My popo 120cc build thread

[Flygti32]

I picked this unit up off a friend of mine, it had been sitting in his garage for a couple years with intention of fixing but life gets in the way. Plus he already has 1 fully functioning 120 for his boys. Its a 2005 model, whoever had it before him really did a number on this poor thing. My boy now 5, I decided to get him on the snow with me this winter. This is how i bought the sled. Over a couple nights I tore the entire sled down to nothing.

 

[Flygti32]

There was more wrong with the sled than i had seen initially, one big thing was the skid. The front limiter bar had been torn out of the sled and someone tried to hold it in there with a bunch of rope. I'd never seen anything like it.

next was the support arms in the front end. They were really bent from the front impact, suprisingly the bulk head is straight, so i heated them up and bent them back

Took the motor and seat frame to work , cleaned both up and painted the seat frame black.

 

[Flygti32]

Then the parts started to fly in. Pretty much new everything, belly pan, support braces, hood latches, hood, seat, skis, skags, headlight, tailight, track, extrovert drivers, front bumper, and i started to get to work. I sanded and painted the a arms and braces all black as well.

tonight i have the throw in the wiring harness, and a few more nuts and bolts, some fresh gas and i can start to test the carb and set it up. Still waiting on a new snow flap as well.

 

[Blown Motor]

Turned out pretty nice and clean, hope the lil tike that gets to rip er enjoys!

 

[swrev]

Nicely done. Sled looks sharp. Unless your 5 year old is very tall, I would move the bars to one of the lower positions. Awesome sled, my kids love theirs.

 

[Flygti32]

Nicely done. Sled looks sharp. Unless your 5 year old is very tall, I would move the bars to one of the lower positions. Awesome sled, my kids love theirs.

Ya i think i will lower them a notch.

 

[H1Pilot]

Wow, what a revival. It looks brand new. Nice JOB!

 

[Flygti32]

Thanks man, first day out on it he was a little tentative, next day he was full throttle and sticking it deep hahahahahaha! " Dad! pull me out i'm stuck" pretty much every 5 minutes. I think i little more motor and a gear set change is coming over summer.