Building a 1988 Suzuki RM250 engine

[Sandblaster]

Ok, well, let me know what you find.
If it still does not work let me know and I'll get Jason to review everything you have done and see if he has some suggestions.

[rocket03]

Mike, I think I'm going to go back to that older clutch cover I thought was from an RM125. It's actually from an 86-87 RM250 (00B20). The guy I bought the bike from might have bastardized the parts from all years and maybe that's why I'm having clutch pull issues. The covers look the same but who knows. I'm willing to try anything about now to get this thing going!

[Sandblaster]

Yeah, that's the issue when buying a older bike.
You never know who has done what over the years.
Let me know what you find.

[rocket03]

Mike, let me run this by you. I just noticed the washer under the clutch basket nut was not bent up around the nut. Could that have any effect on this clutch problem I'm having? Would that maybe make the rack pin sit a bit higher?

I know, I know, I'm reaching for answers now! Anxious to get the bike running before cold weather sets in.

Thanks, bro!

[Sandblaster]

It should not effect anything.
But your on the right track, get the correct year parts on there first...
Once that is done it should work perfectly..

[rocket0322]

Mike, I think I figured this clutch business out. The engine is an 87 while the frame is an 88! The engine number starts with "j106". If you look at the clutch diagrams for 87 compared to 88, there is a vast difference! 87 only has 11 plates total while the 88 holds 15. The rack on the 87 has no circling to hold it in place like the 88 does. The basket, hub, and pressure plate look almost identical to 88 but part-numbers are different. The springs are also different numbers between the years.

I guess the Mitaka 88 basket I have coming is not going to solve this. I'm going to have to buy 87 pieces and put in the lower number of plates along with the 87 rack pin.

SOB this pisses me off for not seeing this before spending more money on a part that's not going to help anyway! Wonder if I just take some plates out of the basket I have, put in an 87 rack, if the clutch would work then....try to avoid having to buy the 87 pieces being they look so close to one another...

Dammit!

[Sandblaster]

Try it... I would... You might also help solve a problem for getting newer clutch parts on a older motor

[rocket03]

Mike, I ordered all new 87 clutch parts (basket, pressure plate, hub, springs) and put them in today and I think it's working! I hooked the cable up and can pull the lever and get movement on the rack. I knew it was right when I put the clutch cover on and it went right on without any playing around. I'll try to send a video and a few pics here. If you see anything out of the ordinary, please let me know!

https://scontent.fagc1-2.fna.fbcdn.net/ ... e=5A5D0F91

https://scontent.fagc1-2.fna.fbcdn.net/ ... e=5A289C49

https://www.facebook.com/ken.veze.3/vid ... =3&theater

[Sandblaster]

Looks good from here...

[crfoot]

Did these bikes get completed?? Would like to see the final outcome. I am also doing a complete rebuild (just started), and of course am coming across parts that are needed and can't find. Clutch basket is first on the list.

Thanks!