Just another 250r build thread.... NOT! PROJECT Polaris Tri-clone/Typhoon

[Trike_crazy]

It's taken a few years to finally find one of these in my price range but I just picked this up this Polaris 250R/ES scrambler last weekend. It's missing the front rack and some other small parts and the front fender is broken but for the price I couldn't beat it. I drove 2 1/2 to 3 hours finally getting to the guys house around 12:45 AM! I didn't get home until 4 AM but I think it was worth it.

http://uploads.tapatalk-cdn.com/20161214/b0332900282b888ca06db04fe17b18fc.jpg

[Matt85'350x]

Nice. You'll like it. Make sure you fix that tank badge or it'll be gone like so many others. Does it run?

[fabiodriven]

Great machines for sure and definitely worth the haul! Just remember when it comes time to wrench that you love this machine, you LOVE it! It will make you angry when it comes time for repairs and maintenance just like any Polaris, but it is well worth it. Fastest utility trike ever made.

[Trike_crazy]

It doesn't run currently but I was told it was a spark issue. I have been wanting one of these for a few years now and the prices were always out of reach at the time. But this one popped up for a great price and within driving distance. (not saying much because I've driven 12+ hours picking up a another 3 wheeler and a $50 brush guard for my Crewcab, thats another story).

Its missing a few parts like the polaris badge on the right side of the tank and the front rack but I think I might make a slight resto mod with it but not do anything that can't easily be reversed. Its not going anywhere so I'm not worried about resale.... don't be too upset if you see it at trikefest with white rear plastics and a few other changes. At least thats my goal. The main thing is getting some time to check it out, make a list of parts and get it running.

[czac]

nice.. i see you got one with a customized front fender... lol

[Trike_crazy]

nice.. i see you got one with a customized front fender... lol
Yeah lol. I have an extra black one for a dx that will go on it along with some white rear fenders from a Polaris cyclone if I can get the money for it.... I just need some time to get it in the garage and work on it and get it running.

[Trike_crazy]

Took a look at the polaris yesterday and got it running. Seems like all it needed was a proper ignition switch. I checked all of the wiring and connections and swapped the plug for a new one. Only issue with the wiring/electrical is the starter solenoid isn't working. Sprayed a little shot of starting fluid in the carb and jumped the solenoid and within a few revolutions it fired up and was running. I still haveva bunch of stuff to do to it but its good knowing that it runs.

List of things that need done:
- New exhaust system. (Mounts are broken and the muffler is currently welded to the frame)
- New floorboards
- New dash
- New drive pulley for the clutch system ( It has a bunch of slop and the bushings are worn or missing)
- New clutch cover
- New vent tube for the clutch cover (if I can find one)
- Getting all of the lights to work
-New fuel and oil lines
And a bunch of new hardware to replace the missing stuff.

This isn't going to be a nut/bolt restoration or anything close to it. I just want it to be 100% complete and working. No broken or bent parts.

http://uploads.tapatalk-cdn.com/20170103/322a566f7249888474a923c2ca8bf37c.jpg
One a side note my garage looks like a Polaris chop shop. I picked up a couple of 400 2 strokes earlier this year that I just started working on last week.

[R-N-D]

I love it. Been looking for one for some time to add to my other Polaris' that I have. But, those all have 4 wheels. Tough to find and for those I have, asking ridiculous, I mean ridiculous numbers for basically junk in my opinion. But, I'll keep looking. Nice find, thanks for sharing.

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[350for350]

I've ridden a 1987 Trail Boss 250 4x4. Since it's basically the same engine, that trike should move pretty good. Now if you really want some looks, take one of those liquid cooled 400's, put it on your trike, and hit the dunes!

[danbur55]

i have a 95 400l that the motor was trashed, do have some of the external parts if you should need something, let me know Just dont have any clutches good luck

[Trike_crazy]

I've been looking over the parts that need and replaced and figured I'd share my findings and post for future reference.

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The top picture is the drive pulley and the second pic shows the bushing on the end that is so worn out that It broke the clutch cover and may have broken an engine mount at one point.
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This set of pictures show the damaged clutch cover and engine seal. Luckily for polaris owners these are basically the same from 85 to 99+ on 250's through 500's. The only differences being is that the inner cover might have one of the 3 bolts that mount it to the frame in a different position and the screws that mount the 2 halves together are different. The boss is cast into the new style covers for the old mount position. I might post a picture later of the differences if anyone cares
http://uploads.tapatalk-cdn.com/20170108/29b90cafe403bd584a1d2a6777bef789.jpg
This picture is of the driven pulley and the holes I had to drill to use a puller to pull it off. The later ones from 250 on up all had threads inside to use a jack screw to remove it.
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Here the difference between the one I had to remove with a puller and the later ones that had the threads. Also pictured is the input shaft that the pulley was rusted to. Normally the pulleys can be pulled right off but mine was rusted solid lol.

