I put about 2400 miles on my new F1000 last winter. By the middle of May i was getting a little bored and wanted to tear my sled completely apart and clean everything up and check for any issues. I also wanted to change the color. I could have prepped & painted the existing panels but to do it the right way is alot of work. So i just went and bought all new panels in the color that was close to what i wanted. It was around $600.00 for all the new panels which i didn't think was too bad.

First i had to pull it in the shed and disassemble some of it. Here are a few pics of the general dissasembly.
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One of the 1st issues i found was the adjustable footwells. I ride with them in the lowered position so i can hook my feet in and ride more aggresive. They had both cracked. I could have had these warrantied but they were about $20 for the pair so i just bought new ones.
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Another issue i found was the left side Spar had actually rubbed about 1/2 way through the tank. To fix this i used a die-grinder to recess the spar piece. I also used a small piece of rubber (like a piece of inner tube) between the spar & tank upon reassembly.
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Here you can see some of the salt damage i had to deal with. (Thanks NY state)
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This is the rear heat exchanger. The snowflap rests against it and you can see where it has rubbed little "divets" in the exchanger. This could be an issue down the road.
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A Mothers Powerball worked well after using WD40 and 000 steel wool to clean the salt damage up.
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A pic of the Diamond Drive cleaned up.
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The tank removed. The screw that holds the coolant bottle to the tank was cross threaded from the factory so i had to trash the coolant bottle to get the tank out. The new coolant bottle was very inexpensive.
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Some pics of the airbox area with the airbox removed.
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I pulled the footwells apart and cleaned everything up like new again.
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Just a few more pics of the cleaning process on the rear tunnel.
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Front lower nose piece removed.
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Skid plate removed (looks like Darth Vader ) and the sticker fridge.
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I just wanna make a comment on the Divets in the rear heat exchanger. I called the Factory about that and emailed them some pics of that very situation. I was assured that they take a set and pretty much stay there from there on out. And that the engineers accounted for that in the design with more material in that area.

Skid removed for cleaning & rebuilding
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Front track shock removed & ready for rebuild
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That's alot of studs
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Front track shock all rebuilt and re-installed
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New wheels
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The upper idler wheels were in pretty rough shape. The mark on the edge of the one is where the track "popped" down below the wheel at some point. I literally had to about destroy them to get them off. (no alcohol was involved though, i promise )
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I said screw it and bought new ones.
Out of the 10 wheels, 8 are new and i replaced the bearings in the other 2. (Rear inners)
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The footwells cleaned up very nicely.
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I used Oxylic acid and a small soft bristle brush to clean up the complete rear suspension.
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Rear suspension mount bushing was broken so i replaced them both
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Good to go
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I decided to go with red so i bought red panels from the Jag Z1. Here are a few pics of the test fitting of the nose pieces & hood.
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Changing over the upper pod panel.
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Starting to take shape
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Cleaning up the lower panels.
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The Jag recoil was apparently in a different location than the F1000. Who knew?
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All i was missing was the red side panels at this point from having the front plastics back together.
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New fuel tank installed.
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The replacement tank has a different style insert to prevent the insert from turning when trying to remove the screw. Very smart on Cats part.
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Front suspension disassembly for powdercoating.
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Rear lower trunk piece prepped for fresh paint.
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I used PPG Deltron 2000 basecoat with DC3000 clear
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Done.
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I bought a new black upper trunk pice and was able to match the red perfectly. I painted it using PPG Concept single stage urethane.
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Cleaning up the front suspension was a pain. I used a bead blaster and a angle grinder with Roloc disks.
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Trunk reassembled & installed.
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Last year i ran a D&D single pipe worth about 10hp. This year im runnining D&D ceramic coated twin pipes. These retail for about $1200 bucks with ceramic coating. Good for an additional 10 hp over the single pipe.
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Got the front section all done and lower A-arms powder coated black
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All back together. Skinz seat cover from Sled Solutions. Rest of the front suspension powdercoated black.
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