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

  1. #1
    MPDano's Avatar
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    MPDano New Project: 1985 ATC 250SX **DONE**

    She's pretty thrashed but 90% there. Just verified starter spins great with good compression. Didn't hook up my compression gauge as the exhaust header is missing and not sure if that would affect the reading. I removed the carb and took it apart and put in my Berrymans Can. Ordered a carb kit, fuel petcock and starter solenoid.

    Here is what I know I will need: (prices shown are already bought)

    ATC cost: $80

    Carb Kit: $16

    Starter Solenoid: $7.50

    Fuel Petcock: $6.50

    All Plastics: $287 (gonna go all white)

    Decal set: $41

    Front brake lever/perch: $23.50

    Front Brake cable: $14

    Front brake lever cover: $20

    Front Brake Cable Stay: $17.50

    Front brake cable holders (top & bottom): $10

    Front brake adjuster parts: $23

    Red Kote fuel tank liner: $25

    Steering Stem nut/washer: $15

    Two rear tires - 22x11-8: $110

    Metal air stems: $6

    Header Pipe: $33

    Flex Pipe/Hanger: $15

    MRP Muffler: $0

    Header Gasket: $7

    Headlight Assembly: $32

    Headlight/bulb: $70

    New Grips: $10

    Handlebars: (I have some Renthal bars lying around) $0

    Seat Cover: $26

    Shock Boots: $16

    Reverse Cable: $14

    Rear Brake Lever Cable: $11

    Choke Cable: $12

    Instrument bulbs: $8.50

    Oil Filter: $5

    Spray Paint: $20

    36 ball bearings for steering: $8

    Ignition Switch: $11

    Starter Switch: $28

    Rear brake adjuster: $19

    Fuel cap gasket: $9

    Fuel Tank Dampers: $11

    Fuel tank L rubber: $12

    Instrument Panel: $25

    Fender holder rubber cushions: $20

    Air Filter: $24.50

    Rear Tail Light: $18.50

    Tail light mounts (rubber,pins and collars): $25.50

    Front and Rear Mud Flaps: $85

    Battery Liner and battery holder: $40

    I'm gonna keep a tally on this post if I am allowed to edit it as I go.

    Total in parts as of 1/8/2017: $1235.00 plus $80 for the ATC

    In disassembling the carb, I broke the pilot jet off, do you have a way to remove the broken piece?

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    Last edited by MPDano; 01-16-2017 at 01:30 PM.

  2. #2
    MPDano's Avatar
    MPDano is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Cleaned out the rusty tank with muratic acid today. Got the idea off a youtube video. I should have taken a before pic but it was covered in rust bumps all over the inside of the tank. Rinsed it out with some water then some pre-mix so it's has a bit of oil in it to keep it from rusting up again. Next is to get some of the Kreem tank liner and be done. I've used Por15 in the past but it was expensive. Also, removed all the paint off the tank exterior to get painted after the tank lining.

    Also, banged up my battery holder so it actually can hold a battery. Also straightened up both foot pegs as they were bent to hell.

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  3. #3
    MPDano's Avatar
    MPDano is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Got the carb kit and starter solenoid. Had to jump the ignition switch as well as the rectifier power. Most likely the igntion switch is faulty, gonna get a new one anyways. Shes running, so it's time for the dismantle and repaint that frame.


  4. #4
    82 250r's Avatar
    82 250r is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Good work getting it running. Did you find that trike at the bottom of a river?

  5. #5
    MPDano's Avatar
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    Quote Originally Posted by 82 250r View Post
    Good work getting it running. Did you find that trike at the bottom of a river?
    No doubt. The Craigslist River.

  6. #6
    MPDano's Avatar
    MPDano is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Removed the engine, pressure washed the frame, engine, skid plates and lower triple clamp. Then painted the engine low gloss black, the rest in semi gloss black. I hit the rusty areas with rust restorer first, it makes a great primer.

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  7. #7
    MPDano's Avatar
    MPDano is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Put the motor back in. Hooked back up the harness. Put new steering bearings, got 36 from the local bike shop. Love the simplicity of these old Honda ATC's.

