[trx250rforlife]

im wondering if i could replace all the bearings, check for cracks and put a gusset kit on without tearing it down to a bare chassie. i would like to keep the electric, steering, motor, and last the brakes. i would take the swinger off, a-arms, intake, radeator, and pretty much everything else to check for wear. i just wanna no if i could replace bearings, and check for damage without going to a bare chassie. im not power couting caz its not in my budget, and i really dont care caz the paint is pretty nice now.

thanks

 

[86Rman]

Why not tear it down if your gona go that far. You would already be 90% of the way there?

 

[trx250rforlife]

caz im scared ill mess up the electric or not be able to put it all back together lol!!! it would be my first time ver doing something in this area.

 

[86R]

Why not tear it down if your gona go that far. You would already be 90% of the way there?

What he said....
Seriously, if you're gonna go through and put gussets in and all, you may as well strip it to the frame. It makes life easier when you are working with it, and you may find things you otherwise wouldn't have caught...... Besides, you'll have to paint the welds when you put the gussets. You'll be okay getting things back together.
That's kinda what the forums are for.......help.

 

[Langbolt]

Once you tear it all down....you'll see they are NOT all that complex. Besides....if you get stuck with something we're here to help walk you through it.

If you need Diagrams or Pictures we can supply that too.

I can't think of a better way for you to get to know your bike inside and out than to do a teardown and build up.

ESPECIALLY remove the Swigarm Bolt and lube it up real good when you put it back in!!!

 

[lilredridenwood]

if you have a digital camera take lots of pictures before you start. the wiring is pretty minimal and fairly self explantary. unhook the spindles and the stering stem and brake line clamps and you can remove the whole setup. same goes for the wirring.

 

[mfr422]

Get yourself a FACTORY manual, it has very clear diagrams for wiring and the cable routing, I wouldn't want to be welding with my engine still installed as it will be in the way. Like the other guys said, you're 90 perscent there anyway!!

 

[diesel]

Don't we have a service manual available as a PDF on this site?

 

[Pumashine]

im wondering if i could replace all the bearings, check for cracks and put a gusset kit on without tearing it down to a bare chassie.

You can strip the paint, install the gussets and repaint. But Its not gonna have a good looking finish. You are not going to see cracks cause they are under the paint. The best way to do the operation is strip it down sandblast then install gussets and repaint. It is the easiest to get a bare frame put on the gussets and PC or paint. Then Take off everything from one quad and put it on the bare frame. Usually only takes a day to do the swap and everything is fresh in your mind. Concentrate on the swingarm first cuase that bolt may take a week to get out. If it does not move freely order a new bolt and cut that one out if you want to do it in one day. Good luck

 

[destey]

Tear it down because to weld the gussets you need to strip the paint. To strip the paint you need to blast. To blast you need everything off. If you leave stuff on, it'll get medium blasted, powder sprayed, then heated to 400.

There was only one thing on my frame when it went to the metal fabricators, the stem bearing and that was because I was lazy and it seconded as a mask. It was being replaced anyways. Basically everything would get ruined going through the powdercoating process.

My suggestion; strip it completely. Save everything. Keep everything in little baggies with labels. Buy a bolt kit off ebay. Between that and the bolts you saved you should have the hardware for a rebuild. Replace all the seals and bearings all over the frame.

I'd leave the motor together. I rebuilt mine during a complete teardown and wish I had done the two separately as they're both big projects.

 

[Lasher-19]

Why strip it done? Easy....it is fun to do!

Every winter I strip my quads down to the frame, to check everything out and it gives me something to do.

Plus, I would never want to weld with the electrical still hooked up. But that is just me.