Inside a Neglected Engine | RM250 Rebuild 4

hey guys got a pretty exciting day planned out here in the shop we will be tearing into the rm250 engine this is for the 2001 or actually 2002 as we've come to find out arm 250 that'll be building up on the channel over the next few months and then when I'm all finished up with it I'll be doing a giveaway with it so if you want to enter that giveaway hit the link down below so back here we have the engine for it top ends already off of it but judging by the condition of the rest of the parts back here we're probably in for some surprises with the engine so why don't we tear into it so I bought this bike with the top end already off the engine and I'm guessing there's something going on haven't really had the chance to take a look at it yet but let's take a peek so the piston the Weis go there was definitely some wear and damage going on here you can see that ring land kind of messed up there's a ring stuck in there cylinder head tiny bit of pitting nothing too crazy now this is what I am worried about scraped up four doesn't actually look too bad let me get some light on it a little bit of corrosion and rust in there maybe some scrapes right there near the intake port wow it's actually not too terrible oh boy we do have a little bit of wear above the exhaust port oh what the heck is going on here there's some chipping right there on the edge of the sleeve I wonder what that could be from actually it's probably from the ring breaking and then getting smashed between the head and the cylinder if there was anything on the head there so the head goes on like that so it would be around here yep there's some chipping away right there but I think the head is fine cylinder is going to need some repair we're gonna have to send this one out to you either get received replated or we'll have to figure out exactly what we're gonna do with that but we have a whole bottom end to tear apart so let's rip into this right now so I'm gonna turn into the flywheel side first usually there's not much in the way of surprises under here found our first damaged part that didn't take too long got some jb weld inside the cover here go ahead and pop this flywheel nut off and that's kind of jacked up so I'm just gonna hold the rod with my hand give this thing a crank man this day is just starting out sweet someone really hacked up that nut alright we're two for two nuts trash well covers trash now we've got a flywheel puller this just reversed threads into the flywheel crank er down make sure it's as far down as you can get you don't want to rip the threads off of there give it a little zap with the impact off she goes the flywheel looks good little crusty on the outside but at least the magnets aren't damaged now we've got a couple bolts for these data it's always a good idea to kind of eyeball where the stator is that before you pull it apart kind of see down here there's marking you line up with the crank case looks like that's dead-on so when you put it back together we'll just refer to that alright stated it looks fine a couple little scrapes but that's a big relief pull the lifter arm out I'm gonna pull off this front sprocket before I flip the engine over and start on the clipped side so that's it for the ignition side let's go after the clutch side let's go ahead and check out this water pump first probably not a whole lot we're gonna find in here all that looks good you can pop off this water pump impeller some bikes it is reversed thread like this one so you want to be really careful not to strip this thing out or mess up the head on it by going the wrong way now we've got the clutch cover or outer clutch cover and when I pull it all these bolts off I like to just separate them and put them in a blable ziplock bags we might have a Hinson basket in here that would be a huge plus I see some some black clutch fingers but take a look at what's inside this clutch cover looks like metal bits that might not be good no it doesn't really feel like gritty sometimes these covers me a little love tap with a rubber mallet there we go there's a dowel up in this corner that was pretty crusty here we go see what we find in here so like I said there's this little locating pin here that gets crusty over time and kind of makes these covers thick so very important to replace those that way everything this goes together smoothly we've got a couple more shavings here I'm not really sure what that is at this point the water pump shaft just pops right out so when you're pulling apart an engine I would recommend just pulling everything apart on it to inspect it obviously if you're gonna split the cases you might as well pull everything apart just to double-check you don't want to put something back together and you know realize you missed something so this inner clutch cover looks pretty good although I did notice on this little nub here I hope you guys can see that there's some scraping and wear on it and then s'more scratches right here so it seems like something was bouncing around in this engine at some point so over here we have the power valve governor shaft this just pops out now before I tear into the clutch I'm gonna loosen up the bolt for the primary gear now on some bikes these are a right hand thread I believe on this one it is a regular thread so go left oh that one wasn't that tight now I'm really curious to check out this clutch it looks pretty fresh judging by the plates in the basket but we'll see once we're inside you want to loosen up these pressure plate bolts evenly so just like a wheel in the car go ahead and pop this thing up so you only want to pull the pressure plate off right now that way we still can pull off the internet there and we've got the push rod that goes through the center so right here there is part of the washer that you bend up to hold that nut in place so we're gonna take a screwdriver hammer and knock that back down and then for this nut you need a big-ass socket for it looks like a 30 mil and then you can just give her the berries and now the entire clutch just slides right off I've got a bushing and a roller bearing underneath all right let's pull apart this clutch and inspect it so we do have a hinted basket sweet that is a big plus these are a billet material so they'll last much longer and it appears like the fingers are in pretty good shape a little bit of notching you can barely fill that with your fingers so definitely a reusable basket and now for the inner hub and plates separate these see if there's any notching here in