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Discussion Starter · #1 ·
Hello all...

It was suggested that I start a thread here. I got this... heap last weekend. plain and simple my wife is terrified of my 17hp diesel tractor but still wants to move the utility trailer around the property to take care of things. We ran across this ATV on craigslist and got it for next to nothing.

To be honest the pictures don't really show the true condition of the ATV. While waiting for gasket set to come in we are literally starting from the front bumper and removing, inspecting, repairing/replacing and putting it back together.

Interestingly enough my wife wants to do the majority of the work needed. I'm just going to consult, advise and watch over her as she is doing the work.

I imagine that I'm going to have to invest in gallons of PB Blaster to start getting all of these to break loose,

more pictures will follow when its not raining but for now ill include the ones fril when I picked up the AtV.
 

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Discussion Starter · #3 ·
I hope so... I hope the excitement that my wife has now is still there in a few months.

Eebay is going to be my best resource for parts. Found complete engine gasket set for under 20 bucks and carb with throttle cable for 18.

Only reason why I got it was because it had good compression on engine. Not the greatest @ 130 but going to pull head off eventually and look inside.

Was thinking that the timing chain (like everything else I've looked at) may be original so it's gonna get a good looking at and probably replaced.

First thing this weekend I guess will be drain the fluids and check them out.

He said he had stuff stacked on front rack of this thing for a few years. Front shocks are completely compressed. When you jack up the front end there is zero travel on the shocks.

After we get finders off we're thinking about starting at front with swing arms and bring spindles. Complete wheel bearing set for front wheels is only 12.00 ...

Wonder why these things didn't have any grease fittings on the joints?

Guess this thing is so old that people are getting rid of their old inventory rather cheaply. Only expensive thing later on will be front fender but that looks to be under 400 and found it in stock in Louisiana.

I was reading another thread where someone was using vinegar, salt and water for a rust removal soultion. Wife likes this idea because of us having a 3yo running and it won't hurt her if she comes in contact with it.

Only one place on rear of frame that has a rust hole in it. Hopefully I can repair or replace that section of pipe. (Good thing I'm a pipe fitter by trade lol)

Enough rambling on...

Where do y'all think I should start this restoration project?
 

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nice find !. where would i start if it were mine ?, lmfaoooo..well..everyone here knows me , when it comes to a restore/rebuild..i start ripping it alllllllll the way down to bare frame, start with getting all the rust gone, places welded that are bad, then lots of black wally world paint, then i start on the engine, complete tear down..allll the way !. then i just work my way through every part, front to back, top to bottom. when i am done with them, they look almost brand new :). plz make sure all your parts are oem..and not some stupid china knock-off parts claiming to be oem ?!. your right, ebay will be your main source, as most parts for that atv has been discontinued !, this is why i stress about getting parts that '' they say are oem ''..lol.
 

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Vinegar works good on parts that don't have seams in them where acid can be trapped. Soak rusty parts (remove seals and other rubber/plastic parts off first) in distilled white vinegar in a plastic container for a few days, then brush them clean with a wire brush and return them to the bath to soak them longer if necessary. When they are free of all rust, brush them again and transfer them into a solution of warm water and baking soda for several minutes to neutralize the Acetic acid. Use lots of baking soda and use your brushes to scrub the soda water solution into the metal. Keep the parts wet while you work. Finally, rinse in clean water and rinse/wipe dry with alcohol. Prime/paint each part immediately to prevent them from forming new rust on your unprotected metal parts.

Pictured below is a fresh 5 gallons batch of vinegar that I began adding parts into this evening, after scrubbing each part clean in soapy water. I'll soon have that old cooler half full of rusty parts. :)
 

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Discussion Starter · #6 ·
@shadetree we are seriously contemplating complete disassemblely. Our concern Is a 3yo helping us loose parts.

Everything so far is still sealed in Honda bags with part numbers on them. Only thing not sure of yet is carb but guts of current carb are solid. I don't even think my bucket if chem dip can break through that. So what ever showed up will be used till I can find Honda. Didn't the use Mkuni carbs? I haven't scraped the crap off mine to find the numbers on it yet.

