Vibration and flywheel freeplay - rm250

[Dirt Addict]

I have a 2005 rm250. It has an unusual amount of vibration. I pulled the ignition cover and found both fore and aft and in n out play on the flywheel. I'm guessing it's time for a rebuild. I'm a decent garage mechanic. Is a bottom end rebuild doable or is it for the experts?
I'm not even sure what I would need to replace? Crank bearings, crank? Seals?
Should I just fork over the dough for someone else to do it?

[_X_]

if racer x can do it any one can do it. ( even 2t institute) just get the special tools and a manual and your golden. remember no pot or beer before or during instalation. crystal meth ok.

[cnrcpla]

You can do it, just get hold of a fly wheel puller, and preferably a case splitter, but I think you can rig one up. You will most likely need new crank bearings/seals, and maybe big end conrod bearings while you have it split open to save the hassle of doing it again down the road. Also, gaskets are a must.

[Dirt Addict]

anyone care to post up a list of parts I should order? I will most likely get a splitter and bearing puller.....

[_X_]

addict, your manuel will list the parts you need. get a manuel. oh yeah may i add not rocket science.

[SachsGS]

Pull your cylinder, remove flywheel, primary drive gear, countershaft sprocket and separate cases. The clutch and tranny can remain in one case half.

[2T Institute]

anyone care to post up a list of parts I should order? I will most likely get a splitter and bearing puller.....

A length of aluminium and a rattle gun is also needed for the primary drive. You might as well replace all the seals and bearings at the same time. Heat the cases to get the bearings out and new ones in.

[Dirt Addict]

I have the flywheel puller and an impact wrench (is that what you mean by ''rattle gun''). I have the manual too. So I'm gonna clear off the work bench and give this a try. No interest in pot or more than 1 beer. I'm more of a caffiene fiend.
So can I leave the whole clutch intact? What about the kick start gear?
Standby for lots of questions......

[_X_]

you might get away with it, sachs says its posible,but when you do split them your tranny will be exposed. just follow the steps in the manual before you actually start work. this will give an overview of the work to be done.

[evo550]

Have you checked the tension on the flywheel nut itself ? A loose flywheel could give you all of those symptons.
Is it an external or internal flywheel ? How much play are we talking about ?

[ford832]

A loose flywheel would give you more of a "rocking" motion as opposed to the movement he described.

[SachsGS]

You can leave the kickstart/clutch intact.

With a loose flywheel the first time the engine fires it will shear the flywheel key.

[eprovenzano]

A bottom end rebuild is not as difficult as it seems.  Yes take your time, do a lot of reading, and video review.  If you think about it, its a mechanical machine, it's just nuts and bolts.  Follow the manual and you will be fine.  I have my son's KTM 250F which I've split the cases and removed the crank  I'm waiting on the parts to arrive so we begin the rebuild.  Yes there are a few specialty tools needed like a flywheel puller.  I took the engine to a local shop and they pulled the flywheel for $5.00  I was able to split the cases without a case splitter. 

If you have any issues, or concerns let us know, we are here to help you.

[Dirt Addict]

thanks. I will keep you guys updated.....

[TMKIWI]

your manuel will list the parts you need. get a manuel.

Who is this manuel guy.?
Is he any good and can I get 1 as well.