Two Stroke Motocross

Two Stroke Motocross Forum => Open Forum => Topic started by: cnrcpla on April 08, 2013, 12:11:01 AM

Title: My next project
Post by: cnrcpla on April 08, 2013, 12:11:01 AM
And boy is this one a project  :-X I'll be picking up a '95 RM250 this weekend. It has a seized motor, ripped radiator, FUBAR'd plastics, and is need of a paint job. I can TIG the radiator, no big deal there, I can give the plastics some life back, no big deal, but the motor... I will be opening it up first thing to see what's wrong. I'm hoping best case scenario its a fried piston and the bore isn't to bad. If it turns out to be the worst case scenario (fried bottom and top) I'll be looking at a used motor. What are my options? I'm thinking another rm250 motor, but at the same time I can't help but wonder what other motors would fit in there with minimum fuss. I can weld mounts, but hopefully wont have to. I'll put up some pics as soon as I get it here.
Title: My next project
Post by: SachsGS on April 08, 2013, 04:11:25 AM
Those case reed RM250 motors were tough! I'd overhaul the existing motor.
Title: My next project
Post by: TMKIWI on April 08, 2013, 07:07:39 AM
Quote from: SachsGS on April 08, 2013, 11:11:25 AM
Those case reed RM250 motors were tough! I'd overhaul the existing motor.

X2.
Easier then trying to make another motor fit.
Title: My next project
Post by: TotalNZ on April 08, 2013, 07:13:25 AM
Yeah rebuild her, it would be rare for a motor to be that trashed that it's not worth fixing.
I don't think they were electro plated bores either were they? that'll give you an option to oversize if you need too.
Title: My next project
Post by: cnrcpla on April 11, 2013, 12:25:13 AM
If it is not electro plated than I will def hone it with a new piston. Anyways, I just got it home. This thing is ROUGH  :-X





Duct tape and elec tape graphics!!! That must have added at least 10 HP easy  ;D I'm gunna be TIGing the sub frame, and then painting it. I hope to open up the engine tonight and see what I'm up against. More pics to come from inside this beast.
Title: My next project
Post by: _X_ on April 11, 2013, 01:20:03 AM
easily ads 10 hp! i'd keep those.
Title: My next project
Post by: cnrcpla on April 11, 2013, 01:43:35 AM
I wont lie, they look good for the tape they were made with
Title: My next project
Post by: cnrcpla on April 11, 2013, 03:18:20 AM
Ok, calling the engine guru's (TMKIWI I believe you were labeled the RM guru). I need help getting the seized piston out of the bore. I got the cylinder loose but the piston refuses to budge. The bore is fine judging by what I can see  :o This may have been a SWEET pick up. I couldn't get any decent shots with a cam, but the bore is perfectly smooth  :o

Title: My next project
Post by: TMKIWI on April 11, 2013, 08:46:21 AM
The bore may look smooth ( what you can see ) but could be worse where the piston sits.
Are you intending to rebuild the bottom end ?.
Is the piston stuck solid.?
If so you can drill a ring around the piston about 15mm in from the outer edge.
Drill a series of 10mm holes 1mm apart and once all holes are drilled use the drill bit to "connect" the holes.
(Move the drill side to side).
Give the center of the piston a decent hit with a hammer and the piston should seperate.
Remove the cylinder and then you can press out the remainder of the piston with a hydraulic press.
( Make a die the correct size to press on the left over piston ).
Rebuild.
Title: My next project
Post by: 2T Institute on April 11, 2013, 09:20:04 AM
Just fill the cylinder with diesel overnight(plug the exhaust with a potato) come back in the morning and try to mover with kick start after removing the diesel
Title: My next project
Post by: cnrcpla on April 11, 2013, 05:14:04 PM
GOT IT! Soaked it in WD40 overnight and tapped it a little with a hammer and socket extension. Came down to BDC and I was able to pull the cylinder off. 

I'm hoping the bottom end is in good shape, only because I figured out the source of the seize last night while taking it all apart. The left radiator had a gaping crack in it (also going to be welded), so I'm assuming the previous owner dinged that, kept riding with out coolant, and heat seized the piston. If the bottom end is shot I do plan on rebuilding it, but it will have to wait for money income to build up a little  :-X  It seems as though the bottom end is alright, but something funky is going on. Probably will be splitting the cases.
Title: My next project
Post by: Coop on April 11, 2013, 08:27:17 PM
Is there any play at the flywheel? Any at all and the crank bearings are bad.

