old 250 2x4 that im trying to revive

[toki891]

So here is my story.

I picked this thing up for 30 bucks off of craigslist. the price seemed right for a running and moving machine. it didnt look TOO bad but i knew i was getting into a project and for 30 bucks? CMON!!!

first off was the rear end. the bearings were gone. electric start does not work and the recoil cover/recoil is screwed up. front rack is missing. seat is toast. plastics are there but faded. it did have 3 new tires tho... which was odd!

anyhow monkeying with the recoil you can start it but the cover cant be tightened all the way down or it rubs and wont retract. i replaced the bearings in the rear and all is good there. runs and rides. it sounds like one of the clutches are hitting the plastic cover tho. somethings fishy in there.

my major problem now that i got the rear fixed and i took it for a proper ride. the front suspension is GONE. front left shock is worn out and has a ratcheting effect. front left ball joint has a ton of play in it. front right shock upper mount let go and the shock was punching the fender.

so my question is. where can i get some shocks that will fit this thing for dirt cheap? and what about the ball joint? is it simple to replace?

last problem. no idea on year. only number i could find on it was 1729397.

[Bruce!]

Welcome to the board!

[toki891]

well i pulled all the plastic off. im sanding them down to remove minor scratches, filling in any major damage, and covering with 3M controltac. a dark red and black. "how original.." i know.. the only colors i have are red, dark red, black, flat black, lime green, dark blue, and blaze orange tho. dark red and black just seem to make sense. ill post some pics tonight if anyone is interested.

also im still having some problems figuring out what year this is. i believe its an 89+. the bearing carrier was cracked and i replaced it with a used ebay unit and from the pics ive seen 88 and older had a different style and 89 up had a new style. right? the one i got was from a 90's trail boss and fit sooo...

meh. thats all for now

[4getful2]

You might want to send a pm to blueline 15, he usually runs the serial numbers for anybody who needs it.

[toki891]

found a thing to look it up. its a 1990. anywho here is a teaser pic.

[buckfever5]

Clutch covers rubbing on those isn't too terribly uncommon. I think they get too hot and warp. Check the bottom side. I've replaced one on a 95 scrambler and one on a 93 trail boss that have rubbed all the way through and were letting the belt get wet.

[toki891]

Yea the cover looks warped and if you wiggle it around the noise gets worse or better. Depends on the day. I haven't rode it too much tho. I want to take that cover off and make sure everything is ok, neeeeeed to check the gearbox oil, and the carb needs a rebuild. Starting it sucks. Also every rubber boot needs to be replaced. I'm sure the carb adapter boot is cracked and dead, all of the boots going from the clutch cover are toast as well.

Here's my list.

Almost done recovering plastics.
Rebuild carb
Ball joints
Stearing bushings needed
Pull clutch cover and inspect everything
All rubber boots need replacing
Need new/used front shocks
Fix brakes and new pads
New battery
Figure out why the electric start doesn't work
Need headlight bulb assembly thinger...
Recover seat. Its baaaaad
Drain gearbox and refill with new fluid.
Ball and socket joints on exhaust leak bad. Replace and wrap with header wrap.
New handlebar grips


Edit:
There is a hole in the side of my clutch cover. Has been there. Didn't really worry about it. But today it was slipping really bad and I noticed some grass and crap come out. There was also an oily black spray that had come out and gotten on my fender.... odd. So I pulled the cover off.... oh...my...god... the smell. The mess... barf. Mice!. Built a nest. Chewed up my belt. Then my belt chewed them up! Sooooooo gross. There was a ball of mousenest, furr, and mouse sludge that had been tossed around and chewed up over and over. Time for a new belt it looks like.
Yikes!

[buckfever5]

Anymore pictures of your controltac project? I'd be interested in doing this to my trail boss.

[toki891]

i have one crappy pic. i should have taken a before picture tho and i dont know where the headlight came from but it doesnt look right. upside down? just in there funny? lol whats going on!

:edit
here is the tank cover. you can see how bad it looked before i covered it... what a lovely pink! uugh. there is still a slight mark showing thru from where the 2x4 decal was on the tank. the decal protected the plastic from the sun, the plastic that wasnt protected dried out and shrunk a bit causing that spot to be raised. i'll slap another decal over it and it wont be noticeable if it really bugs me.