So it begins.....my first complete rebuild

[kfxguy]

I starting stripping it today. Wait. I mean I completely stripped it today. Tomorrow I begin ordering stuff and trying to find a place to powder coat my frame that's not gonna rip me off.
Here's some things planned...(I'm not gonna get into the engine bits just yet)

-brand new black plastics
-candy line green frame and subframe
-completely polished engine except for cases
-polished bolt kit for engine and frame
-green monster graphics....they might be a little played out but I still dig em
-chrome powder coated a-arms and hubs
I've deburred the frame already and removed whatever brackets I don't need.
Basically a bunch of powder coated parts. My oven should be in this week.
I don't need brakes or bearings because those were just replaced. So mainly a bunch of cosmetic stuff. Here's some pics.

When I began today (yes I know the tires are on backwards...lol )



Now some stuff coming off.....

And more stuff.....


Here's my son helping. He really enjoyed this and I enjoyed him helping me. He's 12 and learning how to work on stuff.

He ran inside for a couple minutes and come out to this.....


So he asks me how did I get the engine off so fast? Well he didn't realize that he had removed every bolt required to just grab it off there. So told him I just picked it up and put it on the counter. He was shocked that we dismantled the whole thing in such a short time.

I even re profiled the tabs all over the place in an effort to remove weight. It weighed 34lbs without the subframe when I began. Now it weighs 25lbs. Just kidding. I doubt it lost a pound. Lol. Yea, I've lost my mind.....
The one on the right is ground smaller.

[kfxguy]

One thing....I want to paint the engine cases. Powder coating is not an option. I don't think that everything in it will withstand 400 degrees....so whats the best spray paint I can get? I thought about epoxy paint.... But I dunno. It has to be able to hold up to gasoline. I also thought about that wheel paint you get from the auto parts store. I may experiment with that tomorrow. I want the cases the same color as my frame is now...like a metallic grey. Suggestions?

[z455]

I painted my motor with the Duplicolor engine pain and it has held up past my expectations. Especially on the clutch cover, The only tip I have is prep work. I would clean the engine as best as you can paying attention to the little areas in the corners and hard to get places. I wish i did. BULID THREAD WAR! lol yours is going to turn out sick! gloss black and lime green were ment to go together.

[kfxguy]

Build war! Lol! It's on!!!

[z455]

If you really want to lighten it get a high end step bit and start drilling!

[CFM-Z440]

Agreed, I see lots of un-needed metal in those pegs and a-arms just at a glance.

[kfxguy]

Originally Posted by z455

If you really want to lighten it get a high end step bit and start drilling!

I did....and I have. I drilled a few things already last night.

[kfxguy]

Ok so I ordered the complete polished stainless bolt kit. I also ordered all the wiring harness clips that hold the harness to the frame. Didn't even think they were available until I looked. I thought I had to buy the whole harness. I'm thinking about buying a brand new harness anyway. Mine looks shabby.

Now I'm waiting on a return email for my titanium valves and my plastics. Maybe they are closed today. Chuck, I got the valve spring situation figured out. I talked to cv4 today and they make a spring specifically for ti valves. They are good to .400 lift. My intake cam is .400 and exhaust is .410. The tech guy said just set my installed height .010 higher. I'll only lose 2lbs seat pressure. Now I'm waiting on the vender to get back to me on some del west valves. I heard they are the best ti valves you can get and they will work on the factory seats.

[bparks23]

was there any trick to getting the pivot bolt out? i cant seem to get mine to come loose after removing the nut.

[kfxguy]

Plastics are ordered.

[bobmilspaw]

kfxguy - where'd you get the SS bolt kit? i've bought them off ebay for other project bikes but cannot find a kit for the LTZ400?????

thanks!

[z455]

I have heard bad things about the SS bolt kits, more spicificly the thread quality. Let us know how they are and where you got them.

[kfxguy]

Originally Posted by bparks23

was there any trick to getting the pivot bolt out? i cant seem to get mine to come loose after removing the nut.

Try having two people. Don't have any weight on the swing arm. Disconnect the bottom linkage where the arm moves freely. Get a blunt object (I used a long 3/8 socket extension) and lightly tap on it while your friend holds it up

[kfxguy]

Originally Posted by z455

I have heard bad things about the SS bolt kits, more spicificly the thread quality. Let us know how they are and where you got them.

That's why I bought the engine kit first. To check it out. Excellent quality.

[kfxguy]

Originally Posted by bobmilspaw

kfxguy - where'd you get the SS bolt kit? i've bought them off ebay for other project bikes but cannot find a kit for the LTZ400?????

thanks!

Here you go
LT-Z400F Z400 QUADSPORT 508 pc STAINLESS BOLT KIT ATV | eBay