Building a 1988 Suzuki RM250 engine

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More clean up
Before:

OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 123.JPG (111.17 KiB) Viewed 6799 times

After:

OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 122.JPG (91.88 KiB) Viewed 6799 times

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Got the rod kit in... Nice!

OEM-CYCLE.COM 1988 RM250 ENGINE REBUILD 124.JPG (151.36 KiB) Viewed 6794 times

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Got the crank split and it is now ready for clean up and some polish..

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 121.JPG (107.07 KiB) Viewed 6782 times

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We should make Millennium happy with this order..
Remove sleeve, weld, install new sleeve, port match and grind the deck to clean up.
Rebuild the crank using a IMS Pro rod...
We even Vapor blasted the parts so that they would be nice and clean for them to work on

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 122.JPG (69.64 KiB) Viewed 6762 times

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More clean up and paint test..
Vapor blasted but since it is made from Magnesium you can't leave it unpainted or your asking for trouble.
We used VHT Engine Paint SP134 Ford Light Blue.
Painted the inside and bakes at 200f for an hour.
Then we let it cool and painted the outside and baked it again for another hour.
Turned out pretty good.

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 123.JPG (39.83 KiB) Viewed 6750 times

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 124.JPG (64.86 KiB) Viewed 6750 times

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Lapping and prepping the cases..

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 125.JPG (150.41 KiB) Viewed 6742 times

Ready for main oil passage porting and entry clean up.

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 126.JPG (64.99 KiB) Viewed 6742 times

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 127.JPG (94.28 KiB) Viewed 6742 times

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Almost ready for paint...

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 133.JPG (136.04 KiB) Viewed 6716 times

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 132.JPG (136.39 KiB) Viewed 6716 times

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 131.JPG (113.23 KiB) Viewed 6716 times

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 130.JPG (133.41 KiB) Viewed 6716 times

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 134.JPG (84.8 KiB) Viewed 6716 times

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These look good but didn't pass inspection..
Found some wrinkles

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 135.JPG (68.89 KiB) Viewed 6712 times

These are good to go.

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 136.JPG (152.09 KiB) Viewed 6712 times

Hopefully we will get assembly started this week

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Starting to port the cylinder.
Here is what we are starting with.

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 140.JPG (47.88 KiB) Viewed 6711 times

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 141.JPG (56.33 KiB) Viewed 6711 times

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 142.JPG (41.32 KiB) Viewed 6711 times

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 143.JPG (37.02 KiB) Viewed 6711 times

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 144.JPG (39.36 KiB) Viewed 6711 times

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We are having a rough time finding a inner clutch hub in good condition.
This is the best of 4 that we have available.

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 145.JPG (102.83 KiB) Viewed 6692 times

1988 RM250 ENGINE REBUILD WWW.OEM-CYCLE.COM 146.JPG (108.67 KiB) Viewed 6692 times

But we have something in mind to make this a bit easier to shift