KX Riders

Commercially available service offered by members of KXRiders. => OEM-CYCLE => Topic started by: sandblaster on November 04, 2015, 08:07:03 AM

Title: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on November 04, 2015, 08:07:03 AM
Ok... This one is a little older then we typically deal with and we already know that parts are going to be a bit more difficult to find.
But so what, the customer wants it done so we will get something good to ship him :-)

First things first, get her clean..

(http://www.oem-cycle.com/forum/download/file.php?id=3600)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on November 04, 2015, 08:07:34 AM
Right off the bat, this one has a few issues..

(http://www.oem-cycle.com/forum/download/file.php?id=3603)

(http://www.oem-cycle.com/forum/download/file.php?id=3604)

(http://www.oem-cycle.com/forum/download/file.php?id=3605)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on November 04, 2015, 08:08:02 AM
(http://www.oem-cycle.com/forum/download/file.php?id=3606)

(http://www.oem-cycle.com/forum/download/file.php?id=3607)

(http://www.oem-cycle.com/forum/download/file.php?id=3608)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on November 04, 2015, 08:08:53 AM
(http://www.oem-cycle.com/forum/download/file.php?id=3609)

(http://www.oem-cycle.com/forum/download/file.php?id=3611)

Gears are going to be a issue..

(http://www.oem-cycle.com/forum/download/file.php?id=3615)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on November 04, 2015, 08:10:03 AM
(http://www.oem-cycle.com/forum/download/file.php?id=3614)

Uuuuggghhhh!!!

(http://www.oem-cycle.com/forum/download/file.php?id=3696)

In the mean time the customer sent us two additional engines for parts and I bought another engine to help out..

(http://www.oem-cycle.com/forum/download/file.php?id=3704)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on November 04, 2015, 08:11:02 AM
Gotta get parts clean to inspect..

(http://www.oem-cycle.com/forum/download/file.php?id=3705)

Before

(http://www.oem-cycle.com/forum/download/file.php?id=3711)

After

(http://www.oem-cycle.com/forum/download/file.php?id=3712)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on November 04, 2015, 08:11:24 AM
And this just showed up today :-)

(http://www.oem-cycle.com/forum/download/file.php?id=3743)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on November 25, 2015, 03:17:50 AM
Got the crank split and it is now ready for clean up

(http://www.oem-cycle.com/forum/download/file.php?id=3790)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: tobys 2 strokes on November 25, 2015, 06:48:11 AM

way to make use of free usps boxs! :-D
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on November 25, 2015, 06:51:30 AM
OOPS!
Yeah... I told Jason not to do that again  :-o
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on December 09, 2015, 08:37:31 AM
Magnesium looks great vapor blasted

(http://www.oem-cycle.com/forum/download/file.php?id=3805)

But ya gotta paint it or your gonna have issues..

(http://www.oem-cycle.com/forum/download/file.php?id=3806)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: swordcombat on December 09, 2015, 09:43:10 AM
Just wondering , why must magnesium be painted?
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on December 09, 2015, 02:44:30 PM
It will corrode badly...
Here is the high brow explanation;

http://www.totalmateria.com/Article19.htm (http://www.totalmateria.com/Article19.htm)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on December 28, 2015, 12:31:19 PM
Lapping and prepping the cases..

(http://www.oem-cycle.com/forum/download/file.php?id=3825)

Ready for main oil passage porting and entry clean up.

(http://www.oem-cycle.com/forum/download/file.php?id=3826)

(http://www.oem-cycle.com/forum/download/file.php?id=3827)

Title: Re: Building a 1988 Suzuki RM250 engine
Post by: swordcombat on December 29, 2015, 06:47:19 AM
Quote from: sandblaster on December 09, 2015, 02:44:30 PM
It will corrode badly...
Here is the high brow explanation;

http://www.totalmateria.com/Article19.htm (http://www.totalmateria.com/Article19.htm)

Thanks for that as i was just going to sand and polish mine , also what is lapping?
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on December 29, 2015, 11:11:38 AM
Lapping is using a compound that you put between your cases and move the cases back and forth until they seat together in perfection. No gaps equals no air leaks :-)

