Hi everyone! My 1986 BR!

[BoxerBoss]

Hey guys and gals.. Rob here..

Been following this site for a long time now and I'd like to first off thank you for all the information and links!

/// Start Background

Around 2001-2002 my friend and I got ahold of two 1986 Honda Three wheelers. Mine was a 1986 Big Red and his was a 250sx (exactly like the 2 pictured in the Clymer). We rode the hell out of them and by all means we beat the living crap out of them. Its a shame we did considering how much of a gem these things are today! No regrets for the sake of fun though!!!

Well as life went on, I joined the Navy in 2006 and he let me keep the BR at his house in upstate NY while I served. It was kept under a tarp behind his house outside for 10 years. Mind you, it was running when I left it there.

So, just last year I went back home to visit and he mentioned me taking the BR back. So I did and put it on my truck and thought about what the hell I'm gonna do with this old beat down thing.. Sell it? Part it? Rebuild it?? Brought it back home in North Chicago (where I'm currently stationed) and got it into the garage. Checked the oil, air box, spark plug.. all the normal stuff. I put just a bit of trans oil in the top end and tried to kick it over, betting it was seized up. NOPE!! Cleaned the spark plug up and checked for spark... Yep! So what the hell lets try to start it up! The gas tank is rusted out on the inside and leaks so I rigged up a 2 liter bottle with fuel in it and gave it a whirl.. Sure enough after just a few kicks it fired right up!! I ran through the gears and everything worked just as I parked it 10 years ago!

Just hearing the engine running, and that distinct smell of exhaust when you first fire it up brought back so many memories.. The choice was clear.. Were gonna restore the BR!!

///End Background Story

My daughter (11 y/o) and I cleaned it up and sprayed it down with PB. We already have everything apart and I have even got some replacement parts waiting to be installed. Currently, everything is bagged and tagged with the engine out of the frame. I'm thinking of having it powder coated. Though I'm not sure yet, I enjoy the time and pride it takes to complete a project, though powder coating is much more durable than epoxy.. Thoughts?

So as I said everything is apart and it all went smooth with the exception of the lower motor mount bolt. The issue is it sat outside for 10 years and was probably never removed since manufacturing. I managed to snap both heads off each side and have now resorted to using an easy out and slight heat to get it to turn. Unfortunately the casing snapped on the engine but not where it would cause the engine to leak (I'll add pics of this). Looking for advice on a possible fix or temp repair for this. Id like to not replace the lower end unless I absolutely have to.

Thanks again for the help and inputs on the forum. I considered scrapping her but after I saw the support online here I decided to stick with it!

[RenegadeMaine]

Sounds like an exciting time for you, man. Thanks for your service and good luck with the project!

[BoxerBoss]

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[BoxerBoss]

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[Keepah Rolln]

Welcome to the site...

[BoxerBoss]

Thanks for your support! And, yes it most certainly is a great time!

[filbs]

Nice big red! 230965

[BoxerBoss]

Nice lineup filbs!

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[BoxerBoss]

Update: Had to get a hold of a new top end. Unfortunately the cam tore into the journals pretty bad and damaged thr cam, head and cover.http://uploads.tapatalk-cdn.com/20160502/01e216c0079c3947956afc7453b76925.jpghttp://uploads.tapatalk-cdn.com/20160502/d5f7b1f7f47dbf40e85616ca70ed249e.jpghttp://uploads.tapatalk-cdn.com/20160502/e274693698a85a07df96068695bc65b6.jpg

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[BoxerBoss]

Luckily I was able to obtain a good top end so while I'm waiting on a gasket set I did some polishing.http://uploads.tapatalk-cdn.com/20160502/f97e538ec934679fbe66367f50555816.jpghttp://uploads.tapatalk-cdn.com/20160502/94cc23aa31f6fd9e4f7b72b3a06c9ce4.jpg

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[BoxerBoss]

Valves are now lapped with new valve seals installed. Really want to put it all back together but thinking I should go ahead and replace the lower jug gasket before I do.. Still waiting on warmer weather to get the frame painted anyways..

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[350for350]

If you do replace the cylinder base gasket, you should at least replace the rings and have the cylinder honed. If there's much wear, go ahead and get an oversized piston.

[BoxerBoss]

If you do replace the cylinder base gasket, you should at least replace the rings and have the cylinder honed. If there's much wear, go ahead and get an oversized piston.
After inspecting the bore and taking some inside diameter measurements I decided to just replace the piston rings and lower jug gasket.. it's all put together now..

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[BoxerBoss]

So I was reading the Clymer I have and it specifically details not to lap the valves and if you do it will certainly cause failure? It goes on to say the valves are coated with a "special" material..

I know people who have lapped them before and have no issues .. what's the big deal ?

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[BoxerBoss]

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[BoxerBoss]

Got into some warmer weather so I decided to finally throw in some etching primer..

