Introduction and my 85 ATC250R complete rebuild for trail/MX

[Math]

Hi everyone!
My name is Mathieu, I'm 28 and live in Quebec, Canada (yes I'm a french Canadian so that explain my mistyping :lol: ).
I have always been on motor bike since I was about 5-6 years old. I had a lot of quads including a 86 TRX250R, a 2004 TRX450R and my not forgotten Arens framed TRX265R
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I have been riding Motocross for maybe 8 years now and I must say it cost a lot less to ride then Quads but it's a different feeling and both have their place.
Here is my actual bike, a 2008 YZ250F
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Now comes the interesting part. Having two TRX 250R, I always loved the 85-86 ATC250R but never wanted to pay 4000$ for a 30 years old beated trike. So one day I open my computer and search about anything from Motorcycle to ATV and find this cheap 1985 ATC250R near my house. A little fast forward and it is now mine.

This trike in bone stock. The last owner had it for the last 22 years and he never rebuild the engine or any major part. It was dusty as hell but I thought it wound't cost an arm and a leg to make a good trail ATC that I could bring, occasionly, to some motocross tracks that accept quads.
So here it is when it arrived home
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The engine was very oily but after a couple of ride there is no leak other then the exhaust!
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The control are sh*t! That is one of the first area I modified as I hated all those worn out parts. The light switch casing is cracked, the lights buttons are jumped together so the light is always "ON" and on "HIGH"
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More to come soon...

[Math]

My brother and I used about 4 liters of engine degreasor and pressure washed the bike during an hour or two before the darknest fall. Then I removed the gas tank to inspect a little more the overall condition.

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The original clutch lever was very loose and the parking brake was shot.
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I installed a forged MSR unit. There is a small bearing in the forged clutch lever so the action is very smooth and the lever feel tight.
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There is also a "on the fly" cable ajuster on the MSR perch. The grip are bicycle lock-on grip brought on eBay for like 3$. I may come back to regular ATV grip since these lock on grip are a good 10mm larger witch let no more free space between the thumb throttle and front master cylinder.
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Picked a black Moose parking brake block off plate. Later I will paint the galipers to refresh them a little.
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[SSLS1]

Cool background story any overall nice trike. Just a little part removal (kick starter, shifter, foot pegs, exhaust) and a shot of fresh paint will go a long ways towards cleaning up the look of the machine. The plastic tank and fenders will clean up easily and you should be able to bring a shine back to them with a dry buffing wheel, no compound. If it runs good with no leaks then you are already smiling. A little clean up and it will be something to really be proud of. :)

[Math]

Cool background story any overall nice trike. Just a little part removal (kick starter, shifter, foot pegs, exhaust) and a shot of fresh paint will go a long ways towards cleaning up the look of the machine. The plastic tank and fenders will clean up easily and you should be able to bring a shine back to them with a dry buffing wheel, no compound. If it runs good with no leaks then you are already smiling. A little clean up and it will be something to really be proud of. :)

This trike will see more then spray paint :naughty:
It will get fully disasembled and almost every part will be powder coated. The colors will probably be far from the original red/blue that I see everywhere. I would like to give it a more modern look: grey frame, black wheels, red seat, etc.

[Math]

The gas valve wasn't completely closing so fuel was leaking when the gas tank was removed. The Honda parts fiche only show the petcock has an assembly #16950-HA2-015 and cost 70$

I had the same problem with my 86 TRX250R but the petcock could be brought in seperate parts on the four-wheeler. I searched here on 3wheelerworld but couldn't find any information about it so I took a chance and ordered TRX parts to rebuild my gas valve witch worked perfectly. Maybe this will help other 86-86 ATC250R owner

The petcock fully disasembled
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Obviously, the fuel filter and reserve tube have all been removed by one of the previous owner
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The old original seal vs the new TRX one
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The spring washer was broken so it was also replaced by a TRX one
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Since there is no more fuel filter in the gas tank I added a gas line filter
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Then come the original air filter. Glad I saw this before I used the trike in the dust!
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It's like if it was in a decomposition state?!
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Next to a new Twin air filter
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I wasn't able to use the metal air filter cage with the Twin Air filter. It just fit perfectly directly on the air box ring. I checked with the throttle wide open and the filter doesn't colapse or anything, it stay fully formed and in place. After about 1h30 of riding, no problem at all!
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[Math]

I cutted the forks boots the find what I was expecting: the two oil seals are leaking badly. If it would have been only that, I would have been happy. What I found without the boots is both forks are bent :(
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Therefore more, the right side fork have some major dent on the chrome! It looks like a f*cking idiot used a pipe wrench on the tube so my forks are basicaly destroyed.
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This got me thinking it was time for the complete rebuild to start in order to find any problem and have a reliable, fun to ride 250R.
Starting the disasembly
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[Math]

Been a long time since I updated this rebuild. It's been a realy slow process so I didn't wanted to give an update once in a month but now, all my parts are at the powder coater so when they come back, it should be a faster progress!

