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Last summer I picked up 2 1985 trx250 and a 1987 trx250. I'm trying to at least make 2 good running wheelers. Want to take one and make it little sporty lower it little and do some custom lights and bumpers. And another one I'd like to make a mudder, mount winch and custom bumpers and lights. I know it's only 2 wheel drive but with good tires and ground clearance you can go through a lot.

Any tips or ideas or parts sites would be greatly appreciated. Only have one set of plastics. so I'd like to try to fit just about any random plastics on but I'll see what I can come up with

So far I got one on the 1985s motor takin apart had a stuck valve was able to get it unstuck. Got to see if I can get away with reusing the valve and guide. Going to hone the cylinder and measure it this weekend and get a parts list make up and start ordering.
 

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for bumpers and such ?, unless your really good at fabbing these ?, your not going to find any one that makes them , not that I know of anyway ?. these are utility atvs, they were never meant to be sport atvs ?, sooo..your only choice is to make all your own parts. take the winch mounting plate for starters ?, they never made a mounting plate for that atv model ?, soooo, you must fab your own. as for making one into a 4wd type ?, well..yes..it may look good to you ?, but !!. the problem your going to run into, is the j-shock mounts only allow you so much lift ?, if you go to far up ?, your tie rods are going to drag the frame. these are just a few things off the top of my head from memory :). oh, and you can't go to large of tires !, because the fender flares will bottom out on them !.
 
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..... a plastic 55 gallon drum , jig saw and some imagination can make a set of fenders , I have seen it done and it is not half bad ------------- would you happen to be close to Louisiana , I have a lot of parts for those bikes that I would part with , but don't ship
 

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Was planning on some fab work, I'm pretty good with a grinder and welder. It was just thoughts and ideas I was tossing out there. Your guys ideas are appreciated to the fullest never thought of using a drum. On the 87 someone built some plywood rear fenders. They look pretty good but get in the way of the kick start I'll take pic when I get out to the garage. No flys I live up in northern wi. It's hard to find parts round here been watching Craigslist and Facebook like crazy to see if I can find anything
 

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Was planning on some fab work, I'm pretty good with a grinder and welder. It was just thoughts and ideas I was tossing out there. Your guys ideas are appreciated to the fullest never thought of using a drum. On the 87 someone built some plywood rear fenders. They look pretty good but get in the way of the kick start I'll take pic when I get out to the garage. No flys I live up in northern wi. It's hard to find parts round here been watching Craigslist and Facebook like crazy to see if I can find anything
for parts you can't fab ( oem ) look on ebay for used parts.
 

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Parts are hard to find here in the UK as well, I ended up buying another ATV for spares, that may be your only option.
 

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..... a plastic 55 gallon drum , jig saw and some imagination can make a set of fenders , I have seen it done and it is not half bad ------------- would you happen to be close to Louisiana , I have a lot of parts for those bikes that I would part with , but don't ship
Ya might be a *******
 

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Here's that 87' with the plywood fenders. On my way to pick up some parts for my grizzly 660 when I get home I'm going to start cleaning and measuring for piston
 

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Here's that 87' with the plywood fenders. On my way to pick up some parts for my grizzly 660 when I get home I'm going to start cleaning and measuring for piston
tires are on backwards.
 

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Haha what the heck. That's the way I bought it and never noticed it
my keen eye see's stuff others don't when it comes to looking them over..lol. i'm pretty good at it.
 

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Started cleaning up all the parts today got my cylinder honed and measured up. Think all I am gonna have to do is new piston and gaskets everything is looks pretty good. I don't think that piston is useable at all
 

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Started cleaning up all the parts today got my cylinder honed and measured up. Think all I am gonna have to do is new piston and gaskets everything is looks pretty good. I don't think that piston is useable at all
I seen folks use them for ashtrays after cleaning them up... :)

Did you get all the busted piston chunks out of the crankcase? Find any of them stuck in the big end of the rod?
 

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Started cleaning up all the parts today got my cylinder honed and measured up. Think all I am gonna have to do is new piston and gaskets everything is looks pretty good. I don't think that piston is useable at all
I sure hope you don't have any of whats left of that piston down in the lower motor ??!!..lol.
 

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.... if it were me , I would send the jug to G+H and have it freshened up , for $220 you would have a new piston fitted to a fresh bore and all the gaskets to do the job
 

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.... if it were me , I would send the jug to G+H and have it freshened up , for $220 you would have a new piston fitted to a fresh bore and all the gaskets to do the job
That's a good price by anybodies standards Fish, would cost £200 here!
 

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.... if it were me , I would send the jug to G+H and have it freshened up , for $220 you would have a new piston fitted to a fresh bore and all the gaskets to do the job
Thanks that's not a bad idea. Didn't find anything about my wheeler on there as far as the jug but I'll try calling them to see if they can do it and I think for sure I'm gonna send them my head and have them rebuild that cause it's kind of ruff having that one valve that was stuck locking up the whole motor
 
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