85 atc250r-much needed fresh up !!

[aldochina]

Some of my NH riding buddies may recognize this lucious beauty!! This baby has been worked over by the granite of NH pretty good! I am giving her the love she needs and deserves!
New bearings all around, clutch cable, throttle cable, front and rear pads, both disks are smoked! Need a rear! new hub studs, bunch off missing bolts, rad flush, gear oil change, and a slight cosmetic uplift! Hardest part of dissasembly so far has been the steering stem. Top nut was very loose, wore 1/4" of threads nearly to nothing, and all that metal just bound up them super fine threads. Lots of penetrant and working back and forth!! sprockets dont look bad, but i will probably replace, the clutch actuator doesnt look like it will survive another hit!! I have that welded up eventually, for now i just want to put atleast 5 gallons of fuel through it before the motor needs overhaul. the top is getting close.
Check out the axle situation for me guys. The nut has barely any spline to catch, I am surprised it didnt fail. The sprocket hub looks like it should be pressed on further no? something does not seem right. I need a good rear disk if anyone can help. Get some pics as it goes back together.

http://i674.photobucket.com/albums/vv103/aldochina/DSCN2172_zps23d569a1.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2172_zps23d569a1.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2168_zpsb905ec7d.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2168_zpsb905ec7d.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2170_zpscb7c5334.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2170_zpscb7c5334.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2176_zps7ed64c27.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2176_zps7ed64c27.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2167_zpsec312988.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2167_zpsec312988.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2174_zpse8edbce4.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2174_zpse8edbce4.jpg.html)

[aldochina]

heres some pics of the axle set-up
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2177_zpsdc40771a.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2177_zpsdc40771a.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2178_zpsdd0d3ef0.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2178_zpsdd0d3ef0.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2179_zpsbf26ebb3.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2179_zpsbf26ebb3.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2175_zps0acc944c.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2175_zps0acc944c.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2173_zps12e5cd47.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2173_zps12e5cd47.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2166_zps8259209b.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2166_zps8259209b.jpg.html)

[aldochina]

pic of the new maier on the 350
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2180_zpsfd589151.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2180_zpsfd589151.jpg.html)

[RIDE-RED 250r]

That R definitely needs some love!

To my eye your axle situation looks normal. The axle lock doesn't need much spline to grab and do it's job. But along witt everything else, I would highly recommend getting a Durablue anti-fade axle lock. They don't use the spline at all and don't loosen up.

Wish I could help with your rotor, I just got a really nice one from KASEY that I needed bad. Check with him, he may still have some goodies..

Good of you to rescue another old hot-rod! :)

[aldochina]

axle looks ok huh? guess thats why it wasnt loose. The rear end was the only thing still tight, but once i took it apart the bearing on the one side is not quite as smooth as i would like. I pm'ed KC, never heard back. I will come up with something. I have never had a problem with the stock nut on the 350, I do check it often.

[roostin atc]

Is that Pauls r your saving Rory? Looking forward to seeing another r on the Richmond trails!

[Mr. Clean]

I have a rear disc brake rotor if Kasey does not have one, PM me and we can work out the details.

[aldochina]

It is Craig!! And saving it I am!! thanks for the offer Clean, I will let you know.
Well I suppose at this point I am just gonna strip it right down. I just cant seam to live with all the rust and grime. I will give the frame a fresh coat, and clean up all the little bits! Swinger bolt is frozen, so thats got to be addressed. worked at it for awhile today. she is sure stuck. Gonna end up on the press.
I have some derlin swinger bushings some where, i suppose i will try them when i re assemble. Man, I just wanted to ride this damn thing!! I guess it will have to wait another weak or so. Something seems funny with the spark plug wire, it was not long enough for the coil to reach the mounting point. the wiring harness needs alittle attention. No exposed copper, but some of the pinch points have worn through the tape and are starting to rub the actual insulation, so i will address that. Basically alot of cleaning to do!
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2196_zps5447b8cf.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2196_zps5447b8cf.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2194_zpsb5ca74b1.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2194_zpsb5ca74b1.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2193_zps2b162126.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2193_zps2b162126.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2195_zpsb4b2741c.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2195_zpsb4b2741c.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2191_zpsc5acc32b.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2191_zpsc5acc32b.jpg.html)
red tool is my home made clutch basket removal tool. works great!

