Thought I'd start a new thread seeing as Mudbogger's previous forsake thread started this journey. I picked up this Dave-Co pilot from a guy in Indiana, who bought it from Greg. Seems like an awesome machine! Theres a build thread under Mudbogger's world for this btw. In short, Dave-Co modified the suspension with long travel Fox Shocks, axles, and power steering! Also the top cage was enlarged so its slightly easier to get in/out of.

The front power steering and suspension linkages & tiered linkages look tricked out. Lots of adjustability in the front. Rear as well. Shocks are also 3-way fully adjustable. I've actually never had a machine with so much adjustability. Its going to be nice!

The Engine seems to be an over-bored cylinder, but I'm unsure if the cylinder has been ported. My suspicion is not ported. Engine has a SpeedChaser head, a PWK39 carb, PowerBlock clutch, and a Torque pipe.

In all this Pilot is in really good shape. Except the plastics. Within this thread I'll be posting my work at some airless plastic welding Polyethylene at some point. Also the radiator overflow bottle needs some cracks plastic welded as well.

Pics coming in a moment

Pics hold

Pics

Pics

So far I've just been combing through all systems. Checking wiring, fan operation, all lights, adjusting brakes and cables. Adjusted seatbelts and wrist restraints. Found lots of nuts and bolts not tightened. Replaced fuel lines and pulse lines. Drained the fuel tank. Found the right rear axle was binding the suspension at 80% compressed. Compression test yields 170psi. Engine holds pressure and vacuum. Re-did the exhaust from Engine back with copper rtv. Changes all oils. Coolant looks like Engine ice and looks fresh. Changed the plug. Redid about 5 of the CV boot clamps. Replaced a broken radiator cap.

Still need to flow-test the fuel pump before first go. Its got an OE fuel pump

After seeing the welds on the powersteering setup im not surprised Apollo 11 exploded on takeoff didn't he say he welded on all the space shuttles lol

Hopefully Houston won’t have a problem with this one.

Now if Farr Off-road wants to start “Making Pilots Great Again”; I have 2 other Pilots in line for something better.

Congrats dude! She's a jumper!

Most here don't think too highly of Dave, but he probably has more real off road racing experience than everyone here put together.

What's the red bushing looking things on the steering shaft? Poly? I'm not a fan of that poly crap. It gets "sticky" if not lubed. I'd take a look at it if it were mine.

Yea its a Poly bushing. Looks like a big job taking it all apart. I may be able to drill and tap for a grease fitting while it is still in place though. Suggested?

funny the first thing I noticed was the weld on the power steering lol..should be a fun pilot though

Fuel flow rate FAILED at 3oz/10 seconds. Out came the seat. Drained the fuel out the the fuel tank. System is using factory on-off valves and an OE style fuel pump and filter.

I disassembled the OE Keihin fuel pump but it was clean as could be. There was some stuff in the tank that is now drained and cleaned out. The OE fuel filter was actually quite difficult to 'blow' through and so I came up with an AWSOME solution! Went to my local Auto Parts store and located a suitable HIGH FLOW, REAL replacement. This is not a plastic pos lawnmower filter. The item/filter is a FRAM 33293, which may also be a Micro Guard or WIX filter (FRAM G7092 or PTC PG7092 also on the box). This is a FUEL INJECTION filter for a small car, but the in-store blow-through test yields a very surprisingly non-restrictive fuel filter. AND it has 5/16" mail ends which easily connect to fuel lines; AND it fits the factory rubber holder.

Observe photo:

Fancy!

Once you replaced the filter, did you pass the fuel flow rate?

Congrats on your find, can't wait to see what happens

NOPE! Still failed. Time to replace the OE fuel pump with a Polaris!

Congratulations,

If you take that upper ps mount off you will not like what you find, it is a piece of metal tube stuffed in the bushings with the steering shaft in the tube, the tube does not even fit the steering shaft correctly, metal to metal surface shaft and tube. I bet you have a little play in the wheel as well.

I used to own the rims you have on that, got them with my first LT, they were pretty much new when I sold them to Gregg.

You should pull your front shocks off and check for ball joint bind there as well.

Thanks. That bushing on mine seems tight. I’ll take the wheel off and really check it over. I wonder if a needle bearing would fit in its place, or maybe this ones just not worn? Or Dave-Co used a better size here?

That's strange that he would put an extra sleeve in there.

There's a lot of different ways to do it. The Briggs I have just has the shaft going through an aluminum mount, No bushing/bearing or lube. Works great.

It may not be a problem, But the power steering may hide it if it's sticky. Grease is going to attract dirt.

Any chance you have a lathe or a friend with one? I'd just replace those bushings with delrin ones and be done. And take the metal sleeve out.

Oh, and needle bearings should only be used on a hardened surface/shaft, It'll "pick up" if the race is too soft.

How much fuel was in the tank when you did the test?
Would be cool to see any pact on test result using a cold variable level and a warm variable level test. Maybe a happy medium let's say at the point the the the valve is on reserve and half full and pretty full.
Since fuel has weight and and the weight impacts pressure which in turn will have an effect of volume once it rises about the tank fuel level. This should have an impact on output volume at a given pump pressure since the return line dumped into the top of the tank after the bowl is full. I would think it's important to be sure you have enough fulel rate when the fuel light come on as a minium set point.

Adnoh,

The oe pump failed at both 1/4 and full tank. Only got about 3 oz

I put this Polaris in and it’s now pumping 5.5 oz. Full tank.

And I’m using that fuel filter above, with the factory fuel switch both to reserve and on. Same readings.

Good to go now

Is that pump still around 60$ or do you have a source for less$

Nice looking pump.
CO will be happy now.

I think it was $70 shipped but I got it next day.

Someone can try the dual output Mikuni. It’s rated for 65 liters/hour. That should be 7oz

Pretty sure most of us run on reserve.
That way we don't that short lean condition when the tank gets low and fuel light comes on that is why I head in or did when it starts to come on. Mine burned between 4 to 4.5 gal a machine hour. Sixty or seventy bucks is cheap compared to an Engine failure. For me it would be a no brainier. Glad to see you do you due diligence.
I'm enjoying your thread keep it coming

So checked over suspension clearance/binding once again. Alls good in the way of linkages, axles, heims, and balljoints.

The one thing; front tires scrub the fender at full turn lock under full suspension compression. I wonder if I need to move the front 'axle' forward about 1/2" so that tires wont scrub the fenders? Surely that would mess up a bunch of geometry things if I tried that though.

Front caster is a bit off left/right.

Left is 7.5 degrees positive
Right is 9.5 degrees positive

What should Caster be set to anyways?

If the tire just scrubs under the conditions you describe and assuming you are referring to the rear of the tire (left tire inside and rear of tire rubs as you turn left), I wouldn’t change anything. Full lock turning under full suspension compression is likely going to be very rare. If it was bugging me I’d try smaller diameter tires (this will have other negative impacts, ground clearance for one or raising the fender slightly with a spacer before I’d change anything else.

I like a “lot” of positive camber, more high speed stability and a bit more cornering bite.
I don’t know that anyone could tell you what it should be though, the Dave-co setup changes everything/nearly everything Honda did... I’ve only seen and read about the DC setups, so my knowledge is severely limited. I’d drive it and see how it feels, sand will be different than hard pack.