Tearing A Quad Down

[ShiftFMX]

Ok, I'm seriously thinking about tearing my quad down for some pc and gussets. I have never torn down a quad before. It's not the tearing apart, its the putting back together that scares me. How was some of your guys first time tearing a quad down? If I did It I know I would organize the crap out of everything.

[clutt225]

I did my 400ex three times and have done my 450r once the best thing you can do for your self is use zip lock bags and label the crap out of everything. the more bags you use the easier it will be to put it back together.
good luck and have fun

[Mxjunkie]

Keep everything organized, Baggies, boxes, empty rooms, tubber ware anything really.. :macho

Label every bags with parts and be specific so you will know what you ment 3 months ago :p

[Mxjunkie]

And when you take the motor off make sure to put a rag in any intakes etc

[ny300exrider]

Originally posted by ShiftFMX
Ok, I'm seriously thinking about tearing my quad down for some pc and gussets. I have never torn down a quad before. It's not the tearing apart, its the putting back together that scares me. How was some of your guys first time tearing a quad down? If I did It I know I would organize the crap out of everything. i was actually going to make the exact same post today....close to word for word. im thinking some pc would be cool and the learning experience of stripping and rebuilding a quad would be sweet but im alittle worried lol

i gotta do my first quad teardown too one day whenever i get my new frame for my 450r...nt looking ofrward to it but whatever

[ShiftFMX]

How hard is the Electrical system to put back?

[awsomeaussies]

A digital camera comes in handy too;)

[gbcap]

take many pictures of how wires, cables, and lines are run. unless you tear down one day and put back together the next it is pretty hard to get right the first time.

one of the hardest things was getting the wire harness back the way it was.

i got a tool box and put the different nuts and bolts in seperate sections. baggies work better for the first timer because they can label them.

[MX MaNiAc 06]

Originally posted by Mxjunkie
Keep everything organized, Baggies, boxes, empty rooms, tubber ware anything really.. :macho

Label every bags with parts and be specific so you will know what you ment 3 months ago :p

Thats the most organized mess ive ever seen.

[Doober]

For the wiring harness, i just unplugged one at a time put tape on each side thats connects and marked each of then "a" then the next was "b" and so on

another thing is to try and get it done as fast as you can...dont tear it down untill you have everything planned out

[fwm416ex]

start off by getting the bike as clean as possible,bag and tag works fine.the digital camera and camcorder are great tools. the hardest things to reassemble are the electronics and oil and coolant lines(if applicable),after that bolting up the chassis is a cinch

[zack221]

lol yea thats when i would get confused when i had all the bolts laying out like that i was thinking about tearing my dirtbike down and getting the frame powdercoated by pappy but im not sure if i want to i ordered a service manual i will read over that and i ordered a torque wrench because i was thinking about rebuilding the motor just so i would have a fresh topend while the frame was being powdercoated

[Mxjunkie]

Originally posted by MX MaNiAc 06
Thats the most organized mess ive ever seen.

lol sometimes a mess works better then absolutely organized :p

[Pappy]

This isnt a hard process....just takes a little pre-planning and some thought as to what your doing.


The labeled bags work well. Pictures help you remember what things look like etc. And you cant take anything apart the members on this site cant help you put back together:p

Around here, they come apart and go in a box or two. After youve done a few hundred you can do it in your sleep:p

[HondaEXrider22]

Is that a 250EX motor?

And, another good option is to take masking tape and tape bolts and stuff that go together and label on the masking tape.

And dont forget to buy some Loctite!

[JW450R1]

i just did my 450r this last summer.it was a little more then i expected,but it really wasn't that bad.just take your time and do everything right or u will be fixing it again later.run a tap/dye threw all the threads and loc-tite every thing.also if u have any problems u can call on all your freinds on this site.

[CRich[814]]

Originally posted by HondaEXrider22
Is that a 250EX motor?

400.

[zack221]

whats the kickstart lever for

[400ex28]

zip lock bags, end of story.

[HondaEXrider22]

Originally posted by CRich[814]
400.

Yea, i was looking at it wrong. The back of the 400s motor looks like the side of the 250s.

