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Old 02-08-2012, 06:55 PM
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Cool Ricko's 1992 Trailboss 350L Project

Bonjour ! Hello !

Voici mon projet de restoration d'un trailboss 350L 1992 que j'ai commencé cet hiver.
This is my 1992 trailboss 350L restoration project that i began this winter.

J'ai fait cet achat en me faisant un cadeau pour mon aniversaire que j'ai donc reçu le 12 janvier.
I have bought it as a self gift for my birthday that i received on jan. 12

Comme vous pouvez le voir ci-bas, ici c'est l'hiver et nous avons beaucoup de neige. Heureusement, le club local de VTT est ouvert 4 saisons, alors nous avons de beaux sentiers dammés.

As you can see, here it is winter with snow. But local ATV club is a 4 seasons one, so we have many open trails.

Jour de la livraison:
Delivery day:


Premièrement, il n'y a plus de batterie. Comme j'en avais une de honda civic, j'ai fabriqué un support que j'ai soudé directement sur le chassis après avoir coupé l'ancien. Avec ca, toujours de bon démarrage et je ne manque pas de puissance pour le treuil.
First there is no battery, so i have an honda civic battery. To fit it, i make an home made rack that i welded on the frame after cuted old one. With it, always have a good start and no lack of power for the winch.



Avant d'aller plus loin, voici un lien très utile pour ce projet, le manuel de service.
Before going further, this link is a very usefull one for this project, service manual.
https://skydrive.live.com/embed?cid=...GaTkseqhYH161E

Maintenant une petite liste de ce qu'il y a à faire:
My to do list:

-changer la batterie ; Replace battery
-fabriquer un support pour la batterie ; make a battery rack
-changer les 2 lumières de route ; Replace 2 headlights
-Installer le fillage relais lumieres de route + interrupteur ; install new headlights relay and wiring
-peinturer support batterie noir ; paint battery rack in black
-peinturer Support à bagage avant et arrière rouge ; paint front and read rack in red
-cirer plastiques ; wax all plastic
-fabriquer un support pour le treuil + installer le treuil ; make a rack for the front winch and install it
-installer le fillage relais du treuil + interrupteur ; install winch wiring and relays
-installer un connecteur pour charger la batterie + interrupteur ; install a battery charging plug with switch
-changer reserve prestone ; replace prestone reserv tank
-changer les boulons du couvercle de la courroie ; replace strap cover bolts
-faire recouvrir le banc ; replace seat cover
-changer le essieu de sortie de la transmission ; replace transmission output shaft
-changer la roue dentelée avant ; replace front sprocket
-éliminer le jeu dans le support d'essieu arrière (manque 5 rondelles sur 8) ; repare slack in swingarm ( miss 5 washers on 8)
-Réparer le frein arrière ; repare rear brake system
-Installer un klaxon ; install a horn
-Installer un relai commander par la clef pour alimenter tout les accessoires ; install a relay command by key switch to drive all acessories.
-Changer la courroie ; replace the strap
-Changer l'embrayage ; replace the clutch
-Ajuster la tension des chaines ; adjust chains
-Changer les 2 amortisseurs avant ; replace 2 front struts
-Peinturer les roues en rouge ; paint wheels in red
-Ajuster la pression des pneus ; adjust tires presure

Voila c'est ce que j'ai trouvé à date ; This is what i have found for now.

Last edited by Ricko; 03-26-2012 at 06:13 PM. Reason: Continue
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Old 02-10-2012, 09:38 PM
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Erick,
Just opened the .zip file of the shop manual you sent. This is a great manual. I have the Hayne's Manual that covers the same basic machines, but I like this one much better. I prefer the exploded drawings over pictures. The Hayne's manual is all pictures so I have to search the net to find out how things fit together sometimes. Pictures have their value, and this manual has both, but I particularly like the exploded diagrams. Much more instructive.

You have the makings of a jam-up restoration thread here. Looking good. Are you able to do all the things you listed, yourself? Metal work, welding, all that. You have special skills if you can do all that. I had to job mine out (that means to give it to someone else to work on, for a fee). Hopefully we'll be riding soon.

Keep up the good work.

Mick
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Old 02-11-2012, 03:45 AM
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Cool ... continue

Thank's Mick i'm very happy that be usefull to you.
For now, only the seat cover job i needed to use help.
in further post i put some pictures on my little workshop and equipement.

Je continue donc avec ce qui est maintenant fait.
I continue with what it is done for now.

