My ATC250ES, my baby...

[djm0242]

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Ok here's the deal. I went to buy a 350X. The 350X was really a 250R with a 350X engine. I sadly told the guy- "sorry I really want a real 350X." As I turned around there she was, my 85 ATC 250ES busted, rusted, beat, broken, and engine in the locked position. Metal tank missing, side covers gone. Rear brakes seized, all of this hidden slightly- obscured from full view by a rotting blue tarp. I asked what do you want for that one over there? We looked at it- he shrugged his shoulders... $100? I said ok :)
That was 6 months ago. So what did it need? Why was it locked up you ask? The exciter coil was bad. It sat for so long because of a $30 part. The top end was locked because of sitting for 8 years. I bought some Marvel Mystery Oil. (By the way if you aren't using this stuff- you are missing out on something your fathers knew about long ago.) Top cylinder lubrication is a must for long lasting air cooled or water cooled machines. I removed the spark plug and poured a few oz into the chamber. I walked away for three days. I came back and removed the engine case plug to reveal the fly wheel bolt. I spent a few minutes turning left and then right gently and when the crud inside broke free there was a wonderful shower of red oil as the piston travelled to the top of the cylinder! A few days later my eBay won Clarke tank arrived and I was almost ready to ride. I pulled the rear hubs to inspect condition. It was tough from sitting so long. I packed everything with grease and she was ready to go. The rest is history- new plastics, rear Atv basket, brakes, bearings, wheel spacers, front shock rebuild with seals and boots, larger carb upgrade, new lenses, decals, rear bearings from All Balls. 14" SS 212's with BajaCross 8ply tires.

[dougspcs]

Looking pretty badness..but you're in for a few on that project!

[Flyingw]

Nice rescue on the ES. I am hosting a ride at Little Sahara OK the first weekend in May. load up your ES and come on out. There is a thread on it. You're in Rockwall so your not that far away.

[djm0242]

Oh yeah I'm locked in with a pretty good investment! I got a good deal on just about everything I've bought and I do all the work myself so it's not too bad :)

[djm0242]

Thanks for the invite FlyingW. I've heard of Little Sahara but never been. Ill check it out!

[Flyingw]

Here's the tread. I'll post more details soon.

http://www.3wheelerworld.com/showthread.php/152161-Midwest-Trike-Rampage

[dustrunner]

turned out great = whats the hose coiled around the handlebar for ? does that hook-up to a tasty drink on your helmet ?

[djm0242]

Hey 123456. I put that clear hose on the rear differential and was in process or routing it through the frame when I noticed I was running out of day light. I am trying the clear hose so I can keep a close eye on contaminants. I also want to know if I lose a seal. My theory is that if the differential gets filled with water and mud I should see a mess in the tube and then ill be able to catch something early instead of destroying it. :)

[atc007]

Gorgeous machine sir. Very nice, I love it.

[userj8670]

niiiiiiiiiiice

[Super350]

great job! let use know how the decals hold up on the plastic tank if you can :beer

[djm0242]

Actually I fought with them. They bubbled up and I pulled them off. I wrote the people I got them from and they said they didn't know what the problem was. They sent me another set and they bubbled up too. :) so now I'm frustrated. Anyway I put them back on the backing that they peeled off of when new. I put the matting back on the top. I took a hot iron and carefully ironed the bubbles used a pin to let the air out and got them good and hot. Let them cool off and pulled the backing off again and sprayed them with 3M spray adhesive really well. They don't seem to be bubbling up now. Time will tell. :) I bet you've been through the bubbling up thing before too?

[threewheelin-feelin]

it looks like you made a 2inch? lift for the rear? that is a good looking red.

[Super350]

Actually I fought with them. They bubbled up and I pulled them off. I wrote the people I got them from and they said they didn't know what the problem was. They sent me another set and they bubbled up too. :) so now I'm frustrated. Anyway I put them back on the backing that they peeled off of when new. I put the matting back on the top. I took a hot iron and carefully ironed the bubbles used a pin to let the air out and got them good and hot. Let them cool off and pulled the backing off again and sprayed them with 3M spray adhesive really well. They don't seem to be bubbling up now. Time will tell. :) I bet you've been through the bubbling up thing before too?

thats why i was asking, usually w/ plastic tanks you need special decals with little slits in them so the can breath w/ the tank itself

[djm0242]

Thanks threewheelin! - I just bought an aluminum bracket for $2 from eBay- it's on my page. It was too easy and works great.

[Big G]

Very well done djm. Anyone who rescues an ATC is deserving of full recognition!

[djm0242]

Right on BigG thanks man!

[rttuck21]

Really nice, thats an awesome job!!!!!!!! I would like my big red to look that good, been focussed on my 200x and looking for a 350x, if I dont find one soon I'll start on the restore of mine, mines a beater, got pics of it on my page, Mine was my baby for over 10 years now, I owe it too it to make it shine again!!!

[djm0242]

Rttuck make her shine again and Roll Tide!

[rttuck21]

Will do, Roll Tide!!!!!!

[kb0nly]

Who makes that basket/rack that you bolted on the back?? Thats nice!

[djm0242]

Thanks Kb - Its made by TMS I ordered it as a universal application after taking some measurements. It fits nicely.

[Thorpe]

Tell me about the carb upgrade...?

