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Discussion Starter · #1 ·
New to the forum and will be building my first quad to use as a backup bike / all around play bike for the desert, mountains and sand-dunes for the wife and I. I currently ride a Ktm 300xc and wife rides a kx100 and it’s not ideal to use in sand not enough torque, small wheels and short wheel base. A week ago I picked up 2 86trx250rs pretty much complete. One with a hacked up frame and blown motor and one with an ok frame and running motor.
Running motor had 180psi compression and leak down test was performed. The jugs Base gasket had a small leak so after removal it appeared the piston had signs of a slight cold seize at one point in its life. End goal is to have an easy and comfortable bike to ride with a broad power band. So I stripped the good frame and found some repairs to make after it gets sand blasted.
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Lucky to find them really..
I would love to find project like that to build
Was gonna do another build just don’t want to sell my motors I have
You’ll be an R addict in no time
 

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Discussion Starter · #3 ·
Lucky to find them really..
I would love to find project like that to build
Was gonna do another build just don’t want to sell my motors I have
You’ll be an R addict in no time
Yeah should be a fun build. If anyone has recommendations on things to do or parts to stay away from I’d like to hear all opinions. Currently looking into getting parts to rebuild the stock swing arm, front hubs, all brake calipers and both master cylinders. Between frame gusseting and welding this should give me a start
 

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Discussion Starter · #4 ·
Center motor mount busted probably going to cut out the whole piece and weld in new metal
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Discussion Starter · #9 ·
Anybody have recommendations on a front master cylinder rebuild kit? Most kits I find are for 87-89 and looking at service Honda there are different part numbers for the rebuild kit and the 86 seems to be discontinued. Having a hard time finding one for an 86. All balls has one and claims 86-89 but worried it might not work.
 

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I've rebuilt 2 complete sets of brakes using Shindy rebuild kits. Both sets were from 86's & I used the front mc kit that is listed for the 87-89 & they worked just fine. Got 7 years on one set of brakes & 5 years on the other set & they all still work great.
 

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Good luck with the build!

Just curious, did you get the standard BVC gusset kit or the expanded kit with the front motor mounts? If the kit with the front motor mounts, I’m curious how it works out for you. I’ve been considering them for a new 86 frame build.
 

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Discussion Starter · #12 ·
Thank you that’s good to know. I will order the 87-89 just ordered rear master rebuild, all caliper rebuild, steering stem bearings, and swing arm rebuild
 

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Discussion Starter · #13 ·
Thanks man. Got the full kit I believe. Came with front mounts and shock tower brace. But mine are boxed at the front so won’t be using them. After my frame gets back from blasting I’ll start on all the welding and post pics with my opinion on the fit and finish
 

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Discussion Starter · #14 ·
Thank you that’s good to know. I will order the 87-89 just ordered rear master rebuild, all caliper rebuild, steering stem bearings, and swing arm rebuild
 

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Discussion Starter · #16 ·
So these bushings that go into this linkage here are they supposed to be a press fit or move freely inside? I assume move freely because each end has a grease fitting but I had to use a socket and hammer to get them out.
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The linkage bushings should move freely but if they don't even after everything is clean consider yourself lucky because a tight bushing can be made to fit just right. Usually its the other way around & those bushings get excessively worn & fit sloppy & there's currently no pivotworks replacement kits available
 

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Discussion Starter · #19 ·
The linkage bushings should move freely but if they don't even after everything is clean consider yourself lucky because a tight bushing can be made to fit just right. Usually its the other way around & those bushings get excessively worn & fit sloppy & there's currently no pivotworks replacement kits available
Thanks good to know. I’ll polish them up to get a good fit. I called pivot works they told me they should be getting some in February so I ordered those for now. Temporary I’ll just use all the old seals
 

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Discussion Starter · #20 ·
pivotworks stopped offering them but just in case other people reading this do need replacements, there are alternatives available now. This is one of them:

I saw that I was looking for a phone number on their site to call them first but can’t seem to find one.
 
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