$20 atc 90 build.

[chuckiedog04]

i picked up a decent condition 1977 honda atc 90 on ebay, it is in need of a carb (already ordered), throttle assembly and cable, and the spark plug hole is stripped out. So far i have started the tear down on it, it has good spark and compression. My plans for this is to make it a decent runner for my nephew. here are some pictures, remember i only paid 20 bucks for it. any advice is greatly appreciated.

[atc007]

Says it's a 500R? :lol::lol:Clean your tank out,provide fresh fuel to the new carb. New plug,clean and oil your air filter. Drop the oil,flush the engine,new oil,lube and adjust the chain and brakes,, Do a once over all the important nuts and bolts etc..see how she runs. And tweak her from there. Nice buy!!

[yt125man]

dude you got the ultra rare 500r! lol but anyways looks like a good project especially for $20

[chuckiedog04]

i just took a razor blade to the 500r. came off pretty easy. thinking of doing a war-theme on this one. camo it up. get some army star decals for the tank. what do you guys think? first thing is to get it running though.

[chuckiedog04]

where is the oil drain hole on this guy? and how much oil do they generally take? ive never had anything smaller than a 200 so im new to this little thing

[HONDA_ATC_FREAK]

You need to get in touch with monroe mike he's the king of manuals around here once you get that it should have every thing you need.

[badass350x]

Hum, I would think at the very bottom of the motor!!!!

[chuckiedog04]

could be, but no need to be a smart trailprotrailprotrailprotrailprotrailpro...to dark to go look now. i was just asking cause on my 200 it was on the side by the pull start.

[badass350x]

could be, but no need to be a smart trailprotrailprotrailprotrailprotrailpro...to dark to go look now. i was just asking cause on my 200 it was on the side by the pull start.

At the bottom! Am I wrong?

[skidmorejr88]

Good snag! The smaller trikes are alot of fun it always amazes me as to how small they really are. I had a atc 70 growing up and remember it being monstrous to me lol. I am sure your nephew will love it.

[chuckiedog04]

okay so the next thing on my list is to fix the stripped spark plug hole, any suggestions? should i helicoil it? should i loctite it with this http://www.amazon.com/Loctite-Form-Thread-repair-grey/dp/B000WSEUII/ref=cm_cr_pr_product_top or what should i do? if i helicoil it what size do i need? this is trying to be built on a budget. any suggestions are greatly appreciated!

[TECATEMATT]

Hum, I would think at the very bottom of the motor!!!!

^^^ couldn't help but lol

[TECATEMATT]

I would helicoil it imo and not to sure on the size, I haven't done it in awhile but don't they come in a little kit with multiply sizes? Been awhile haha

[JasonB]

do want. lol. nice "R"

[ctbale]

14mm tap, and use a NGK B8HS plug, lotsa grease on the tap. pitch is 1.25. pre drill with a 1/2" bit

[thestud25]

14mm tap, and use a NGK B8HS plug, lotsa grease on the tap. pitch is 1.25. pre drill with a 1/2" bit

Be ultra careful not to get any metal shaving in the motor if you decide to tap it out.

[ctbale]

yea, thestud is right on about that, if you do the helicoil or start using a 14mm plug, if it were mine, the head is coming off, takes about 45 mins, you can reuse/aneal the copper head gasket, and if nuthin else gives you a chance to lube the advancer up.

[bigworm626]

Ctbale,
You da man dude. Right on the button, that would be doing it the right way.

[ctbale]

you doggin me worm? lol The right way would be a timesert, but hell, those kits are way too spendy, my fix cost $5 for the tap, and its good for another 30 years. dam, rough thread.

[coolpool]

http://www.3wheelerworld.com/showthread.php/93524-Fix-those-stripped-Threads!!!-A-how-to-on-Heli-Coil-installation..

Here's a helpful link on heli-coil installs. Good luck.

[chuckiedog04]

well i have been waiting for parts in the mail. finally got the carb today http://www.ebay.com/itm/370485109299?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649 then i realized the choke is on the wrong side. trail pro trail pro trail pro any ideas? I can't return it. I still plan on fixing up the wheeler! ive just been busy hunting

[Thorpe]

Mount the carb backward??? JK Headed back to the woods bright and early tomorrow!

