Sleeper Quad - Yamaha YFZ450 Forum : YFZ450, YFZ450R, YFZ450X Forums
  • 1 Post By southern_thunder
  • 1 Post By gibble888
  • 1 Post By Johnrodg
LinkBack Thread Tools
post #1 of 10 (permalink) Old 03-15-2013, 04:17 PM Thread Starter
Junior Member
Join Date: Mar 2013
Location: Flint, MI
Posts: 8
Sleeper Quad

I need to brag a bit being that this is the first time I've ever done a project this big by myself. I took my 04 YFZ450 to the Silver Lake sand dunes in Summer 2011. The air box fell off and sand destroyed the cylinder/piston. The quad was given to me by a friend going into the USAF and it wasn't maintained very well to begin with.

I spent last spring, summer, and most of fall rebuilding the top end and learning everything there is to know about these quads. After all was said and done, I had $1320 into a 478 big bore kit, new titanium valves, starter, solenoid,gaskets and o-rings, and timing chain and slides. I had the piston coated at Line 2 Line for a good 2/1000s clearance and better compression.

I thought that was the end of it. After we got it all back together, it ran for a few minutes and came to a screeching halt AGAIN. WTF!? The crankshaft assembly had seized up completely.

I ripped it apart again and had my mechanic friend help me with the lower end because we all know how much of a doozy those trannys are not to mention all the syncing that has to take place while building it back up. I replaced the old with the new. A Hot Rod crankshaft asy, hot rod crank bearings, Wiseco clutch plates, gear stator gear case cover (cracked in previous reassembly of motor), battery, new front and rear sprocket and chain, lots of oil to flush the metal shavings and crap from the lines, new filter, and jets. Thus bringing my grand total to $2,065. FML. Parents aren't happy. I don't care, I was in too deep already.

Definitely worth it! After lots of breaking in in first gear around the neighborhood, I got it up into 3rd gear and she's still lifting up in the front!
Can't wait to see how it really performs out there. There is an excessive amount of torque and power like I have never felt from a 450, even the newer Bill Balance that my friend bought new (but I do envy his fuel injection).

I call it a sleeper quad because all the modifications are unseen. The plastics are sh*t and have white stress marks and will eventually be replaced. Tires are God awful and are 10 years old. My best friends cousin hit a tree at 40+ mph and demolished the front bumper which in turn ripped a weld point from the frame. That will get fixed soon. The frame itself looks like it has been sitting in a sand blaster too long. The exhaust will get heat wrapped or coated at Line 2 Line.

All in all, it may not look pretty, but it'll definitely kick some ass! Warmer weather would be much appreciated at this point!
Attached Thumbnails
Click image for larger version

Name:	20130310_161741.jpg
Views:	399
Size:	95.9 KB
ID:	17401  
FishKU7 is offline  
Sponsored Links
post #2 of 10 (permalink) Old 03-20-2013, 10:45 AM Thread Starter
Junior Member
Join Date: Mar 2013
Location: Flint, MI
Posts: 8
Spent a few hours in the shop on Monday night to make this custom front bumper. My best friend's cousin put it into a tree a couple summers ago. It broke the lower weld mount off the frame. We fixed that up with an almost identical washer/nut combo and welded it in place. It's not structural so it will be fine.

We tried our hand at MIG and TIG welding the old aluminum bumper back together and failed miserably. We stood puzzled for a while and off went the light bulbs! Over to the scrap bin to find some 1" steel electrical conduit tubing and some 1/4" steel angle bar. A hand tube bender made it easy to bend the corners or the 20" bar, then we cut the angle bar to length for the four supports.

After tacking it in place, we took it off and welded it. With the added notching to form the angle bar around the tubing, it makes for nice bending stress at certain points if ever in a front end impact and the it would bend instead of destroying the frame again. After a quick wire wheel clean, it went into the sand blaster. That was clutch in this situation and the chrome paint stuck to it and evened out perfectly.

The result is the beautiful hand made bumper that looks straight out of the factory. I'm really proud of how it came out with both my friend and I being rookie welders.
Attached Thumbnails
Click image for larger version

Name:	20130318_214155.jpg
Views:	240
Size:	92.7 KB
ID:	18041   Click image for larger version

Name:	20130318_203140.jpg
Views:	245
Size:	83.2 KB
ID:	18049   Click image for larger version

Name:	facebook_-401041522.jpg
Views:	268
Size:	75.7 KB
ID:	18057  
FishKU7 is offline  
post #3 of 10 (permalink) Old 03-20-2013, 11:03 AM
Senior Member
southern_thunder's Avatar
Join Date: Nov 2009
Posts: 740
FishKU7 likes this.