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[BoxerBoss]

I used this engine enamel on some parts and it turned out very well.. says that it is oil and grease resistant.. looks like I'll be using it on the frame..http://uploads.tapatalk-cdn.com/20160519/ac2aa4db00258aac00c7ee50d71209d3.jpg

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[BoxerBoss]

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[BoxerBoss]

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[coolpool]

Looking good. As for your lapping question a few posts up, I've also heard to not lap them as thay have a hardening material on the seats? I'm here to say I've lapped valves on two Honda and one Suzuki engine and never had an issue. Bear in mind it was a light lapping and not grinding away for an extended period of time.

[BoxerBoss]

Looking good. As for your lapping question a few posts up, I've also heard to not lap them as thay have a hardening material on the seats? I'm here to say I've lapped valves on two Honda and one Suzuki engine and never had an issue. Bear in mind it was a light lapping and not grinding away for an extended period of time.
Thanks. I've done the same on different engines just was wondering what was so special they has to mention it in the book. I used light compound and a hand lapper.

Guess I'll see how it goes when we run it.. would be a shame if I had to Crack it back open after all this work.

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[BoxerBoss]

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[BoxerBoss]

Made it in with minor scrapes to the frame and engine.. along with a crushed finger.. didnt break but bleeding underneath the nail

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[BoxerBoss]

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[scubasteveo]

What did you use to clean up the aluminum on the head? I want to do this on mine, but mine looks horrible!

[BoxerBoss]

Easy.. portable sand blaster using aluminum oxide with glass bead.. Took about 15 minutes to blast. Used pressurized air to remove any left over media.. wiped it down and sprayed it with acetone to prep for paint.. Then only 2 coats of VHT Flame resistant aluminum color paint on the heat fins and a few more coats on the gear box. I decided not use any clear coat.. mainly because I don't plan on running it often and I saw some posts where the clear coat failed.. (probably some mixed opinions out there)

Obviously.. if you decide to use blast media on thr engine be damn sure to tape everything off and stay away from those areas while blasting if possible.. I even stuffed rags into the exahust and intake ports.. Leave the oil line on during the process..

I think it turned out better than expected.. I do plan on replacing all the fasteners with stainless.. I'll be putting the rear end back together and installing that this weekend.

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[jkg2003]

Keep coming with the updates! Looks great!

[BoxerBoss]

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[BoxerBoss]

Question.

As I am getting closer to standing her up on tires.. The ones I have are dry rotted and severely cracked.. I would like to keep the original rims and stock tire size. Where can I get some tires at a decent price?

Couple other things.. what type of foam is used on thr seat ? Mine was repaired years ago however the type of foam used was wrong so it's too soft.. Anywhere sell the correct foam.. maybe possibly cut to match the stock seat?

Last one.. Anyone have any spare swing arm dust caps? Inspected and repacked the bearings today..Where can I find the swing arm dust caps?

Thanks again for the comments, been slowly picking at the build one day at a time..

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[Degoragon]

looking good!

[tripledog]

Welcome to the site, BoxerBoss, and thanks for providing the great pics (something I have a difficult time with). I repaired the seat on one of my 250 Big Reds with foam that I cut from a motorcycle seat and some 3M spray glue. I replaced the missing foam in thin layers, and although it is not perfect, it looks MUCH better than what I started with.

[BoxerBoss]

Thanks! Wow nice work!

So where did you get the seat cover? I saw some on ebay.. I would like to try to make it look stock.



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[BoxerBoss]

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[BoxerBoss]

Rebuilt the final drive.. new seals and bearings.. Axle housings are on.. stooped since I don't have the outer bearings yet..

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[tripledog]

Thanks! Wow nice work!

So where did you get the seat cover? I saw some on ebay.. I would like to try to make it look stock.



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Here you go... http://www.ebay.com/itm/Honda-ATC-250ES-BIG-RED-seat-cover-other-colors-/291748977580?hash=item43ed981bac:m:mCsmW18BZlmIcqY iIU23dFQ&vxp=mtr They offer many color options/combos to choose from.

[BoxerBoss]

Thanks !

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[86125m]

This is as cheap as tires in that size come http://www.amazon.com/Cheng-Shin-C829-Tire-Application/dp/B0012TTCJI?ie=UTF8&psc=1&redirect=true&ref_=ox_sc_sfl_title_1&smid=AJO8BSPGGJBVI. I just put 2 of these on the back of my 200m and they are great.

[BoxerBoss]

Yeah that is pretty cheap.. Thanks !

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[BoxerBoss]

What about rims ?

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[86125m]

as long as you original rims are ok those tires will be just fine as these are the stock size. But if you are in need of new rims these rims are great replacement for the rear rims. https://www.rockymountainatvmc.com/p/3376/8633/ITP-Steel-Wheel?v=1909 they are also the cheapest you can find.