I'm currently working on cleaning up the outside of the tank and will have pictures of the progress in the next day or so.

[hoosierlogger]

Rust, natures loctite!

[Trike_crazy]

Did some sanding on the tank last night. I started out by carefully scraping off the oxidation with a razor blade and then brought it inside to wet sand with 220 grit. I've only worked on one side with the razor blade and sanding. You could tell a difference just with the razor blade. Hopefully I will get some more time to finish it here in the next few days. The picture shows what I started with and what I have at the moment. http://uploads.tapatalk-cdn.com/20170108/4f25e77fb483cf0b4832007d3e294e78.jpg
http://uploads.tapatalk-cdn.com/20170108/d549e830db4046f6aa44343364910666.jpg
The oxidation is so bad that the tank has a noticeable texture to it. Its much smoother after the initial sanding.

[Trike_crazy]

I sanded a little bit more on the tank last night and finished it off at 1000 grit. I would've went with a finer grit but with the depth of the oxidation it would've taken a long time to get down into good plastic and I don't want to ruin the tank by going too deep. So with that I used some armor all trim and plastic restorer to polish it out and give it a good shine. I know that if I spend a bit more time on it that it will look better but this is going to be a rider.
https://uploads.tapatalk-cdn.com/20170110/a4dabf8199da8ef536ffcb52961a1f4d.jpg
I think it looks pretty good considering I only have about 3 hours on the one side. Now for the other side!

[Trike_crazy]

https://uploads.tapatalk-cdn.com/20170110/5571722ad46da4269298e2ed94365355.jpg
Well the picture isn't so great but the tank is world's better than when I started.

[efhondakid]

Vegetable oil on oxidized plastic works wonders. Wet sand with 220 first then put some on a shop towel and get the whole piece covered in a light coat let it sit for a day or so then put a little more on a clean towel and rub it in.

[Trike_crazy]

So I found myself another Polaris 3 wheeler. MRSOUND in all of his awesomeness picked it up for me since I was too far away to make the trip. https://uploads.tapatalk-cdn.com/20170126/6584a3998a39b62612dca13efc0386e8.jpg
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It looks rougher than the first one I picked up a few months ago but it looks to be mostly complete. There's enough there to justify putting it back together.

[R-N-D]

Nice find. Man, why can't I find one? Hopefully one day.

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[Trike_crazy]

Nice find. Man, why can't I find one? Hopefully one day.

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I'm always looking all over to find stuff. Facebook was the key for both of these. The first one was listed on Craigslist too but I seen it on Facebook first and was the first one to comment on the post. You just have to keep your eyes peeled and some cash in your pocket and you'd be surprised.

[Trike_crazy]

Picked up another piece of the puzzle. I picked up an 87 polaris cyclone to use the engine/exhaust/carb on one of these scramblers. Its still not going to be honda 250r fast but it beats buying aftermarket parts that cost more than what I paid for the cyclone. These were 30+ hp from the factory where a normal scrambler/trail boss/trailblazer was around 22hp
https://uploads.tapatalk-cdn.com/20170131/b26f092eefc80e3a459d665c23016373.jpg
Part of the plan was to use the rear plastics on my build but they have a melted portion by the exhaust so I will figure that out when I get to that point.

[Matt85'350x]

Very nice. I too have been looking for a cyclone to do the same thing. You'd think the hard part would be finding the P3 right? I've bought 4 of those and passed on a few more but finding a cyclone at a price I'm comfortable with hasn't happened. I'm not paying $600-$1000 for it when all I really want is the engine.

[R-N-D]

Very nice. I too have been looking for a cyclone to do the same thing. You'd think the hard part would be finding the P3 right? I've bought 4 of those and passed on a few more but finding a cyclone at a price I'm comfortable with hasn't happened. I'm not paying $600-$1000 for it when all I really want is the engine.
Looking to pass any of those this way?

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[Matt85'350x]

Looking to pass any of those this way?

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I've already sold 2. Not sure I'm ready to part with either of mine. One is together as was running until very recently (I believe there's an electrical problem). The other one has the engine out of it as I planned on a full restore but really it's pretty far down the list and I would have been better off keeping it together. PM me if you're interested and I can send you pics and you can make an offer on the one that's apart if you'd like.

