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My Moto4 project


tin
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 A few weeks ago, I foolishly asked my girlfriend about a quad that's been sitting under a tree at her parents' place for 25 years... This thread will be a sort of log of my attempt to resurrect it. I'm actually a computer guy, not a mechanic, so this will be quite conical for some of you, I'm fairly sure 🤣

So far I've found out it's likely a 200. Not sure what year yet... The frame has a serial of 53J-001343 (I think). Engine appears to have the same number.

We inflated the tyres on Saturday, which were still up today, so that seems a win. This also confirmed that the wheels do turn, as it rolled back into its 25 year old indentations as the 4th tyre started coming up.

Oil looks used but otherwise OK. I'll change it if I actually get it running, but looks good enough for attempting to start it up again.

Fuel tank had.... something in it. It smelt more like old stagnant water than fuel of any sort. Drained that out and flushed some clean fuel through to be sure.

Fuel tap was jammed in the off position. WD40 and some force got it free. Did that after the fuel hose was off, so hopefully the carb isn't full of whatever it was in the ttank.

Engine turns fairly easily with the rope start. Made typical exhaust puffing sounds.

Unfortunately the rope mechanism was not fully rewinding, so I was limited to about half its length... And today it jammed fully pulled out. I attempted to remove the rusty screws, but one stripped it's head out. So for now the rope rewind is jammed.

Spark plug connector seems possibly burnt inside. Black crap on both the plug and up in the connector, and the connector doesn't seem to actually stay on.

Throttle lever is stuck fast. See photo for possible reason... Cable also feels jammed. I assume the throttle itself is jammed. That'll be fun given my skill level.

Electrical stuff all seems dead. No headlights. No starter. No indicator lights. Could be a fuse. Could be bad connection. Not something I'm too worried about at this point.

Front brake handle works. Parking brake clip thing was bent out of shape, but that's now fixed and working. Front brake only works on one wheel. Other one seemed rusted in place (off). WD40 and hammer got it free, although still stiff. Cable might be broken as it doesn't move at all when the handle is pulled.

Rear foot brake works but needs adjusting.

Other handlebar lever doesn't budge. Not sure if that's a clutch lever or rear brake... If this is the 200 version, I gather it's got a centrifugal clutch so it would be a brake lever... But I'm not yet sure exactly which model I'm working with. And the cables all disappear under the plastics and fuel tank and I didn't bother trying to trace where it goes yet.

Thats probably about it for this post.

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Sound like the engine is not locked up I would squirt some oil down in the cylinder to make sure rings are well lubricated before I turn it over much. I would pull the drain plug not completely at first just to see if any water comes out then pull it all the way out and let all the oil drain out look at it to see if its milky looking, and change the oil. From the photo it appears the master cylinder needs replacing you can take it all apart clean it and try soaking the rubber parts in brake fluid but in my experience it won't come back. As far as electrical look for corrosion on connectors and fuse box and check the ground. Hope this helps a little, 25 years is a long time to sit out in the weather.

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The photo is just the thumb lever full of ants.... I'm not that worried about that part at this stage. I cleaned the ants out and sprayed the inside of the lever with plenty of WD40, so hopefully by the time I get to look at it next it'll have come free.

They did have it covered with a tarp for most of the 25 years, so it's not too bad.

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I just rehabbed a 88 MOTO 4 200 that I picked up for $300 off of Market Place.  I got a fully operational machine on the trails for under $600.  Parts are cheap and plentiful on Amazon.

All I needed was a coil, a carb (the price of a carb is not much more than a rebuild kit, saving a lot of tedious work), a new petcock (the handle was broke off) brake pads and front brake cables).

 

Oh yeah and redneck engineer the the air box as the door and cage were gone and I was unable to source them for a reasonable price.

 

Good luck on your project and have fun.

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  • 2 weeks later...

Hi Tin, that doesn't sound foolish at all to me! That's what my grandson and I do for fun, we've been restoring a 91 Moto 4 250 that we got as a basket case a while back. A least yours is all together 😂. But most parts are available with a little scrounging on Amazon or Ebay, and there are quite a few in the salvage yards as well (we've had really good luck with Power Sports Nation), and you can usually get an answer to any problem you run into on the forums here. Look in to downloading a manual for it here, that's pretty much a gotta have.

Good luck with it

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I'm not exactly young... I'm older than the bike 🤣

The plan for it is mostly to do with weed control, fence maintenance and eventually stock movement. We may still buy a newer one aswell, but I want to get this one going anyway.

Unfortunately I've had no chance to look at it any further because it's been so wet here lately. Can't even drive down the driveway at the place it's at, and we had to make a rush trip to a different property the other day to feed chickens before the road got cut off from flooding.

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That can be a dangerous road to go down! 😆  I have way to many hobbies that started out as ways to possibly make a bit of spare cash to help support them, and they all seem to snowball and end up costing a bunch. But I definitely enjoy them. I find we get to attached to our quad collection lol

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I'm a mechanic and I always find there's a bit of a moral dilemma too in fixing thing up to sell for a profit..  Just how gooder job do you do, and how honest are you going to be when you sell it. 

I decided early in my career not to ever do that, buy and sell, after seeing mates do it.. to their discredit.

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Also, over here, the tax rules say that anything you do, even a hobby, is taxable if it's "ongoing", or "regular".

I value my reputation for honesty, given I operate in a small community, and my integrity, too much to be seen as dishonest in any way... even to  the IRD.  Even though people would consider it ok to deceivethe IRD, it would still reflect on the worth of my word..

The crux of professional behavior is giving people confidence and trust in your methods and procedures. Anything that detracts from your trustworthiness undermines that.

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Now, my son is a qualified mechanic, and he started doing bikes up, against my advice, and after having the dilemma explained to him, and he found out real quick, despite his resolve to do it honestly and fairly, that it was really hard to make money without cutting corners.

Now he just fixes them for fun and to get bikes back on the road or track.. That works. He does a good job then, and breaks even, and everyone is happy.

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