[Jeepster]

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.

 

[Jeepster]

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

 

[Jeepster]

Center motor mount busted probably going to cut out the whole piece and weld in new metal

 

[Jeepster]

How'd the swingarm pivot bolt removal go?

Frustrating. It was free and spinning but would not come out. After 30 min of trying I cut it out. Currently apart

 

[Jeepster]

Looks like you need a gusset kit for your love engine mount, get untouched with pumashine

Yeah I ended up ordering a kit from BVC.

 

[Jeepster]

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.

 

[Jeepster]

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

 

[Jeepster]

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

 

[Jeepster]

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

 

[Jeepster]

Nothing to interesting going on yet but cleaned up my linkage.

 

[Jeepster]

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.

 

[Jeepster]

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

 

[Jeepster]

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:

METAL 1986-1989 HONDA TRX250R LINKAGE BEARINGS.

METAL 1986-1989 HONDA TRX250R LINKAGE BEARINGS.

www.dscatvparts.com

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

 

[Jeepster]

i make delrin pivot bushing and washer kits.$150 a set complete.

Got pics? I might have to do that if pivot works falls through in February

 

[Jeepster]

Frame back from blasting. Hopefully in two days I can knock out the frame repair and gusseting

 

[Jeepster]

How good do the seal out sand from the bushings?
View attachment 65468
View attachment 65467

 

[Jeepster]

Given the fact there just flat delrin washers I would say they most likely don't seal or keep anything from getting in there. If the bushings are machined to the same specs as the original steel bushings than you should be able to put the stock seals back in for some protection or maybe just use o-rings between the washers & linkage

Yeah it doesn't look that great. I couldn’t imagine getting sand in there and wearing it out quickly but I could be wrong.

 

[Jeepster]

Looking into a long travel set up if anybody has any suggestions on shocks and A arms. I know about Roll design and lone star. So far lone star is 3 months out. I’m not in a hurry but if I wait a few months to buy suspension then have to wait another 3-4 months after purchasing that will be a big hold up. Might just have to bite the bullet and order very soon. So far K B motor sports recommended me to run lone star Dc-4 A arms and Elka legacy with rebound adjustment shipped to me for about 2500-2600$ next step above that I’d want to possibly run elka stage 4s so I can have full adjustability but about 1,000$ more. I called 2 other places but 1 was quick to get off the phone and another didn’t seem very knowledgeable.

 

[Jeepster]

they are not just flat washers.i machine each one to fit on or in the link and make the shoulder to keep dirt and dust out.

Are those little washers rubber or what are they? My problem is my linkage is not perfectly round where the washers sit so the rubber will seal and fit better

 

[Jeepster]

Another option for new LT a arms is JD Performance.

Ima try to give them a call later maybe they can get me some faster than 3 months. How’s there quality? Have you ran them?