the splines no that all feels pretty good nothing on the surface either sweet all these plates are stuck together but they actually look pretty fresh I don't see any heat markings or heat coloring on the steels fibers looks like they got plenty meat left on them so this build is more of a budget type project so I'm hoping to reuse as many of these parts as possible so looks like I'm in luck with a clutch now the primary gear off the crank pops off mmm looks like the end of the crank has some hammering on it let me zoom in and show you yeah not too good I don't think that'll affect the usability of the crank though we'll see what's to be diggin further again we can see more of this kind of crummy looking oil it's got all these bits in there but they're not greedy I'm kind of thinking that's just really sludgy oil from the other side the engine you can push out the ship shaft slides right out on these shafts what to look for is it being bent that one looks nice and straight and then also damaged splines on the end all right we've got a couple little things pop up here these screws that hold the gear shift mechanism our little jacked up little stripped out and then the post for the shift shaft return spring was also loose you can see that thing is just about to thread out on its own I had a little heads-up for my buddy Josh he told me about these things comin loose gave me a heads up on it so yeah Josh you all right now we got to figure out how we're gonna get these stripped out screws out of here so we're gonna go at it with this impact screwdriver got a nice tip on the end here that'll fit good in there and we'll listen have to cross our fingers saved us from a lot of hassle having to drill up that screw now with these gearshift mechanisms there's a lot of moving pieces a lot of pins and springs so you want to be really careful when you're pulling it out that way you don't lose them it also falls apart you're not going really have a good idea of how it went together so just pull it out nice and smooth pull off the plate here and I kind of show you what I was talking about there's a pole on the end of it you've got a pin and that inside of that hole there there is a spring so same on both sides now we have a few more pieces with the shift assembly little tensioner arm and the center pin as well as this outer piece now the center pin is held in by red loctite which is really strong stuff sometimes you got to heat them up to loosen them up but we're gonna see what can do with an impact doesn't even look like there was much Loctite on there just wiggle this thing free now the tensioner arm is held in by a single bolt and spring you might even want to release that tension before you pull that bolt out holy crap this oil is so sludgy now for the power valve shaft I like to use an impact screwdriver on this as well so I'm going to swap out the number three bit for the number two this one fits a little better in there oh yeah yeah these impact screwdrivers are the bomb you guys gotta go pick one up I will have these things linked down below in case you guys don't have one they are a lifesaver I'm gonna fish this out of there oh that looks good and then for the kickstart assembly let's pop off the idler gear you've got a washer on top of there and then the actual kickstart shaft lift it straight up there's a spring and a gear underneath cool that looks good oh shoot just notice that we got a busted-up case here thankfully that's not in the structure at all I don't think that'll be a huge problem I should be able to just kind of grind that down smooth it out and we'll be good there's also a bunch of scrapes up here too now some of you guys might have heard I am putting $1,000 up for grabs in a bike bell contest being held this winter it's open to anyone and everyone any motorcycles welcome it could be any age you can live anywhere in the world so what we're going for here is a biggest transformation so you have until April 15th to get your bikes done so in four months from now you could have a completely fresh bike and a couple extra hundred dollars in your pocket so it's a win-win if you want more info hit the link down below I got a cool little clip for you guys check this out that was done by my buddy Nick he does a bunch of stop-motion animation with dirt bikes actually so he'll take apart an engine or suspension and it's really cool-looking it just looks like it falls apart on its own so if you want to check out its work go down below and hit the link all right so at this point we are ready to split cases and just got some bolts to pull off on this side let's go ahead and spin these out right now all right this is a sketchy part so if Suzuki's are notorious for soft transmissions so the gears like to eat away and just wear out quickly so as soon as we split the cases we'll know whether or not this transmission is good to go now before I give the case splitter a shot I always like to tap on the crank with a soft hammer yeah this thing is kind of crusty we're gonna have to use a splitter all right so to set up the splitter way the engine flat slide the splitter over and you want these three arms spread out evenly so something like that snug them down make sure you got plenty of thread in those cases and then you want all three of these nuts cinch down evenly so I like to leave about I don't know a quarter inch above the splitter and then just get after it with the impact after you apply some torque look for the case splitting it all make sure it goes evenly but it helps to give the puller a little tap with a hammer we're splittin after a couple zaps with the impact just look around make sure it's splitting evenly like we're good sometimes this countershaft can be a little stuck in there now we're just gonna be really careful pulling this thing off of here we want to keep everything together as much as possible and you're gonna just weasel it right off and then as soon as I pull this side crankcase off like to check inside for any washers this washer was on the counter shaft put that back on just so we don't misplace it alright now we can get to work pulling apart the transmission I'm gonna pull out the pins for the shift Forks you want to keep these all together got one more on this side pop the drum out of there get this other fork out of there as well and now both shafts and all the gears will just pop right out so have your hand on the other side of the crankcase give it a little push kind of tilt the crankcase down that way all the gears stay on the shaft I'm really gonna have to