MPDano New Project: 1985 ATC 250SX **DONE**

[MPDano]

She's pretty thrashed but 90% there. Just verified starter spins great with good compression. Didn't hook up my compression gauge as the exhaust header is missing and not sure if that would affect the reading. I removed the carb and took it apart and put in my Berrymans Can. Ordered a carb kit, fuel petcock and starter solenoid.

Here is what I know I will need: (prices shown are already bought)

ATC cost: $80

Carb Kit: $16

Starter Solenoid: $7.50

Fuel Petcock: $6.50

All Plastics: $287 (gonna go all white)

Decal set: $41

Front brake lever/perch: $23.50

Front Brake cable: $14

Front brake lever cover: $20

Front Brake Cable Stay: $17.50

Front brake cable holders (top & bottom): $10

Front brake adjuster parts: $23

Red Kote fuel tank liner: $25

Steering Stem nut/washer: $15

Two rear tires - 22x11-8: $110

Metal air stems: $6

Header Pipe: $33

Flex Pipe/Hanger: $15

MRP Muffler: $0

Header Gasket: $7

Headlight Assembly: $32

Headlight/bulb: $70

New Grips: $10

Handlebars: (I have some Renthal bars lying around) $0

Seat Cover: $26

Shock Boots: $16

Reverse Cable: $14

Rear Brake Lever Cable: $11

Choke Cable: $12

Instrument bulbs: $8.50

Oil Filter: $5

Spray Paint: $20

36 ball bearings for steering: $8

Ignition Switch: $11

Starter Switch: $28

Rear brake adjuster: $19

Fuel cap gasket: $9

Fuel Tank Dampers: $11

Fuel tank L rubber: $12

Instrument Panel: $25

Fender holder rubber cushions: $20

Air Filter: $24.50

Rear Tail Light: $18.50

Tail light mounts (rubber,pins and collars): $25.50

Front and Rear Mud Flaps: $85

Battery Liner and battery holder: $40

I'm gonna keep a tally on this post if I am allowed to edit it as I go.

Total in parts as of 1/8/2017: $1235.00 plus $80 for the ATC

In disassembling the carb, I broke the pilot jet off, do you have a way to remove the broken piece?

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[MPDano]

Cleaned out the rusty tank with muratic acid today. Got the idea off a youtube video. I should have taken a before pic but it was covered in rust bumps all over the inside of the tank. Rinsed it out with some water then some pre-mix so it's has a bit of oil in it to keep it from rusting up again. Next is to get some of the Kreem tank liner and be done. I've used Por15 in the past but it was expensive. Also, removed all the paint off the tank exterior to get painted after the tank lining.

Also, banged up my battery holder so it actually can hold a battery. Also straightened up both foot pegs as they were bent to hell.

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[MPDano]

Got the carb kit and starter solenoid. Had to jump the ignition switch as well as the rectifier power. Most likely the igntion switch is faulty, gonna get a new one anyways. Shes running, so it's time for the dismantle and repaint that frame.


https://www.youtube.com/watch?v=IDfmF35dJEw

[82 250r]

Good work getting it running. Did you find that trike at the bottom of a river?

[MPDano]

Good work getting it running. Did you find that trike at the bottom of a river?

No doubt. The Craigslist River.

[MPDano]

Removed the engine, pressure washed the frame, engine, skid plates and lower triple clamp. Then painted the engine low gloss black, the rest in semi gloss black. I hit the rusty areas with rust restorer first, it makes a great primer.

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[MPDano]

Put the motor back in. Hooked back up the harness. Put new steering bearings, got 36 from the local bike shop. Love the simplicity of these old Honda ATC's.

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[Big G]

Nice to see you decided to give her a restore, rather than part it out. It's coming along real nice. Did you have any problems removing the front axle? My new 250SX's front wheel bearings are shot, and I've heard the front axle can be a real bugger to remove. I also notice pic #12 the drive shaft boot has an impression the same as mine did when I bought it, however I was able to shape it back to it's original 'ripple', and it seems to be holding. After seeing yours I'm thinking now that maybe it's common for them to develop a divet like that.

