Renegade Rebuild and Review 2007 model

rknight111

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I got my Renegade in November of 2006, it was one of the first Renegades on the market. Now a few years later, with about 2500 good hard Km on the unit I will let you know what issues Ive had and what im currently finding and repairing.

Ive done all the regular maintenance on the unit since brand new, had it in to the dealer all of the regular scheduled appointments for adjustments and oil changes. Had the recall done for the CVT Belt case, they put a thicker one on. Changed the sensor several times that enables you to start in any gear as long as you have the break on. The valve cover gaskets were changed two times as well as the valve covers got changed once. The water pump was changed as it was defective. Ive broken the front axles at the CV joint closest to the tire several times, then switched the front to Gorilla and havn't had an issue. I twisted the shaft that comes out of the engine that goes to the front differential then it broke. Done the brakes about 3 times now. Changed the Battery but that was really my fault for leaving it out side all winter. Did the clutch upgrade, added an HMF muffler, snorkelled it, put a 2" lift on with 27" Mud Bitches. Changed the belt 3 times, once every season. Changed the handlebars, replaced the hood because all the fasteners broke. Done the Brakes several times and when changing them did not go with Can-Am pads, went with aftermarket pads. Ive also changed the front bushings on the a-arms, the tie-rod ends, ball joints and the front bearings. I had a rear swing arm bearing fail as well. I do grease this ATV each weekend ride as well.

If your riding a renegade in the mud, your going to get dirty. Mud fly's everywhere, its alot more fun than your average utility quad. This is more of a sporty quad. The only thing I really missed was storage racks, but there is now a back rack kit. Ive purchased the Can-Am bag but it never really lasted to long, the zipper failed after 2 rides.

So after 2500 km, Ive taken it apart to do some fixing.
- Shock ends are not round anymore and the rubbers are worn out.
- Steering shaft is broken (I rolled it a few times last year and bent it)
- Bolts that bolt the lower front a-arms to the differential have loosed and need replaced.
- Bearing at base of steering shaft requires replacement
- Bushing and o-rings that support steering shaft require replacement
- Aluminum frame that supports rad and front body is broken, bought replacement and that is aluminum and the mounting piece is been upgraded to steel.
- Need to repair the frame, found a crack under the seat 3/4 way the bottom of the upper frame.
- General cleaning and re-greasing to complete unit.
- Change brake pads, and check all bearings.
- Take rear swing arms off, clean and repack bearings with grease and reinstall.
- Change engine mount bushings.
- Install 2 new front headlight mount brackets.

I will be posting pictures and my additional findings here.
 

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rknight111

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A few more pics.

Does anyone know where I can get new bushings for the shocks?

And notice the steering post was full of water causing it to rust.
 

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rknight111

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Hope the above pics help you out and show people what to look for.
It has been so far a good fun solid ATV and I cant wait to get it back together, and Ride again with no rattles. Any one have a front pair of shocks?
 
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rknight111

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Upon opening up the frame I noticed there was a bit of mud and moisture inside and this is a low spot. There may be a possibility that it was full of water there and froze in the winter. Same with the steering post it was full of water and the top is open the bottom is sealed. I can see that being an issue on more than this ATV. This thread is not to knock the renegade in any way it is showing what to look for and what you may expect when you push a quad as hard as I have for 2500 km. So far I'm very happy with the quad, best ride I've had and rode so far.
 

gforce

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ya but did you find a winch????just wonderin..so ya coulda/sholuda got a grizz..just sayin!:d
 

99summitx

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I found the frame on my Teryx also fills with water after taking off a skid plate and getting an eye full of water from a bolt hole,so now I drain it after wet rides, sooo that would be every ride:d
 

rknight111

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So I took it apart, ive got 10 hrs into it now and that's with filling getting the frame welded from the inside at the bottom, closing the open piece and getting it all ready for the reinforcement. I probably spent 4 hrs just cleaning the mud from every part. Went to Martin South and made an order for $480 worth of parts, hopefully nothings back ordered. I ordered new motor vibration mounts as well there is 4 of them at $25.00 piece. I picked up sheet metal stock today from metal supermarkets they cut all to the sizes i requested, so i will get it fabricated up and install on three sides of the frame. Should have the welding all complete on the weekend, then ill be waiting for parts. Checked what the new power steering module would cost, $1150 just for that, then all the other parts and additional stuff you would need would run about 2K :eek: in total plus install time, fabricating and welding brackets, I'll stick to what I have.:d
 

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rknight111

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Im not sure but these motor mounts on the front of the frame seem to have the holes elongated. I'll have to check with the dealer but I think I should order those as well rather than having to replace them 6 months later.

Had to turn the welder down a bit, could blow a hole right through the frame pretty easily. Any one else weld these frames. I filled all the cracks and straightened everything out. Now I will install extra support on the top, bottom and the one side, drill holes in the plate steel stiffeners and weld it to the frame.
 

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Sweigh

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This is great info, thanks Ron! I'll be keeping an eye on these things as I dissect my machine for maintenance.
 

rknight111

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I maintain my machine very well, when I ride it get greased every trip. When something is worn out it is replaced. When it comes back home it is washed spotless. I have driven this machine to beyond it's potental and I would say it has been ridden quite hard. Don't believe me ask my friends, or go to my profile and watch some of mountains and mud. This machine owes me absolutely nothing, it's outperformed every thing I've put it through. When it gets old it's just like us and needs some TLC. So it's time. These are just some things that could happen or to look for. If you got a rattle it could be.... So far it's been an easy job, not sure what I'm in for but always looking for a challange. When cleaning the inside of the frame there is quite a few areas where water can come in. Has any one filled there frame with foam? The upper frame that is not the lower one. I was thinking getting it done to prevent this further as I know that ice caused this bulging of the frame in that area. I would get it done next week at J&G urethanes. I'm also going with that square pipe idea in the lower frame as well. I will update this in another day with the repair job on the frame.
And I checked all the universal joints and they are like new, good grease all the time saves lots.
 

catmando

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Is this a sales PLOY???????
LOL! LMAO!
Just kidding,Wow Ron,Looks like a lot of work!
catmando!
 

gforce

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is that quad from ikea??just sayin!..oh thats gonna require more beer..oh i mean time:beer::beer::beer::beer::d
 

rknight111

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I filled the cracks and gaps with a bead of weld then grinded some off till it was flush and I fabricated some braces with flat 3/16" metal. Then drilled holes for additional bonding. I welded everything together then cleaned up and applied some DTM(direct to metal) paint. Then installed the frame stiffners. Found some other cracks and issues and cleaned, welded and painted.
 

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rknight111

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Here's a few more pictures.
I got the 1.25 x 1.25 x 53" Steel square tubing and drove it into the center of the frame.
 

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