1985 250SX Resurrection

[themotoviking]

I picked up a '85 250SX a few weeks back for basically $100. It had been sitting neglected for a few years in the back field. PO decided to put it on Craigslist with a little pull behind trailer so I nabbed the whole lot for $200. He said it had not ran in a year but with the condition everything was in and how disintegrated the front tire was I am willing to bet a few years. Either way the motor turned over with good compression so I took a gamble. I only got a bill of sale and until the title process was finished I wasn't putting one finger on it in case someone tried to claim ti during the process. Luckily though no one did and now its all mine with a clear title!

I was not sure of the full condition of the motor so I did the bare minimal to see if it would run. Changed the oil and filter. cleaned the carb, put some deep creep in the top end to lube it up a bit and a new spark plug. I grabbed the battery from my XR650L and a quick prime and a second on the starter button and it fired right up! I even got a video of it starting for the first time in years.


https://www.youtube.com/watch?v=8ziF2rHyEpc

Well it fired up and ran so its all fair game now. First with the cleaning.

This was the day it came home

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Cleaning the carb. Man this was some of the thickest turpentine Ive ever seen. Pull the slide up and it just sat there slowly sliming its way down.

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After the cleaning. I didn't put no new parts or gaskets in because I didn't want to put any money into this if it was shot.I got lucky as you can see in the video the carb held together and didn't leak.

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The initial cleaning was a ton of work, a couple cans of degreaser two brushes and a lot of elbow grease.

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Her former glory is starting to shine through after all these years.

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[themotoviking]

Along with cleaning her up I also made a quick trip down to Tucson and scored a 1985 250SX motor with harness, controls, carb, exhaust, airbox and rear swing arm assembly with drive shaft for $150. The plan is to rebuild that motor down the road and then swap it out.

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Since the motor checked out with 160lbs compression I went on a shopping spree for this old girl.

Carb rebuild kit
UNI Filter
New battery
New Red Maier plastics
New petcock
New Clarke tank
New seat foam
New seat cover OEM style
New PRM-ATV Grab bar
OEM style sticker kit
New10x5 ITP steel front wheel
New 9x9 ITP steel rear wheels
Duro Thrasher front Tire 23x7-10
CST Ambush rear Tires 22x10-9
Pro-Taper SE 7/8" ATV High Bend Silver bars
New front brakes
New steering stem bearing
New front wheel bearings
Fork seals and oil
Some new grips
and some small misc OEM replacement parts.

Thinking about maybe taking the rear shock out and down to ZR1 Suspension and having him rebuild the shock and maybe install a heavier spring since I am viking sized anyways.

[UPNATM]

That's a pretty sweet price. It's a lot nicer than the one I bought back in 13.
That's a killer list also. Those items are gunna make that old SX bling!
Make sure to keep us updated on your progress.

[themotoviking]

Upnatm it's actually your build thread that I got most of my ideas from. All the way down to the HRC decals, I love those.

So credit for the ideas of this forth coming build mainly goes to you.

[Flyingw]

Nice score. The SX is my favorite trike. I've done ground up rebuilds on several. That's the one they will pry from my cold dead hands. My daily driver is the one with the white star. The others I've sold.

[themotoviking]

I thought about doing other color schemes but decided to stay with the original 85 red.

Flying w are you any where else? Your name sounds familiar

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[Flyingw]

I was a moderator at 3WO for years. I'm Baldwin JRB on Facebook and I'm a riot at parties.

[themotoviking]

Found ya!

Its going to be a long week waiting for parts to show up.

[Flyingw]

If you need help on anything, give me a shout. You can always get me at jamesbaldwin99@gmail.com. I rebuild the ES/SX carbs and differentials. I have a tutorial on both here if you need information.

http://www.3wheelerworld.com/showthread.php/161746-ES-SX-350X-Carb-rebuild-Tutoral?p=1257154#post1257154

http://www.3wheelerworld.com/showthread.php/164483-ATC-250SX-and-250ES-Differential-Rebuild-Tutorial?p=1282554#post1282554

[UPNATM]

Upnatm it's actually your build thread that I got most of my ideas from. All the way down to the HRC decals, I love those.