[djm0242]

Hey Thorpe, I purchased a brand new for 91 (i believe)- TRX 300 carb for $75 on eBay. It's a little bit bigger and has the primer plunger on the side. I obtained a used throttle cable that doesn't have the curved metal tube like the OEM throttle cable has- the 300 carb is a little taller and there wasn't room for the tube. I just bolted it on and it runs like a champ. Idles great- if the bike has been sitting for a day or two I do have to choke it to get it to start but once it's warmed up she's good to go. Could also be the cold weather... :)

[djm0242]

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This is the carb I bought...

[djm0242]

Oh heck somehow I must've closed the thread! I didn't do it on purpose! Darned iPhones! :D

[threewheelin-feelin]

Thanks threewheelin! - I just bought an aluminum bracket for $2 from eBay- it's on my page. It was too easy and works great.

that is a very cool find... however i think i will buy a few of them...you never know how long a 1.99 piece of aluminum will hold up lol

[djm0242]

Hah! True! Hey $2 gets you 2 of them. I bought an extra pair just in case. Beats the heck outta making your own. :)

[kb0nly]

Thanks Kb - Its made by TMS I ordered it as a universal application after taking some measurements. It fits nicely.

You got a website link to them? I seriously want one, would be perfect to haul my chainsaw and gear in the back. Did you make the seat pad thats on it behind the factory seat or did that come with it? That would be a very handy item for me.

Edit.. I think i found it..

http://www.amazon.com/T-ATVCargoCarrier-TSC1205B-1-Storage-Basket-Steel-Carrier/sim/B00699GA96/2

Not a bad price either!

[djm0242]

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Item number-380555059423
I got mine on eBay there are lots of other options on there too. Most sellers put the dimensions on there so you can measure. I liked the tailgate, some of them don't have the gate- they are just solid across the back. They are a great price! After I put it together and put it on, I found myself saying "why the heck didn't I do this sooner?" :) I actually did make that seat pad myself. 3/4 treated plywood used a large drill bit to put some big air holes where the seat could breathe with two layers of 1.5" foam from Joann Fabrics -then I used marine grade vinyl that they also sell at Joann Fabric. I used 9/16 staples and stretched the vinyl tightly across and stapled it on. I got about six wood screws that were about an inch long and made sure that they had big heads so they'd catch on the expanded metal. (I also decided to use washers.) If the screws are too long you'll get a nasty surprise when you sit on that seat!! They'd also tear your new vinyl. I used that seat before I had the basket too. I had some electrical conduit straps (metal) and had the seat pad just bolted to the rack.

[djm0242]

Oh by the way - this basket is one of the reasons that I added the lift. The basket adds 40lbs. So a little lift really helps.

[rouseanator]

Awsome looking 250 im workin on one too love the rims why didnt you put one on the front??

[djm0242]

Well two reasons. One is the lower profile tire on the front may ruin the shock absorption. The other is money! Hah- it may take me some time to buy another rim and figure out the back spacing. I may go with a 12" rim that matches and get a taller tire to add some cushion. By the way I'm on BRRH group and I like your fork video. I posted a response to it :)thanks for making it!

[Woodsrider]

Nice looking Big Red...real nice! Just curious about the tubes sticking out from each side of your front rack...what are they for?

[djm0242]

Pegs to keep my boots dry! :)

[IronBear]

Very nice Big Red!!!

[djm0242]

Thanks looks like you have a really nice one too!

[kebby28]

Where did you find the two side covers? I am replacing my plastics and cant find them anywhere...

[djm0242]

eBay - you'll find everything you need on eBay. Jesswineheart on here makes them new reproduction. I bought a pair once on Clist for $30 from a guy who had no idea what his side covers were for. This bike was a rare case where the previous owner had the foresight to take them off and bring them inside when he parked it under the edge of his barn roof and threw a tarp over it.

[djm0242]

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Still loving this bike with zero problems! I did have to pull the tank decals cause they bubbled up pretty bad, but I knew that was coming.

[kebby28]

I'm searching this thread because I just ordered rear axle bearings for my 85 250es. According to the diagram there is two per side that sit side by side. I'm a little weary because the picture of the aftermarket set I got only shows two bearings and two seals. That could just be the same pic they use for all of them...
Also. Do the axle housing and outer seals hold gear oil like a rear of a truck? Or are they just prepacked and run them till they ware?

[djm0242]

There are double bearings on both ends of the axle. There is no oil inside the axle housing. The seals keep water and dirt from getting inside of the axle housing. It is easy to dissassemble the housing. If you need pointers let me know.

[kebby28]

Well just one question. Am I going to have trouble pulling the existing bearings with out a special puller? I can usually rigg something up, but if you have a easy solution I would greatly appreciate it.

[djm0242]

No puller is needed, I used a heat gun, and a socket and a hammer. The left side is easiest. You'll take the wheels then the hubs off and support the trike with some stands or wood, then use a jack to support the axle. Unbolt the shock at the bottom only. Then swing it out of the way. Unbolt the short tube from the rear differential. Apply heat to the tube spray with penetrant. Remove the outer seal before knocking the old bearings out. Once out, clean the tube bearing surface very well. You can also place the bearings in your freezer to shrink them. Keep in mind -as I recall two bearings for one side are smaller than the other, figure that put before you slather everything with fresh marine grade grease.

[kebby28]

Thank you. I decided to do the bearings and seals in the diff too. The left outer bearing was pretty bad so I minus well go right through it. Ahh, did I forget to get a gasket for when I split the diff? I better go look.