Is there any up/down play in the rod? Any at all and the rod bearings are bad. Some side to side is normal.
Title: My next project
Post by: cnrcpla on April 11, 2013, 08:37:02 PM
No movement in the crank bearings, the wrist pin needle bearing was shot though. I think there is some debris in the bottom end, as it moves freely, then stops, then wont move back. I am surprised that the cyl is still in good shape, perfectly smooth except for one small groove then I will be honing out.
Title: My next project
Post by: cnrcpla on April 11, 2013, 09:47:05 PM
Well the big end bearing seems to have grenaded in the bottom end. That would explain the odd movement. The main bearings seem alright, no movement, but I'm not saying anything for sure until I split the cases and see for sure. Now, on to my next question. I get the whole case splitting cases concept (this will be my frist one), but how do I check the timing after I remove the flywheel upon reassembly?

Anyways, the swing arm pivot axle is frozen to the engine... shocker  ::)  Whats the best method to removing this? Heat and a press?

Also, here's a pic of the cooked piston:


Expect more questions as I get into the cases, just a heads up  ;D
Title: My next project
Post by: TMKIWI on April 12, 2013, 01:30:15 AM
The stator plate has a groove in it that lines up with a casting mark.
Scribe a line on the plate to mark where it is at now.
Just line the mark up when you put it back together.
Title: My next project
Post by: cnrcpla on April 12, 2013, 01:38:16 AM
Gotcha. Will do. There are only two thing I've never messed with on a bike, case splitting, and shock rebuilding.
Title: My next project
Post by: Coop on April 12, 2013, 01:54:27 PM
From the looks of that piston it looks like one of the rod bearings fragged. I am really surprised the cylinder doesn't need repaired/replated. I am pretty sure those were plated. Try sticking a magnet to the bore. No stick, plated. Unless someone had it sleeved it previously a 1995 should be plated. I had a 1992 RM125 and it was plated.
Title: My next project
Post by: cnrcpla on April 12, 2013, 05:21:01 PM
Yeah the big end blew. The magnet sticks to the cylinder walls, kind of weakly, but it sticks. So I guess that means steal sleeve?  :-  If that's the case I will be honing out the shallow grooves that you should be able to see in these picks:





Also, the PV is all dented, I will be grinding the burrs out and hoping for the best.
Title: My next project
Post by: factoryX on April 12, 2013, 07:49:33 PM
Looks like a sleeve, take a pic from the bottom.
Title: My next project
Post by: cnrcpla on April 12, 2013, 07:56:02 PM
From the bottom:

Title: My next project
Post by: TMKIWI on April 12, 2013, 10:13:58 PM
Don't hone it, take it out to the next oversize.
Title: My next project
Post by: factoryX on April 12, 2013, 10:39:15 PM
Its sleeved. As kiwi says, bore that sucker.
Title: My next project
Post by: cnrcpla on April 12, 2013, 10:46:41 PM
Alright, I'll see what I can get my hands on. I'll be buying the big end bearing and splitting the cases as soon as I get the damn SA pivot bolt out.
Title: My next project
Post by: Coop on April 12, 2013, 11:20:10 PM
Quote from: WTFactoryX on April 13, 2013, 02:49:33 AM
Looks like a sleeve, take a pic from the bottom.

Agreed, the pictures were very helpful. The thickness of the sleeve and if it was bored already will determine how far you can if you want to go bigger. Can you see any markings on the top of the piston or is it in too bad of shape to see?
Title: My next project
Post by: cnrcpla on April 14, 2013, 03:21:42 PM
The whole top of the piston is melted, I don't think I'll be getting any info from that sucker hahaha. I've been moving for the past few days and going now I'm going on vacation for a few days. I haven't had time to pound that SA bolt out, but I've been soaking in WD40, so hopefully it'll come out as soon as I get home.
Title: My next project
Post by: cnrcpla on April 16, 2013, 02:10:44 AM
Are you sure its a sleeve? Some suzuki people think its plated. If it was plated it wouldn't stick at all right? Like no connection at all? I can bore it for free but not plate it...
Title: My next project
Post by: factoryX on April 16, 2013, 02:45:34 AM
It could be plated but the pics(Blurry) are kind of hard to tell. I wouldn't be shocked if it were sleeved, you can get a steel sleeve for practically any bike.