Mix some Timesaver lapping compound with some trans fluid.
(http://www.oem-cycle.com/forum/download/file.php?id=709)

Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on December 29, 2015, 11:13:01 AM
Even new factory cases should be checked as every KX500 case set I have seen has the same hollow spot as marked in red:

(http://www.oem-cycle.com/forum/download/file.php?id=3298)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on January 06, 2016, 12:30:30 PM
Ready for paint, then assembly

(http://www.oem-cycle.com/forum/download/file.php?id=3838)

(http://www.oem-cycle.com/forum/download/file.php?id=3839)

Still have some port work to do, then clean up and paint..
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on January 10, 2016, 09:57:17 AM
These look good but didn't pass inspection..
Found some wrinkles  :|

(http://www.oem-cycle.com/forum/download/file.php?id=3841)

These are good to go.

(http://www.oem-cycle.com/forum/download/file.php?id=3842)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: swordcombat on January 10, 2016, 10:53:03 AM
Quote from: sandblaster on January 10, 2016, 09:57:17 AM
These look good but didn't pass inspection..
Found some wrinkles  :|

(http://www.oem-cycle.com/forum/download/file.php?id=3841)

These are good to go.

(http://www.oem-cycle.com/forum/download/file.php?id=3842)

Is that powder coat?
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on January 10, 2016, 01:53:30 PM
It is VHT engine paint.
We bake them.
Not as good as powder coating but decent.
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: swordcombat on January 11, 2016, 04:15:35 AM
Quote from: sandblaster on January 10, 2016, 01:53:30 PM
It is VHT engine paint.
We bake them.
Not as good as powder coating but decent.

Looks amazing buddy :-D
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on January 11, 2016, 06:27:31 AM
Thanks!  8-)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: alexander-vmann on January 11, 2016, 08:41:53 AM
no doubt where you should send your engine for service, nice build! :mrgreen:
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: swordcombat on February 16, 2016, 06:40:33 AM
Quote from: sandblaster on January 10, 2016, 01:53:30 PM
It is VHT engine paint.
We bake them.
Not as good as powder coating but decent.

Is it just a case of paint on to bare metal and put in a conventional cooking oven?
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on February 16, 2016, 02:18:54 PM
Degrease and clean the cases to perfection.
Mask where you do not want paint.
Paint.
Let tack up and remove tape.
Place in preheated oven at 200f.
Let bake for an hour.
Remove from oven and allow to cool.

Basic kitchen oven... Don't use your wife or mothers oven  :lol:

(http://www.oem-cycle.com/forum/download/file.php?id=3881)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: swordcombat on February 20, 2016, 01:39:40 AM
Cheers buddy , so you didnt bother using the primer or the lacquer?
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on February 20, 2016, 01:52:11 AM
No, VHT engine paint does not require either.
That being said, I'm always looking for better paint or methods.
I plan to start dabbling with powder coating.
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: swordcombat on February 20, 2016, 09:18:23 AM
Quote from: sandblaster on February 20, 2016, 01:52:11 AM
No, VHT engine paint does not require either.
That being said, I'm always looking for better paint or methods.
I plan to start dabbling with powder coating.

Yes i have just been watching home powder coating on youtube and looks very easy
But i only have one oven that we cook with and i dont want to poison everyone by baking painted stuff in there
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: umberto on February 20, 2016, 10:29:16 AM
Quote from: sandblaster on February 20, 2016, 01:52:11 AM
No, VHT engine paint does not require either.
That being said, I'm always looking for better paint or methods.
I plan to start dabbling with powder coating.
Are you thinking about the Eastwood system or something similar, or are you going for a little more hard core?

http://www.eastwood.com/paints/hotcoat-powder-coating/powder-coat-guns.html (http://www.eastwood.com/paints/hotcoat-powder-coating/powder-coat-guns.html)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: Brute on February 20, 2016, 01:14:32 PM
Looking great! Nice work!
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on February 20, 2016, 04:23:29 PM
You know guys, I have no idea what powder coating system I will go with.
Probably start with something ridiculous and go from there  :-D
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on February 23, 2016, 01:35:49 PM
Getting there

