Hi all, I hope everyone is well. I still have both of my FL250s that I bought for my boys. I sold my FL350 last year and bought a 1980 toyota side by side (pickup) to build and then I can take my daughter with me. Last year around July I got a craigslist email for a go kart. I opened the link and saw pictures of a pile of FL250 parts. Called the guy and went and picked it up. I figured at least I could use it for parts, I pulled the carb and cleaned it, blocked the intake and exhaust port and then put it on the side until yesterday.


First thing I did was a compression test, 120 psi and a leak down test at 6psi and it passed. I looked through the intake and exhaust and the piston looked like it was in great shape. I put the carb on and hooked up the coil but I couldn't get it to run, it did pop off for a second.




It looks like its missing the front skid plate and the three rear belt covers, lower seat, exhaust, air cleaner and clutch cover. I'm going to pull the Engine apart a little this weekend and test/check the points. I'm also going to test the coil and see if I can repair plug wire. I think the only thing I really need is an exhaust to see if I can get it running. If the Engine is in good shape and I can get this running then it might go from a parts machine into a runner.

That's how it always starts, parts turns into a fleet..lol

How many qualifies as a fleet?

I pulled the Engine out and I have it in the garage, I'm going to spend some time this weekend working on the ignition and checking things over. Can I run this for a minute without exhaust? I just want to see and hear that the Engine runs good before I start buying anything for it.

I think 3 qualifies..lol As far as running it with no exhaust, I've heard it can damage the piston due to a lean condition, but I don't really have a solid answer.

I was reading and researching yesterday and learned something new. Both of my other machines are CDI (Capacitor Discharge Ignition) and this one is a 79 so its points. However the Engine has three wires coming out of it not two like a 79 should. I think mine has a 12V points ignition out of a 1980. I didn't know that there even was a 12V points ignition. I check the frame and Engine numbers and they are both 1979. I'll know more when I pull it apart to check the points this weekend.

Pulled the ignition apart this weekend. The friction plate in the pull start is breaking off chunks and getting ground and covering everything in metal.




I got everything cleaned up, cleaned the points and tested with the light per the manual. Light goes dim when the mark is lined up with the line at F. I found a NGK plug boot for the coil. I connected a new plug to the coil, connected the coil and spun the Engine by hand and had great spark. I also welded up the slotted holes in the starter cage and filed them back into circles.

I also made a exhaust pipe spring stay.



And I had some time to clean the gas tank. I filled my ultrasonic bath with water, then I filled the tank with water and about a quart of POR15 marine clean. Ran it for a few hours turn the tank at times. Worked great, and I had gotten the POR15 stuff for free from a friend.

I pulled the e brake apart, the lever that rotates was a little stuck. I got the lever free, and the brake works good. Only problem is it is missing the bracket that slides on the splines that the cable attaches to. The PO jammed an eye bolt on there and clamped the cable on. I have a bunch of parts on the way, new motor (( Internal Combustion Engine ? )) mounts and throttle cable, pull start parts, plus some used parts, lower skid, exhaust and lower seat brace.

My clutch is missing the ramp plate, mounting hardware and long bolt and one spring is broken.


What are my chances of finding that stuff separate from the rest of a clutch? Should I just look for another complete clutch instead of trying to find the parts?

Looks like lots ODDATV has quite a few parts for those clutches, including new clutches: https://oddatv.com/?s=FL250+Clutch&post_type=product
Otherwise ebay is a safe bet for a used clutch

Pull start is all back together and working nice.


I hooked up the coil and tried the pull star, nice blue spark.


Also started working on the body tub, I need to remove the rattle can black and do some repair.

Had some time this weekend to work on the odyssey. I was going to start taking it apart more to paint the frame and cage and after taking a good look at everything its not worth it. I'm going to paint the tub and lower skid yellow but leave everything else. The PO cut all the tabs off for seat mounting, the cage is bashed up but usable and there was no fluid in the reduction unit. I also found the end of the axle was broken off.