So credit for the ideas of this forth coming build mainly goes to you.

Thanks man, it was a fun build. Actually, without the help from the folks here on this site, like Jim, it would have been a lot harder to finish. I sorta wish it wasn't done, and I was still working on it.
It's been a while since there has been an sx build thread here, so I look forward to watching yours unfold.

[themotoviking]

If you need help on anything, give me a shout. You can always get me at jamesbaldwin99@gmail.com. I rebuild the ES/SX carbs and differentials. I have a tutorial on both here if you need information.

http://www.3wheelerworld.com/showthread.php/161746-ES-SX-350X-Carb-rebuild-Tutoral?p=1257154#post1257154

http://www.3wheelerworld.com/showthread.php/164483-ATC-250SX-and-250ES-Differential-Rebuild-Tutorial?p=1282554#post1282554


Nice write-ups! Picture are what make them possible. I did similar of on some chevy truck forums and they got pinned to the top they were so detailed.

I'll be using some of your carb thread for sure this week and the diff thread when I attack the rear end. GOD I LOVE DETAILED WRITE-UPS!

Does rubbing alcohol,really work? Does it break all the dirt and hardened gas down? Never thought of using that before.

[themotoviking]

You go well above and beyond what I normally do for a carb cleaning and rebuild. Just curious what you charge for the carb service? Do you have a carb to ship out and I send you mine in than? If not whats turn around time?

[Flyingw]

I use 99% Isopropyl alcohol (technical grade)for many things. For the carbs, It dries out any residual varnish, dirt, or whatever is on the carbs. It makes bead blasting the bodies and bowls go faster. My cleaning process is done in several steps but the final step is to shoot carb cleaner through all the holes in the carb. I prefer to soak the carbs in Heptane but that stuff is a little spendy. Alcohol works pretty good and it doesn't leave any residue behind. I also use alcohol to clean and degrease parts prior to powder coat. Isopropyl alcohol has many uses. I buy it by the gallon on Ebay.

[Flyingw]

I charge 95.00 for my rebuild services. I have done dozens of the ES/SX/350X carbs so I've got pretty good at it. My turn around time is only a couple of days but most of the time I try to get them back in the mail the next day. Right now I'm out of ready to go carbs but I am more then happy to give yours the love it needs. I have plenty of spare parts if I need to replace anything. I do all my carbs the same way every time and it seems to work.

[themotoviking]

Ok Ill have to see if I have that lying around. As you can see from my list I went on a spending spree plus the spare motor I just bought has kind of left me stripped of play money.

[Flyingw]

Ya I totally understand. Been down that road many times and it does add up very quickly.

[themotoviking]

Got the rear wheels off, breaking down the front end for a full rebuild and removed the exhaust. Thats about it for today. Might have parts in tomorrow and should have the carb rebuild kit as well.

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[BigRedGrizzly]

Nice. I just replaced the fork seals and changed the fluid in mine. I found one was bent pretty good.
http://images.tapatalk-cdn.com/15/07/13/0bdea6b4d8fa7d035d9e3852167ad7f3.jpg
I hope to give mine a deep cleaning and rebuild worn parts as well.

[Flyingw]

Ya I'd say that's just a little bent. Forks are readily available. The upper tubes are the same for both sides.

[themotoviking]

Dang that sucks!

Yeah doing these forks are going to be a breeze compared to the inverted Showas on my XR650L.

[themotoviking]

Oh found out that other motor I scored is locked up. Carb is seized as well. I think they left it outside. Bummer. Either way Ill toss it in storage until I decide to putz with it.

[Flyingw]

On the motor, remove the spark plug and shoot in a 50/50 mix of acetone and ATF. Let it soak.

[themotoviking]

Nertz I was going to toss deep creep in there before I took it to storage. I just got back. Its in a climate controlled room so its not going to get any worse at least.

