Body removal? By alansd (Read 773 times)

[alansd]

I am trying to take off the main body section under the seat and all. I am not sure what clips on and what screws on. I removed the screws I found also inside the storage area, took off the luggage rack, now what?

[jct842]

What are you working on? Pictures would help.

[Bashan]

The next step is Jack Daniels. You'll need some by the end of the process. The body panels are held together by a combination of screws, bolts, and tabs/slots. Each body type is different and you just have to find your way. First take the seat and bucket off and get them out of your way. There are several different seat configurations but there's usually a bolt running through the hinge and it's obvious. Then you'll want to get the access panel off that's under the seat. There will be screws or bolts where you see the dots and the floorboards must come off:

Here's where the Jack Daniels comes into play, you have to carefully pop the tabs out of the slots and work around the panel until all of them are loose.

The panel should then slide out.

Once the front access panel is off you can remove the bolts or screws holding the side panes and start working on the tabs for these pieces:

I wish I could give you an easy step 1 thru 12 process but you just have to find your way as each scooter is different. But for each panel, there are screws, maybe bolts, and the dreaded tab/slots. If the plastic is cheap, some tabs will break off. The better quality plastics are more rubber like and will bend and give a little. If a panel won't come off, there is a screw or tab holding it. It's there, you just have to find it.

[Guitarman]

If you don't like Jack straight up, then mix it with Mountain dew. Dew was actually made for mixing with whiskey. Yes, its true. Even I couldn't make that one up. LOL
Everytime you break one of those stupid little tear-off tabs, take a big swig of your drink. By the time you get it all off, you won't mind the damages.

[Bashan]

Oh no kidding on the Mountain Dew!? That makes sense because it's so syrupy. Huh.....L & L.

[alansd]

thanks. I prefer Irish whiskey but I get the point. Those tabs are a b**ch. I got a crack in the side I am going to fill and sand, better to have the body parts off to do it.

[cookees]

I usually just use a big hammer and a pair of bolt cutters. Duct tape helps put it all back together

[mxmatt]

I have found that straight up Super Glue will actually do very well at holding those broken tabs in place as well as other cracked or broken panel pieces. I have some serious damage to my front shroud that I took the time and was careful to glue back together, even puzzle like. After a full cure I placed a good quality packaging tape on the underneath side and have been crack free for months. Good luck!

[Bashan]

Cookees could not figure out why the customers were not happy with the body repair jobs.