[MPDano]

Nice to see you decided to give her a restore, rather than part it out. It's coming along real nice. Did you have any problems removing the front axle? My new 250SX's front wheel bearings are shot, and I've heard the front axle can be a real bugger to remove. I also notice pic #12 the drive shaft boot has an impression the same as mine did when I bought it, however I was able to shape it back to it's original 'ripple', and it seems to be holding. After seeing yours I'm thinking now that maybe it's common for them to develop a divet like that.

Thanks, yes I hate parting out stuff. I always see value in getting a thrashed atv and bringing her back to life. This is a keeper. My front axle came out easily, surprisingly. I had a 250R that gave me issues with the axle.

I was going to add some heat and get that ripple out of the boot, but it will most likely come back after time. The boot is the original and I decided not to replace it as there no cracks and it was still supple. I like to spray all rubber parts with silicone.

The plastics will be the last things to replace as they are costly, almost $300 for the set. I'll do more to it this weekend as I bought more bits off ebay.

[Rob Canadian]

It is coming along nice. It was in rough shape.

Engine looks great. I like the way you removed the paint on the side. Little things like that make a big difference in looks.

[MPDano]

It is coming along nice. It was in rough shape.

Engine looks great. I like the way you removed the paint on the side. Little things like that make a big difference in looks.

Yes, used my orbital sander, which already had a very fine disk on it. I saw a real nice restored one (250SX) with that paint removed and said, why not. If I only had deep pockets, this project would be done already. We are heading on the first Desert Trip of the season the weekend before Thanksgiving and I'm bummed I wont be able to take it. Will have to make do with my other toys.

[MPDano]

Got my header, oil filter and rear brake lever in the mail. Wire wheeled the header and heat shield and gave it some paint. Installed the oil filter. Sanded off the faded blue off the Renthal Bars and installed the new left lever.

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[MPDano]

Just got my shock covers in tonight. Gonna get those installed tomorrow and get the forks back on.

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[MPDano]

Installed the new shock covers, reinstalled the forks. Installed the bars back and put on the new grips. Used some old wet/dry vac tubing hose I saved when the vacuum broke, and it fit like a glove for the frame to airbox tube I was missing. Saved $45 there. Sweet!

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[MPDano]

Used muratic acid to clean the tank of all rust. Put in a gallon and the rest water, let it soak for about an hour. Drain and put baking soda/water to deactivate the acid. Once dried, I used the Red Kote to seal it. I may do another seal just in case. Painted the tank white. Reinstalled the rear foot brake cable. Removed all the tires, pressure washed them, fixed what needed fixing and repainted one of them. Front and left rear wheels are aluminum and the right rear is steel, repainted the steel one with silver wheel paint. Diassembled the front brake as it was stuck. Brake shoes stuck to the drum. This happens when they are left in the rain and rust builds up in the puddle of water over time. All sorted now.

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[Hair Bear Bunch]

All this in under a month? I salute you sir!

[MPDano]

All this in under a month? I salute you sir!

Thanks sir. This is a real fun project.

[MPDano]

Mounted the front tire. Put a patch repair on it first, nice having a pool to check for leaks, lol. Put the wheel back on, which is a bear to line up and not without scratching my newly painted forks up too. Brakes work great, now to source the brake handle and cable. Painted some tank sealer on the gas gap so it will never rust. Installed a new gas cap seal too. Hooked up a new key switch so I don't have to jump wires now. Got a 2nd hand OEM starter switch coming so I can then hook up the choke and rear brake cables.

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[Big G]

Did you install a new rear drum seal? Couldn't see one in the pic. Also let me know if you're still looking for a front brake lever. I have an extra one which is new - I don't need it anymore.

[MPDano]

Did you install a new rear drum seal? Couldn't see one in the pic. Also let me know if you're still looking for a front brake lever. I have an extra one which is new - I don't need it anymore.