[Flyingw]

HAHAHA, Identified!!!! A Frank Burns fan.. I thought I was the only one who says nertz

[themotoviking]

Gin machine and golfing all day!

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[themotoviking]

Bringing the heat shield into the 21st Century! I used DEI Thermal tape I had laying around.

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Cleaning up the exhaust system. I used a scotchbrite pad and some degreaser and scrubbed 30 years of gunk off. I have had great luck with VHT Flame header paint (1500*) for a base coat than the VHT gloss black engine enamel (500*) for a final coat on top.

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[themotoviking]

VHT Epoxy paint in satin black, matches powder coating real good.

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[Flyingw]

Looks good. Nice attention to detail.

[themotoviking]

Pile-O-Parts!

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The tires came dang near vacuum sealed compressed so I had to let them sit in the AZ sun for a bit for them to get back to their natural shape.

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New ITP wheels all around

9x9 3x6 rears
10x5 2x3 front

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I got them mounted and I am starting to think I screwed up on the size. the wheels are 9" wide (stock 200x/350x wheels) and the tires are 22x10-9. The tire itself says for 8" wide wheel. I am worried if I may roll them off the bead. I dunno what do you guys think?

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[Flyingw]

I hate it when they compress the tires like that. A bead blaster fixes that but I don't have a bead blaster so I have had to resort to more manual means. Don't worry about the wheels, they will be fine.

[themotoviking]

I hate it when they compress the tires like that. A bead blaster fixes that but I don't have a bead blaster so I have had to resort to more manual means. Don't worry about the wheels, they will be fine.

Wasnt to sure on the tires. Last time I bought ATV tires they were balloons in 1990 so this is kind of new to me. I'll admit when I screw up so... just checking, thanks!

[Flyingw]

On the SX, one thing to watch out for are front tires that bulge out beyond the edge of the rim. If the tire rubs the inside of the fork tube, it WILL rub a hole in the fork tubes. I have seen tires rub all the way through to the inside.

[themotoviking]

You must have missed the info I posted. The front wheel is now 10x5 with a 23x7x10 tire.

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[Flyingw]

Oh ya, missed that

[jinxd12]

Nice trike man! I'm in phx too, just wondering if you could shed some light on the title process? I need to get one for mine that I just scored off craigslist in roughhhh condition for cheap.

[themotoviking]

Shoot me an email and I'll give you my number. It's just easier to explain that way. Just let me know your name and forum name.

Rob

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[UPNATM]

Looks like Christmas over at your place!
Sweet choice on the tires, they are going to look killer on there.

[themotoviking]

I still have New seat cushion seat cover and plastics and a task coming in and OEM stickers.

I also found the team Honda stickers like you have so don't mind me if I copy cat ya a bit! :-) I just really love the sticker look you did.

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[UPNATM]

I still have New seat cushion seat cover and plastics and a task coming in and OEM stickers.

I also found the team Honda stickers like you have so don't mind me if I copy cat ya a bit! :-) I just really love the sucker look you did.

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It's all good man, don't mind at all. :cool:
I'm diggin your build so far.

[ps2fixer]

Subbed for more pics!

The 250sx is my 2nd fav trike just below the 350x and just above the 250es big red.

[Jason125m]

Looks great. That engine and frame sure did clean up nice. I find most people just look for nice machines. I prefer to do it your way, in the end it is something to be proud of. Great job! Can't wait for finished pictures.

[themotoviking]

Looks great. That engine and frame sure did clean up nice. I find most people just look for nice machines. I prefer to do it your way, in the end it is something to be proud of. Great job! Can't wait for finished pictures.

Im not happy unless I'm workin' on something. I scored this so cheap it was perfect. I love building stuff. Between 12 and 22 I went through 23 (memory starting to fade) bikes and atcs. Would fix them up ride them a bit sell and get something else. I loved it.

[themotoviking]

It's all good man, don't mind at all. :cool:
I'm diggin your build so far.

Question UPNATM

What rear tires and wheels are you using? I was trying to get yours but what I ended up with was a bit bigger.