After checking a few threads on other forums I guess sometimes other alloys make into the nikasil and a magnets will sometimes slightly stick(1/8 pull or less.) Scrub the top of the piston, you might get lucky. Again sorry for any missinfo (If any), pics can be deceiving. 
Title: My next project
Post by: cnrcpla on April 16, 2013, 03:23:44 AM
It's all good man, things are hard to determine over pics hahaha. If it has a steel sleeve, but is in fact plated on the sleeve, can I bore it, which would get the plating off, and match a piston and run it with the steel?
Title: My next project
Post by: Stusmoke on April 16, 2013, 09:43:39 AM
This is gonna be sweet once its done. I can't offer advice as far as engines go, but I'm reading it anyway to learn :D
Title: My next project
Post by: cnrcpla on April 21, 2013, 07:42:12 PM
My patience is running very low with the bolt. It's the ONE thing holding me up from the rest of the project. I literally pounded on it for 10 minutes today with a 3 lb hammer and then upgraded to a 10 lb sledge with no luck. It wont press out. What do I do now? Can I cut it? If so, where with out damaging the frame and swing arm?
Title: My next project
Post by: cnrcpla on April 23, 2013, 03:25:49 AM
Finally got the @*%^@# $^@($% out. Didn't even mushroom the threads, I figured out a good system of bolts and washers to break it free. Anyways, the engine is out now. I'll be taking pics tomorrow hopefully. My goals for this week are to weld up the frame, its cracked (subframe, don't abandon all hope yet) in three places, and to split the cases. Next week will come sand blasting and hopefully paint for the frame while I wait for parts. What color should I do the frame? Plastics will be yellow, and I'm thinking black, but I'm caught between that and silver  :- 

Clutch is messed up too, I think it's missing the push rod, but I haven't gotten into the guts of the tranny yet. Swing arm bearings seem fine, though I'll likely replace them anyways. Linkage bearings are shot completely. I'm hoping to measure the cyl and bore it accordingly sometime next month. Its looking up, but there is a lot of work ahead........
Title: My next project
Post by: Coop on April 24, 2013, 02:33:52 PM
Quote from: cnrcpla on April 23, 2013, 10:25:49 AM
Clutch is messed up too, I think it's missing the push rod, but I haven't gotten into the guts of the tranny yet.

Take the pressure plate off and lay the bike or engine  over. The rod and ball bearing (if it has one) should fall out.

I vote silver for the frame but I am not a fan of black frames. They look dirty really easy and show scratches more than lighter colors. Especially if you are planning to rattle can the frame, use a lighter color because it will scratch very easily. Even with primer and clear coat, that stuff isn't very durable on a frame.
Title: My next project
Post by: cnrcpla on April 24, 2013, 07:53:50 PM
I actually figured out the clutch issue, this one has no push rod, but a gear and spline shaft that work to separate the plates. Someone must have taken it apart because the spline shaft was freely floating around the clutch basket. I'm leaning towards silver at the moment  ;D

Update: I got the cases split today. Man that job seem so intimidating but it really isn't that bad at all. I got the crank out. Main bearings are fine, but I'm doing a full rebuild anyway. Now, the pin that the con rod is connected to the crank through presses out? I couldn't get it to budge in the press. How much pressure does it take?

Also, to get the mains out, I heard there was an oven trick to heat them up face down and they'll fall right out. What temp do I set the oven at?
Title: My next project
Post by: Coop on April 24, 2013, 08:32:50 PM
That pin is pressed out. It usually takes some serious pressure. The guy who used to rebuild my cranks (he closed up shop) insisted a 20 ton was the minimum.

I can usually get the bearings out with a socket and hammer (one side often comes out on the crank, you need a puller if that happened). Sometimes I have to apply some heat to the case (propane torch NOT oxy-acetylene). I've never tried using the oven to remove them.

To re-install I freeze the bearings and heat the cases and they almost drop right in. Then freeze the crank and again heat the cases with the new bearings now installed and it is usually a smooth process.
Title: My next project
Post by: cnrcpla on April 24, 2013, 09:09:23 PM
Ohhhh 20 tons... I'll see what the max is for the one in the shop. If it isn't that strong than I guess I'll be sending it out. In the event that I am able to press out the pin, do I need to worry about truing the crank again?
Title: My next project
Post by: moto867 on April 25, 2013, 06:39:24 AM
i rebuild them all the time with a 12 ton press.  lots to it other than pressing it apart and back together.  measure the width of the crank before you begin, side play on the big end of the rod should be between .020-.030".  you should cut the pin in half and press each side out individually to the inside.  that way the munged up pin wont be pressed through the bore of the crank half.  i made an assembly jig to press them back together true.  they usually end up with only about .0005" or so runout.  trueing the crank is critical.  that cyl is plated, no sleeve.  some plated cyls will attract a magnet, that one looks done for.  time for a replate or sleeve job.  honing grooves out of a cyl is never a good idea, cant do it on plated cyl anyway.  even if it was sleeved by the time you honed the grooves out the piston to cyl clearance would be way too big.
Title: My next project
Post by: cnrcpla on April 25, 2013, 01:24:28 PM
Alright, I'll probably send the crank out. I don't need a grenade under me hahah. Damn I was really hoping I could do the cyl myself. Oh well, more $$$.
Title: My next project
Post by: eprovenzano on April 25, 2013, 05:34:42 PM
The crank is the one area that unless you have the equipment and proper training...  send it out to professional.
Title: My next project
Post by: cnrcpla on April 25, 2013, 06:24:29 PM
But I'm a pro at everything!  ;D :P hahah I wish... Yeah cranks and rear shocks are the only things I've never messed with on a bike.
Title: My next project
Post by: cnrcpla on April 28, 2013, 07:46:02 PM
Got the frame mostly welded up today. All that's missing is the bracket on the end of the round tubing I welded on. I'm waiting for my wallet to refill with money before I start ordering parts for the motor.

