MPDano New Project: 1985 ATC 250SX **DONE**

[Hair Bear Bunch]

All this in under a month? I salute you sir!

[MPDano]

All this in under a month? I salute you sir!

Thanks sir. This is a real fun project.

[MPDano]

Mounted the front tire. Put a patch repair on it first, nice having a pool to check for leaks, lol. Put the wheel back on, which is a bear to line up and not without scratching my newly painted forks up too. Brakes work great, now to source the brake handle and cable. Painted some tank sealer on the gas gap so it will never rust. Installed a new gas cap seal too. Hooked up a new key switch so I don't have to jump wires now. Got a 2nd hand OEM starter switch coming so I can then hook up the choke and rear brake cables.

[Big G]

Did you install a new rear drum seal? Couldn't see one in the pic. Also let me know if you're still looking for a front brake lever. I have an extra one which is new - I don't need it anymore.

[MPDano]

Did you install a new rear drum seal? Couldn't see one in the pic. Also let me know if you're still looking for a front brake lever. I have an extra one which is new - I don't need it anymore.

Didn't know there was a drum seal, all I saw was a large metal clip in there. I do desert riding so not too worried about moisture. Good to know tho. Oh wait, you said rear. I never opened the drum up, the brakes work so didn't feel the need to.

Yupper, still looking for parts and they are in my ebay shopping cart, but funds come in slow, lol. Do you have the full right front brake perch/handle? If so, how much do you want for it shipped to 92021?

Thanks,
Leo

[Big G]

Ah dang...just the lever, no perch

[MPDano]

Ah dang...just the lever, no perch

Bummer, yeah all front brake including the cable and bottom loom holder missing on my ATC. Seems like they started to part out at some point.

[MPDano]

Finally got a working starter switch. Attached a new choke cable and she works like a charm. Found a large nut and ground off the threads and installed on the front axle to fix my centering issue. It is a little bit too wide but at least i know to get a couple large washers and this will fix it. Also, got an inline fuel filter installed. Will probably not use the in tank filter as it probably wont fit anyways with the tank seal lining. At least this way, I can replace filters without draining the tank.

[Big G]

Glad to see you got the front wheel centering issue resolved, but from looking at pic #4, it seems like the tab from the front shock is just barely catching the slot in the drum due to the extra spacing now?

Also, where did you get the new switch?

[MPDano]

Glad to see you got the front wheel centering issue resolved, but from looking at pic #4, it seems like the tab from the front shock is just barely catching the slot in the drum due to the extra spacing now?

Also, where did you get the new switch?

Yes, this is why I am going to washers versus that large nut. This will get more of the slot in. Switch came from eBay. Got it for $28 with a broken choke lever, swapped with my good choke lever, done.

[MPDano]

Mounted the new kicks on the rear wheels. Yes, the left wheel is 3/4" wider and is aluminum, right is steel. I'll sort that out at a later date. Installed the new rear brake cable/adjuster, reverse cable and new petcock.

OMG! Do these 250SX 4 strokes have torque. Popping a wheelie without effort was awesome. Was itching to do this test run, especially to see if the reverse worked. And yup, works great.

[Big G]

Where'd ya get your petcock from? The aftermarket one I got for my SX was from Dr. ATV, and it sticks out past the side of the tank when threaded on, which I find looks kinda odd. Yours appears to be almost dead on to OEM, unless it's just the angle of the picture.

[MPDano]

Where'd ya get your petcock from? The aftermarket one I got for my SX was from Dr. ATV, and it sticks out past the side of the tank when threaded on, which I find looks kinda odd. Yours appears to be almost dead on to OEM, unless it's just the angle of the picture.

Nope, it's pretty flush. Lever slightly hits the tank when putting on reserve. It was a cheepie chinese one off ebay. Got it for $6.49 shipped.

[Rob Canadian]

Most people would have torched what you had at the beginning. GREAT save. Props to you.

[MPDano]

Most people would have torched what you had at the beginning. GREAT save. Props to you.

Ha ha, yeah. I love a good challenge though. Plus, I get to learn on these as well. Always a fun process.