More importantly, what tail light are you using one the SX with the PRM -ATV grab bar. I got the same grab bar and my stock light wont fit. I think they screwed up the mounting spacing and notches. It looks like you used a different light. any info on that?

[UPNATM]

Question UPNATM

What rear tires and wheels are you using? I was trying to get yours but what I ended up with was a bit bigger.

More importantly, what tail light are you using one the SX with the PRM -ATV grab bar. I got the same grab bar and my stock light wont fit. I think they screwed up the mounting spacing and notches. It looks like you used a different light. any info on that?

For the wheels, I went with ITP's in the stock size, using Duro - Power Trail DI2009 18-9.50-8 tires.
I see you went with 9' wheels. No biggie, im sure they will look sweet on there.

On the rear light, I couldn't at the time find a stock SX light, so I opted for a 200X rear light, that I got off of ebay for a song. Through Honda, all the SX OE mounting hardware is still available, so I grabbed the p#s, and ordered it all up. No issues mounting the X light to the PRM bar using the original SX hardware. :cool:

[themotoviking]

Yeah something is funky then. I emailed PRM so we will see what happened. there is no way I can mount my SX light at all on there mounts. The notch is cut at the wrong angle and they brackets are closer together than the OEM grab bar. Im not really too impressed with the product. they had the aluminum Plasma cut and didn't bother to cleans up the edges so I have to finish that up otherwise it will cut up the bushings in the mount.

[UPNATM]

Yeah, I hear ya. I called PRM prior to ordering my grab bar to make sure it even came with the mounting tabs for the rear light. If you notice, in their website pic, it doesn't even show the tabs. They reassured me that they did, so I ordered it. Im sure they will make it right, since yours is screwed up, and hopefully send you out a replacement bar.

[themotoviking]

Well there is that, then I found out Allballsracing did a seal change on the stem bearing kit so I cant install that until I have the new seal and when I went to mount the tires I free spun the rear end and it sounds like bearings are blown. I cracked open the drain plug and got out about 1/4 cup of brown something liquid.

Everything was going so good until today!DeepaDeepaDeepaDammit

[Flyingw]

Look in the diff hole and look at the ring gear teeth. They should have square edges. If they are good, fill the diff with a solvent and roll the diff around. drain the solvent. Fill with oil and run it about 30 minutes then drain and fill again. Brown is never good.

[Flyingw]

Axle bearings are more than likely shot.

[themotoviking]

I got new bearings and seals coming in. I'll flush it out with some mineral spirits refill it and see

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[themotoviking]

I just pulled metal chunk out of the fill hole on the diff. it dun gone and blowed up i recon!


Anyways. I suppose since i am a new member that I can't post in the for sale section. I am going to sell my OEM rear fender, rack and grab bar. I was also thinking of having the rack stripped and powdercoated first.

[Flyingw]

What are you going to do about the diff? I am tooled up to rebuild diffs so if you find one, I can rebuild it like new.

[themotoviking]

Gonna rebuild it. Ive got a spare diff but I am capable myself but just curious if I gave you all the new bearings and seals how much?

[Flyingw]

125.00 with return shipping

[Flyingw]

http://www.3wheelerworld.com/showthread.php/164483-ATC-250SX-and-250ES-Differential-Rebuild-Tutorial?p=1282554#post1282554

[themotoviking]

ok I found "The curious case of Jims' SX" thread. thats a full on restoration there. Im just cleaning mine up and putting new plastics on Pftt.... I know nothing John Snow.

[themotoviking]

http://www.3wheelerworld.com/showthread.php/164483-ATC-250SX-and-250ES-Differential-Rebuild-Tutorial?p=1282554#post1282554

Thanks Im going to read thru that first. I got time before my bearing kits come in.

[Flyingw]

My SX build thread?

[themotoviking]

Nah ise talking about the diff thread but we got it figured out.