2008 yfz450
2006 yfz450 drag bike
2003 banshee drag bike
1990 banshee......beater :)

To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.
southern_thunder is offline  
post #4 of 10 (permalink) Old 06-25-2013, 11:33 AM Thread Starter
Junior Member
Join Date: Mar 2013
Location: Flint, MI
Posts: 8
This quad was put to the test at Twisted Trails in Copemish, MI near the end of May. It withstood the brutal pounding of the uneven land and the hard gassing I was doing around corners and through the trails.

It's fate came once again after I hit a 2 foot kicker at about 30 mph and caught some massive air to flat. Came down hard on the rear tires. I didn't know the damage I had done until I hear a loud whine while in 4th gear and I start slowing down. I thought the worst of course but I soon realized it was only my chain that had fallen off. I got it back on fairly easily and continued until it fell off 3... 4.... 5 more times. I put a jack under it to rotate the hub back and tighten the chain and found that my rear axle bearings/seals were shot and the axle was moving in all sorts of directions. Should be a quick hour fix at most and around $60 to get this POS back on her feet.

Worth it.
FishKU7 is offline  
post #5 of 10 (permalink) Old 06-25-2013, 11:46 AM
Senior Member
gibble888's Avatar
Join Date: Apr 2013
Location: norlanco pa
Posts: 124
Glad u didnt break something that didnt need
FishKU7 likes this.
gibble888 is offline  
post #6 of 10 (permalink) Old 01-15-2014, 03:29 PM
Johnrodg's Avatar
Join Date: Dec 2013
Location: SE Iowa
Posts: 37
Thing sounds pretty awesome if you ask me.
FishKU7 likes this.
Johnrodg is offline  
post #7 of 10 (permalink) Old 01-21-2014, 01:56 PM Thread Starter
Junior Member
Join Date: Mar 2013
Location: Flint, MI
Posts: 8
Thanks guys! Your responses got me in the newsletter! That's pretty awesome if you ask me. I have some updates for ya'll.

I finally did the hub bearing swap. It was a lot worse than I thought (see picture 1 & 2). The bearings had practically exploded and had shred the inside of that hub. I was finding pieces of bearings in there for hours; many balls had been shaved into half spheres! Probably wasn't the best idea to keep riding that day... You can see the pieces of the ball bearings, the outer raceway, shield, and cage in a mangled carnage. Picture 3 is how I cut the outer raceway out with an angle grinder on one of the hottest, most humid days in Michigan weather. Is that sweat or tears? I like to think it's a little of both.

I still have a little play in the rear axle after the swap which means I probably need a new (billet aluminum!) bearing carrier, but for now, she's holdin' up.

Picture 4 is a whole new story. I had just gotten back from Silver Lake Sand Dunes. My cousin was coming over. He had been up from Ohio multiple times and every time my quad was decommissioned. He joked, "don't break it before I get there!" As he was making a short drive from my relatives house only 20 minutes away, I decided to warm it up around the yard. All of the sudden, a loud bang a sharp burning sensation on my right calf; the header shot off. If it ain't one thing, it's another... The welded ring that mates to the cylinder head had heated up so much that it had ripped clean off. I learned a little about tuning that day. I needed a new header but the FMF power/megabombs didn't suit me. I opted for the Yoshimura RS-2. This quad is now a little less of a sleeper with that shimmering beauty!

My next projects include:
1. Plasti-dipping the plastics flat black to match my riding gear.
2. a total transmission rebuild (I need suggestions on this). At full throttle, it will slip out of gear, into neutral in 4th and 5th gear. It is the hardest shift when sitting in one place.
3. I need to get on a dyno after #2 is done so I can report my efforts in numbers!

Last edited by FishKU7; 01-21-2014 at 02:07 PM. Reason: Pictures did not show up
FishKU7 is offline  
post #8 of 10 (permalink) Old 01-21-2014, 02:09 PM Thread Starter
Junior Member
Join Date: Mar 2013
Location: Flint, MI
Posts: 8
Pics aren't working.

Try here:
fishku7's's Library | Photobucket
FishKU7 is offline  
post #9 of 10 (permalink) Old 01-21-2014, 03:40 PM
The Stig's Avatar
Join Date: Jul 2011
Posts: 40
"Credit for the building the top end that gives me all that power, goes to The Stig"

You forgot something^^

2010 YFZ450X Bill Ballance Edition
The Stig is offline  
post #10 of 10 (permalink) Old 01-21-2014, 03:52 PM Thread Starter
Junior Member
Join Date: Mar 2013
Location: Flint, MI
Posts: 8
Indeed, the Stig does get credit for rebuilding the top end while I was studying in Germany :)
FishKU7 is offline  
Sponsored Links

Quick Reply

Register Now

In order to be able to post messages on the Yamaha YFZ450 Forum : YFZ450, YFZ450R, YFZ450X Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:


Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.

Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome