OZ ATV :: The Australian ATV Forum

[richie_supercharged]

Started this on airfoolers.com so i Thought I'd post a build thread here to,it gunna be a real slow one
Mods:DG pipe and silence ,air box lid removed uni filter ,pro taper bars ,gforce hubs ,douglas rims
History: bought it off a mate 4 yrs back he bought a dg pipe and silencer, rode it once on the dunes and hit a tree bent the forks and handle bars and cracked plastics ,he straightened the forks then I bought it
It was in good condition when I got it and I havnt done to much in the way of restoration over the years so this year being it 30th bday I'd treat it to a make over
To do list:
   Sandblast frame and swinger repaint red ..thinking powder coating
   Strip old paint off engine and repaint red
   Pretty much strip and paint everything..
   Rebuild forks
   Replace front bearings ,bearing carrier
   Piston and rings
   Then buy new plastics and fit my new seatpan and fit all original decals
Some pics
few years ago
 

more recent







as you can see it need a real good clean up
its going to be a slow process ,i live right in the city in sydney in a 2 bedroom apartment with the girlfriend so i dont have any room for trikes here so i keep them at her parents which is 2hrs north at maitland, it has alot more room, a shed to keep my trikes and is closer to the dunes anyway
the shed im working out of ..there's a 84 250r in there somewhere
_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[richie_supercharged]

picked up some bearings and seals from ric(atcheaven) few weeks ago
And started rebuilding the forks on weekend
Was easy to pull em apart there wasn't to much oil on there but there was a bit in the spring section which I'm sure was meant to be up that far
.. Hardest part was removing the old seals also I can't get fork tubes out of the clamps but I don't think this is a real prob ..only when I comes time to fill but il work it out

The oil smelt terrible

All painted up

Tried to get the front wheel bearings out and the outer race got jammed in




Should I clear coat the painted metal bits?
_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[ForeverThreeWheels]

Looking good mate, I've gotta do the same to my 82. Yeah I'd clear coat them.
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[HaggLE]

Wedge the claps apart with a screwdriver and hammer them in, then use a rubber mallet to drive the forks out of the clamps.

The wheel bearing is stuck because you were hitting the inner, not the outer. find a piece of tube that fits the hole and hits the outer ring evenly. An old socket always works a treat.

When you get to the point to put the fork oil in, use the measurement from the top not the ml measurement. Make sure you give them a good pump up before you check that level.

Looks like its really coming along Richie, wish I had the time to do this on Haggletron... maybe over winter.

[richie_supercharged]

HaggLE wrote:

Wedge the claps apart with a screwdriver and hammer them in, then use a rubber mallet to drive the forks out of the clamps.

I tried that but I didn't wanna get to rough and damage any thing

Quote:

The wheel bearing is stuck because you were hitting the inner, not the outer. find a piece of tube that fits the hole and hits the outer ring evenly. An old socket always works a treat.

Again I was worried bout the lip on there that the bearing is sitting on on the other side, the other side came out but was in pieces , this one is still in but pices shattered off

Cheers for the advice on oil..
_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[Mart 300r]

Lookin good mate. Good to see ya given it a birthday love it.
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1984 ATC 300R, 1986 TRX 500R,1984 ATC 200X, ATC 70 WITH CUSTOM LAYDOWN 250R ENGINE, 125CC CUSTOM THUMPSTER TRIKE

[richie_supercharged]

Finally got these bastards out..snapped the tip off the big screw driver doing it
But I managed to get em without having to use a mallet




All right so I've just got the piston and spring and oil lock seal bolted back into the slider

Problem now is its been that long I can't remember the order the seals an rings go in 
Is it oil seal then ring then snap ring then dust seal


Which way does the oil seal go in?

Also where does this one go??

??????????????????????


_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[Oldrodder]

[richie_supercharged]

Thanks mate I found that one an it helped abit but still doesn't tell me what this is

I'm positive it's from the forks
_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[ForeverThreeWheels]

Any progress buddy? (because im so fast when it comes to building a trike and all )
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[richie_supercharged]

ForeverThreeWheels wrote:

Any progress buddy? (because im so fast when it comes to building a trike and all )

Nah I'm back home in Sydney mate won't be working on em till next weekend il have the forks back together and in the clamps ,which are now painted up all black
Then il start to take the engine out .. Not looking forward to that swinger bolt
_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[richie_supercharged]

So mostly stripped, Carby cleaned up really well
Swing skid plate is toast rusted and the sand has rubbed straight though some sections is there a better replacement for this or is it easy to just source a good second hand one?
Having trouble with the swing arm bolt can't get it to budge at all any tips
_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[Oldrodder]

richie_supercharged wrote:

So mostly stripped, Carby cleaned up really well Swing skid plate is toast rusted and the sand has rubbed straight though some sections is there a better replacement for this or is it easy to just source a good second hand one? Having trouble with the swing arm bolt can't get it to budge at all any tips

Mate there is no easy way, some things I tried on previous 250's are, soaked with lots of WD40, or some form of penetrating oil, heated with oxy and then use a decent bar whilst hot to drive out. The problem is the bolt rusts to the bushes as you probably know. Put lots of anti seize compound on when re assembling.

[richie_supercharged]

Il try more wd40 or another oil ..
Once removed the castle nut and spacer the swinger bolt was tacky to touch so I think whatever grease was once there has become a glue..
Was thinking of covering it in marine grease when I put it back in
_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[Mart 300r]

The old swingarm bolt ay lol.Mate i would go with grease on the bolt more so than antiseize,anti seize can become quite abrasive on moving parts its more for threads.(great for stopping stainless threads binding up).i tried everything to get mine out an had no luck had to cut it with the thinest cutting disc we could find.Im pretty sure the bolts are pretty easy to get for your model unlike the 83/84's.good job with it mate cant wait to see it done.
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1984 ATC 300R, 1986 TRX 500R,1984 ATC 200X, ATC 70 WITH CUSTOM LAYDOWN 250R ENGINE, 125CC CUSTOM THUMPSTER TRIKE

[HaggLE]

Lots of heat.

[richie_supercharged]

Yeah had another crack this morning it's going no where .. The right side doesn't even slide well in the adjuster ... Yep gunna have to heat It



_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[richie_supercharged]

a little bit more done today .. removed engine, axle and fork clamps

didnt realise i need all the balls out of the race in the clamps they fell out everywhere but i managed to find them all on the floor of the shed

that swinger bolt is F@#ked
cant get it to budge at all, i air hammered it n heated then hammered it, swore at it ..nothing works
may have to cut it but i want to find another one before i do
anyone have a spare i can buy or know of where i can get another?






_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[Oldrodder]

This is the correct colour in powder that you need, if you import it your self Pro Strip at Redhead can put it on for you.
http://absolutepowdercoating.com/store/product_info.php?products_id=28&osCsid=98bd22337822c37da2bb7b2647c4bc8a

[ForeverThreeWheels]

Oldrodder wrote:

This is the correct colour in powder that you need, if you import it your self Pro Strip at Redhead can put it on for you. http://absolutepowdercoating.com/store/product_info.php?products_id=28&osCsid=98bd22337822c37da2bb7b2647c4bc8a

Thanx for that Glen, i'm re-doing the 86 in a few months and ive been looking for the best match for months.
How many lb's should be bought to do a frame?
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[richie_supercharged]

Yeah thanks i was looking into that company, have you delt with them?
Few years back i was goin to turn my 84 fluro orange pc'd frame and motor white plastic and found that site
how much would i need for frame and swinger?
_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90

[Oldrodder]

I had them send me a 1 lb lot and I did the frame and other parts on the 70 and probably had about half left over which i recently gave to Dave.
I think he is getting some more sent over just in case but the 1 lb lot should be enough to do a frame and various other parts.

[ylwgtr]

i just looked it up on the parts dvd and ferk me its $244.00 and its prob not available

[Mart 300r]

Im thinkin out aloud here but i reckon if we could set one of these frames up on a good drill/mill set the swingarm up perfect square, Then drill the center out of the bolt we would only have to go the depth that the bearing/bush goes in.I know the bolt would be as hard as a honeymooners but with the right speeds high quality drill bits and fluid i reckon we could drill the guts out of the bolts then id bet my left nut we could hit em out lol.I wish i had tried doin this to mine before cutting it.Heat only heats up the outer part of swingarm not the actual sleeve/roller that the bolt gets stuck in.Kinda same principal as a oxy acyetlene gouging tip works.

Richie i think youll be able to find a bolt for it without to many probs, when i was lookin around on egay for a 2nd gen all i could find was first and 3rd gens.and there were plenty of em.
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1984 ATC 300R, 1986 TRX 500R,1984 ATC 200X, ATC 70 WITH CUSTOM LAYDOWN 250R ENGINE, 125CC CUSTOM THUMPSTER TRIKE

[richie_supercharged]

http://www.youtube.com/watch?v=UoSffK_AuQA&list=UUImsVjnM2b_AOXNnnYYqveQ&index=1&feature=plcp

I'm bidding on one now
_________________
If in Doubt.. Flat out

84 ATC 250r (290kit)
82 ATC 250r
77 ATC 90