1999 rebuild/project

[cyprusriverrun]

Hey guys this is my first rebuild of a motor or fourwheeler for that matter. I didn't take a whole lot of pics but I thought you guys might like to see them. I know rebuilds are my favorite part of the forums:)

When I bought the bike I was told it was a 440 with a port and polish and stage two hotcam. That was not true at all. It was one bore size bigger but everything internally was stock. And about a month after I got it the starter clutch went bad:mad: Earlier this spring the head gasket had started leaking a little but I left it to till it started leaking pretty good. That is when I decided to do the rebuild.


Heres a pic of before the bike when I had it all cleaned up.
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/000_0217.jpg

and a side view
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/000_0216-1.jpg

one of the tear down.
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_21651.jpg

We'll see if those load. my internet is kind of slow so it might take a while lol

[cyprusriverrun]

here's one with the cylinder off and sent out for boring. I went with a 86mm 10:1 compresion je piston. that should keep it pretty reliable but still give it a nice power boost hopefully.
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_21731.jpg

the frame and subframe and primed. I used a metal etching primer.
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_21761.jpg

I used automotive paint and used a spray gun but am disappointed with the results. It just chips easy. Looking back I should have spent the extra doe on powdercoating.
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_21811.jpg

[cyprusriverrun]

another frame shot. It looks pretty good i think. Maybe if it was a little darker it might be better
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_21801.jpg

I used the stock a arms for now. Later on down the road I will probably upgrade to +1's. This is just a rattle can paint. No matter what paint I use it will probably wear off. This way it should be easier to touch up.

http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_21831.jpg

new pro elite bumper and hls shocks. I don't know what brakelines those are actually meant for but they work good
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_21842.jpg

an overall shot. the trail tech lights aren't hids but are still pretty bright
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_21851.jpg

[JOHNDOE83]

Wow, thats looking really nice!

[CJM]

Clear coat it, it wont flake off then.

[jman7290]

If its not to late I would go with 11:1 compression. Makes the bike feel so much better and still very dependable.

[Pittsburgh400ex]

Nice bike man, Only one i've seen that has the carbon fibers like mine.

[cyprusriverrun]

cjm - I put two coats of clear coat on. Maybe that wasn't enough or I didn't do it right. i don't know


j man - its already too late for the 11:1 piston. If I ever rebuild this one again I will keep that in mind.

Thanks for the complements guys

[cyprusriverrun]

Got the cylinder on and the piston in
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_21941.jpg

pic with the head on
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_21961.jpg

engine put back together
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_21981.jpg

tank on and basically done
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_22001.jpg

[CJM]

Drying time inbetween. Did you bake it or airdry it?

I rattlecanned my throttle cover black then cleared it. It took a fall down a coal hill to scratch it. I musta sprayed like 8 coats of clear.

[Stickman400]

Originally posted by Pittsburgh400ex
Nice bike man, Only one i've seen that has the carbon fibers like mine. You've never seen Thumpin's 440?

[Pittsburgh400ex]

Originally posted by Stickman400
You've never seen Thumpin's 440?


Obviously not..

[Stickman400]

Not gunna hijack the thread so I'm just gunna post 1 pic.

http://i683.photobucket.com/albums/vv192/Stickman400/Random%20Pics/002-1.jpg

[cyprusriverrun]

Thumpins ex is one of my favorites. I put on maiers race front fenders only the race style instead of the normal fronts

[cyprusriverrun]

here's the rest of the pics

front view
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_22051.jpg

side view
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_22041.jpg

back view
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_22061.jpg

[cyprusriverrun]

This was finished back a few weeks ago. Since then I put a big gun evo r slip on on it. Also I got a gtthunder rear skid plate but I haven't put that on. I made some handle bar risers that raise it 1.25 inches and also made a thing for my key so it wasn't just ziptied to the handle bars. I took the airbox lid off and rejetted. I still have to get it a little better though. I think it needs a bigger pilot jet and the air fuel screw adjusted a little bit more.

It's running pretty good though. The shocks are awesome. I need to do something with my rear shock. Right now the preload is backed off all the way.

[cyprusriverrun]

The big gun is awesome. My old fmf was leaking like a sive and didn't sound very beastly. This one is almost brand new and sounds way better. I also ground off the heat shield things on the stock head pipe to make it look cleaner.
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_2261_zpsfc36cfc1.jpg

header
http://i1298.photobucket.com/albums/ag55/Tim_Stoltzfus/100_2260_zps34ae9f6f.jpg


Well thats it. I'll probably keep changing stuff over time until I get it exactly how I want it. I think it turned out all right. Thanks for looking.

[Stickman400]

Lookin' good. Get some new tires and some nice looking rims on it and that thing will be a looker. I don't know if you want a new tip for that pipe but I have a black tip for one of those old style Big Guns that I used to have but traded in for a new one and I kept that tip. If you want a black one I'll sell it to you dirt cheap. Lmk.

[jman7290]

Stickman, do you ever ride that thing?!!! Looks awesome Bro!

[Stickman400]

That's another members 400. Thumpin440ex. I asked him that same question when I saw pictures of it. He takes really good care of it and likes to keep his stuff very clean, obviously.

[jman7290]

Damn nice looking quad, props to him. I clean mine, but never turns out that nice. Mine has only been that clean twice, once when I bought it off of the showroom floor and the other when I saw it on Craigslist after it was stolen and I recovered it!!! Thank god for the recovery...

[jman7290]

Cyprus, good job man. Your quad looks kick butt!