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 Post subject: 1990 pilot restoration
PostPosted: Thu Jun 19, 2014 10:15 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Decided to tear apart my pilot and redo it since it was overdue

Here is my project pics


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PostPosted: Thu Jun 19, 2014 10:17 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Tearing it apart


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PostPosted: Thu Jun 19, 2014 10:22 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Frame had a bad diamond to it. Guy before me nap must have hit it straight into the lower right corner hard enough to bring the whole right side frame back ..I had to straighten it out on a frame machine at work. A little improvising and it worked well


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PostPosted: Thu Jun 19, 2014 10:24 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
You can see here the front section out of square


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PostPosted: Thu Jun 19, 2014 10:25 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
There was no kind or any previous repairs so the frame was a really good piece except for that . The oem hondaline bumper was pretty beat when I got it,,,here's a pic from when I first got it from my (now) friend ken


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PostPosted: Thu Jun 19, 2014 10:28 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Off to my powdercoater for a fresh coat,..the powdercoater by me does awesome work... Better than factory !!

Home now ready for assembly


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PostPosted: Thu Jun 19, 2014 10:32 pm 
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Posts: 307
Rear end


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PostPosted: Thu Jun 19, 2014 10:34 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Putting parts onto frame

Painted or replaced most parts
Lots were reused

Painted a arms,,a Auto paint and clear

Powdercoated springs


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PostPosted: Thu Jun 19, 2014 10:37 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Was able to come across some mint parts as I go
Nice hondaline front bumper and oem hondaline skid plate in greT shape


This ones getting all the hondaline tube parts

Front rear and nerf bars

Had a mint set of nerfs and rear that came with my 89 pilot that i pulled off for this one


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PostPosted: Thu Jun 19, 2014 10:40 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Going with the aluminum rear trailing arms....they look purdy! :)

Really good design actually ...good quality

I adjusted them to the length of the oem ones and bolted in with all new oem hardware!


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PostPosted: Thu Jun 19, 2014 10:45 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
The Engine was sent to hoser to be rebuilt
Great job . Here are some progress pics!
It's sitting on the bench waiting to be dropped in

I wanna get it as a roller first


Here Is original thread

viewtopic.php?f=1&t=13143


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PostPosted: Fri Jun 20, 2014 12:22 am 
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Joined: Wed Jan 21, 2009 10:11 pm
Posts: 2950
Location: houston
Damn that's looking good


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PostPosted: Fri Jun 20, 2014 9:03 am 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22133
Location: Chicago
Looking real good are you almost done?


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PostPosted: Fri Jun 20, 2014 9:35 am 
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Joined: Sun Dec 24, 2006 5:58 pm
Posts: 2027
Location: near NJ rider
Sweet.

Regarding the aluminum rods? Have they been proven? To me, the hex section looks like a huge stress riser. Probably depends on how you ride.


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PostPosted: Fri Jun 20, 2014 10:12 am 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Hoser- no it's at the latest stage you see in pics....taking my time,,,putting my 89 back together to ride it ( non resto)

I haven't tested the arms but they are solid throughout except where they are threaded... I wiping be hammering this one so they should hold up lol


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PostPosted: Fri Jun 20, 2014 10:35 am 
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Joined: Mon Oct 25, 2004 10:02 am
Posts: 2255
Location: East Peoria IL
Looks nice - great work. I like the Blue brake levers. Are you rebuilding the drive train? What are you doing for the plastics? Do you have the small decals to put on the frame? Are those the stock reservoirs on the rear shocks? What is the red on them?


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PostPosted: Tue Jun 24, 2014 9:15 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Thanks for the compliment
The red is just red carbon fiber vinyl I wrapped them in since they were a little aged
I threw the blue levers on there to get a little more blue on the machine without getting crazy

The drivetrain is going to consist of a rebuilt Engine from hoser and the tranny I'm going to open up and put new seals and gasket
that is once I get the stubs out!!
I'm having trouble getting them out
I went as far as drilling through one side and trying to beat it out with a punch and hammer,,nothing..been soaking in on blaster for months lol

I don't know what to tow..I made a decent puller as well and nothing...any suggestions.??

Plastics I have a clean set I was running on there before I tore it down...I bought the 4 fenders new and the others were decent..I also bought all the warning labels for the frame
I'm still trying to hunt down someone to print me the year decal for the back of the frame
I've seen a lot to atc ones on eBay and even fl250 ones


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PostPosted: Tue Jun 24, 2014 11:20 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Also want to add that I used CERAKOTE for the first time
Wow does this stuff work awesome

It's a ceramic paint that many use for guns etc...it's a high temperature coating that comes in air dry form or bake form
I bought a pint of the air dry,,,pretty pricey but well worth it -----60$
Parts need to be sandblasted clean,,,then a few light consistent coats and your good,,need to have a mini spray gun to apply
It looks like factory oem satin black
Btw I have half the pint left after doing 2 expansion chambers and silencers

Have one of the pipes set up on my 89""" no discoloration or burn off and I've ran it pretty hard for a couple hours


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PostPosted: Wed Jun 25, 2014 7:52 am 
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Joined: Thu Jun 21, 2012 12:58 pm
Posts: 363
Location: Anniston, Al
Great Job.. Looks like a new one to me. Thanks Billy


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PostPosted: Wed Jun 25, 2014 10:01 am 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Yea I didn't know how it would hold up..I've used other high temp paints etc in the past,,not really any good

This is comparable to JET HOT or similar...very happy

Good if your pipe is looking a little ratty and want to keep it from rotting away


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PostPosted: Wed Apr 06, 2016 10:58 pm 
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Joined: Thu Mar 18, 2010 7:39 pm
Posts: 307
Hey guys..its been a while I finally got around to finishing th 1990 project!! Stayed pretty close to original as possible ..I still have a couple pieces to put back on but it's pretty much there


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