2002 Rm 250 cylinder issue

[suzook241]

Hey guys, Looking for some advice and maybe some help if anyone has something laying around.  Recently purchased an 02 rm 250 as a project bike.  Got the thing at a decent price knowing it was going to need a few things.

I tore the bike down and split the cases to have a look around and make sure all was well inside,  well aside from needing new main bearings everything in the bottom end area looks great!  Overall the whole bike looked good, not alot of time on the bike total, however it was forgotten about at times and needs some TLC.

Enough of the lead up, the problem I face is that sometime in its life time, the piston gernaded...  taking out the head and the cylinder.  Guy before me had the cylinder sleeved.....  yeah I know not the best choice, but upon having it sleeved the people doing it must of been drunk or something because the sleeve is off a tad when it was put in.  To correct the problem they ground down the sleeve around the port holes to make everything line up.....  It isn't the best looking job in the word but I guess it gets the job done.  However me being the way I am i can't stand having something that isn't right.  The question I have is, what are my options???  i know since it is sleeved im stuck with the sleeve crap, or get a new cylinder...  can I have someone put in a stock bore sleeve and atleast do a better job than the last guy???

Any way, any advice or help is greatly appreciated,  if any one has a 02 cylinder laying around that needs re plated I would gladly take it off your hands, or even a cylinder that is good,  Id rather not have a sleeved cylinder...

[TMKIWI]

Depending on how much you want to spend.
Mr Cycles has new cylinder kits for $599. Normal retail is $799.
You can get the sleeve pressed out and a new 1 fitted but I would try and get another.
Check evil bay.

[eprovenzano]

I was thinking the same thing.  1st I would check about getting your cylinder fixed properly, 2nd watch flea bay for a replacement, and 3rd look for a new one.  MR cycles always seem to have lower prices on OEM parts.

Here's an option on flea bay, $250
http://www.ebay.com/itm/SUZUKI-RM250-RM-250-Replated-Cylinder-Exchange-2002-/130627177941?pt=Motorcycles_Parts_Accessories&hash=item1e69fc8dd5&vxp=mtr

[Premixed]

1. find out all the compatible cylinder years for your bike

2. Google all the nikasil platers in the country, and check and see if they have any work that someone didnt pick up. 

You could potentially get a fresh jug for the price of the nikasil work if your timing is right. If I had a big 4 Japanese 250, this is what i'd have done, but I have a KTM.

[SachsGS]

You might be able to press the sleeve out and get the bore plated to end up with a RM300.

[Premixed]

are they sleeved?  I think these are just aluminum with a nikasil coating.

[suzook241]

Stock Rm cylinders (atleast the later years) are coated aluminum cylinders.  My cylinder on this bike has  a sleeve because the guy before had a piston gernade.  It must have taken out the cylinder and he had it sleeved.  Def not my first choice but it is what it is.

I called Eric Gorr,  He said I can send it to him and he can fix it up.  But to clarify it just looks as tho the sleeve was twisted just ever so slightly when it was pressed in.  It is just off a tad.  They ground a few of the port holes out to make everything look ok but to me being the neat freak I am, I just think it looks like shit.... I am not sure if it will affect the performance of the bike at all.  it ran good before I tore it down to redo everything and build it back up, so im unsure if it is worth fixing or not.  This is going to be a woods bike for me, and the cylinder is already at its max bore with cylinder at a 68.50mm

So at the moment Im unsure what to do, i can post pictures if anyone is interested in seeing what I am talking about?  let me know Id be glad to show

[2T Institute]

Resleeved cylinders on orginaly nicasil cylinder will ping it's head off every time it gets hot. Getting a used cylinder is good option and the exchange cylinder looks like awesome value.
It is impossible to stop the sleeve twisting when it is pressed in, the way to do it is leave the port windows under size and finish off to the duct after installation.

Not sure if the years are interchangable, but Alpha Sports shows different p/n for 02 and 05 but the cylinders look very similar.

http://www.ebay.com/itm/05-suzuki-rm-250-cylinder-new-/150809518979?hash=item231cf2a383&item=150809518979&pt=Motorcycles_Parts_Accessories&vxp=mtr

[Premixed]

i hate to do this, but don't send it to Gorr if you want to see it back in reasonable time.  He took 3.5 months on Chuck's and he doesn't even know where mine is after a month.  "millenium must still have it."

[suzook241]

Resleeved cylinders on orginaly nicasil cylinder will ping it's head off every time it gets hot. Getting a used cylinder is good option and the exchange cylinder looks like awesome value.
It is impossible to stop the sleeve twisting when it is pressed in, the way to do it is leave the port windows under size and finish off to the duct after installation.

Not sure if the years are interchangable, but Alpha Sports shows different p/n for 02 and 05 but the cylinders look very similar.

http://www.ebay.com/itm/05-suzuki-rm-250-cylinder-new-/150809518979?hash=item231cf2a383&item=150809518979&pt=Motorcycles_Parts_Accessories&vxp=mtr

So your saying depending on the severity the cylinder is prob more than likely ok?  I took some time today and cleaned they cylinder up good and take a closer look, the sleeve twisted just a tad, like maybe 3 mm or less, im not experienced with sleeves so this is new to me.   The ports aren't ground to perfection.  They are opened up enough to match cylinder but it isn't the best job.



Thanks for the info about eric,   if you guys think im probably alright, ill run it as is...