Didn't know there was a drum seal, all I saw was a large metal clip in there. I do desert riding so not too worried about moisture. Good to know tho. Oh wait, you said rear. I never opened the drum up, the brakes work so didn't feel the need to.

Yupper, still looking for parts and they are in my ebay shopping cart, but funds come in slow, lol. Do you have the full right front brake perch/handle? If so, how much do you want for it shipped to 92021?

Thanks,
Leo

[Big G]

Ah dang...just the lever, no perch :(

[MPDano]

Ah dang...just the lever, no perch :(

Bummer, yeah all front brake including the cable and bottom loom holder missing on my ATC. Seems like they started to part out at some point.

[MPDano]

Finally got a working starter switch. Attached a new choke cable and she works like a charm. Found a large nut and ground off the threads and installed on the front axle to fix my centering issue. It is a little bit too wide but at least i know to get a couple large washers and this will fix it. Also, got an inline fuel filter installed. Will probably not use the in tank filter as it probably wont fit anyways with the tank seal lining. At least this way, I can replace filters without draining the tank.

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[Big G]

Glad to see you got the front wheel centering issue resolved, but from looking at pic #4, it seems like the tab from the front shock is just barely catching the slot in the drum due to the extra spacing now?

Also, where did you get the new switch?

[MPDano]

Glad to see you got the front wheel centering issue resolved, but from looking at pic #4, it seems like the tab from the front shock is just barely catching the slot in the drum due to the extra spacing now?

Also, where did you get the new switch?

Yes, this is why I am going to washers versus that large nut. This will get more of the slot in. Switch came from eBay. Got it for $28 with a broken choke lever, swapped with my good choke lever, done.

[MPDano]

Mounted the new kicks on the rear wheels. Yes, the left wheel is 3/4" wider and is aluminum, right is steel. I'll sort that out at a later date. Installed the new rear brake cable/adjuster, reverse cable and new petcock.

OMG! Do these 250SX 4 strokes have torque. Popping a wheelie without effort was awesome. Was itching to do this test run, especially to see if the reverse worked. And yup, works great.

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[Big G]

Where'd ya get your petcock from? The aftermarket one I got for my SX was from Dr. ATV, and it sticks out past the side of the tank when threaded on, which I find looks kinda odd. Yours appears to be almost dead on to OEM, unless it's just the angle of the picture.

[MPDano]

Where'd ya get your petcock from? The aftermarket one I got for my SX was from Dr. ATV, and it sticks out past the side of the tank when threaded on, which I find looks kinda odd. Yours appears to be almost dead on to OEM, unless it's just the angle of the picture.

Nope, it's pretty flush. Lever slightly hits the tank when putting on reserve. It was a cheepie chinese one off ebay. Got it for $6.49 shipped.

[Rob Canadian]

Most people would have torched what you had at the beginning. GREAT save. Props to you.

[MPDano]

Most people would have torched what you had at the beginning. GREAT save. Props to you.

Ha ha, yeah. I love a good challenge though. Plus, I get to learn on these as well. Always a fun process.

[jakep53]

Looking very nice espically since what you started with!!

[MPDano]

Looking very nice espically since what you started with!!

Thanks Jake!! I'm shooting for December to complete this project.

[MPDano]

Finally got my muffler sorted. Welded a 1-1/2" adapter to the stock header. Welded a muffler hanger to the muffler and mated them up using 1-1/2" flex pipe. This thing sounds badass.

Gave it a test run around my pool thinking I was going to lose torque as this MRP muffler is for a 150cc. So far from that, this thing has wicked torque and power.

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[MPDano]

A little exhaust vid


https://youtu.be/ZjDmuQRqgIE

[MPDano]

Just purchased a bunch of stuff to finish this project out, including the plastics. Wanna take it out during the my Christmas holiday 2 week vacation. Time to start ramping this up.

[UPNATM]

Just purchased a bunch of stuff to finish this project out, including the plastics. Wanna take it out during the my Christmas holiday 2 week vacation. Time to start ramping this up.