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[themotoviking]

Disassembled the spare rear axle. Exterior parts of shafts were definitely leaking and if the splines on this shaft are any indication of what's to come on the axle on the 250sx I may need a new axle shaft. :(

The center section had no gear oil in it but it spines nice and smooth. The seal surface on the hubs still look good. You can see where the seal sat but there is no defined groove.

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[themotoviking]

I have the original rear fender If anyone is interested, no breaks in it just sun faded. No hardware is included $160 and that includes shipping within the lower 48 states.

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[themotoviking]

Rear end on the bike itself was in pretty good shape except for the diff. It appears someone has already been in here and didn't do a proper job probably resulting in this "hand grenade"

Brake section almost looks untouched from factory.

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Splines and seal surface look really good. Looks like I can still use this current axle shaft. :cool:

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[themotoviking]

Quick video of the diff from the 250sx


https://www.youtube.com/watch?v=uY4aNg1LlO8

BAAAAAHHHHHH Its still good! :rolleyes::D

[themotoviking]

Diff has been sent to FlyingW for a rebuild. Hoping to get the front end back together this week. Been busy with other stuff and have quickly acquired some other toys

1985 ATC 70
1983 ATC 185S
1983 ATC 200E

Going to try and flip them for some cash.

[ps2fixer]

Just a suggestion, might want to send off the rear axle to get sand blasted, acid dipped, then zinc plated. It is somewhat common for the rear axle to get pretty rusty and take out the splines for the ring gear, I have one that came like that. Make sure to seal the axle tubes up well when you re-assemble :).

I think I read members getting it done on sports 3 wheelers for around $70ish.

[themotoviking]

Not a bad idea. I have a friend that works at a shop that gets stuff zinc plated. I'll have to ask. The shaft is in relatively good condition better then the other one I have for sure.

The tubes were petty clean but you can see where it leaked thru. The sister rear end I had looked like it sat in a swamp for 20yrs.

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[themotoviking]

So much for using Hi-FLite (CEET) foams. wrong size or cut or whatever and they say no returns. We'll see how this goes down.

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Ok thumbnails are being stupid now.

[ps2fixer]

That seems a bit shotty for the company not to take responsibility if they have it listed for the wrong machine or they made a mistake. Have any idea what it actually fits? Maybe you can ebay it off and find another company that has the correct part. Seems it is a bit too far off to make it work of what I can see in the pics.

[themotoviking]

Just got off the phone with Roy at CEET. they did in fact send wrong one. but still no returns so they are shipping out another stock shaped foam. I told them since they didnt show or list the stock shaped foam I had already ordered another one from Saddleman and they said they will exchange but no return.

Ugh, so now I will have a spare new foam and cover I have to sell.

[BigRedGrizzly]

Probably costs more to ship than it does to produce.

[themotoviking]

Probably costs more to ship than it does to produce.

Nah, dont think so cause I can ship it back to them for $14 bucks fedex ground. Either way I'll get ti figured out.

[themotoviking]

Next up found a shop recommended by my local MC parts store on stripping the gas tank I do have. There are no dents but a rust pin hole up top and no indication of rust below at all. $80 to strip and and then I can take it to my powder coat guy and have it finished for $50. So for $130 I have a new metal tank and will send the Clarke back. Which means i can use the 86 SX decal set I have!

[ps2fixer]

Glad you got something worked out with the seat foam supplier, maybe someone on here could use one and save a ton on ebay fees :).

[themotoviking]

Now that I can save the tank I am going with the '86 color scheme.

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[UPNATM]

Any updates? :naughty:

[themotoviking]

FlyingW received rebuilt and sent off my diff in under a week!

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I finally started assembly on the front end

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[themotoviking]

The axle shaft that came out of the trike was in really good shape so I dropped that off for Zinc plating.

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I actually found a place that can do gas tank acid baths so I dropped it off to strip it to nothing and remove the bad tank sealant form the inside. I may have to weld up some holes when I get it back but then I can send it off for powdercoating. Tank dip is $80 and the powdercoat will be $30

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So I have a New hand picked Clarke tank that needs a home!