[Pipeless416]

when i tore down my 400 i left it in an absolute mess. i had parts all over the garage, but my best advice is if you have a friend with the same quad, ask them to bring it over for a day. i had my dad's 400 to look off of. if thats not an option, then do what everybody has said.. take as many pictures as possible. good luck! :macho

[416exmx]

Originally posted by Pappy

Around here, they come apart and go in a box or two. After youve done a few hundred you can do it in your sleep:p


LOL, oh yeah I could do it in my sleep as well.

I just throw every nut/bolt in a big tub. I have two different tubs, one for stock bolts and one for allen head stainless bolts. Both tubs have a couple hundred bolts each from all the quads I've done up. When it is time to go back together I just look at a bolt and know where it goes. Some guys will come in and see 3 or so quads tore down and parts all over the shelfs and cant even grasp the idea of how everything will get back together.

[JW450R1]

it's just like putting a puzzel together.it would be easier if you had another quad to compare too.

[HondaEXrider22]

Another great helper is a manuel for the machine.

[mrusk]

I remember putting my old 250r back together. It was easy considering the only things old that were used were the frame, motor (which was all new) swingarm, radiator, airbox, and gas tank. Everything and i mean everythnig else was all new.

[BigFish]

rebuild....

good times;)

[WhiteYFZ]

im 14 and i can do it.:o :p
its not hard.

sequence
http://i29.photobucket.com/albums/c278/tjespo22/thomasyfzyfzcentral.jpg

http://i29.photobucket.com/albums/c278/tjespo22/part8.jpg

http://i29.photobucket.com/albums/c278/tjespo22/HPIM0182.jpg

http://i29.photobucket.com/albums/c278/tjespo22/HPIM0213.jpg

http://i29.photobucket.com/albums/c278/tjespo22/aarms1.jpg

http://i29.photobucket.com/albums/c278/tjespo22/itsdone22.jpg

http://i29.photobucket.com/albums/c278/tjespo22/itsdone5JPG.jpg

[zack221]

cool im glad to hear someone 14 can do it im 15 and i am fixing to do a 2stroke motor so it should be alot easier than a 4 stroke

[yamablaster24]

i remember when i was 11 or 12 i had to tear down my blaster with no mechanical skills besides working on BMX bikes and watching my dad work on cars. I took everything apart with my 12 piece craftsmen set, couple screw drivers and my dads pipe wrench and a claw hammer i believe. I stripped a couple nuts and bolts, and then put everything in one box, all together. Somehow managed to get everything back together...and ended up with like 10 extra nuts-bolts haha

[zack221]

lol im going to replace all the screws on mine just so i know its all new

[JW450R1]

how about running a tap / dye threw and over the threads.then they are like new.don't for-get the loc-tite.that what i did with mind.

[zack221]

which loctite did you use blue or red i know red is permanent but it seems like if i use blue the bolts would come loose after riding it

[JW450R1]

i use red on everything.red loc-tite is not like it used to be years ago.i took a brand new bolt and nut and sealed it up with red loc-tite.i came back 5 days later(and this was in my house now),and nut came off with a little bit of a drag.years ago u would have to heat and melt it off to remove it and still have issues.now i guess metals r different.

[knighttime]

Originally posted by JW450R1
i use red on everything.red loc-tite is not like it used to be years ago.i took a brand new bolt and nut and sealed it up with red loc-tite.i came back 5 days later(and this was in my house now),and nut came off with a little bit of a drag.years ago u would have to heat and melt it off to remove it and still have issues.now i guess metals r different.

your brand new bolt and nut must have had some type of manufacturing oil on it that compromised the loctite. you need HEAT to break loose red loctite if the fasteners are cleaned/prepped before install.

[JW450R1]

so i tried another that was prepped.i sprayed brake wash on both.same resolts.try it

[thump4863]

Originally posted by JW450R1
i use red on everything.red loc-tite is not like it used to be years ago.i took a brand new bolt and nut and sealed it up with red loc-tite.i came back 5 days later(and this was in my house now),and nut came off with a little bit of a drag.years ago u would have to heat and melt it off to remove it and still have issues.now i guess metals r different.

I'm with you - I use red on everything and never had a problem taking them out. And I use plenty of it to!

[JW450R1]

so i called loc-tite the company.they basically said there are 2 different red loc-tites.i forget the # of the other red.so i ordered it right threw loc-tite.it still didn't work very good.they basically told me that it is the type of metals,thats why it would hold tight.