Merveilleux, j'ai reçu le siège qui est revenu du recouvrement.
Je suis très content, cela ne m'a couté que 40$
Good, received seat from new job cover, i'm very happy, it cost to me only 40$

Avant ; before

Après ; after




Un relai d'automobile que jai scellé dans le silicone pour remplacer le relai de démarreur
An automotive relay that i scelled in silicone mastic and be use as starter relay


L'essieu de sortie de la transmission, cassé entre l'engrenage arrière et l'engrenage avant.
Broken output shaft, cut between rear and front gear


La transmission finallement extraite
Transmission finally extract



Les ailes sont nettoyées et cirées (photo arrière)
Fenders are cleaned and waxed (picture rear fender)


Assemblage de l'essieu arrière
rear axel assembly


Peinture neuve en rouge pour les 2 supports à bagage et les 4 roues, remplacer les 2 lumières de route par des 55W halogènes connectés par un relai, fabriquer un support pour le treuil, ajouter un ensemble de 2 klaxons d'automobile avec interrupteur et relai, fillage du treuil branché par des relais. au total 4 relais d'automobile pour cette étape, le tout ne fonctionant que lorsque la clé est en position de marche. Petit truc: utiliser du fil de calibre 8 ou 6 pour avoir une bonne alimentation du treuil.
New front and rear racks and 4 wheels red paint, home made winch holder, replaced head light by 55W hallogen on relay , add twin car horns and connect all with 4 automotive relays that can only work with key on. tip: use caliber 8 or 6 wire to have good power on winch.




Arghh ! un des 2 boulons de montage de l'étrier du frein arrière est cassé dans la transmission, une journée de perdu a chauffer, percer et refaire des fillets.
Arghh ! bolt from calipermount has broke in transmission case, a day just for drilling and tap.


La transmission est maintenant réparée.
J'ai utilisé une vieille friteuse pour chauffer les roulements à billes à 150 C, et laissé le nouvel essieu de sortie à la température extérieure de -27 d'hier.
L'essieu étant contracté et les roulements à billes en expension par la chaleur, ils ont glissé avec un bon jeu sur l'essieu.
10 minutes plus tard le tout était saisi l'un sur l'autre.
Transmission is now fixed.
Using an old fryer with motor oil to warm up to 150 C bearing, and let the new shaft at -27 outdoor yesterday temp. So contracted shaft and expanded bearing had slip in with slack.
10 min later it was seized together.





J'ai trouvé pourquoi la courroie s'est détruite, l'embrayage est endommagé.
I have found why the strap has been destroyed, drive clutch is broken.

J'ai du utiliser un embrayage de motoneige 340 après avoir coupé les ancrages de roue dentellée de démarage. Il n'était pas complet j'ai donc utilisé mes anciennes rampes et mon ancien ressort pour la reconstruire.
Have to use a snowmobile 340 one, after cut ring gear's anchors and use old mine spring and ramps.


Après un peu de réassemblage, voila le résultat à date.
il manquait 5 rondelles sur 8 pour l'assemblage de l'essieu arrière, pas surprenant qu'il y avait du jeu !
After rebuilting a lot, this is what i have for now.
There was missing 5 washers on 8 in swingarm assembly, not a surprise that was it slack !



J'ai passé toute une journée à nettoyer, décoincer et remonter le frein arrière. Tout est saisi par la rouille comme si c'était dans l'eau sallée parmi l'épave du titanic, Je crois que le précédent propriétaire est allé sur les plages d'eau sallée et ne l'a pas lavé après.
Now get a all day to restore rear break system. all is seized rusty like it was in titanic salted water. maybe previous owner had run on salted water beach and do not wash after the ride.


Je continue à rager après les 2 tiges de sabots de frein. Elles sont toujours coincées dans l'étrier.
I still raging on 2 pads pins, it still jammed in caliper.

A suivre,
To be continue,

Erick

Last edited by Ricko; 03-26-2012 at 06:19 PM.
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Old 02-11-2012, 04:34 AM
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Hello Erick,

At some point, I am going to paint and polish th' Beast for his debut presentation to the world. The gray plastic has seemed to be resistant to my efforts to make it shine. What kind of wax did you use on the plastic?
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Old 02-12-2012, 06:32 AM
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Finition des plastiques - Plastic finish

Voici le produit que j'ai utilisé pour redonner un lustre à tout mes plastiques.
Je l'ai acheté chez canadian tire.
Le produit a une texture laiteuse.

There is what i used to polish all my plastic.
Ibought it at canadian tire store.
This stuff as a milky texture.

Ricko


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Old 02-12-2012, 08:19 AM
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bon travail, hope you are having fun , it looks like it
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Old 02-12-2012, 08:52 AM
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Hey Ricko, great to see you got your own thread started so we can follow your progress on your rebuild. Just an observation though, it looks like your have your rear tires on the wrong sides of the machine. The center of the tread should point in the direction of normal forward rotation. It helps clean the mud and snow out of the lugs when you get into the nasty stuff. Looking good so far and keep the pictures coming, Buddy.
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Old 02-12-2012, 09:08 AM
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i am commenting on the seat cover you did. did you send it off to get it redone or just found someone where you live to redo it?
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Old 02-12-2012, 09:46 AM
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for you changer DIYMotorcycleSeat.com - Home Page
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Old 02-12-2012, 03:32 PM
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seat job cover

Quote:
Originally Posted by changer View Post
i am commenting on the seat cover you did. did you send it off to get it redone or just found someone where you live to redo it?
It is a local city leather worker. i bring him my old seat and he do the job for 40$, including new material.

he said i can refer him for any seat job for atv and snowmobile.
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