Building a 1988 Suzuki RM250 engine

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Sandblaster
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Building a 1988 Suzuki RM250 engine

Post by Sandblaster » Wed Sep 16, 2015 9:00 pm

We just received a 1988 RM250 that we are going to most likely do a full rebuild on.
First things first, let's give it a good washing before disassembly.
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 101.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 101.JPG (65.58 KiB) Viewed 2698 times
There is nothing worse then dropping dirt, sand, grease, and grim into a motor.
Regardless if we are going to clean it all up later, we want to keep it as nice as possible...
Who knows, at this point, it may not be worth rebuilding... :o

Here is what we are starting with..
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 102.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 102.JPG (78.91 KiB) Viewed 2698 times
At first glance it does not look too bad..
But a closer inspection reveals a few things..
Missing carb cap..
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 103.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 103.JPG (64.2 KiB) Viewed 2698 times
Broken right side exhaust valve cover
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 104.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 104.JPG (51.42 KiB) Viewed 2698 times
If bikes are for kids I'll never grow up.

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Sandblaster
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Re: Building a 1988 RM250 engine

Post by Sandblaster » Wed Sep 16, 2015 9:02 pm

Broken exhaust flange
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 105.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 105.JPG (46.81 KiB) Viewed 2697 times
The drain plug has been repaired.
Externally it looks good but we won't know until we get it apart and inspect it.
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 106.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 106.JPG (63.74 KiB) Viewed 2697 times
Some buggered up parts.
We might be able to clean them up and polish them out a bit..
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 107.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 107.JPG (45.38 KiB) Viewed 2697 times
Broken shift shaft spacer..
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 108.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 108.JPG (31.71 KiB) Viewed 2697 times
If bikes are for kids I'll never grow up.

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Sandblaster
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Re: Building a 1988 RM250 engine

Post by Sandblaster » Wed Sep 16, 2015 9:03 pm

And heavy wear around the engine case..
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 109.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 109.JPG (81.81 KiB) Viewed 2697 times
Yes, it is repairable but it may be cheaper to get a new case...
We will see 8-)
If bikes are for kids I'll never grow up.

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Sandblaster
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Re: Building a 1988 Suzuki RM250 engine

Post by Sandblaster » Wed Sep 16, 2015 10:30 pm

Clutch basket is REALLY worn..
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 110.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 110.JPG (60.24 KiB) Viewed 2695 times
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Re: Building a 1988 Suzuki RM250 engine

Post by Sandblaster » Wed Sep 16, 2015 11:15 pm

More disassembly..
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 111.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 111.JPG (184.15 KiB) Viewed 2694 times
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 112.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 112.JPG (181.85 KiB) Viewed 2694 times
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 113.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 113.JPG (173.47 KiB) Viewed 2694 times
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 114.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 114.JPG (173.33 KiB) Viewed 2694 times
If bikes are for kids I'll never grow up.

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Sandblaster
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Re: Building a 1988 Suzuki RM250 engine

Post by Sandblaster » Wed Sep 16, 2015 11:16 pm

AH HA!
Found the transmission problem...
Rounded dog ears..
The big question is, can we find replacements that are better?
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 115.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 115.JPG (74.29 KiB) Viewed 2694 times
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 116.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 116.JPG (71.31 KiB) Viewed 2694 times
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Sandblaster
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Re: Building a 1988 Suzuki RM250 engine

Post by Sandblaster » Mon Oct 19, 2015 11:46 pm

Cylinder issues....
Look at the sleeve.... and cracks in the bridges.
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 117.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 117.JPG (69.69 KiB) Viewed 2672 times
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 118.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 118.JPG (84.25 KiB) Viewed 2672 times
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Sandblaster
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Re: Building a 1988 Suzuki RM250 engine

Post by Sandblaster » Mon Oct 19, 2015 11:49 pm

It should look more like this:
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 119.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 119.JPG (34.97 KiB) Viewed 2672 times
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Sandblaster
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Re: Building a 1988 Suzuki RM250 engine

Post by Sandblaster » Mon Oct 19, 2015 11:52 pm

And when we are done it will be better 8-)
If bikes are for kids I'll never grow up.

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Re: Building a 1988 Suzuki RM250 engine

Post by Sandblaster » Thu Oct 22, 2015 9:20 pm

We have parts from 4 different engines to help us in getting the best parts available.
Keeping things organized becomes a priority...
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 120.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 120.JPG (134.4 KiB) Viewed 2668 times
And how can you decide which part to use unless you have clean parts to inspect?
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 121.JPG
OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 121.JPG (53.54 KiB) Viewed 2668 times
I think Jason is OCD sometimes :o :lol:
If bikes are for kids I'll never grow up.

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