[fabiodriven]

Awesome Rory. Paul got MORE than his money's worth out of that bike. Let's face it, it was roached hard.

If I might suggest, I wouldn't bother waiting to do the top end. The top end in that thing is just as roached as the rest of it was, no offense Paul. :D I used to watch him kicking, and kicking, and kicking to start that thing. First thing in the morning count on 10+ kicks if it didn't foul the plug. Once she's warm count on 3-5 kicks. That's too many IMO. She's clapped out man.

[Dirtcrasher]

Yeah, Paul dd excellent with that machine and I imagine he'd tell you it was time to do some maintenance.

That trike proved how an old clapped out 250R ju8st kept going and going and going................

[aldochina]

I knew full well what I was getting into with this! I know your right Fabs, but I am still gonna try to get a tank threw her. lol, I think it will be no problem just bombing around the yard a bit! I wont be taking it in the mountains without an engine overhall though! I think part of Pauls starting issues had to do with the airbox being plugged with mouse nest!! 2 kicks is all it takes, when it can breathe!!!

[aldochina]

well, down to the last 2 bolts! You all know wich 2 i mean!! Lol. If you've worked on an R in the northeast!
I guess its gonna be a bit before I can ride it, but i got a ton to do here. I will keep updating though. Yup, its almost may, and i got the heavy coat on lol, 33 degrees!
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2205_zps51f9209f.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2205_zps51f9209f.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2218_zpsc7699ed7.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2218_zpsc7699ed7.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2217_zpsbc81b2c4.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2217_zpsbc81b2c4.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2219_zpsbe92e1f5.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2219_zpsbe92e1f5.jpg.html)

[atc007]

If I have learned only One thing in my life. Degrease and steam,BEFORE disassembly :). Seat and fenders off,tank loose,lay them on their side,skids off,and get every ounce of grime off I can before turning wrenches ! Looking great Rory,good luck with those 2 prick bolts,I wouldn't start with anything less than the Tranny/acetone mix.. Will be watching !

[bkm]

Ahh, the old, lets address a few things/total teardown snowball effect. Its hard to tear into them and not want to rebuild the whole damn thing.

[RIDE-RED 250r]

And what was I thinking??!! Mr. Clean has been a HUGE help to me and my build! I don't know that I would have been able to take mine out on her maiden ride yesterday if not for him! Highly recommended! :)

(not to leave out others either mind ya) ;)

[aldochina]

I got the last 2 prick bolts out! had to cut the swinger bolt to free it from the frame. just couldnt get it in my narrow press properly. didnt damage anything, just barely grazed the swinger on the one side. Just kept heating and beating the front mount, and hitting it with the impact and it FINALLY started to move.
Swinger needs the one rear skid mount rebuilt, and will get a design works slider, and derlin bushings. Gonna blast the frame and look it over good, and go from there.
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2235_zps23bf0411.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2235_zps23bf0411.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2236_zps2246ad64.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2236_zps2246ad64.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2237_zps091aa646.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2237_zps091aa646.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2239_zpsf398308b.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2239_zpsf398308b.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2238_zpsb412843d.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2238_zpsb412843d.jpg.html)
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2231_zpsf711b3b6.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2231_zpsf711b3b6.jpg.html)
here is another wonderful surprise!! That has got to be the largest wad of JB I have ever seen!! lol, god only knows whats under there!!
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2234_zpsf165a14e.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2234_zpsf165a14e.jpg.html)

[RoscoW]

here is another wonderful surprise!! That has got to be the largest wad of JB I have ever seen!! lol, god only knows whats under there!!
http://i674.photobucket.com/albums/vv103/aldochina/DSCN2234_zpsf165a14e.jpg (http://s674.photobucket.com/user/aldochina/media/DSCN2234_zpsf165a14e.jpg.html)[/QUOTE]

Could be almost anything except for threads.............

[atc007]

Awesome job Rory! Somebody likes bubble gum!!! What a mess? Didn't he know anyone with a tap???

[aldochina]

I'm hoping its just stripped, and needs a retap, or helicoil. I have know idea the madness behind this repair!! lol