[chuckiedog04]

any help please?

[tri again]

Whoa, sorry, I missed the whole second page of great suggestions.
but no real reason to change the following.


There are 2 drain looking bolts on the bottom.
One is the cam chain tensioner and is at an angle.
The oil drain is dead vertical.
With a stripped sparkplug, I'd be cautious with the oil drain plug too.
Just dump the oil out the fill dipstick hole for starters.

The plug hole may not even need to be drilled.
The tap may just do it. Depends on how wallered it is.
I had one trike someone just tapped for an automotive spark plug or maybe they just
screwed in the next largest diameter plug.

If you decide to do it right, head off is best but we used to
stuff the cylinder with cotton rope, grease the tap to grab filings and chips,
do the drill and tap, either insert or helicoil, and then pull the rope out slowly to pull
all the pieces out.

I'd either stand it on it's tail or set the whole trike on a picnic table.
Get real comfortable, heat, good light, no distractions
and take your time.

If it's really toast, I think I have an extra head you can just have.

ok, now what's the deal with the carb?

choke on the wrong side? does it matter really?
I'll have to go look at one when it gets light out.
No room for the choke lever to move?

[chuckiedog04]

Whoa, sorry, I missed the whole second page of great suggestions.
but no real reason to change the following.


There are 2 drain looking bolts on the bottom.
One is the cam chain tensioner and is at an angle.
The oil drain is dead vertical.
With a stripped sparkplug, I'd be cautious with the oil drain plug too.
Just dump the oil out the fill dipstick hole for starters.

The plug hole may not even need to be drilled.
The tap may just do it. Depends on how wallered it is.
I had one trike someone just tapped for an automotive spark plug or maybe they just
screwed in the next largest diameter plug.

If you decide to do it right, head off is best but we used to
stuff the cylinder with cotton rope, grease the tap to grab filings and chips,
do the drill and tap, either insert or helicoil, and then pull the rope out slowly to pull
all the pieces out.

I'd either stand it on it's tail or set the whole trike on a picnic table.
Get real comfortable, heat, good light, no distractions
and take your time.

If it's really toast, I think I have an extra head you can just have.

ok, now what's the deal with the carb?

choke on the wrong side? does it matter really?
I'll have to go look at one when it gets light out.
No room for the choke lever to move?

the problem with the choke on the wrong side is i cant even bolt it on, the frame is in the way. thank you a lot for all the help. I really should have looked closer before i bought it. how much would you be willing to part with the head for? i did drain the oil and put new oil in already. thanks again for all the help.

[ctbale]

The head is EZ to pull off, there are vids on you tube.

[chuckiedog04]

well ive been busy hunting, i finally got around to it today. i took the motor out of the frame, got it in the shed and pulled the head off. Looks NASTY in it. like it never got an oil change. so im debating now whether to buy a head or try to fix the old one?

[Lil Earl]

should have left the 500 on the fenders and to make it match, put a 500 in it

[bigworm626]

chuckie,
please don't think I forgot about you, the tire, tube & thumb throttle assembly for your 90 will go out this week. I was out of town dude.

[chuckiedog04]

chuckie,
please don't think I forgot about you, the tire, tube & thumb throttle assembly for your 90 will go out this week. I was out of town dude. okay good! i started to think you were out of the deal!

[chuckiedog04]

ordered a heli coil kit on ebay last night. should be here next weekend. i will definetely get some more pictures up! the head is off and i will be carefull with the heli coil. Started doing a little cosmetic stuff on it. sanding down the fenders, wire wheeled the wheels, etc. i looked at my exhaust and noticed there is a nice hole in it. any good cheap aftermarket exhausts out there? maybe i will just weld the one back to shape.

[web3wheels]

i think your best bet is to fix the exhaust you have. in case you dont know, there is a bolt right thru the center of the exhaust hidden in the frame. there maybe something aftermarket out there, but its going to be expensive new! i think cobra finally quit making them for 90's. lots of aftermarket stuff at www.dratv.com. your motor takes one quart of oil. i also have a 77 but havent started restoring it yet.

[ezmoney1979]

The last Cobra 90/110 exhaust I was watching on Ebay a few months ago sold for $180. And the last OEM NOS one I saw was.............. $350!!! It is definately worth putting some time into the exhaust you have.