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  8. #8
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    Nice to see you decided to give her a restore, rather than part it out. It's coming along real nice. Did you have any problems removing the front axle? My new 250SX's front wheel bearings are shot, and I've heard the front axle can be a real bugger to remove. I also notice pic #12 the drive shaft boot has an impression the same as mine did when I bought it, however I was able to shape it back to it's original 'ripple', and it seems to be holding. After seeing yours I'm thinking now that maybe it's common for them to develop a divet like that.
    1985 Honda ATC 250ES
    1985 Honda ATC 250SX
    1984 Honda ATC 200M
    1983 Honda ATC 200
    1984 Honda ATC 110

  9. #9
    MPDano's Avatar
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    Quote Originally Posted by Big G View Post
    Nice to see you decided to give her a restore, rather than part it out. It's coming along real nice. Did you have any problems removing the front axle? My new 250SX's front wheel bearings are shot, and I've heard the front axle can be a real bugger to remove. I also notice pic #12 the drive shaft boot has an impression the same as mine did when I bought it, however I was able to shape it back to it's original 'ripple', and it seems to be holding. After seeing yours I'm thinking now that maybe it's common for them to develop a divet like that.
    Thanks, yes I hate parting out stuff. I always see value in getting a thrashed atv and bringing her back to life. This is a keeper. My front axle came out easily, surprisingly. I had a 250R that gave me issues with the axle.

    I was going to add some heat and get that ripple out of the boot, but it will most likely come back after time. The boot is the original and I decided not to replace it as there no cracks and it was still supple. I like to spray all rubber parts with silicone.

    The plastics will be the last things to replace as they are costly, almost $300 for the set. I'll do more to it this weekend as I bought more bits off ebay.

  10. #10
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    It is coming along nice. It was in rough shape.

    Engine looks great. I like the way you removed the paint on the side. Little things like that make a big difference in looks.

  11. #11
    MPDano's Avatar
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    Quote Originally Posted by Rob Canadian View Post
    It is coming along nice. It was in rough shape.

    Engine looks great. I like the way you removed the paint on the side. Little things like that make a big difference in looks.
    Yes, used my orbital sander, which already had a very fine disk on it. I saw a real nice restored one (250SX) with that paint removed and said, why not. If I only had deep pockets, this project would be done already. We are heading on the first Desert Trip of the season the weekend before Thanksgiving and I'm bummed I wont be able to take it. Will have to make do with my other toys.

  12. #12
    MPDano's Avatar
    MPDano is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Got my header, oil filter and rear brake lever in the mail. Wire wheeled the header and heat shield and gave it some paint. Installed the oil filter. Sanded off the faded blue off the Renthal Bars and installed the new left lever.

    Click image for larger version. 

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    Last edited by MPDano; 11-03-2016 at 09:13 PM.

  13. #13
    MPDano's Avatar
    MPDano is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Just got my shock covers in tonight. Gonna get those installed tomorrow and get the forks back on.

    Click image for larger version. 

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  14. #14
    MPDano's Avatar
    MPDano is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Installed the new shock covers, reinstalled the forks. Installed the bars back and put on the new grips. Used some old wet/dry vac tubing hose I saved when the vacuum broke, and it fit like a glove for the frame to airbox tube I was missing. Saved $45 there. Sweet!

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  15. #15
    MPDano's Avatar
    MPDano is offline At The Back Of The Pack Arm chair racerAt the back of the pack
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    Used muratic acid to clean the tank of all rust. Put in a gallon and the rest water, let it soak for about an hour. Drain and put baking soda/water to deactivate the acid. Once dried, I used the Red Kote to seal it. I may do another seal just in case. Painted the tank white. Reinstalled the rear foot brake cable. Removed all the tires, pressure washed them, fixed what needed fixing and repainted one of them. Front and left rear wheels are aluminum and the right rear is steel, repainted the steel one with silver wheel paint. Diassembled the front brake as it was stuck. Brake shoes stuck to the drum. This happens when they are left in the rain and rust builds up in the puddle of water over time. All sorted now.

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