So my frame has some scratches on it and there starting rust being in B.C. I was tempted to just touch up the paint, but since I have a ruckus as transportation I was thinking I would tear it down to the frame and then either fully repaint the frame or get it powder coated.

My main questions are, being that I have never torn down a bike...

How hard is it for someone with a bit of mech experience?

How many sub assemblies need to come off?

How hard is it to put the swing arm back on and have the chain properly tensioned (or any other torquing and such I have a toque wrench)?

I couldent find anything with searches so maybe you guys have some insight. thanks!

 

There are many torque values. Get yourself a manual and take pics as you disassemble. Not much to it. You will be fine.

 

Tearing it down is easy, putting it back correctly, now that's something else lol. As stated above manual and pics will help.

 

Yes, the big question.... have you ever put something very complicated back together? we are not talking toaster!

 

For me the biggest concern will be wire routing. Take pictures of that. A manual will get you through virtually everything if you have fair mechanical skills access to any special tools or a way to get the bike to a dealer to deal with special tool situations to have them remove the item.

I can't really think of anything in a tear down to paint a frame though that would take a special tool that nothing could substitute for it. Only thing that comes to mind would be a spanner for the head set top race/retainer.

 

I tore my parts bike down in a couple of hours, but I wasn't planning to put it back together. I have torn an ATV down to replace a bent frame though. I would suggest a couple of sizes of zip lock bags, a few boxes and a sharpie to group and label parts/hardware. This is critical to help break the bike into bite size pieces for reassembly. As stated by others, take photos of EVERYTHING, especially the routing of wiring harness and control cables. If you don't have 100 pics you probably haven't taken enough. If you plan to replace bearings,brake pads, carb kit, etc. order parts in advance. My last suggestion is don't start until you have the time and motivation to finish the project quickly. It is MUCH easier to reassemble a complicated mechanic project if the disassembly is fresh in your mind. Everything looks foreign after it sits in boxes for a couple of months. Good luck, pics please!

 

Take a boatload of pictures for refference.

 

Best advice ever.


Everything I tear down these days, I bag and tag.


Take out the front motor mount bolts. Into a bag labeled, "Front motor mount bolts" ect ect. It is time consuming but when you are putting it back together and not guessing it is wonderful.


Wiring would be a bit of a nightmare on a dual sport. But I'm sure doable with pictures and taking your time.

 

One more thing when you take the pictures you might photo a label to go in baggie with parts group and then when transferring pictures to laptop or tablet put them in seperate folders numbered the same as the baggie. When you get to re-assembly number 4 baggie and number 4 folder go together! I wished I had done that as well as used a notebook or pen and pad to make notations when I stripped down a majesty yp400 for a top end overhaul. Half of that job was all the crap you get rid of before you get into the motor.

 

Not ever done this, but what everyone else says. Baggies, notes, as in longer bolt here, shorter bolt there. Actually i keep the bolts in their respective cases if possible. This along with a bunch of photo's, notes and baggies.

Torque settings, make notes on the baggie itself. Also, re-assemble whilst fresh.