 







Title: My next project
Post by: SachsGS on April 29, 2013, 04:03:07 PM
Usually takes around 10 to 12 tons pressure to separate a Japanese crank. The old Maicos were 18+ tons (find a hiding place in the shop  :-X).
Title: My next project
Post by: eprovenzano on April 29, 2013, 09:30:15 PM
Quote from: SachsGS on April 29, 2013, 11:03:07 PM
Usually takes around 10 to 12 tons pressure to separate a Japanese crank. The old Maicos were 18+ tons (find a hiding place in the shop  :-X).

This is why I would send it out to a professional
Title: My next project
Post by: cnrcpla on April 29, 2013, 09:40:52 PM
Yeah I am sending it out. Luckily not to far  ;D Just waiting for money at this point. Seems to be the thing that holds me back the most  :(
Title: My next project
Post by: eprovenzano on April 30, 2013, 01:31:41 PM
Quote from: cnrcpla on April 30, 2013, 04:40:52 AM
Yeah I am sending it out. Luckily not to far  ;D Just waiting for money at this point. Seems to be the thing that holds me back the most  :(

Yea, that's one thing that hold all of us back...   >:-D
Title: My next project
Post by: cnrcpla on May 08, 2013, 01:47:34 AM
Well I finished welding up the frame. I also fabricated some side plates out of aluminum sheet metal because the ones that came with the bike look very odd. The alu is way lighter than the plastic anyways. I'm holding off on sand blasting the frame until I have time to paint. I'm taking my finals for some classes this week, so it probably wont be until next week. Other than that I'm waiting on parts for the motor. I still have to get the old mains out and send my crank out. I noticed the bottom of the crank case got really scratched up from fragments of the needle bearings getting wedged between that and the crank, can I use a dremmel and smooth out the burrs?
Title: My next project
Post by: TMKIWI on May 08, 2013, 08:11:01 AM
Yes you can. Just get rid of any sharp edges.
Title: My next project
Post by: cnrcpla on May 15, 2013, 11:24:23 PM
Small update: I have the frame sand blasted and willl be getting primed. I have the crank parts on order right now. Haven't gotten much done, I've been busy with finals  :(
Title: My next project
Post by: Coop on May 17, 2013, 01:00:30 AM
Finals do take a lot of focus. Good for you for keeping your priorities in line.

Looking forward to progress pictures.
Title: My next project
Post by: cnrcpla on May 29, 2013, 03:51:59 AM
Well after finals week ended my computer broke  :-X To many essays I guess... Anyways, I've been moving at a snail's pace due to school work, but I got the frame sand blasted and primed. It's going in for paint tomorrow and friday. I got the burrs out of the crank cases and cleaned those up. I got the parts in and have my friend working on the crank for me. I have more bearings on the way and will hopefully be putting the cases back together and in the frame next week. I had to machine the cylinder head because it got pretty smashed up, but I was able to salvage that. Can't get any pics on this new computer  >:(

Title: My next project
Post by: Coop on May 29, 2013, 12:39:29 PM
Nice to read you are making progress.
Title: My next project
Post by: cnrcpla on May 31, 2013, 12:10:54 AM
Finished most of it today. Frame is all painted, plastics, and all the little nik-naks are painted. I had to paint the gas tank because a new one was like $200  :o It looks much better in person...  Anyways, I also got the cylinder taken care of, the burrs filed out of the crank cases, and the cases cleaned up and painted. Got my crank back all nice and trued. Got the main bearings and seals out, those are on order.