[R-N-D]

Apart? Yeah I'd love to say that I'd be interested in it but with time, and more so, mechanical ability, I'm not sure I'd want to take that on. I think I could squeak by but if not, then I'm stuck.

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[Trike_crazy]

Very nice. I too have been looking for a cyclone to do the same thing. You'd think the hard part would be finding the P3 right? I've bought 4 of those and passed on a few more but finding a cyclone at a price I'm comfortable with hasn't happened. I'm not paying $600-$1000 for it when all I really want is the engine.
I found cyclone in st Louis last week for $350 that ran and rode. All it needed was a tank. If I would've had the cash I would have picked it up too since I picked mine up in the same area.
https://uploads.tapatalk-cdn.com/20170131/6660876fec2dae6d8942f70b3451f5a0.jpg
It seems with every cyclone I find someone has painted the plastics.

[Trike_crazy]

So the engine on the cyclone runs. I started the teardown process last night on the cyclone to get the exhaust and engine off. Once I got the engine out I took a look at the piston through the exhaust port to check for any obvious problems and found that at some point some had bored the cylinder for a 1.00 millimeter over piston. I think it being bored over plus the fact that they had disabled the auto oil injection was the cause of it running hotter than it should have since they didn't rejet it at all. I'll do a compression check (something I should've done before I pulled it) to see if that has been affected by running hot. The cylinder walls and piston look fine but I'd like to get a baseline for reference. So far so good!

Sorry for not posting pictures. I'll get some once I get home

[NeverLift]

Can you take a picture inside the rear wheel of the hub? I was given a set of rear tires/rims and hubs and was told they were for a Polaris 3 wheeler.

[Trike_crazy]

Can you take a picture inside the rear wheel of the hub? I was given a set of rear tires/rims and hubs and was told they were for a Polaris 3 wheeler.
https://uploads.tapatalk-cdn.com/20170203/fde0339d52d27d2c8c185de3dc936331.jpg
Is that what you were looking for?

[NeverLift]

Perfect thanks.

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[Trike_crazy]

So I've held off on working on the polaris because I found and bought another one. This one I'm going to use the parts from the first one to make this one complete then I'll take the engine/plastics/seat/aluminum skid plate and a few other parts probably the cyclone that I picked up a few months ago and make it look like one. 3 wheeled cyclone clone? Lol
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This one is in better shape than the first but is missing the floorboards and some hardware. I pretty sure the reason they started taking it apart is the starter isn't working. Surprisingly it started once I put a recoil starter on it and hit it with a shot of ether. I took it down to the car wash to give it a bath last night and over the next few days I'm going to get everything together and get it riding.

[Trike_crazy]

Sandblasted the floorboards from the cyclone so I can use them on the newest P3. I have to pick up some supplies on the way home and then I should be able to paint them tonight.https://uploads.tapatalk-cdn.com/20170421/af539a38cde75ee3123664c4e171bc02.jpg

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[Trike_crazy]

Floorboards are painted and mounted up. Now the rest of the bike looks like crap lol. Its fine, I'll try to give it some more attention later down the road. https://uploads.tapatalk-cdn.com/20170422/5a73dfc24234f6a0ce2804b956bf767b.jpghttps://uploads.tapatalk-cdn.com/20170422/b52998633a152d69f437d156495942af.jpg

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[Trike_crazy]

So after the last few hours I finally got the disc brake and shifter handle off. It took a lot of heating, beating, some drilling, and creative prying but they both came off. The shifter was seized in the handle so I couldn't pull out to shift it. In the process of getting it out I bent the black part of the handle and cracked the weld. Luckily I have the other Polaris to pull parts from and wouldn't you know it the handle on that one came off easily.... but the threads where the knob go are messed up so I'm using the 2 and making on good one.

The brake disc had to come off so I could get the caliper off to put on the new cable that I ordered when it gets here. Needless to say I'm going to have to find a good brake disc since this one is warped from pulling on it.

I have a few little things to get today if I get a chance and that's new fuel and oil lines, new filters and some hardware to remount the tank and rear fenders/rack. I should have it buttoned up enough to fire it up then maybe I'll dive into the couple of drive clutches and clutch covers I have and find a good one to work on this. https://uploads.tapatalk-cdn.com/20170422/885c3edf24e7213929bbf7611e044a54.jpghttps://uploads.tapatalk-cdn.com/20170422/bda9910a2f1d6274954f38711f5f0e1d.jpghttps://uploads.tapatalk-cdn.com/20170422/9ae63df42c2e574f72d32a96bde836bb.jpghttps://uploads.tapatalk-cdn.com/20170422/130ff874e256b1d2a11f05dee7514687.jpg

