'86 Mugen 250R racer build (updated 8/17/14)

[Buster Brown]

Just started this 250 build last weekend. It'll be an '86 ATC 250R with vintage period aftermarket items. Don't expect any lightning fast progress, but hope to have it done by the end of the summer. Won't really ride it, so no hurry. (here come the haters ) This one will be just a looker! (CAL FAB, WEST COAST, SELVYS) I dismantled an old flat track project to harvest parts for a couple new builds, so some of these parts here, are from that old project.
The Selvy 200R is also almost underway, but I will be using it's frame as a display piece in a local parade for PC'n late May. I'll post another thread on the SELVY 200R build starting in early June.
Hopefully with the leftover parts, between these two builds, I'll have enough to slap a good rider together! It's been way too long since I've had the joy of riding a trike. Anyhow, here's the start of the chassis, and a shot of the future heart transplant. Might even use the Steve Wright SELVY cylinder on this project. More pics and progress to come.

[NINJA]

Andy, you never cease to make me jealous! Sounds like a sweet build.

[ceaserthethird]

Now i know who's hogging all the parts up...

Snap ON gee best of the best LOL

[Dr.Kyosho]

Sounds Great Andy I can't wait visit the Museum when these are all done. You are so far ahead of me I am still looking for a ATC110 new in crate yet!!!!!. I feel like I'm in the showroom of a HONDA dealership in the 1980s when I am there.

[Dirtcrasher]

Nice work Andy!!

That CAL-FAB make ALL the difference in the world!!

[jeffatc250r]

That is a sharp looking swinger! Looking forward to the finished product. You gonna go with a flat track getup?

[Buster Brown]

Got some parts and a little problem. The good news is that no one stole the boxes left on the front porch by the UPS man (darn "driver release"). Bad news is, well........ Calling all Mugen fork kit owners..........I'm scratching my head a little here and hoping someone can give me a little advise on how the pistons are removed from the lower Mugen fork tubes. I can't install the new upper fork tubes, unless I get the pistons out of the Mugen lower tubes first. Unfortunately, the Mugen instruction sheet is missing , but instead I received these handy rear Mugen shock instructions (WTF). The Mugen lowers are different than typical run of the mill factory issue forks (for those who don't know). I've rebuilt OEM forks numerous times, with great success, but I'm just a little hesitant on these, beings they ran so much money. The normal allen head bolt on the very bottom of an OEM style is an adjustable screw style on the Mugen forks. It's located under a rubber dust cap on the bottom of each lower fork leg. -Any kit owners out there, that can help here?? Thanks for any thoughts and guidance!
Here are a few pics of the arrived goodies to be assembled on this build. Hope to get the front end together this weekend.
-Andy

[Dirtcrasher]

I take it that lower nut under them does not release them? or allow a brass punch in there to gently tap it out??

[Buster Brown]

Good morning DC. That bottom nut is crimped on and only seems to turn in relation to the valve. If you look real close down the tubular piston there is a tiny nut and screw. After I shake the cob webs out and finish my coffee I'll see if a 1/4 drive extension and socket will fit down there. This may be the simple answer. I hope so. I really want to make some progress on this bike.

[Buster Brown]

Well I got it figured out and apart. For the sake of sharing and possibly enlightening others on the Mugen fork kit, here are some pictures of the valves and pistons. I had to simply hold the piston from spinning inside the lower tubes and back the valve body out with a 19mm socket. The nuts on both ends of the valves are permanently crimped secure.
Back to work.....................

[jonathandexter]

Nice Build. By the way what is your home / shop address?

LOL Just Teasing. Keep them Safe Bro.

[Buster Brown]

I hear ya! Plenty of locks & lights here. It happens though. Somebody stole my LP tanks off my travel trailer/camper a couple weeks ago. Just had them filled too........ Thieves SUCK!

[Red Rider]

Those Mugen forks look like the forerunners of the technology found in inverted forks of today. Cool stuff!

[jeffatc250r]

Where did you get the S-T Kit? Reminds me of the day I got mine. I really didnt know anything about it or what it was worth since I had never seen one before. I scored it for $75 and it was all nestled in the box just like yours. Looking back, I should have kept it new in the box and sold it to someone doing a resto like you are doing here. I like it and all, It's just im scared to death of rolling it over and breaking it. For the abusive riding I do, I feel bad using it.

[Buster Brown]

$75............... Oh, I wish. A member from another ATV site hooked me up with a buddy of his who had this S/T kit in storage.