I attached the hub, torqued the castle nut and drilled through the nut and axle and installed a pin.


I found an exhaust but the mount was broken off. I made a new mount, wired wheeled the exhaust, painted and installed it. Some of this will have to come back apart to install the gas tank and the clutch when I find one.




I found a better steering wheel cover that came with a new kill switch and the light switch and installed that too. So the bad news is its not worth restoring into a nice machine. The good news is it has working throttle, brakes, kill switch, e brake and solid steering, everything to make a great runner.

I didn't spend too much time on this one this weekend but I did pull both of my other ones out and my boys drove them around a bit. Both started right up and ran awesome. I hope I can get this one running soon and maybe take a trip to the badlands. I need to find a clutch still, fix the leak in the gas tank, make some kind of lower seat and I need some kind of air filter and that should be enough for a trip to the badlands.

Found the leak in the gas tank by pressurizing it with 3 psi. It was around the petcock, pulled it apart cleaned and assembled and its fine now. I installed the fuel pump and ran new lines. I also install a new fuel filter, I bought a few of these before and had one new one left. I'm sure most know that you can get these from places like rockauto or other auto parts store.



Left some extra length for carb and crankcase connections once I get it installed.



I also put a post out on facebook group looking for clutch parts and got a reply so those are now on the way.

Nice.

Got the gas tank in, made and welded on the missing seat brackets, and started fitting the the tub. I had to do some repairs so i needed to re-drilll the mounting holes. Worked on the front lower skid a bit too.

Had a little time this evening. Got the parts I needed for my clutch and installed it. I also put on seat belts and replaced a missing castle nut from one of the steering arms. I shortened some stainless steel screws for the exhaust heat shield and put them in. New belt is on the way and and then I should be able to drive it for the first time.

I put the belt on, filled the line going to the carb with fuel, filled the lines going to the fuel pump and fuel filter and put 1 gallon of 32:1 in the tank. Pulled the pull start and started on the first pull... couldn't believe it. I let it run for a few minutes while I check things over then took it for the first ride. Drove from the back yard to the front and back and then it bogged and stalled, now I have no spark.

I checked a bunch of stuff, I do have a ground from the coil mount to the Engine case, new plug, checked the kill switch wiring and it was all fine. I pulled the pull starter and checked the points. They are opening and closing and seem to be making contact inline with the marks on the flywheel. I never changed the points because I adjusted them and they work. Do points just go out like that?

No real update, I put the new points in and it fired right back up. I drove from the front to the back yard and then it bogged and stalled. I still have spark and its really good spark but during my testing of the spark the pull start cord frayed so I just pushed it back in the shed.

I took the pull start apart the other day and found a few burrs that may have caused it. I put the pull start back together and it should be nice outside this weekend so I'm going to try it again. I'm going to double check that the light dims when on the line at F and if it does and I have spark then its probably a fuel issue. More to come.

Its been awhile... still working on it here and there in-between other projects. I was looking for a lower seat pan for a while, then I was going to just make one but I bought this Jaz seat for $10 at a swap meet. I used my "expired" seat belts from my race car and now I just need to make wrist restraints.


I also found out the hard way that the Engine is sensitive to the air filter/air box. The bogging problem I had was from my home made air intake. After I install a UNI filter right on the intake elbow it ran fine. I need to do a plug chop or figure out if I need to re-jet because of the open air filter.


I found a headlight at a garage sale for $1 and wired it up.


Last was sandblasting and painting the front rims. They had tubes in them because the rim orings where missing and the tires where shot. I bought a pack of orings from mcmaster carr part number 4061T272. I put them together with some used but decent tires that I had laying around.


Besides fenders then only other piece I really need is the lower rear skid plate. My boys still have their FL250s, my oldest moved onto a TTR125 and rides with me when I go out on my 400ex. My middle son is now looking at quads and dirt bikes too. However we talk about taking all three odysseys to the badlands and rip around a bit.