(http://www.oem-cycle.com/forum/download/file.php?id=3912)

(http://www.oem-cycle.com/forum/download/file.php?id=3911)

(http://www.oem-cycle.com/forum/download/file.php?id=3913)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on February 24, 2016, 11:56:12 AM
(http://www.oem-cycle.com/forum/download/file.php?id=3918)

(http://www.oem-cycle.com/forum/download/file.php?id=3920)

(http://www.oem-cycle.com/forum/download/file.php?id=3923)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on February 25, 2016, 03:56:52 AM
(http://www.oem-cycle.com/forum/download/file.php?id=3939)

(http://www.oem-cycle.com/forum/download/file.php?id=3942)

(http://www.oem-cycle.com/forum/download/file.php?id=3940)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: Foxx4Beaver on February 25, 2016, 05:17:12 AM
that blue looks so nice!
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on February 26, 2016, 01:19:15 PM
Yeah.... It almost makes me wish..... Nah!!!

(http://www.oem-cycle.com/forum/download/file.php?id=3944)

(http://www.oem-cycle.com/forum/download/file.php?id=3954)

(http://www.oem-cycle.com/forum/download/file.php?id=3955)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: Foxx4Beaver on February 26, 2016, 01:44:10 PM
I've never had the opportunity to open up a Suzuki....
what are your thoughts on their exhaust valve design, compared to the Kawie?...and did they change the design much after '88?
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on February 26, 2016, 02:14:03 PM
Well.... Suzuki changed theirs several times after this and too a greater degree then Kawi , so I guess they weren't too happy with what they did.
I think they are both overly complicated but would take the Kawi over the Suzi.
I like KTM's design the best but feel there is room for improvement.
Then again I haven't looked at their latest versions..
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: RoostDaddy on February 26, 2016, 02:24:12 PM
The nice thing about these power valves are that you can adjust the tension external as to suit rider style and/or conditions. Unlike the kaws where you have to pull the cover to adjust.
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on February 26, 2016, 02:25:04 PM
Quote from: RoostDaddy on February 26, 2016, 02:24:12 PM
The nice thing about these power valves are that you can adjust the tension external as to suit rider style and/or conditions. Unlike the kaws where you have to pull the cover to adjust.

Good point
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: Foxx4Beaver on February 26, 2016, 09:35:33 PM
Seems it took a few of the manufacturers several years to find a set-up they were happy with in that era...Honda changed theirs a few times too.   
I haven't done anything with the KTM's either, so I can't comment on them...between the Yamaha and Honda, I still like the Kawie design the best also...and they're the only ones that weren't drastically changed over 20 years.
One of the reasons I switched to Kawie from Honda in '88, was the poor exhaust valve design...entirely way too many un-necessary parts that just caused more headaches than benefits.
Being able to adjust the tension on a whim is a "plus"...too bad Kawie never did that.

We gonna get a chance to see and hear this Suzuki run when she's done? :-)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on February 27, 2016, 06:52:41 AM
Quote from: Foxx4Beaver on February 26, 2016, 09:35:33 PM

We gonna get a chance to see and hear this Suzuki run when she's done? :-)

Unfortunately not unless the customer want's to send us some vids or pics.
All we have is the engine...  :-)
I wish he let us build the entire bike... But you never know what doors may open up with a awesome build.
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: Foxx4Beaver on February 27, 2016, 06:59:15 AM
Request he send you some pics when he completes it.
I hope he makes the roller/chassis look as new as that motor!...so it matches it's luster. :-)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: sandblaster on February 27, 2016, 08:03:12 AM
We have told him how... I guess we will see what he does  8-)
Title: Re: Building a 1988 Suzuki RM250 engine
Post by: Foxx4Beaver on February 27, 2016, 08:41:04 AM
Quote from: sandblaster on February 27, 2016, 08:03:12 AM
We have told him how... I guess we will see what he does  8-)

cool...that could be a sharp lookin Bob Hannah replica.