[BoxerBoss]

I've got one rim where one of the stud holes are broken.. I'm sure I could run it but cosmetically it looks like crap..

Thanks for the help

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[BoxerBoss]

as long as you original rims are ok those tires will be just fine as these are the stock size. But if you are in need of new rims these rims are great replacement for the rear rims. https://www.rockymountainatvmc.com/p/3376/8633/ITP-Steel-Wheel?v=1909 they are also the cheapest you can find.
Thanks!! I'm just gonna go ahead and order all new rims and tires. Hoping to spend around 300 at most.

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[BoxerBoss]

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Since im waiting for outer axle bearings to finish up the rear end I Went ahead and started running the electrical.. anyone have any pics of theirs ? I've forgotten where all these mount on the frame. (I know I should have took pics)...

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[86125m]

Yea I have been there will it work yes but will it look good not really. I just had to put to new rims and two new tires on my 200m and it was not cheap but it look and rides so much better

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[BoxerBoss]

Gas Tank....

Externally mine is in good order in regards to paint.. sticker.. no major dents.. However...

Internally it is severely rusted, and not just surface rust..

I've seen alot of videos on YouTube along with many different methods.

What have you guys used that is effective, excluding taking it to a shop.. I'm not looking for a "quick fix".. I'm taking my time on this build so if it's somehing that takes time for it to be right then that's what I'll do.

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[BoxerBoss]

Fresh oil and spark plug.. let's see of she runs!!


https://youtu.be/TmHIM_zFr0g

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[deejaycee_2000]

With regards to your wiring path, the manual shows you exactly where to route each section. With your tank, pool acid really works well, I have used it on about 5 tanks and it works great. If it is badly rusted I first add a few hand fulls of nuts and bolts with old fuel to get the big rust off and then use the pool acid. After that coat the inside with Kreem fuel tank liner. Problem solved for life.

[BoxerBoss]

With regards to your wiring path, the manual shows you exactly where to route each section. With your tank, pool acid really works well, I have used it on about 5 tanks and it works great. If it is badly rusted I first add a few hand fulls of nuts and bolts with old fuel to get the big rust off and then use the pool acid. After that coat the inside with Kreem fuel tank liner. Problem solved for life.


Is the pool acid the same as murlatic acid ? I've seen it used on YouTube.. I've since figured out the wiring. Was actually pretty easy.

Thanks !

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[deejaycee_2000]

Hydrochloric (Muriatic) Acid that is correct yes, its cheap and easy to use.

[83ATC185]

i use apple cider vinegar. It takes longer, might take 2 or 3 days of soaking but it wont eat through what good metal is left. Use gravel or bbs or nuts to shake the big chunks out. Might take a few rinses to get it to come clean but it will be spotless when you're done. Be sure to rinse a few times with water followed by alcohol, then oil the inside until you're ready to coat.

[BoxerBoss]

Hey all - sorry it's been radio silence here for quite some time but life happens, ya know!! I didn't give up on her !!!! Moved in a new house with a bigger workshop so more projects!! Got back into the BR!! Here's some pics !

About to run through the electrical system.. Never had a battery in it before - any recommendations? Is it a standard ATV battery?

Also, I put the gas tank project on hold and opted for the plastic one for now. I plan to ride and use this machine so maybe later on I'll get one of my original tanks redone..

I really dont like the China carb so I decided to rebuild the OEM carb and found the choke plunger is frozen. I was able to remove it but unfortunately during the process I broke the slide arm. (I threw a lot of things around and cussed a lot.. cant believe I did that !!!) Luckily I have a spare parts carb from an 85 for that.. I have a Shindy rebuild kit ordered.

ITP universal rims, tubes and tires mounted (that was fun lol). Rear/front brake cables and foot brake cables are here. Right now I'm looking for cable routing information so if anyone has that please let me know =]

Other than that she's going together fine so hopefully after next week we will have a rolling and ridable unit on our hands.
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[BoxerBoss]

Well, I been pushing a bit to get her trail ready by memorial day and it looks like we made it. Here she is in all her "glory".. She's not as pretty as some out there but mechanically she runs perfect. Been putting her to work around the yard. Amazing how even after all these years I can hop on it and ride er' just as I did when i was 19!! After this memorial day weekend ride I'm going to take the plastics off and paint them with Krylon to try and get the deeper "honda" ATC red again.. Gonna' take all the bent front/rear racks off and try to repair.. Sandblast and paint them as well. I dont really like the looks of the plastic tank but even if I did have one of my metal tanks in good enough working order to put on the machine I'd probobly run the plastic in fear of damaging the metal one.. I'll get to it one day ;)

Here's some pics for all to enjoy. 3WW is an awesome community and great resource! Thanks everyone!

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[fabiodriven]

You know you could wet sand and buff the plastics to get them deep shiny red again.

[BoxerBoss]

You know you could wet sand and buff the plastics to get them deep shiny red again.

Had no idea. Thanks!