 









Title: My next project
Post by: cnrcpla on May 31, 2013, 12:13:42 AM
Oh yeah, and there seems to be quite a bit of rust in the cooling jackets in the cylinder. Can I pour some CLR down there to dissolve the rust away with out messing with the cylinder?
Title: My next project
Post by: cnrcpla on June 05, 2013, 01:53:09 PM
Anyone know how to get that corrosion out of the cooling jackets? I would really rather not reassemble it with crap in there  :-X
Title: My next project
Post by: Coop on June 05, 2013, 02:20:44 PM
The paint is not going to stay on the tank unfortunately. First it will bubble, then any spills will wash it away. I know from experience lol.

I have used brushes like this to clean hard areas like you mention.


Title: My next project
Post by: cnrcpla on June 05, 2013, 03:59:13 PM
That's what I thought about the gas tank too, but someone already had tried to rattle can it white and it looked like crap. I used paint that was supposed to bond with the plastic, so I'm hoping it will hold up... And I'll have to look around for those pipe cleaner looking things, maybe at a hardware store  :)
Title: My next project
Post by: TotalNZ on June 06, 2013, 05:41:03 AM
Quote from: cnrcpla on June 05, 2013, 10:59:13 PM
That's what I thought about the gas tank too, but someone already had tried to rattle can it white and it looked like crap. I used paint that was supposed to bond with the plastic, so I'm hoping it will hold up... And I'll have to look around for those pipe cleaner looking things, maybe at a hardware store  :)
It's not the paint bonding thats the problem, it's the gas escaping through the plastic tank and causing bubbles under the paint.
Title: My next project
Post by: evo550 on June 06, 2013, 06:52:27 AM
Quote from: cnrcpla on May 31, 2013, 07:13:42 AM
Oh yeah, and there seems to be quite a bit of rust in the cooling jackets in the cylinder. Can I pour some CLR down there to dissolve the rust away with out messing with the cylinder?

Where is the rust coming from? The whole cooling system is alloy isn't it?
Title: My next project
Post by: cnrcpla on June 06, 2013, 11:54:15 AM
That's what I thought  :- I was thinking maybe its just a sludge from crappy coolant sitting there?  ??? Either way it'll be gone before I put the engine back together

Quote
It's not the paint bonding thats the problem, it's the gas escaping through the plastic tank and causing bubbles under the paint.
  Oh well, I guess I'll cross that bridge when it rears it's ugly head. But it was bubbling up anyways from the white paint that I sanded off.
Title: My next project
Post by: rlaj1004 on June 06, 2013, 08:45:44 PM
Quote from: cnrcpla on June 05, 2013, 10:59:13 PM
That's what I thought about the gas tank too, but someone already had tried to rattle can it white and it looked like crap. I used paint that was supposed to bond with the plastic, so I'm hoping it will hold up... And I'll have to look around for those pipe cleaner looking things, maybe at a hardware store  :)

Harbor freight if you got one in your area, or you can order online. Not top quality but they are thow away stuff usually anyway.

Nice project  :D
Title: My next project
Post by: evo550 on June 06, 2013, 11:35:03 PM
Why are you painting the tank anyway ? Most of the tank should be covered by the radiator shrouds on that model..
Title: My next project
Post by: cnrcpla on June 07, 2013, 03:09:59 AM
It is mostly covered, but it was painted white before, flaking, bubbling and looking terrible. I just wanted to get rid of the white paint. If the black paint flakes and stuff, than it will reveal black plastic underneath and be MUCH less noticeable.
Title: My next project
Post by: moto867 on June 08, 2013, 04:53:00 AM
that plastic looks like its from a newer model
Title: My next project
Post by: cnrcpla on June 11, 2013, 12:54:36 AM
Yeah plastics are from a newer model. The guy had them shoe laced to the bike, but while I was already welding the frame, I figured I'd throw in some custom mounts to keep the newer generation plastics. Anyways, I'm half way through this finals week, and haven't gotten much done. I got the front end assembled and airbox in, but that's about all I've had time for  :( I'm waiting to go pick up the crank bearings, but my car broke down (go figure). I'm also waiting on my wallet to regenerate money so I can buy a swing arm bearing kit, and then, aside from a top end, the bike will be (hopefully I don't stumble across anymore broken parts) done.
Title: My next project
Post by: evo550 on June 11, 2013, 10:33:10 AM
Quote from: moto867 on June 08, 2013, 11:53:00 AM
that plastic looks like its from a newer model
The plastics look like they are from a KTM to me...
Title: My next project
Post by: cnrcpla on June 11, 2013, 03:12:55 PM
Your good! They are from a ktm. Or at least the rear and front fender. The shrouds might be too.
Title: My next project
Post by: cnrcpla on June 12, 2013, 01:22:09 AM
Progress thus far:








All I need is the engine and the swing arm in there. I'm picking up the main bearings and seals and all the gaskets Friday and will hopefully have the bottom end reassembled and in the frame. I now need swing arm pivot bearings, and a top end kit. Oh and the rear fender is not mounted in the pics, I haven't picked the best looking angle for it to be mounted yet.
Title: My next project
Post by: evo550 on June 12, 2013, 08:33:48 AM
Quote from: cnrcpla on June 11, 2013, 10:12:55 PM
Your good! They are from a ktm. Or at least the rear and front fender. The shrouds might be too.
Yep shrouds as well, just cut off at the bottom.
Title: My next project
Post by: cnrcpla on June 12, 2013, 11:34:44 AM
The shrouds look a little iffy, but I'm to antsy to ride this thing, so I just wanna get it running and then I'll worry about ordering in stock shrouds or something.
Title: My next project
Post by: SachsGS on June 12, 2013, 03:24:32 PM
Where can I get one of those money regenerating wallets? ;D
Title: My next project
Post by: cnrcpla on June 15, 2013, 11:18:10 PM
Ran the vin through a decoder. The engine is infact a '93. I'll see if I can return the parts and swap them out for the correct ones. This SUCKS having my car broken down, it took me all week to get a ride to pick them up... To bad my bike isn't registered  :(
Title: My next project
Post by: cnrcpla on June 26, 2013, 04:13:56 AM
Alright, the correct bearings are in the freezer getting ready to be installed tonight. But now I am confused. The gasket that goes between the cases STILL doesn't match... The 94'-02' one didn't, and now the '93 and down doesn't. I'm tired of swapping parts, so I'm just going to use liquid gasket I guess... It odd because the inner clutch cover gasket lines up perfectly  ??? ??? Is it safe to use liquid gasket? I want to do this right, but it seems as though there is no gasket that can match these cases  ::) Anyways, I am hoping to get a hold of some liquid gasket and putting the bottom portion of the engine in tomorrow. All I'll be waiting on is the top end and some swing arm bearings and she'll be good to go. I'm kind of hoping this bike will turn out to be a good track bike handling wise. I like my YZ for the woods...
Title: My next project
Post by: riffraff on June 26, 2013, 04:45:25 AM
How doesn't fit? Screw holes don't line up, extends into the case or sticks out of the case?
Title: My next project
Post by: cnrcpla on June 26, 2013, 04:47:40 AM
Dark pic, but you can see it is way off...

Got the main bearings in no problem so far. The left side seal was rubbing up on the bearing causing friction, so I tried to push it out a little and ended up putting a hole in it  >:( Guess I'll be ordering one of those AGAIN...
Title: My next project
Post by: riffraff on June 26, 2013, 05:53:20 AM
Damn, that sucks. The other gasket fit just as bad? Problem with not having a gasket in there could cause a clearance issue, not to mention that's a lot of surface area to try to seal with a liquid gasket, any leaks in the crank area and you're scewed.
Title: My next project
Post by: TMKIWI on June 26, 2013, 08:19:20 AM
1990,91,92 use gasket 11482-28C01
93' gasket                     11481-28C00
94,95'                            11481-28E10
96',97',98                      11481-37E01

Not sure what gasket kits you are using but the gaskets don't match from 94'-02.

Have a look at this http://www.alpha-sports.com/suzuki_parts.htm  and check the pictures to find your year.


Title: My next project
Post by: cnrcpla on June 26, 2013, 03:37:02 PM
It's definetly a '93 case. The gasket they sent is definetly not from a '93 I guess, as you can see in the reed induction area there is a small piece that should come seperate from the gasket. Neither of the ones I got had come like that. The VIN confirms it is a '93, so I don't understand... Maybe the wrong part came in  ???  Thanks for the pics TMKIWI.
Title: My next project
Post by: cnrcpla on July 13, 2013, 06:33:24 PM
Sorry for the lack of updates, I just got a new job so I've been working my @ss off for the last couple weeks. Luckely, I finally got more money to throw at this project. I finally got the correct gasket on order, apparently the one that came in was for an RMX or something like that. So by Tuesday I hope to have the cases back together and mounted back in the back. I'd also like to have my new swingarm bearings in and have a rolling chassis once again. After that, I'll be waiting on money for a top end kit for this bike and she'll be ripping. Can't wait to hear this thing run. I'm definitely gunna wring it's neck for all the crap it's put me through  ;D
Title: My next project
Post by: cnrcpla on July 25, 2013, 04:33:32 AM
Finally got some time to wrok on the thing. Got the cases all put back together, new bearings, seals, crank, and some other odds and ends in her. Got the clutch straightened out as well. I'll hopefully be dropping the bottom end in the frame tomorrow, and I'll be hooking up the carb and reeds and radiator, as well as wiring it all up. I got swingarm bearings and new tires on order. So now all I need is a piston and rings and this thing will be ready to rip! Here's my progress thus far:

Title: My next project
Post by: cnrcpla on July 25, 2013, 04:38:01 AM
Oh yeah, the crank seemed a tiny bit hesitant to move until I put the trans oil in. I guess the oil got the right side crank seal all lubed up? This is my first bottom end rebuild so I don't have any experience here  ;D
Title: My next project
Post by: _X_ on July 25, 2013, 10:04:21 AM
keep at it cnrcpla.
Title: My next project
Post by: TotalNZ on July 25, 2013, 10:09:13 AM
Don't panic, She'll feel a bit tight at first. New seals and grease in the new bearings will do that.
Looks like you're doing a top job of the rebuild.
Title: My next project
Post by: cnrcpla on July 25, 2013, 03:11:32 PM
Thanks guys! I'm getting so impatient to hear this thing run. Can't wait to swing a leg over and let it rip.
Title: My next project
Post by: gpnewhouse7 on July 25, 2013, 05:24:39 PM
Quote from: cnrcpla on July 25, 2013, 10:11:32 PM
Thanks guys! I'm getting so impatient to hear this thing run. Can't wait to swing a leg over and let it rip.

Just don't do what a friend of mine has just done with his 2011 sx 150 after a full bottom and top end rebuild. He ran it in as instructed in the manual then went ahead changed the gearbox oil and air filter and went back out again to really give it some, unfortunately he didn't quite fit his new filter properly and a whole load of gritty dust and water got into his freshly rebuilt engine and he is now rebuilding it all over again.


Title: My next project
Post by: cnrcpla on July 25, 2013, 06:51:57 PM
I've run into a little snag. I can't get the right side cover to seat evenly which is causing a massive leak of trans fluid. I've ruled out everything, the centering dowels, the governor, and even the main crank. All are seated and installed properly. I looked at the shift shaft and it seemed to be sticking out more than it should which I suspect is causing my clearance issues. Is it supposed to be lined up so that the small stud is in the machined hole in the gear selector? If so, how can I align it properly?
Title: My next project
Post by: citabjockey on July 25, 2013, 09:00:53 PM
Looks like your shifter return spring is not centered oveer its boss on the inner case? I will take a guess and say you can't shift gears properly by hand right now? I think you need to pull out the shifter shaft and re-insert it and make sure  the fingers on the spring properly surround the boss and that that pin on the shifter plate goes in there as well.



Quote from: cnrcpla on July 26, 2013, 01:51:57 AM
I've run into a little snag. I can't get the right side cover to seat evenly which is causing a massive leak of trans fluid. I've ruled out everything, the centering dowels, the governor, and even the main crank. All are seated and installed properly. I looked at the shift shaft and it seemed to be sticking out more than it should which I suspect is causing my clearance issues. Is it supposed to be lined up so that the small stud is in the machined hole in the gear selector? If so, how can I align it properly?

Title: My next project
Post by: cnrcpla on July 25, 2013, 10:24:03 PM
That was exactly it. Thanks a bunch man! Got it all buttoned up and put it. Also got the rear fender mounted and tail pipe mounted. Good to know that the part of the frame I fabricated had the correct measurements  ;D Anyways, here's how it sits now.




Title: My next project
Post by: TMKIWI on July 26, 2013, 12:22:34 AM
Looking good.
Title: My next project
Post by: TotalNZ on July 26, 2013, 03:10:45 AM
Looking good, but personally i'd ditch those KTM shrouds and put some RM ones back on.
Title: My next project
Post by: Stusmoke on July 26, 2013, 03:12:59 AM
Quote from: TotalNZ on July 26, 2013, 10:10:45 AM
Looking good, but personally i'd ditch those KTM shrouds and put some RM ones back on.

Yeah definitely. If only because they look like such a dodgey job by the PO.
Title: My next project
Post by: cnrcpla on July 26, 2013, 03:26:29 AM
That's the plan. Only problem is it isn't a '93 RM tank. So i have to find out what year/make the tank is and get shrouds accordingly. But I honestly want to get it running and ridable before I worry to much about cosmetics  ;D
Title: My next project
Post by: Stusmoke on July 26, 2013, 03:31:17 AM
Course :P Does the tank fit into the cradle alright?
Title: My next project
Post by: cnrcpla on July 26, 2013, 04:24:40 AM
Oh yeah, the tank mounts right up perfectly. I actually just went all mad scientist on it in the garage, I created a few custom mounts that will make these shrouds look decent for the time being. I have to cut them a bit, but it'll pick them up and stop making them look ghetto rigged and droopy.
Title: My next project
Post by: _X_ on August 08, 2013, 10:03:05 PM
whats up with the rear fender cnr? thing is sky high, you loop out on it already?
Title: My next project
Post by: cnrcpla on August 08, 2013, 10:15:03 PM
HA not yet, cylinder is still at millennium tech, but I fixed that fender today  ;D I made my mounts adjustable, so I lowered it a lot, no longer looks like a hill climber  8)  I have everything else on it, carb got a good cleaning and re-set, reeds are in, everything else is literally all in and ready, just waiting on my cylinder, so excited. Pics as soon as I get back home.

