Project Bikes

PROJECT BIKES / QUADS
This page will show the step by step process taken to repair a bike/quad to the condition in which a customer will be prepared to buy the quad for the advertised selling price!

INTRODUCTION On the 21 January 2009 I traded in a Honda TRX 400 (2003) and decided I would make this a project bike. My aim is to give it a unique appeal that will stand out amongst other quads. The engine starts and that's about it! The quad was in a head on collsion with another quad and the frame is bent to the right.
FIRST ASSESSMENT 1. Handle Bars are bent 2. Bull Bar is totally damaged 3. Front fender is damaged 4. Main frame is bent to the right and upwards. 5. Upper A-Arm damaged 6. Lower A-Arm damaged 7. Right front Rim damaged 8. Right front shock damaged
STRIPPING AND PREPARATION The first major task was to strip the quad totally. The frame had to be completely bare in order to put it through the straightening process. It took about a day to get everything off. It was also noticed in this process that the top engine mounting had broken from the impact of the accident. The right hand front shock may have also sustained damaged but at this point we are uncertain and will test it later when assembling is ready to begin.
A 12 ton press and a 10 ton Frame straightening kit was used to repair this frame and the A-arms.
The Frame was sent to the Powder Coaters and was painted in a Aluminium colour. The A-Arms were painted with a 2k enamel paint. The A-Arms could not be powder coated otherwise the ball joints would be damaged by the heat which is used to bake the powder coating.
ENGINE & SWINGARM ASSEMBLY Basically, what came out last needs to go back in first. So it was a matter of putting the engine into the frame and securing it on the bottom and front bolts. Then it was time to move the swingarm in place and to put the pivot bolt through that secures the swingarm to the engine and the frame.
Pivot Bearings still looks perfect. Just for good measure we repacked them with grease to make sure they still perform for a long time. You will notice in the second photo that sub frame has also been mounted.
FRONT A-ARM AND SHOCK ASSEMBLY This was going to be interesting to see everything would aline properly. As the damage on this quad was all on the right side and we had to repair the upper A-Arm, we would now find out if the repairs were successfull or not. All went well and we managed to fit the A-Arms without any hassle. The alignment of the A-Arms couldn't have been better.
We first assembled the left side which did not have any damage. Then we assembled the right side to make sure everything fitted properly. You will also noticed that we painted the A-Arms black to give them a aftermarket appeal.
OIL SYSTEM & STEERING ASSEMBLY It was now time to start filling in all the gaps. We started with the oil system. We put the oil tank and radiator back. Connected all the hoses and made sure that the hoses were placed in the correct paths. The steering column was also mounted. We replaced the bearing at the bottom of the steering shaft as it was a bit sticky.
We used Tusk T10 aluminium handle bars to replace the ones that had bent from the accident. We also replace the stock clutch lever with a billet click adjuster lever. We also replaced the twist throttle with a new one for smoother operation. You will notice in the second picture that we have also put on a new bumper. You will also notice the exhaust is on but not tightened as we wanted to check the fitment.
FRONT FENDER REPAIR

REAR BEARING REPLACEMENT

QUAD IS FINISHED!
Now that the quad is finished I can list the following extra's: Tusk T10 Handle Bars Billet Click Adjuster Clutch New AC Bumper New Nerf Bars Hot Cam Pro Circuit Slip On Exhaust Spacers All Round Tusl Billet Brake Block Off Twist Throttle Black Number Board

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