Well, due to my accident last month, my four-wheeler was damaged thoroughly. After looking at my options, I came to two conclusions. One, completely cut my losses and eat the 5k I still owe on the loan. Or two, completely rebuild the quad myself. As you can tell from the title of the thread, I opted for number two. So far I have order about $1400 worth of parts and probably need about another $200 or $300 and it should be all set. I'm doing all the work myself so I figured maybe some of you had an interest in seeing a quad built from the frame up. I'm guessing this project will take me a couple of weeks seeing as I can only work on it in my free time but I'll keep up with pictures and let you guys know how it goes. And if anybody actually cares and has questions I would be happy to answer them. I'll only post the "usual" pictures but I have a ton so if anybody wants something specific I can get it to you. The quad being rebuilt is a 2006 Kawasaki Brute Force 650.

Here's the new frame


Radiator and Front Differential install


Wiring harness laid out on new frame


Starting to break down the rear suspension on the old frame

 

Well good luck with the rebuild! Sounds like it would be fun to do. Keep me posted on your progress.

Oh you need a project name for this bike.

 

Project: Disaster Remaster

I cant eblive your leaving the frame stock... I'd take this opportunity to now both reinforce and lighten it. JMO

 

I actually never really thought about beefing up the stock frame. It wouldn't really be hard considering I have a welder and everything in the garage. Don't really know how much beefing up it needs, the old one took everything I threw at it. Only reason I had to switch was cause of the truck/trailer accident cause that's where it received all the damage. I guess when you hit a telephone pole at 50+ MPH it doesn't really matter what type of frame would be on the thing, I'm pretty sure it would have mangled regardless.

I also never thought about having a project name. I'm up for suggestions

 

Everything can be improved, either lighter, heavier, stronger, narrower, wider, shorter, longer, higher, lower or sometimes on rare occasionas all of the above. While I had it to bare bones I'd decide if I wanted something moved or changed. Will never get a time to do it when it's this easy to do.

I vote naming it Project: Disaster Remaster

 

I am going to be lifting it but I never really thought about beefing up the frame itself. The lift is a 2" kit that is really easy to put on while I'm putting the suspension on the new frame. Eventually 28" tires are going to be put under it but right now I'm trying to just get the thing put together. I'm going to be building a new front end for it eventually. The stock bumper is just the same style tubing as the rest of the frame but I would like to fabricate something nice and beefy, sorta like a grille guard. This won't happen until after the quad is put back together because this part is exposed all the time anyways.

Project Disaster Remaster is the only suggestion thus far. I don't think a lot of people are interested in quad rebuilds though so you may have won this fairly easily.

 

Wouldnt be hard right now to drop the A-Arm mounts 4" top and bottom as well as the rear swing arm. A few $'s in metal or free if you have some laying around scrap...then you wont have to buy the kit later.

I'm not trying to talk you into it, but dang what an opportunity to build it just for you.

 

Looks like fun, too bad you didn't have some type of insurance on the quad.

 

Good luck in the rebuild of the kawi... lats year a buddy of mine ran into a car.. and wrote the car off. he had a 700 prairie. He stripped er down and rebuilt it in no time at all. it even ran faster and much more power after the accident.. well anyways goodluck!

 

First, atv insurance is hella cheap. Purchase it.



Powder coat the frame a cool color, rework the motor to make it badass, elka shocks, silver or black plastic.. maybe team green or orange, performance radiator. If I had it down that far and put that much work into it, it would be undergoing some mega changes.

When I changed my plastic from green to silver, I named my 750 ''The Silver Bullet'' and used the Coors logo on it.

If I had kept it green I was going to call it Sergeant Rock.




How about ''Saving Private Brute'' for the name?

 

Yea I know now would be the time to do everything up right and make it badass the only problem is that cash flow on my "toy funds" isn't that large right now. With the recent accident and other bills, I don't have much extra money floating around. If I did, I would throw a big bore kit in the engine and do everything up as much as possible. With a limited budget, just fixing it back to original is going to free up most of my extra money.

And yes I will be purchasing ATV insurance

 

Got some free time today to work some more on the quad. I first got the rear swingarm off and broke open the rear axle to swap out the old broken one and then my buddy finally came over to help me swap out the motor. Only had a couple of hours but everything went well. Now, I just have to do everything all over again backwards. I'll post more pictures as it evolves.

Motor swapped over to new frame


Old axle and gear

 

Well had a day off so I worked some more on the quad. I swapped out the rear axle and then put the whole rearend (suspension and all) back together. Even decided to bolt on the rear plastic and rack. Coolant system is all hooked up along with all the electrical. Re-ran the wires for the winch and started to do the front suspension. I'm waiting for the bushings for the new a-arm and the new front brake lines to come in and then I will be able to finish up with the front. Still have to swap out the throttle cable along with some other stupid little things. Can't do much more til I get the parts I need but I should have it up and running by end of next week depending on how long the shipment takes.

Front Suspension back on


Rear Axle and suspension back on


Rear plastic and rack

 

Looks like progress!

 

Cool!