[themotoviking]

One of the things I ordered was a PRM-ATV grab bar. I received it from their Ebay store and was in awe of the cool factor. When I finally went to mount it I found out the tail ligh mounts were to close together and the notch for the grommet to go into was at the wrong angle. I sent multiple pics and descriptions and this is what I get back


Dear prmproductsinc,

Attached are 3 pics showing the incorrect mounts. if I even mount one side it pushes the light too far to the other side. I placed the stock OEM grab bar above so you can see the difference in slot angle and spacing between the holes which is about 3/4".

also these pieces appear to be plasma cut. you may want to spend just a bit of time cleaning up the edges so the mount holes do not tear up an already non available rubber mount.

--Rob
---------------------------

Dear roughneck556, (me)

I have an employee that has one of these ATC 250SX. He is going to get the light mount off it tonight and bring it in so we can check whats going on.
Will get back to you.
Deborah

Have you figured anything out yet?

--Rob
-----------------------

Dear roughneck556,

I'll send a call tag for it. Please package it up and UPS should pick up soon. The taillight is tight we are aware but it needs to be that way so that it does not fall out. Sorry for the problems but we won't be changing the design. The stock taillight in it is tight like I said but if your not happy we will give you a full refund. I'll send the call tag to your email address. Print it off and UPS will pick it up at the location it was dropped off at in a couple of days.
Deborah

-----------------------

Can you send me a pic of your employees grab bar with light installed and a tape measure across so I can see whats going on? I understand it has to be "tight" but if it was built to stock dimension as it should have been than it would fit just fine. If it does fit as the mounts are designed would you care to send pics or instructions on how it fits in without tearing the rubber grommets?

How about instead of you spending money on shipping would you be willing to do a partial credit? Then I can just modify it myself so it meets OEM dimensions. this is not right at all BUT no one else makes a grab bar for this bike.

--Rob

And we are waiting to see what they say. Flat out crappy finish on the light mount area. plasms slag still existent and the holes and notches are nowhere where they should be

This is what I sent them.
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[UPNATM]

I was able to mount up my light no problem, but If it will help you out at all, I can take a better up close pic of my PRM bar on my SX. Let me know...

http://i157.photobucket.com/albums/t73/dalbey58/Honda%20atc/20140906_120519_zps162d8826.jpg (http://s157.photobucket.com/user/dalbey58/media/Honda%20atc/20140906_120519_zps162d8826.jpg.html)

Btw, your SX is really taking form, and looking great!

Jim does amazing work, and that diff he supplied you with looks every bit of awesome.

[themotoviking]

They are giving me a partial refund and I will fix it myself. I got the PRM idea from ... you guessed it your build UPNATM! Yes if you could take some pics of yours close up and even give me a measurement center to center of the holes that would be great.

[UPNATM]

They are giving me a partial refund and I will fix it myself. I got the PRM idea from ... you guessed it your build UPNATM! Yes if you could take some pics of yours close up and even give me a measurement center to center of the holes that would be great.

No problem, ill try and snap some pics tonight. :cool:

[UPNATM]

So, unfortunately I didn't have a tape measure on me, (I have this SX in storage at the moment) so I couldn't get any measurements, but I was able to snap a couple of pics for you.

http://i157.photobucket.com/albums/t73/dalbey58/Honda%20atc/20150804_171756_resized_zpspckkfitg.jpg (http://s157.photobucket.com/user/dalbey58/media/Honda%20atc/20150804_171756_resized_zpspckkfitg.jpg.html)

http://i157.photobucket.com/albums/t73/dalbey58/Honda%20atc/20150804_172006_resized_zpse6qjnvtj.jpg (http://s157.photobucket.com/user/dalbey58/media/Honda%20atc/20150804_172006_resized_zpse6qjnvtj.jpg.html)

[themotoviking]

Yeah when you get a chance if you could let me know on the measurement. That's going to tell me the most info.

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[UPNATM]

Yeah when you get a chance if you could let me know on the measurement. That's going to tell me the most info.

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Center of hole to center of hole, 7 5/8.

[UPNATM]

Been a while, any updates?

