1. Know what you’re getting into. Restoration (done properly) can consume many, many hours (and many dollars). If you’re the kind of person who starts a project with enthusiasm and the lets it peter out when the volume of work becomes apparent, don’t do this.
2. You’ll probably exceed your budget. When people update something in their homes, they run into the "you might as well" phenomenon. "Since we’re replacing the tub we might as well get a new vanity/sink/mirror/new tile" etc. ATV restoration is no different. Save up your money before you start or you’ll spend 8-9 months restoring like I did.
3. I’d probably powder coat or galvanize the frame rather than rattle-can it.
4. When you buy used parts off Ebay or wherever, look for parts from the middle-to-western part of the country. Drier climate means less rust/corrosion.
5. When you need a particular small part (such as new swing-arm bolts), instead of paying $15-20 for the one part, look at the stuff labeled "misc. nuts/bolts" for your particular bike. Your part (plus a half-dozen more parts you need) might be in there for like $30. For example, I saw tool kits in the little black case for Honda 300s going for $30-50 each. I got the tool kit plus several other hard-to-find, useful parts off a miscellaneous ad for $25.
6. Check the frame carefully before you buy, especially the underside where it can contact the ground going over rocks/rough ground. Having to come up with another frame can add a significant chunk to your rebuild. If it hadn’t been for one of my brothers (a master welder), I would have been screwed here.
7. I’d avoid buying a blue 300 to restore unless you plan to go with a different color. The plastics are getting hard to find.
8. Places I can recommend for buying parts: Manny, from this website; Honda East Toledo; Power Sports Nation in Nebraska; G&H Discount in TN; and Boss Bearing.
9. There is no comparison between an impact wrench and a ratchet. The proper tool may cost a few dollars more, but after your knuckles are bleeding and you’ve been cussing one particular bolt for 2 hours that refuses to break free it becomes worth it.
10. Never, under any circumstances, hide your purchases from your wife :ph34r:. Do it once and you’ll understand.
I’ll add more later. Throw in some of your own if you like. Good day, all.
