just like the factory, for $150. When
we put the engine back in the frame,
we installed a complete CT exhaust
system and silencer for $379.
That stock frame needed a lot of
work before things started getting
bolted back up. First, we sandblasted
it entirely and began counting cracks.
There were at least a half-dozen
cracks in different parts of the frame
and a few tabs had broken off. While
we were welding those up, we also
welded in a Bare Performance flat
steel plate and gusset kit. This is a
17-piece kit that strengthens all the
known weak areas of the stock frame.
The company supplied a detailed
template and photos showing exactly
where every piece goes. In total, the
kit adds about 3 pounds to the frame
and will set you back $80. After the
gusset kit was welded up, we took the
frame back to Aires Sandblasting in
Lancaster, California, and had them
powdercoat it Honda red for $200.
Before we started reinstalling the
parts, we ordered up a $50 250-piece
Maintenance Kit from Spec Bolt. This
is a super-handy assortment of nuts
and bolts and other fasteners exclusively selected for your particular
machine. All the bolts are as strong
or stronger than OEM bolts. If you
were to source these bolts at the local
hardware store you would pay double and probably triple at the dealer.
Spec Bolt has bodywork, suspension
and engine assembly bolt kits as
well. Some bolts, like the swingarm
bolt, we had to get from a different
bolt supplier. The swingarm bolt was
totally roached, so we sourced a new
one from Lonestar Racing for $65.
Another $74 was spent on a new
seat latch also from LSR. The stock
seat had a big problem with popping
off unexpectedly. OMF Performance
has a 250R seat latch too. The seat
itself received brand-new foam and
a custom-embroidered cover from
More products are on order from
Lonestar Racing, and we will be
installing them in part three of this
project. Up front we are using sport
A-arms, which will be 2 inches wider
and 1 inch further forward from stock.
This will extend the wheelbase numbers and give the quad more straight-line stability. The wide, front A-arms
will be matched with a stock-length
swingarm also from LSR. At both
ends Elka Stage 4 shocks will be bolted up and provide a huge advantage
over the stock non-adjustable shocks.
Lonestar Racing is still your one-stop shop for almost every chassis component
for new and old quads alike. They make all suspension components, and even full
frames for Hondas and Yamahas, as well as custom one-offs.
Honda experimented by using square tubing on some of the early ATV frames. It
might have been lighter than round tubing but probably more rigid, causing cracks.
We used a Bare Performance gusset kit to strengthen the frame in the known weak
This is one of the lightest sport quad engines ever made. In stock trim it’s fast and
a blast to ride. We did a full rebuild for under $1000 in parts. Try that with a modern