Thankfully it has a plastic gas tank because you can smell the thing from 20 feet away (the gas is that bad)
@retro we were thinking of the really big (think like 4' long Rubbermaid tote with lid and going to Sam's club to buy vinegar buy the 5 gal bucket

Only thing that would be hard would be the frame. I was thinking kiddie pool but don't think that would work
 

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I wouldn't attempt to dunk the frame in acid if I were you. There are drain holes in the tubing, so acid may fill those tubes, no way to reliably flush the tubing with a neutralizer solution. It might rust through shortly after the bike is back together. Vinegar is useful and cheap, but gotta be selective dunking your parts. Major pieces like swingarms and the like have welded seams on the outer surfaces of the tubing which look safe... until you look inside and see the opposite side of those joints. I usually just wire wheel (always wear safety glasses/full face shield! Wire can/will be airborne.) those types of parts. If heavy rust has taken hold I use some phosphoric acid after wire wheeling to stop & convert the rust. You guys will have fun on that project for sure!
 

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Looks like a great project. If its like any other of the builds, most of us on here enjoy the pics of the process.
that's cuz ya'll are a bunch of pic pervs !!!..lmfaooooooo.
 
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Discussion Starter · #11 · (Edited)
Trust me I'm gonna flood y'all with pics that way maybe y'all's vast experience might spot something that I have overlooked.

Tonight is my 13th night of 7-12's hopefully tomorrow morning I'm gonna tape up the exhaust and intake on air cleaner box and pressure wash the sucker. I gotta get that several year old sticky stale fuel off of everything so I can see what I really have to work with. Then the fun will begin...

And once again thank y'all in advance for all comments and advice y'all can give
 

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Trust me I'm gonna flood y'all with pics that way maybe y'all's gast experience might spot something that I have overlooked.

Tonight is my 13th night of 7-12's hopefully tomorrow morning I'm gonna tape up the exhaust and intake on air cleaner box and pressure wash the sucker. I gotta get that several year old sticky stale fuel off of everything so I can see what I really have to work with. Then the fun will begin...

And once again thank y'all in advance for all comments and advice y'all can give
your deff in good hands here ferret, lots of great members and info to be had here !.
 

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Discussion Starter · #13 ·
So courtesy of a severe thunderstorm creeping through the area pressure washing didn't get done.

My wife is making a list of paint that we need to get so as soon as we clean parts up in the vinegar bath we can spray paint them to keep them from rusting.

For all things black (besides the frame) she is planning on using Rust-Oleum Satan black.
The question she want me to ask y'all (shake my head) what color is the correct color for the front brake drums and wheels? "Plain silver or aluminum?" Attached is the picture that she is using for a reference...

It looks like the case is black. Is the top half of engine panted silver/grey?

I have a quart of Grey Por-20 exhaust manifold paint on hand that she's wanting to paint the new exhaust manifold when we get it but other than that what colors of paint should I tell her to get?



Will Rust-Oleum be ok or does anyone have a better recommendation on a brand of paint to use for this restoration project?

(Sorry no more pics yet but trust me they're coming lol)
 

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Discussion Starter · #14 ·
@retro ". I usually just wire wheel (always wear safety glasses/full face shield! Wire can/will be airborne.) "

We use little wire brushes on the end of end grinders at work for cleaning up pipes. I'm always amazed how you never feel it when it happens but you get home and start pulling off clothes only to find them stapled to your skin courtesy of those little wires lol.
 

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black gloss from wally world, and krylon silver for anything chrome looking is what i use. as for the exhaust system ?, MAKE SURE TO USE B.B.Q. paint, it's rated to 1200F !. anything else will just flake off first time you get it hot..lol.
 

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I have no experience with those rust-oleum spray paints you listed, but you can use almost anything that sticks, doesn't come off with the power washer, doesn't melt when oils greases and/or fuel comes in contact with the coatings and doesn't fade away under the sun. There are many cheap paint options to choose from and each bike requires different flats & glossy color combinations. I choose different paints for every project... for a number of reasons, costs being only one of them, and I'm always looking for something different & better out of a cheap spray can.... though we all know there is no such thing as quality from a rattle can!

