My 1985 Honda ATC 250r Restore Project

[k00leo]

Well, I've been wanting to do this for awhile, and since I just broke up with my girlfriend of 5 years, i thought this would be a good time to start the project.

Anyway, I'm planning to do a whole frame up restoration. I want the bike to be something different, something that stands out, and something that when someone sees it, it will leave an impression.

I am thinking about two different color combinations. I really like seadoo's blue and silver 250r that he had so I thought about doing something similar, OR i was going to go with white and blue.

Since I haven't been able to find any blue plastics (so far) it looks like I am going to be doing white, blue and black as my color combinations. I'm thinking the stock blue seat, fork guards, and then Powder coating the frame blue with all white plastics. Other various parts such as the motor, thumb throttle, etc. will be black.

I'm going to rebuild & powder coat the motor too. It will be my first time rebuilding / even opening a motor up, so it should be a learning experience. I have the OEM 1985 atc 250r service manual so I will be following that down to the "T". I will still have a lot of questions though so be prepared lol

Here are some pictures of the progress so far.





Goofy looking picture of me

Damn Wheel hub castle nut was giving me a hard time. I had to cut the thing off.

WOW. Swing arm bolt was NOT Seized? I was screwing around and decided to tap it with a and it started to moved. I was all like

This is how it sits so far

[jr315rn]

nice start to a build! keep us posted!

[Tri-Z Pilot]

You lucked out on the swingarm bolt, I had to cut mine out like many others have before me. An intersting note, the 400ex uses the same swinger bolt, could use one of those chromoly ones for extra pizazz! Also if you can get some of Xsystem's nylon swinger bushings if you can, they work awesome. I think he's still making them.

[k00leo]

I know, i cant believe how lucky i got. I have read SO many horror stories about that swing arm bolt being seized in there. I just sprayed it down with PB Blaster for a few days as I was taking apart the rest of the bike. I also made sure to detach the shock, take off the axle, etc. to make sure there wasn't any pressure on the bolt.


Here is one bigger problem that I have ran in to. I hope someone can help me. Its the darn front motor mount bolt.




Can anyone give me some advise on how to get this thing out? I have been spraying it down with some PB Blaster and Liquid Wrench. I have tried to twist it with a socket but it wouldn't budge. I haven't tried hitting it with a because I am afraid of cracking the cases.

[bkm]

Have you tried an air impact?

[Mosh]

I know, i cant believe how lucky i got. I have read SO many horror stories about that swing arm bolt being seized in there. I just sprayed it down with PB Blaster for a few days as I was taking apart the rest of the bike. I also made sure to detach the shock, take off the axle, etc. to make sure there wasn't any pressure on the bolt.


Here is one bigger problem that I have ran in to. I hope someone can help me. Its the darn front motor mount bolt.




Can anyone give me some advise on how to get this thing out? I have been spraying it down with some PB Blaster and Liquid Wrench. I have tried to twist it with a socket but it wouldn't budge. I haven't tried hitting it with a because I am afraid of cracking the cases.

I have done a handful of these.
Heat the thread end of the bolt. Not red hot but hot. Then heat the center of the bolt hot too, but not red hot. Melt bees wax into the thread end and also the top part of the case and let set for 5 minutes. The wax will wick down into the cases and help lube the bolt. Then gently heat the 2 areas again and drive it out with an air while the bolt is still warm. They always slide right out for me.
The pipe leaks oil into that open area and hardens into crust. Heating the bolt will soften that old oil. Then run a long round wire brush on a drill through the cases to get them clean.

[Tri-Z Pilot]

Any way to fashion a press?

[k00leo]

Have you tried an air impact?

No I have not. I do not have access to an air impact. I will have to go buy one.

I have done a handful of these.
Heat the thread end of the bolt. Not red hot but hot. Then heat the center of the bolt hot too, but not red hot. Melt bees wax into the thread end and also the top part of the case and let set for 5 minutes. The wax will wick down into the cases and help lube the bolt. Then gently heat the 2 areas again and drive it out with an air while the bolt is still warm. They always slide right out for me.
The pipe leaks oil into that open area and hardens into crust. Heating the bolt will soften that old oil. Then run a long round wire brush on a drill through the cases to get them clean.

Aha. I thought I heard something along the lines of wax.

What is your preferred method of heating it up? Mini torch? heat gun? I bought one of those cheap-o propane handheld torches and I'm worried putting a flame that close to the exhaust opening it might blow something up

[Mosh]

If you are that nervous about torches, then you could try a heat gun.
I always just used regular oxy acetlyne torches. Just jam a wet rag up the exhaust port.
We arent talking about pure barbarian red hot heat, just enough to get the bolt hot to soften the crud.
Dont heat the case, just the steel portions of the bolt. The bolt will transfer the heat to the hidden areas.

[k00leo]

Sounds good, thanks for the advise.

I will report back when I give it a go.

[Tri-Z Pilot]

I'll have to remember that one Mosh, beezwax ya say

[Mosh]

Yes old machinist trick that works really well.

[k00leo]

Worked on the project a little yesterday.

Took the front end off. It was a lot easier then i expected.



I have a bolt that broke off in the frame. I've been spraying liquid wrench on it but it has not been working. Need to drill it out.



Lets see who can spot the bolt that broke off in the above picture.

Once that bolt it out, its time for sandblasting and power coat!

[motoman1012002]

looks like rad bolt is stuck in there

[Gripit'n'ripit]

Nice start on the trike man! I'm finishing up an 81 250r restore and in hindsight, i kinda wish I'd gone the route of powder coat. Keep working at it.