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[Trike_crazy]

Well other than the seal that goes between the inner clutch cover and engine, some hardware for the rear rack and clutch cover and some fuel and oil lines I think this one is complete. Now to start back on the 85 Polaris and get to replacing all of the parts I've pulled from it lol.https://uploads.tapatalk-cdn.com/20170423/1cbbc3b44d32e2e99148097bdacd5106.jpg

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[Trike_crazy]

Well ladies and gents.... she's a runner. And she runs pretty damn good. I took it out and rode it for 2 good solid hours and it didn't miss a lick. It seems a bit top heavy and the floorboards take some getting used to bit all in all I'm pretty impressed with it. Especially the speed it has, damn this thing is fast....... I might swap the rear wheels and tires for some 20's for a little lower center of gravity and put some wheel spacers on to make it a bit more stable on the off camber stuff. I still have a few things to button up but that just getting some hardware and putting the clutch cover back on.

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[Trike_crazy]

Been working on the 85 scrambler. I swapped the original engine and transmission for the cyclone. I also swapped the cdi box because of some wiring length differences.The other picture is of the difference between the original intake on top and the cyclone intake and carb on the bottom.https://uploads.tapatalk-cdn.com/20170430/2d39232dc88f1a6f4a4d2d3109655202.jpghttps://uploads.tapatalk-cdn.com/20170430/a28dc6fe36805c6f62de8fe14638b369.jpg

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[Matt85'350x]

Been working on the 85 scrambler. I swapped the original engine and transmission for the cyclone. I also swapped the cdi box because of some wiring length differences.The other picture is of the difference between the original intake on top and the cyclone intake and carb on the bottom.https://uploads.tapatalk-cdn.com/20170430/2d39232dc88f1a6f4a4d2d3109655202.jpghttps://uploads.tapatalk-cdn.com/20170430/a28dc6fe36805c6f62de8fe14638b369.jpg

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Sounds like a fun swap

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[Trike_crazy]

Sounds like a fun swap

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It should be when I'm done. It's not that hard of a swap other than the exhaust mounts on the frame are different between the scrambler and the cyclone. Once I get a few measurements and pictures of the mount placement on the cyclone I'll cut them off and weld them to the scramber's frame. I've also been working on trying to use a BW200 wheel and hub on it. I just have make some spacers for the hub and for the drum to space it back towards the fork and I should be in business. The hardest of this whole thing is just getting time to work on it without ending up working on someone else's stuff lol. It's like everyone knows when I'm in the garage so they bring all of their stuff for me to help with or do the work on. It's all good though lol.

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[Trike_crazy]

Since the last post I had a buddy of mine weld the mounts on for the cyclone exhaust. I also ordered a new front tire for a different wheel I plan on using and mounted a set of handlebars that I had purchased for another project that didn't end up fitting as well as I wanted. They seem like a better fit on this. As soon as I get paid this week I'm going to make 1 last order for parts like a new belt, an air filter and floorboards.

Oh yeah, did I mention it's running now? Lol. Thing sounds pretty good.https://uploads.tapatalk-cdn.com/20170607/c1a13a6ef5067f6fc33d397e0bac1a19.jpg

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[Matt85'350x]

Since the last post I had a buddy of mine weld the mounts on for the cyclone exhaust. I also ordered a new front tire for a different wheel I plan on using and mounted a set of handlebars that I had purchased for another project that didn't end up fitting as well as I wanted. They seem like a better fit on this. As soon as I get paid this week I'm going to make 1 last order for parts like a new belt, an air filter and floorboards.

Oh yeah, did I mention it's running now? Lol. Thing sounds pretty good.https://uploads.tapatalk-cdn.com/20170607/c1a13a6ef5067f6fc33d397e0bac1a19.jpg

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Hey, we need a video. I've always had interest in doing this. I'm curious to see how much faster it is than stock. Thanks for sharing

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[Trike_crazy]

I won't have a video for at least a week. I'm waiting on a new belt, air filter and some used floorboards to come in. Then the last bit of hardware to put it all back together.

On another note the tire my wife ordered for me came in. I had it mounted within 30 mins of UPS dropping it of. Looks pretty good to me.https://uploads.tapatalk-cdn.com/20170608/a3e2115c9017b65deb6c6cfb0ce27519.jpg

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[Matt85'350x]

I won't have a video for at least a week. I'm waiting on a new belt, air filter and some used floorboards to come in. Then the last bit of hardware to put it all back together.

