tachometer will work on this sled? Is this a four pulse engine? The previous owner put on a hood with a hole for the tach; might as well install one.
 
#20 ·
Thanks RJ. I'll look for a 4 pulse tach. And I'll clean up the seat cover to get that ready to sell on ebay. It's OEM, so hoping to get a few bucks for it. I'll sell the tank and foam as well.

I have a set of handlebars (with all the controls and cables) on order.

Next order of business is pulling the seat and console to start getting at the fuel system. I'm going to rebuild the carb and the fuel pump. It's like deja vu all over again; I did this with the Puma awhile back. But in this case, it's not winter and I'm not doing this in our backwoods up in VT! Working on this thing in the garage has been a pleasure. I gave the sled a good washing yesterday. I took many layers of grime off. I even used a little rubbing compound on the hood. Shines up nice.
 
#21 ·
A few pics of the work this weekend. I washed the sled and used some rubbing compound on the hood. I also pulled the seat to get to all the fuel lines. I'm going to try to pick up some new lines this week.

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#23 ·
Sledhead,
Great advice! I'll do that wile I have things apart. Does that shroud just bolt into the heads? I take it it doesn't use the actual studs to hold it in.

I had a lawn mower that had that same issue with a dead mouse; lost the engine because of it.

Started getting into the fuel system as of late.

The fuel pump wasn't too bad. Just a little liquid varnish in there. Gaskets were in good shape as was the plastic in the center of the "pump sandwich" The carb was another story! I soaked the bowl for a bit, but there was still some scale at the bottom. Maybe it needs a longer soak in the dip tank.

Here's what it looked like before cleaning:

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#25 ·
Now that cleaner sounds cool! I should look into one.

I was able to clean and rebuild the carb. I've done this to a few carbs before. I've never had the issue where some of the carb material rubbed off on the towel. I didn't soak it that long either.

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