Here's some of the parts I repared as of right now:

My rear shock was leaking oil and the rear suspension realy didn't seems to work fine.
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In this process, I also wanted to move the shock reservoir on the back of the frame, like the TRX250R. I know it will not improve the suspension but I simply like the looks of it and also, the reservoir will catch less chain oil.
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I removed the big frame brace and buffed the frame.
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To replace the short reservoir line I ordered Russel brake line parts
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The reservoir bolt is a little special and seal with a o-ring so the stock bolt was used on this side.
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On the shock body, the hose fitting is build-in the hose. I ordered a banjo bolt from Russel that has the same tread.
I was worried about the oil flow in the hose but the diameter of the hose and the banjo bolts are the same so it should affect anything.
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I and problem finding a kit to rebuild every shock seals but found everything I needed at Schmidty Racing Suspension. They have a nice kit with all the seals, clip and nut. I also ordered two rubber reservoir mount and a bottom out bumper since mine was breaking down.
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Some pictures of the rebuild. I will add more when the spring and retainer come back from the gloss black powder coat
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[Math]

Then comes the brake system...oh god...
EVERYTHING was shot! It's like every single part needed to be replaced, repaired, painted, clean, etc.
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The front and rear brake were constantly applying a little pressure. On slipery terrain, like mud, the front end would drag or lock reasulting in a very dangerous ride!
The rear caliper.
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The caliper body was corroded and the seals were coming off. No wonder why the brakes weren't working right :wondering
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My brother sand blasted the caliper at is job. Then I used JB Weld to fill the missing material on the caliper.
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Then I used a Dremel to remove the excess stuff and to rebuild the dust seals grooves.
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Sorry guys, don't have pics of the finished caliper yet but I will update you soon.

At this time, I realised I needed a new tool to rebuild this ATC and I made myself a longtime wanted gift: a sandblast cabinet! I don't understand why I never brough this before.
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Here is the front caliper before.
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Completely glass blasted. It is hard to see it looked like the caliper was polished!
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So I decided to clear it and it kind of ruined the shiny finish :( I should have painted the caliper like I did with the rear one. For the moment, it will stay like that and maybe I will paint it later.
Reasembled
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[Math]

For the rear master cylinder, I realy wanted to replace it by a modern motocross bike unit with an integrated reservoir. I tried my 2008 YZ250F NISSIN rear master cylinder and like you can see, it is far from perfect.
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I then checked master's from CRF, TRX450R, KFX450, YFZ450, etc, etc. and I don't thing any of those would be an easy/logical fit. So I decided to rebuild my original one.

Disassembled.
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Glass blasted
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Rebuild kit from eBay. Made by K&L and actualy made in Japan
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Rebuilded
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Always hated cross head bolts so I replaced then with hexagone bolts
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[hatc200x1]

I am not sure if you are still looking for a kill switch or not, but there are reproductions on ebay and they look great and work great, I have had mine for a year now and have had no problems. It is modeled after the 86 250r, which has a much more modern look to it. Fit right on my 85r harness no problems. Link below.

http://www.ebay.com/itm/L-H-Switch-Honda-ATC250R-ATC-250R-Light-Kill-Start-NEW-/191843713879?hash=item2caac6c357:g:-I8AAOSwEK9T6ZH0&vxp=mtr

It might be a wise idea to put a brace back in the area where that shock reservoir mount was on the subframe...

[Math]

I brought one of those reproduction switch and I think they are not so wonderfull :cry:
The look and fonction of the switchs seem really good to me.
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The problem I had with my kill switch is the wires poped out the first time I connected the two connnectors together!
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I tried to glue the wires in the connector without success
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I also tried to open the kind of hook on the wires male connector and they still popped out. So I pushed the wires one at the time in the two connectors and hope it will be fine when taped together. If not, I may cut the original connector from my switch and weld it on my eBay switch.

[Math]

For the forks, since my original were bented and dented, I ordered used ones on eBay
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Didn't need to be Einstein to know a rebuild would be necessary.
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I unassembled the 2 forks kit I had, cleaned all the parts and took the best of each forks to build one good kit
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I installed new OEM Honda oil seals and dust seals
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I read good reviews about the Progressive Suspension spring so I installed a pair of their springs
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Poured 10W fork oil and installed black Daystar 83 series fork boots
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Waiting for the frame from the powder coater
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[Math]

Finally received my parts from the powder coater!
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First, I started with the electronics and then the rear suspension.
For swing arm, the stock bearing, sleeve and caps were all rusted together. I ordered Helment bushing here: http://www.atvbushings.com/id2.html
The fit seems very good as for the quality
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In the process to remove the stock part, I crushed one of the sleeves, which is no more available. I used a 450R sleeve and shortened it.
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Then I mounted the swing arm, linkage and rear shock. I must say that I realy like the looks of the remote reservoir :cool:
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Here is the Yamaha Banshee chain guide mounted on the bracked my brother welded on the swing arm
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[Math]

Mounted the triple clamps, temporary handlebar, skid plate, air box and the radiators
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The rear reservoir clears everything nicely
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[hatc200x1]

Excellent progress man. Looking good, keep us updated!