On another note the tire my wife ordered for me came in. I had it mounted within 30 mins of UPS dropping it of. Looks pretty good to me.https://uploads.tapatalk-cdn.com/20170608/a3e2115c9017b65deb6c6cfb0ce27519.jpg

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I like the tire but it looks to be sitting low?

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[Trike_crazy]

I like the tire but it looks to be sitting low?

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At the rear portion of the frame the swapped cyclone/scrambler sits about 1 1/4 inches lower than my 86 scrambler. The front at the axle center line is about the same on both. I attribute most of the drop in the rear to properly inflated 20 inch tires vs. 22 inch, old and probably over inflated tires. I have some 1.5 in wheel spacers on the way to make it a little bit wider and more stable. If I like them I plan on buying another set that convert from 4 on 4 to 4x110. That way I can use the wheels that I run on some of my other bikes.

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[Blown 331]

I found cyclone in st Louis last week for $350 that ran and rode. All it needed was a tank. If I would've had the cash I would have picked it up too since I picked mine up in the same area.
https://uploads.tapatalk-cdn.com/20170131/6660876fec2dae6d8942f70b3451f5a0.jpg
It seems with every cyclone I find someone has painted the plastics.

I remember seeing that one on craigslist. I'm about 25 minutes from St. Louis on the IL side. I also have 5 Scramblers. I've passed on several others. I could probably have about 8 by now. lol. There was one on STL craigslist about 6 months ago for $400. It ran and I passed on it. Kicking myself in the ass now but do I really need 6? lol.

[Blown 331]

They cyclone also has a stiffer primary clutch spring than the Scambler which kind of gives a little more stall speed. Also you can run a belt from a RZR 800. They grip harder and are cogged on both sides for better cooling. I run them in all my Polaris's, they make a huge difference. Just that belt turned my Scrambler into a wheelie machine. I also tried a Dalton black/white spring in mine but had to take it out because I seriously could not keep the front end down. That spring is in my Sportsman 400 now.

[Trike_crazy]

I used the clutch parts from the cyclone on this. I ended up having to basically build 1 clutch from all of the extra drive pulleys I had laying around. The belt I used was a Gates G-force belt. I took it for a test run last night and the clutch was working pretty good. I can't do much else until my air filter comes in and I get the air box fully installed.

On a side note. I swapped the rear axle for one from a 400. Its an inch wider overall and you can use the aluminum hubs from the later style Polaris's.

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[Trike_crazy]

So I've been having a weird issue with this that I thought I'd share. When I would rev this up it would rev then quit like it hit the rev limiter or the bowl was running out of fuel then would backfire out of the carb. Took the carb apart and it was clean, petcock was clean and I had plenty of fuel and good flow. While I the carb apart I noted that the main jet was a #145. Thinking nothing of it I put it back together again and still had the same problem. Then I had the idea to check partzilla and found out that the proper jet size is a #200 which is also used on the 400's. Seeing as I have some parts for those I found a carb with the proper jet. Best I can tell is someone alone the line tried to do the right thing and clean and rebuild the carb but used the wrong kit with the wrong jets.

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[Trike_crazy]

Little late on the update but I put this turd in 3rd place on the podium at TF 2018 in the 2 stroke novice class. Future plans are either big bore/stroker or a full 400 swap that will put me in a different class. I had so much fun on this during trikefest and almost set it on fire at one point accidentally lol (fuel line melted on hot exhaust). I love putting oddball stuff on the podium and this it probably the most odd thing in a long time for that class. Unfortunately I wouldn't be there this year to to a military deployment but 2020 should be a good year if I can get this thing to someone who can work some magic on it and refine it or go all out for me with it lol. https://uploads.tapatalk-cdn.com/20190524/ff07dd6b83e4a729d62af4c54577b093.jpghttps://uploads.tapatalk-cdn.com/20190524/d9fcfa7e038add724d0f64d727568a9b.jpghttps://uploads.tapatalk-cdn.com/20190524/4334833b15bbe92254e206c4c9a97452.jpg

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[czac]

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lol... Nice "Turd"! Is that a hard plastic seat? What size is it?

[Trike_crazy]

lol... Nice "Turd"! Is that a hard plastic seat? What size is it?It's pretty soft. The seat looks like that from the rain that day. Its 250cc but was over 30hp stock for a cyclone (what the engine is originally from) compared to the original engine that was around 22hp. It has a pretty high rpm range but runs like crap (loads up at idle) because I've never had the time or jets to properly set it up. Hopefully one day I'll have it dialed in and put the hurt to some more 250r's and other sport trikes with this.

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[czac]

nice....sounds like fun. yeah jets can be fun...lol i had to do mine when i put the new pipe on it and it was a PITA for sure! good luck!