Sweet! Make sure to post up some more updated pics.
Btw, that exhaust sounds great. :D

[MPDano]

Got a few parts in today. Ignition panel and front brake perch. Also started on the seat foam repair.

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[Big G]

Where'd ya get the front brake perch from? I'm looking for one as well...

[MPDano]

Where'd ya get the front brake perch from? I'm looking for one as well...

http://www.ebay.com/itm/161192601776?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

[MPDano]

Not too much activity, and got 95% of all the parts and plastics but trying to find the time.

I did install the 200X rear light. Have to get this all done by Saturday and I plan to take it to the desert on Sunday.

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[MPDano]

Decals installed on the rear fender

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[MPDano]

Well, she didn't make it to the desert this time around. Was too busy getting my sons E-Ton Rovers going. Got the decals on and installed the light. Put the Rear Fender on but still need to install the hardware.

After all that, work on the seat cover.

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[MPDano]

Bought the last pieces that I know of. The front and rear mud flaps with fasteners.

In the last parts to get done.

1) modify and install washers for front wheel
2) install front brake cable and support pieces
3) install Renthal crossbar/pad
4) heat and bend seat plastic, seat hardware and seat cover
5) install seat to rear fender
6) install rubber hole covers to fender supports
7) make ignition switch mount to instrument cover
8) install mud flaps and install front fender
9) white touch ups

[Merge_88]

Nicely done, that's a good looking SX!

[MPDano]

Nicely done, that's a good looking SX!

Thanks. Hopeful to get this done by New Years.

[MPDano]

Mud flaps installed on the new Maier Fenders. Really lame they couldn't pre-drill those holes on the rear fender, yet they did on the front one. Also, had to dremel the 4 slots as the OEM flaps have tabs on them. Anyways, thats done.

Also, installed the new front brake cable and hardware. Finally have some front brakes on it now.

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[Ranvier]

The white looks sharp.

[MPDano]

The white looks sharp.

Thanks. I'm afraid to add up all the costs in this project ;)

[Ranvier]

Thanks. I'm afraid to add up all the costs in this project ;)

Whatever you do, not near the wife....and close that ebay purchase history!

[brandonlowe2]

Looks great! What color seat is going on it?


Sent from my iPhone using Tapatalk

[MPDano]

Looks great! What color seat is going on it?


Sent from my iPhone using Tapatalk

Thanks! Black with White HONDA writing. Nothing special.

[UPNATM]

I agree, im diggin the white. Lookin good!

[MPDano]

I agree, im diggin the white. Lookin good!

Thanks Brotha.

[MPDano]

Love how we can use some 200X pieces on the 250SX. Found some front brake cable holders for my 250SX. Work perfect. Just need to put the brake cable thru them tomorrow.

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[MPDano]

Spent some time fixing my seat foam and plate by adding a metal bracket to keep the front from bending up. Also, put a metal piece on one of the rear corners missing some plastic.

The bad news is that I put my new seat cover on and it was too small. I couldn't stretch it far enough and it tore in a few mounting places. It's function-able but it really bothers me on how it looks. What say you?

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[dman10]

I'd fix the seat properly. No use going through all this work just to leave it like that.

[MPDano]

I'd fix the seat properly. No use going through all this work just to leave it like that.

Agreed. Gonna try and work on this during the weekend.

[UPNATM]

I'd fix the seat properly. No use going through all this work just to leave it like that.

Agreed. I would post up a wtb add in the classifieds, and in the least try and find a new seat pan. Maybe you will get lucky, and somebody will have a complete seat with good foam.

[MPDano]

I had another seat cover which was too tall in the rear, so I removed the other one and built up the foam on the rear of the seat. Re-covered and now I am satisfied with the outcome. Also, the material is marine grade vinyl, a lot tougher than the previous one.

I also started on the ignition switch mount mod. Used some small water pipe I had laying around and siliconed the switch inside of it. Just need to now silicone it to the instrument light panel. Have to let silicone dry so this project should be done by next week, hopefully.