On a side note, the clutch seems way hard to pull, like it isn't totally disengaging  ??? Maybe it's just different than what I'm used to, I'll see when I get it running
Title: My next project
Post by: cnrcpla on August 09, 2013, 01:11:18 AM
Pics as promised. Lowered rear fender and everything else in.

Title: My next project
Post by: _X_ on August 09, 2013, 01:18:20 AM
better.
Title: My next project
Post by: cnrcpla on August 12, 2013, 04:47:38 AM
Are keihin carbs stock on these bikes? Just wondering what kind of jetting nightmare I'll be up against soon  ::)
Title: My next project
Post by: Stusmoke on August 12, 2013, 09:13:52 AM
Quote from: cnrcpla on August 09, 2013, 08:11:18 AM
Pics as promised. Lowered rear fender and everything else in.



That looks alot like a 250 pipe. Unless it is a 250, I had it set in my mind as a 125. Can't go back to look either, internets so slow  :-X

You've really done a ripper job. If it is a 125, you'll be able to race both the 125 vintage and 250 vintage. That would be sick.
Title: My next project
Post by: cnrcpla on August 12, 2013, 05:00:58 PM
Thanks man! Its a 250, I almost wish it was a 125 because I've never raced one of my own, but I will some day. How fast is millennium tech's turn around time? Its been almost 2 years since I last sent out a cylinder to them, just wondering if it's still about 2 weeks or so?
Title: My next project
Post by: mj4trax on August 12, 2013, 05:16:05 PM
It's still about two weeks.... at least it was a year and a half ago when I last sent them a cylinder. 
Title: My next project
Post by: cnrcpla on August 12, 2013, 05:17:47 PM
Alright, thanks! I'm so excited to get this thing going
Title: My next project
Post by: cnrcpla on August 13, 2013, 05:05:22 AM
After fighting this bike some more I finally got all the wiring all set. I had to tap the threads in on the stator side of the crank because I guess they got damaged somehow. Got a new shifter put on, this thing is freaky, it bends in like three directions, weirdest shifter I've ever seen  ???
Title: My next project
Post by: cnrcpla on August 25, 2013, 05:34:20 AM
I'll be going to pick up the cylinder and top end kit tomorrow hopefully so I can at least get it running. I'm tying up some loose ends now, I got the chain on and one of the adjuster bolts is seized while the other snapped. So I'll likely be drilling and re-taping those at some point. I'm aiming to get this thing jetted and set up completely before I move in to my dorm and it takes it's new home in the storage unit near the local track.
Title: My next project
Post by: cnrcpla on September 07, 2013, 04:00:35 AM
Apparently their turn around time is closer to a month. They said I'll be getting it back by next friday, but I was told that a week ago too  :) Apparently its taking longer because the dude who had it before me heat seized it, I dunno why that would take an extra week to fix but as long as the bill is still about $200 I wont be complaining...
Title: My next project
Post by: cnrcpla on September 13, 2013, 01:40:46 AM
Got my cylinder in  :) They must have been short on cylinder head studs as they took mine and didn't give them back. Also, who would have thought that a $150 top end kit wouldn't come with gaskets and a wrist pin bearing? Those are on order and I guess maybe there is a slim chance this bike will run before it snows! Maybe...
Title: My next project
Post by: _X_ on September 13, 2013, 01:44:15 AM
Quote from: cnrcpla on September 13, 2013, 08:40:46 AM
Got my cylinder in  :) They must have been short on cylinder head studs as they took mine and didn't give them back. Also, who would have thought that a $150 top end kit wouldn't come with gaskets and a wrist pin bearing? Those are on order and I guess maybe there is a slim chance this bike will run before it snows! Maybe...
HA! stud nazis! how is college cnr?
Title: My next project
Post by: rlaj1004 on September 13, 2013, 01:48:44 AM
snow??? whats snow
Ahhh, winter is coming, good riding weather, sometimes I have to wear pants to the track to stay warm

Nice job on the bike, send it down my way, I will keep it warm this winter for you