I have a 2005 SUNL 90 purchased from Racewayatv.com that my 6 year old rode until the frame broke at the rear a few months ago. I have been fighting with SUNL since then to get a new frame and it finally came this week. Has anyone ever swapped frames on one of these or have a parts breakdown/manual? Thanks.

 

much, much, much easier to just weld and reinforce the frame you already have, both of my sunl 70's have been reinforced, it is alot easier to just do that, than it will be to change everything over, also unless you reinforce or got the newer model frame, the new one might break as well if you don't reinforce it. Just my opinion.

 

i agree with dealseaker, why would you want to replace a junk frame with the same junk frame, better off reinforcing the existing frame, i assumed it broke at the swing arm bracket like the rest of sunl frames, reinforce both top and bottom of the swing arm brackets both sides and you'd have a much better frame without worrying about the new frame breaking again, if you don't have a welder , you can take it to a weld shop and the cost should be somewhere around $100, cheap compared to the 3-4 hours of labor to replace the frame and still have the same junk frame you began with

 

They did send me the new model frame. Does that change your opinion? I just didn't want to get started without some kind of instructions.

 

does not change my opinion, a guy up the road did both of mine CHEAP, well he races motorcycles and said I think 15 dollars on the first one, I think I gave him more, but he did such a good job, I took the other one to him, it was about the same price, I think, I think I gave him more that time too, but I don't think both quads cost 50 to do, if it is just one, heck you can get it done for cheaper than 100, I'm pretty sure of it.

 

spike282

As far as anyone's opinion goes, it's really entirely up to you. They're your quads. If you want to spend a few hours replacing parts, then do so. If you would rather have them welded, then have them welded. Save the new frames for when you can no longer weld on the old ones.

If you decide to do the swap out, and you do not have the service manual, remove the plastic from one of your 90's, use this as your go to quad for reference. There will probably be some point during your parts swap out when you forget where a part goes or which way it should face. Without the service manual the second quad used for reference is the next best thing. The quads will be similar in design if not identical.

When you remove a part, go to the new frame and install it right away. That way there is little room for error. There may be times when it is better to wait and install some parts because it will make it easier to install the ones that are going to give you trouble or get in the way of others. Obviously take the plastic off first and install it last.

Just remember the swap out may be time consuming, but you will gain the knowledge on how to put your quads together. I'm sure there is going to be some frustration involved too, but just remember to be patient.

Make sure you have plenty of plastic ties, cotter pins, and thread locker handy.

Good Luck. [img]i/expressions/face-icon-small-smile.gif[/img]

SB.

 

new design sunl frame yea right. you need to reweld the frame then grind the weld down and add a 3/4" 6" long tube wrap around the area of the broken frame , 4 places , above and below the swing arm gussets both sides,

 

Okay. I am done. The only issue I have is that I had to unscrew the throttle cable from the carb during the swap and now the throttle seems to just move free like it not moving anything in the carb. Any ideas?

 

Unscrew the cap then spin the slide around until it drops into the throttle body, screw the cap back on. Then retest the throttle.

At least you got it done in an afternoon.

Again it doesn't really matter what the others think you should do. As long as you are happy with the end result that's all that matters. [img]i/expressions/face-icon-small-smile.gif[/img]

SB.

 

I call myself spinning the black piece around until it fell in but I will try again tomorrow. Thanks. I am just proud of myself that this is the only issue I have since I have never done anything like this before.