Below is a photo of the spray paint choices I have made concerning my current project, with the exception of the wally world paint. Those wally paints I've had on hand for months, but I'm afraid to use any of them on an ATV because of my harsh environment. My area has thick, wet, very salty red clay that builds up on metal parts (very difficult to remove!) and stains and corrodes the metals. I also live where high levels of UV sunlight is a big issue, many paints fade fast, break down, and then blow off the metals while the ATV is being power washed. Other folks get by OK using wally world paints in their environment, but I'm still searching for better, more durable solutions here.

Bottom line: Rattle can paints are cheap but quality is quite low. Ya gotta work a lot harder using cheap paints, to get decent, long lasting results.

With all that said, I am currently using Rust-oleum rattle cans on ATVs and am having pretty good results with them. Amazon has some good deals going from time to time and thats where I get most of mine. One thing to keep in mind is that the rust-oleum paints require several days drying time to reach a fully cured condition. Most of the cans state 24 hours for full dry... thats nonsense though. I don't lay a finger on any of my painted parts until 3-4 days have passed minimum, because the finishes will still be very soft. Expect two weeks minimum to reach a decent finish cure.... three weeks are even better if you can wait that long. Do not expose any painted parts to fuel, oils or other chemical compounds until fully cured if you can help it.

I use the Duplicolor silver caliper paint on a lot of parts requiring a light silver color. For darker silver hues I prefer the Rust-oleum caliper paint, because it can be sprayed on a bit thicker, it flows out well when its wet and provides a more durable cured finish than the Dupli-color caliper paint will. Rust-oleum caliper paints stand up to motor oils quite well too, possibly even better than the Rust-oleum engine paints do.

I use engine paint where I want a very high gloss finish, but it takes a lot of coats to make engine paint look good and they take forever to fully cure. Once cured they work fine though. Black Rust-oleum caliper paint works well on handlebar controls such as throttle housings, master cylinder, switch housings, touching up bumpers, frames, racks, A-arms, swingarms, brake pedals, etc.

I use high temp paints on exhaust parts only and I do them in two steps: 1st step is applying the color coats then let them cure (don't handle them, pay no attention to the instructions on the can) for a couple hours. 2nd step is done with Rust-oleum 2000 degrees clear coating. Beware if you use the 2000 degrees clear coat on exhaust parts that it sprays out very thin and it runs like crazy! Hold the can back away from parts and move your spray pattern fast... you must wet the part fully each coat, but anymore than wet is too much and it will run! It takes patience and practice and good bright lighting to succeed. Once you get three wet coats of that clear on though, its an awesome sealing finish! Let those exhaust parts fully cure for two full weeks minimum! Then if they aren't too long put them in the wife's oven at 250 degrees for about 30 minutes then shut the oven off and let them slowly cool. Repeat at 350 degrees... then you're done! If you can't heat treat them in the oven then heat cycle them on the motor... sneak up on full exhaust operating temps by shutting the motor down and allowing parts to cool between heat cycling sessions. The key to success using exhaust paints is the two full weeks (or more) of cure time. Once fully cured they gas off very little during heat treating, which means they look great on your parts.

Its your call on paint choices... we each do things differently to satisfy our own logic and reasoning. Every ATV model is different too, so each might require different brands, hues of rattle cans.

Have fun!
 

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Never ask or comment on your pans, just wait till she's away......
 

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No worries, let the coatings cure for 2-3 weeks then put them on the bike and heat cycle them using the motor. Only folks that fail in this game are those that are in a hurry, do half-azzed work and attempt shortcuts.
 

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Discussion Starter · #20 ·
So while I was at work today wifey started removing parts.

I'd say a new petcock is in order don't y'all!

She's been really good about taking pictures so I can see and I figured y'all might get a chuckle out of them as much as I did. She pulled out the air filter box too along with the birds nest inside (no air filter what so ever).

So here's a dumb question...

Should I just say to hell with it and split the case and go through the whole engine first or go ahead and put new carb on, change the oil and try to start it then go from there?
 

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