get up close and inspect this thing I want to make sure all these gears are in good shape and then all that's left is the crankshaft sometimes these just come right out with little help with a rubber mallet I was a little more than a little help but did the trick that looks like we have an OEM crank which is good now with the engine completely apart them to go through inspect everything gonna pull out all the bearings I will be replacing all the bearings and seals it only makes sense to do that while you have everything apart so I'll go through these things gear by gear looking at the face of the gear also the top edge make sure that's not chipped also check out the little transfer nubs here or the docks in between it's pretty common for those to get rounded off surprisingly this thing actually looks really good so far I don't see any reason why I'd need to replace anything it's gonna do the same thing on the main shaft here oh I do see a little bit of wear on these transfer pegs yeah I might need to pull these apart and either file them or replace that gear let me show you guys what I'm talking about here so these four pegs have a little bit of a rounded edge on each one I do see a little nick in the gear on this tooth right here just on the face of it so everything on this shaft looks pretty good besides that one gear these little Nick's here just aren't severe enough to worry about that's fairly normal but for this gear right here I'm gonna do some filing or if it's really cheap I'm just gonna replace it now a couple more things to inspect are the ShipWorks you want to look at the tips of them as well as the top edge they're all scraped up probably want to replace them both of these look good I'm also gonna check out the shift drum it does happen from time to time I'll see it once in a while where they'll be a little chip in the the grooves here this one looks good okay so she's all stripped down we've got quite a bit of work ahead of us here got some stuff to fix up or replace so the cylinder will need either a Reese leave will reap late I figured that out see what people think about it the piston is trash crankshaft that is an OEM Suzuki crank those are pretty solid I might send it out to have it rebuilt with a new rod and rod bearings if you guys have any recommendations there leave them down below we'll need to replace that worn out gear on the tranny let's see the right crankcase I think we should be able to smooth that out call it good that isn't gonna hurt anything with that chip there and then get a new ignition cover I think that's pretty much it so obviously new bearings new seals gaskets and just wear items now on the bright side of things the clutch is actually in really good shape I should be able to reuse the basket the hubs plates I need to measure those out to make certain of that clutch cover was good water pump is solid so all in all not too bad come to think of it I do need to pull apart this power valve see what kind of shape that's in see if I need to replace anything there so let's go ahead and do that right now sometimes these power valves can have quite a lot of pieces to them so make sure you take some pictures or have a video as you're taking it apart there's a little nick on the edge of this valve or like more like where should be able to smooth that out and call it good though it's very minor yeah that's really not deep enough to worry about we should be fine and one last thing let's take a look at these reeds not too bad not too bad yeah nothing chipped up or cracked they're surprisingly okay now I can say that the cylinder is completely bare now we just got to figure out exactly what we're gonna do with it so like I was showing you guys earlier there's a good sized chunk out of the sleeve right there so either we're gonna need a sleeve or I really don't know what else we're gonna do there I don't think a replate would fix that all right so I've got a mess on my hands I need to clean up here and once I get that tidied up I'm a transition back over to this stuff and just kind of break things down a little bit further after some more teardown sad to say we have a few more casualties here swingarm is pretty frickin beat-up you can see back here that is not good those things are all Waller doubt both sides and there's something else going on here - oh the mount for the break carrier that thing's all chipped up and worn away so I'm afraid this swing arm it is not going to be able to be reused so I'll have to find a different one and then over here we've got some more busted up stuff the bar mounts had some janky bolts in here these things are all bent up look how floppy this one is that's pretty bad and the damper rubbers those things are pretty hammered and then we've just got regular wear and tear items chance sprockets chain guides cables grips bent lever so the parts list continues to grow hopefully we can find a single oh my Nev effort cheap that would be the best option actually one more issue over here I was pulling some stuff off the rear wheel and notice all these spokes are really loose and there are a couple broken ones and of course the bearings are pretty shot to you now at this point I have a pretty good idea of everything that's busted up it needs to be replaced I've got a big long list of parts here so it is time to start submitting some orders but I think right now I'm going to focus on the engine stuff first so send off the crank and cylinder for rebuild order up everything I need for that and then I can move to the suspension parts stuff for the wheels all the bearings and brake parts I hope you guys enjoy this one I had a ton of fun tearing down this engine kind of going through and seeing what's all busted up but I'll be seeing you all in some future videos where I'll be doing some parts cleaning replacement of bearings and seals and some coating so lots of great stuff on the way and until then keep it Prime

Channel: Cameron Niemela

Views: 401,280

Rating: 4.9338369 out of 5

Keywords: Dirt Bike, Motorcycle, 2 Stroke, Two Stroke, Dirt Bike Build, Cameron Niemela, Niemela, Dirt Bike Repair, Two Stroke Build, Two Stroke Rebuild, Dirt Bike Rebuild, Dirt Bike Project, Suzuki, RM250, Suzuki RM250, RM250 Project, 2001 RM250, RM250 Build, Niemela RM250, Team Pryme, RM250 Rebuild, Fixing RM250, Dirt Bike Giveaway, Inside a Neglected Engine, engine disassembly, Damaged Engine, Blown Engine, RM250 Engine, Engine Rebuild, 2 Stroke Engine, Two Stroke Engine

Id: 3O7BtQnN5Q0

Length: 26min 47sec (1607 seconds)

Published: Sun Dec 22 2019