Vibration and flywheel freeplay - rm250

[_X_]

you got a problem with my spelling kiwi? HA! you can see my training video in the open forum, i'm a bad dude.

[TMKIWI]

Don't have a problem with your spelling.
Just thought you said you had your own mexican and wanted to know where to get one.

[evo550]

I thought it was the spanish waiter from Faulty Towers...

[_X_]

no, every time i aquire a mexican they always seem to runaway to the nearby stables where thee seek amnisty. the last one was named manuel...i'm going to miss that little guy. so if you are quick enough to elude the stable owners may aquire one there. hope this helps. evo, we used to get faulty towers here in the states, good show.

[Dirt Addict]

what is the best way to remove the main bearings? Heat the cases up on the outside?

[cnrcpla]

I heard somewhere but never tried this, you put the cases in the oven facing down and heat them up and the bearings will fall right out. I don't know what temperature or if this even works, but search around on google, I'm sure you'll find something, or another member with more experience with this will know a better trick.

[Dirt Addict]

Does anyone have pointers on installing oil seals for the crank bearings?
Before or after installing the bearings?
From the inside of the cases or the outside?

[_X_]

bearings then seals, install seals from outside. i use a bearing/seal driver. if you turn old seals over you could use them to drive the new seals in.

[2T Institute]

Heat the cases up with a heat gun or stick in the oven and heat to 160deg C Freeze bearings and they will drop straight in. Fill the V in the seal with grease before installing.

[Dirt Addict]

I got the bearings in. The left side was easy. It practically dropped in. The right, not so much. I got it 1/2 way in and it locked up. I put it in the oven at 350* f for an hour  . After that I was able to tap it in using the old bearing as a driver. It took quite a few taps. The seals were the same.... left side easy, right was difficult. I'm not 100% happy with the right side install. It looks ok but it left my a little uncertain.
I did the install with the trans still in. some gears slipped off. I re-installed using the manual, and again, I hope it's right. I rearranged them about 100 times till it matched the diagram as close as possible.....
I'm waiting for the crank to get here to finish the job.

[evo550]

If the left bearing was quite easy to fit, I would check to see if the movement wasn't caused by a worn bearing surface on the case.
Bolt up cases with old crank (no trans if you like) and see if any play there.

[2T Institute]

To check the gearbox put the case halves back together,put the gear lever on the selector shaft, spin the clutch shaft backwards and use the lever to change gears

[Dirt Addict]

holy cow Batman! cases are back together and the tranny shifts!
I still need to piece everything else back on, but the scary part is done. Everything seems nice and solid.
I will bolt it back together over the weekend. I found a broken engine mount while pulling the motor. I will strip the frame, get it welded and maybe powder coated while I'm at it.
Thanks to everyone who helped.

[Dirt Addict]

I took my frame to a welder buddy to get the broken motor mount fixed. We were looking at the bare frame and welds. Has anyone noticed how rough the welds are? They look almost frankenstein. I was thinking that the frame may have been previously repaired but my buddy pointed out other welds all over the bike that were rough. And the amount of slag painted over was surprising too. Is this common with suzuki?

[2T Institute]

Most steel/CrMo were robotic MIG welded whereas later aluminium frames are hand welded which you will be lucky to even spot the slightest defect