[themotoviking]

I'm still here. Just been busy. Wife got laid off so we're just scrambling to get bills paid.

I got the tank back from the cleaner. There are two pin holes I have to weeks up and then get it off to powder coating.

I just got the rest axle back last week from cleaning and plating. It's a nice gold color not.

I just need to get around to putting it all back together.

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[themotoviking]

Sorry for the long gap in the rebuild. Not sure if I mentioned it before but the wife got laid off work in early September and she was the bread bringer in the family. Things were a bit tight but its finally starting to level off as I am bringing in more work myself

Anyways, this meant I finally had enough time and finances to finish the rear end rebuild. A big thanks goes to FlyingW for the diff rebuild. Next up is assembling the new rear plastics and upholstering the new seat foam from CEET Racing. I still have tot take the carb out and do a full rebuild on it. Lube the severely dried throttle cable and start wiring the headlight area back up. I still have not taken the gas tank to powdercoating yet, maybe next week.

Due to Honda's awesome machining and tight tolerances the nice plating I had done on the axle shaft had to be stripped back off due to the hubs not being able to slip onto the splines at all! Took that over tot he same place that stripped my tank. $20 and a day later and its nice clean non plated metal.

Here it is sitting on it is finally sitting on its own three paws!
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[UPNATM]

Looks good. Did you ever figure out what the story was with the rear light, and the prm grab bar?

[themotoviking]

Looks good. Did you ever figure out what the story was with the rear light, and the prm grab bar?

I have not got that far yet.

[Keepah Rolln]

Nice build. Got to love the sx's. I have a couple stock ones and am thinking about grabbing a couple more this winter cheap and making them totally unstock...

[themotoviking]

Got the tank back from the welder. I need to sand it down and then do a pressure check. I officially have the carb thoroughly cleaned and rebuilt. I used that Chem-Dip carb cleaner stuff. Oh boy is is strong! I'm going to be selling my Fourtrax 300 in favor of a 400EX so the 250SX will become a workhorse as back up so I am looking into re mounting the OEM rear rack. The float bowl gasket was so badly dried up I was taking it off buy 1/8" chunks and then cleaning out the gasket channel with a pick to get the rest out. That was about an hour I'll never get back!

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[themotoviking]

Anyone know if there are any handle bars that are the same as the 250SX I can get. I installed some ATV seveneights from Pro taper but they just dont feel right.

[UPNATM]

I have moose racing bars on both of my SX's, and other than the crossbar, they have the look and feel of the OE bars. They fit nicely also...no complaints from me.

[Flyingw]

There used to be a guy on Ebay selling repro bars. About 80 bucks if I recall.

[Legns]

Do you still have the original rear fenders for sale ?

[themotoviking]

Yes, I was just about to put it on ebay.

[Legns]

cool I will PM you then

[J trike]

Hi. New to the forum , trying to post a question when I saw your 250 sx rebuild. I just bought one in great shape but was looking for a choke lever that are discontinued. Where or what do you suggest I do ? Thx

[BigRedGrizzly]

Do you need the plastic thumb lever? I may have one with the spring, and the entire cable. Post a pic of what you have and I'm sure we can help you out.

[J trike]

Great!
I think I only need the plastic piece with spring, not the cable.
Please let me know how I can pay for it and if u could mail it.
Thx a lot,
John

[J trike]

Great!
I think I only need the plastic piece with spring, not the cable.
Please let me know how I can pay for it and if u could mail it.
Thx a lot,
John

[BigRedGrizzly]

Ok. I'll confirm I have it this evening. Just pay for the shipping.

[J trike]

Any luck finding a choke lever? Mine won't stay on full choke it slides to 3/4 unless I hold it

[BigRedGrizzly]

I cannot find that part. My apologies. Mine does the same thing.