[loshe191]

Looking awesome keep up the good work!

[Math]

Thanks Guys!

Update will come slowly since the warm weather finally arrived and the motocross tracks are now re-open. I will keep you updated of any progress I will make but I will have less time to put on my project this summer than I had during winter :cry:
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Anyway, here's the stock rims powder coated gloss black. The tires are Kenda Klaw 20x11-9 in the back and Kenda Front Max 23x8-11 in the front. In tried the Klaw in the past and really liked how easy it was to drift the rear end of the quad so it should be ideal for a trike
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The rear axle was a little rusted so I painted it with a brass color to look like the Zinc plating it came with. It came out too gold I think but for the moment it will go like this
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[86125m]

The paint really does hold up well just remember to put lots of clear coat on it. Your bike is looking good as well

[Math]

The rear sproket before and after.
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I drilled the aluminium rivets that were holding the sproket guard
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With fresh powder coat
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[Math]

With the axle ready to be mounted, I was able to complete the rear suspension and put it back on it's wheels

To remove it from my work table I hooked the ATC on the ceiling
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Then dropped the rear
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Installed new bearings and bolted the hub in the front wheel
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Front wheel, forks and brakes all bolted
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Making progress
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[Red Rider]

Looking real good Math! Keep us all posted with the updates.

[KDXRon]

Awesome. Good stuff.


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[KDXRon]

I've ran those kenda claw tires in the rear. They are good for breaking loose on corners. Great job on the build.


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[keister]

Good updates, nice trike!!
This is going to look like a new machine when you get done with it.

[Fox250R]

Umm did you need to add spacers for your progressive springs ?

[Math]

Made some progress again!

The engine was working really well except for little clutch drag and the traditionnal exhaust leakage. The previous owner ad this trike from 1987/88 to 2015 and he never touched the engine. To his knowledge, the first owner never touched this engine also. Looking at the piston from the exhaust port I saw that there wasn't major wear so I tought: let's ride it until it brake. Just to see how many more years this engine could do!
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The engine paint was pelling off everywhere so I sandblasted the engine
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Then painted it to look like the 1986 engine color. I think the engine bay look brighter with the grey color then all black
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Then I opened the clutch cover to inspect the clutch. No surprise here: the basket needed to be file
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Completed
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[Math]

Engine back in the frame :p
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Also, I cleaned and sandblasted the exhaust pipe and found several hole in it!
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My brother welded the smallest holes but wasn't able to weld the bigger one as the metal mas to thin. I used a Permatex ciment made for exhaust holes. I don't really trust these kind of stuff so I will check if it hold up or if I need a new pipe. Sorry no pics :(

The pipe and exhaust painted
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I also installed an ESR billet exhaust flange which looks the be great quality. I hope it will stop the exhaust leakage
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[yaegerb]

Nice work mart! Always enjoy seeing your progress. Yes, that ehs flange is bullet proof.

[Math]

So I finaly took the time to finish my project and even ride it a couple of times!

Almost finished
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Little test run in the back yard just to make sure everuthing was fine
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Then loaded the 2R and the bikes for an MX track that accept both the ATV's and bike's
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Me and my brother having a blast on the track. There was a lot of ATV racers at that track and it was quite fun to have them look at us on the track. Like they had no clue why we were beating this old trike on the track and having more fun on it then on our modern dirtbike :naughty:
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My friend testing the balance
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I was used to modified TRX250R in the past and with this stock engine it was kind of a surprise how low in power it actually is! The torque is almost inexistant and the power seems to fall flat with little overrev. You always have to be on the right gear with a finger on the clutch lever. Makes a world of difference compare to my KTM 450 but it's probably what make this trike so much fun.

[yaegerb]

What oil ratio are you running?

[Math]

I was running at 40:1 but switched to 50:1. The plug now as a good color and there is less smoke also. I use the same oil as my snowmobile wich is Motul semi-synthetic 2-stroke oil.

I also saw the exhaust smoking less with every ride a do so I think the exhaust system was covered with old unburned oil.

[yaegerb]

Whew, I hope so brother cause at that ratio and amount of smoke coming out the tailpipe you have no rings left on the piston. I would do a compression test to be in the safe side.

[Griller3Wheeler]

Did you dyno or speed test this thing?