2001 rancher es 4×4 rebuild

so I bought a rancher off of craigslist with the hopes of building it up into a fairly badass off road machine. I got it for cheap enough that I felt like I could take on a project working on it and at the same time modify it a little to suit me for what I want it for.

So the bad. theres a lot.

It seems like every piece of the fenders are broken in some way shape or form. mostly, the clips that hold the fenders together or to the frame are missing.

one of the front cv boots is torn

one front bearing is bad

front brakes are shot. hand brake is mush.

handle bar controls for the rear brakes, reverse, parking brake, and choke are broken, half fixed, or missing entirely.

carb had no air filter, choke cable is broken off. idles high like the choke is stuck open.

rear brake cable on the foot pedal is broken off. when pushing the machine into the shop it seems like the parking brake is locked up? rear brake is locked up? not sure yet. hard to push and it holds itself in place while on a small incline going into my shop.

rear rack is pretty damaged. the mounts on the frame side are snapped off as well.

electronic shift is strange. from neutral at idle, the machine engages hard into gear. no strange noises but jumps the machine forward. while riding it, it wouldn’t upshift and seemed to be bouncing off the rev limiter. did shift into the 2nd after alittle more riding up and down the drive way. I think the machine sat for a year or so the guy said. maybe something wrong with the clutches?

also has parts of the frame that are a little rusted through in the front end. Im going to chop out whats bad, put some slugs in and replace what is bad and reweld.

ok, enough of all the problems. first thing I did this morning was order a Clymer manual.

to make it more of what I wanted I took the crow bar to my wallet and got the old credit card out and ordered some stuff from highlifter. I got a spool locker, disc brake conversion, the wide open front drive shaft disengage unit (same as the warn 4-2-4), and the outlaw clutch kit.

Im debating on whether to do a gear reduction but not sure I need it. I don’t need 29.5 outlaws but would like to get a decent size mud tire to put on the rancher. thinking some size of vampire. Really thinking about doing it now because im going to have the whole thing apart and would rather do it now then have to take it all apart again if that’s what I decide I want. Im not sure what the machine can really handle stock so im open to options.

Ill update this thread as I go, get more parts, and snap more bolts. would appreciate all input and help getting this thing going. so if you guys have any recommendations or tips feel free to chime in.

2001 rancher es 4×4 rebuild

so I bought a rancher off of craigslist with the hopes of building it up into a fairly badass off road machine. I got it for cheap enough that I felt like I could take on a project working on it and at the same time modify it a little to suit me for what I want it for.

So the bad. theres a lot.

It seems like every piece of the fenders are broken in some way shape or form. mostly, the clips that hold the fenders together or to the frame are missing.

one of the front cv boots is torn

one front bearing is bad

front brakes are shot. hand brake is mush.

handle bar controls for the rear brakes, reverse, parking brake, and choke are broken, half fixed, or missing entirely.

carb had no air filter, choke cable is broken off. idles high like the choke is stuck open.

rear brake cable on the foot pedal is broken off. when pushing the machine into the shop it seems like the parking brake is locked up? rear brake is locked up? not sure yet. hard to push and it holds itself in place while on a small incline going into my shop.

rear rack is pretty damaged. the mounts on the frame side are snapped off as well.

electronic shift is strange. from neutral at idle, the machine engages hard into gear. no strange noises but jumps the machine forward. while riding it, it wouldn’t upshift and seemed to be bouncing off the rev limiter. did shift into the 2nd after alittle more riding up and down the drive way. I think the machine sat for a year or so the guy said. maybe something wrong with the clutches?

also has parts of the frame that are a little rusted through in the front end. Im going to chop out whats bad, put some slugs in and replace what is bad and reweld.

ok, enough of all the problems. first thing I did this morning was order a Clymer manual.

to make it more of what I wanted I took the crow bar to my wallet and got the old credit card out and ordered some stuff from highlifter. I got a spool locker, disc brake conversion, the wide open front drive shaft disengage unit (same as the warn 4-2-4), and the outlaw clutch kit.

Im debating on whether to do a gear reduction but not sure I need it. I don’t need 29.5 outlaws but would like to get a decent size mud tire to put on the rancher. thinking some size of vampire. Really thinking about doing it now because im going to have the whole thing apart and would rather do it now then have to take it all apart again if that’s what I decide I want. Im not sure what the machine can really handle stock so im open to options.

Ill update this thread as I go, get more parts, and snap more bolts. would appreciate all input and help getting this thing going. so if you guys have any recommendations or tips feel free to chime in.