[BigRedGrizzly]

https://vimeo.com/149467638
Mine does it also

[J trike]

Any luck finding a choke lever? Mine won't stay on full choke it slides to 3/4 unless I hold it

[J trike]

Ok thanks anyway , appreciate the effort

[BigRedGrizzly]

Ok thanks anyway , appreciate the effort

I will keep my eyes out for one or the one I had. I recently sold a bunch of stuff and packed a lot away. I'll keep looking and reach out to you if I come across it.

[Legns]

that is a common thing with these and the 250es its the carb not the lever. The choke is on a spring. I think when the spring weakens it does this or when the spring is new one of those lol Its late here i can't remember :crazy:

[BigRedGrizzly]

that is a common thing with these and the 250es its the carb not the lever. The choke is on a spring. I think when the spring weakens it does this or when the spring is new one of those lol Its late here i can't remember :crazy:

Yeah... I think it's the new way because I replaced the cable, spring, and jet and this is how it operates. Not a big deal. After a few minutes it warms up and is not an issue.

[J trike]

I replaced the choke lever on my 85 big red a few weeks ago and it works just great. So I thought easy fix for the sx. Wrong lol

[themotoviking]

Hey if you guys could continue this in PM id appreciate it.

[Legns]

Any Updates on the project ?

[themotoviking]

Tank is back from second batch of weld repairs. I got the carb all rebuilt and put back in and was doing test running. I think a vent is clogged because the minute the bowl filled up it would start to over flow out the side vent tube. Also may have ot jet the pilot jet a bit bigger. Due to it getting more air It falls on its face on a quick jab to WOT.

[Greyghost]

Looking Good! I am building an 85sx too, I have to get my tank painted or powder coated to finish up mine, What color are you using for the powder coating?

[themotoviking]

I am actually changing the 85 to the 86 colors so the tank will be white.

[250ES5984]

Loving the buildup. Keep it coming! ������

[250ES5984]

Any updates?

Sent from my SAMSUNG-SM-G890A using Tapatalk

[3is4Fun]

Nice!! here is mine, just started working on it.. although I didn't just run out and buy it, My dad bought it for me in 1985!! Brand new off the boat! I hadn't rode it for probably 20 years... it was in my friends barn for most of that time.

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[3is4Fun]

just saw the picture of the cleaned engine!! You did a great job on that. did you use any special brushes or anything special to get it like that?

[themotoviking]

Not much lately Have not moved any further since last post. Been busy working extra hours and getting other projects done.

[themotoviking]

just saw the picture of the cleaned engine!! You did a great job on that. did you use any special brushes or anything special to get it like that?

Just elbow grease and the engine shine from CRC.

[kilabeez0]

any update?

[themotoviking]

Sorry guys. Have not been doing much in the ATV world. Kinda moved on to Raptor 700s and YZ250s. Anyways some of you have been asking for updates. Well I finally got her all back together and up and running. I had her out on the maiden voyage/shake down run. The 250SX performed just as fun as I remembered. I have all the original decals applied and now I just need to get it all detailed and ready for sale. Its fun but I just cant bring myself to keeping it and riding it. It just looks too good.

Off the top of my head here is what I have done
All new plastics
stripped and powdercoated tank white
new front brakes, bearings and seals
Rebuilt front forks, seals, boots ('86 color) and fluid
Fully rebuilt and assembled rear diff from FlyinW
near bearing and seals fro rear swingarms axleshaft
all new bearings and seals for rear drum and brakes
New petcock (aftermarket)
Shinco carb rebuild kit
Uni Air Filter
refinished full exhaust system with VHT high temp satin black paint to match OEM color
New SS hardware and added heat tape to heatshield
Updated rear rims to 9x9s for better selection of tires.
CST Ambush ATV Tire 22x10-9 tires
updated front rim to 10x5
Duro Thrasher Radial ATV Tire 23x7-10 front tire
New misc control parts
New Renthal bars
New OEM grips
New seat foam and '86 blue honda seat cover from CEET
Tool box and tool kit intacked!
PRM-ATV Grab bar
Motion pro Brake light and license plate holder
Tow hitch
New Exhaust gaskets
Thats all I can think of for now.

I'll post up some better finished pics next week after I detail it for the photo shoot.

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