Found a right rubber cover piece for the gas tank from Chapparel as I have a left serviceable one.

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[MPDano]

Put the front brake cable thru it's holders and did some white paint touchups. Removed the gold anodize off the Renthal crossbar and installed it. I'm in the home stretch now.

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[Rob Canadian]

Man. It looks great. Props to you on this. It looked like a boat anchor at the start.

[MPDano]

Man. It looks great. Props to you on this. It looked like a boat anchor at the start.

Thanks Rob!

[Big G]

Excellent job on the seat...good on ya for redoing it so it looks right. It makes me wanna redo the seat on my 250SX as there's a good 2 inch gap between the tank and top of the seat and it bugs me every time I look at it! Dang vinyl shrinkage after 30 years! Ha ha

[MPDano]

Excellent job on the seat...good on ya for redoing it so it looks right. It makes me wanna redo the seat on my 250SX as there's a good 2 inch gap between the tank and top of the seat and it bugs me every time I look at it! Dang vinyl shrinkage after 30 years! Ha ha

Yeah, and it doesn't help that the seat pan being plastic.

[MPDano]

Got some plastic fender holders from Home Depot for $6.50. Had to drill the holes the next size up on the Front Fender corners but they snapped right in. Installed the Instrument panel with the Ignition Switch mod. Works like a charm. It's pretty close to the Renthal crossbar so I can't use my Renthal Crossbar Pad I had from another project.

This is 99.9% done as I am just waiting on the battery holddown I bought off eBay. Was gonna zip tie it but no need to go ghetto after all this work ;)

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[MPDano]

Here's a quick walkaround running video of it.


https://youtu.be/6kGYyk-jdbE

[dman10]

Looks incredible, I'd like to add one to stable, but when I can find them they want too much, plus I need another project like another hole in my head.

[MPDano]

Looks incredible, I'd like to add one to stable, but when I can find them they want too much, plus I need another project like another hole in my head.

Thanks dman. Can't wait to get her out to the desert.

[MPDano]

Last pieces installed. Battery holder and liner installed. The battery is a little bit taller than a stock one, had to put a spacer on the mounting bolt. Rear light wires zip tied and tank side rubbers installed. I am done. Just have to let the RTV dry on one of the tank side rubbers. I'll wipe it all down and take the final pics of it complete. What a journey!

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[MPDano]

Ok all! She's all done. 100% complete. She runs like new. Everything works perfect. This was a fun project. She needed tons of work but was well worth it. I only replaced what "needed" to be replaced for safety sake. The ATC was missing lots of parts but eBay to the rescue again. The 250SX is getting more and more harder to find, so parts become the same way.

I sold my 250R since I never used it, plus it was just too fast being a 2 stroke with a manual clutch. This 250SX is a keeper as it has all the bells and whistles and way ahead of it's time in 1985. The Semi Auto makes it easy for anyone to ride. Gotta love the electric start and reverse. Also, never needing to oil a chain is a plus with the shaft drive. She's an all around cruiser and will be wicked on the next trip to the Desert.

Here is pretty much what I started out with. Disaster case.

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Here she is in her final glory.

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[250rmanfmf]

Incredible job! That trike was saved. congrats on the nice new trike!

[MPDano]

Incredible job! That trike was saved. congrats on the nice new trike!

Thank you sir!

[MPDano]

Trike is SOLD to a nice couple from Nevada. They drove all the way from there to San Diego for her. I am glad she went to a good family who appreciates an old skool trike.

I got too many toys and although the real reason was the challenge and to keep her, but this restored trike needs to be used. I got a Bombardier DS650 and a KTM 250SXF that I play with and the ATC would just sit pretty. Can't have that. Thanks for all the assistance in my Resto Journey. You guys are awesome!!

[Big G]

...the only thing it's missing is the hitch! Ha ha

[ironchop]

Very nice build

Sent from my Z958 using Tapatalk

[Rob Canadian]

I enjoyed watching this build. Very nice work.