Here's the final (Part 7) reel of the 1996 #RM250 reassembly series. The full build video is now live on my YouTube page (link in bio). #suzuki #2stroke #dirtbike
Here is Part 6 of the 1996 #RM250 reassembly. I have one more reassembly reel to post after this before the final reveal. Thanks for watching.
#suzuki #2stroke #dirtbike #restoration
Here's Part 5 of the 1996 #RM250 reassembly series. I had given up on posting to FB because my posts were getting no engagement. But suddenly a few weeks ago I guess someone in mountain view flipped the engagement switch. 🤷
I have a couple more reassembly reels to post and then comes the reveal.
#suzuki #dirtbike #2stroke
Here's part 4 of the 1996 #RM250 reassembly. Here I finish installing the controls, cables, and rear brake components. Both the oem clutch and throttle cables are discontinued, but I was able to find a nos clutch cable on ebay (notice the black zinc plating on the adjuster nuts). I'm still looking for an oem throttle cable... the aftermarket is just a placeholder :)
#suzuki #2stroke #dirtbikes #restoration
I replaced my grooved out OEM clutch basket as part of this 1996 #RM250 #2stroke restoration with a new one from @wisecopistoninc . The clutch plates were toast too. When I bought the bike the seller threw in a new DCR (@dennycyclesracing ) clutch pack, so that's what I used, with new OEM clutch springs. The inner clutch basket was still in good shape so I reused that, as well as the @fmf73 pressure plate (which I guess was something they used to make in the '90s? #Suzuki #dirtbike
I went through every detail on this 1996 #RM250 #2stroke engine. I tore it down completely, cleaned and polished the engine cases and cylinder, repainted the magnesium side covers, installed all new OEM bearings, rebuilt and balanced the OEM crankshaft with a @prox_racing_parts connecting rod, installed a new @wisecopistoninc clutch basket and piston, secured it all together with a @bolt_motorcycle_hardware engine pack, and I got a new kick starter for it. Even the swingarm pivot bolt mounting sleeves I replated. Watch till the end to see cool before and after shots. And check out my YouTube channel (link in bio) for full video. #suzuki #dirtbike
Two years ago I rebuilt this 1995 #KX250 . Now that I'm on social media 🙄 I'm going to be "documenting the build" (making these reels from old footage) for those of you who didn't follow it on YT. Here's Part 1, the teardown! The bike was clapped out but had a good foundation for a restoration. The engine was in good shape, other than a busted inner and outer clutch cover. The frame needed just a little work (subframe was mostly straight). It was missing a front brake caliper (??), needed new wheels, swingarm was okay-ish, anyways... more to come. I have so much footage to edit (from this, and current... and future project(s), but so little free time...) Thank you for tuning in. #kawasaki #2stroke #dirtbike #restoration
A common problem with these old brake pedals that use copper bushings is they wear out from use and create excessive play. In the case of my 1996 #rm250 it wore out quicker than others because the kick starter was also badly worn and rubbed against it with each kick. Thankfully the fix is easy... just replace the bushing, and also, in my case, the tip of the pedal (which are still available as OEM items). I later bought a second pedal which is in worse shape (the stopper where the bolt goes in on the bottom broke off) from ebay which I'll work on (for fun?) over the summer, hopefully... #suzuki #2stroke #dirtbike #restoration
Those who are following closely may remember I replated the shift lever tip & return spring, and fabricated a new pin from a stainless steel bolt as part of my 1996 #RM250 restoration. I later realized (when reassembling the bike) that the splines were too worn to clamp down tightly on the shift shaft. I did happen to have a new OEM shift lever on hand, but I wanted to save the original one by welding on a new splined end from a cheap aftermarket lever, and it worked 🙌. #suzuki #2stroke #dirtbike #aluminumwelding
Here I refurbish the swingarm and linkage from my 1996 #RM250 . There were the typical gouges & deep scratches you find in an old swingarm. I removed most of those with a 3m silicon carbide wheel on a drill and some sanding by hand. It also had a couple holes drilled into the left side of the swingarm that I assume were there because someone tried installing a kickstand, maybe? I filled those in using a 4043 aluminum welding rod and it came out great, except when I decided to anodize it, which left dark spots there. I drilled them back out and redid it with a 5356 rod, and they came out much nicer after anodizing. The replica "250" graphics are from Evo-MX, which make the coolest replica graphics you can get for old #2stroke dirt bikes. In the end I was happy with the result. #suzuki #dirtbike #restoration #aluminumwelding
Here's part 3 of 1996 #rm250 reassembly series of shorts. Here I install the radiator louvers, triple clamps, forks, wheels, bars, and some controls. More coming soon. #suzuki #2stroke #dirtbike #rebuild
This was a fun project restoring these gouged aluminum seat mounts for my 1996 #rm250 . I finished building the seat with a new seat foam from Ceet Racing, and wrapped it in the coolest "high grip" '90s-style textured seat cover from @evomxgraphics . #suzuki #2stroke #dirtbike #aluminumwelding #restoration
My 1996 #RM250 came with some janky aftermarket stator which I tossed. I bought a used OEM one on ebay which just needed a new rubber grommet. I could only find a grommet for a CR250 from the same era, and it was thankfully a perfect fit. #Suzuki #2stroke #dirtbike #restoration
This video is for the people who have been asking how I clean my aluminum parts... cast aluminum in particular. Don't use "aluminum brightener" (sulferic acid) because it actually has the opposite effect: it reacts with the impurities in cast aluminum and leaves it dark and dull (some come out better/worse than others). Plus it wreaks havoc on your skin. And if you use it on anodized parts it'll destroy the anodizing. And it's totally unnecessary. Clean the parts first with a degreaser, like Simple Green or another brand, and you can use an ultrasonic cleaner with some PH-neutral detergent like Palmolive or aircraft cleaner (Simple Green brand) if you want to loosen the encrusted stuff. And then all you need is a dremel and some scotchbrite pads to make #diy polishing wheels. I cut them in 2" x 2" squares and cut off the corners to round them off (no need to be perfect -- they self-true). I attach them to the mandrels that come with the little cutoff wheels from Harbor Freight. And then you can use a small piece of leftover scotchbrite pad with a stainless steel or brass (stainless steel works better b/c it's stiffer and the pad sticks to it better) brush to get to all the nooks and crannies in your engine cases or wheel hubs, etc... Of course it's never going to be as nice as using a vapor hone which we all dream of having, but I think it's the next best option. #aluminumcleaning #aluminumpolishing #restoration In the video I'm working on engine parts and my carb as part of my #suzuki #rm250 #dirtbike restoration.
In the end I wasn't able to reuse this shift lever on my 1996 #rm250 because the splines were too badly worn, but it was a fun little project anyways. #suzuki #2stroke #dirtbikes
I revalved my 1996 #RM250 shock with a @racetechinc Gold Valve and put in a lighter spring. Cleaned up all the parts and coated the body bronze. #suzuki #2stroke #dirtbikes #restoration #suspension
2002 Honda CR250 Rebuild
Here's a longer version of the CR250 rebuild reel I posted last week.
The gas tank on my 1996 #RM250 had a broken/stuck bolt on one side, and a missing threaded insert on the other. I soaked the broken/stuck bolt in penetrating oil for 2 weeks before trying to extract it, but that stuff never works for me. I got it out using reverse drill bits. Then I fabricated a threaded insert for the other side, and then sanded and polished the tank. I always melt plastic when I try to polish it. But this time I thought filling the tank with water would keep it cool, and it worked. The awesome replica shroud graphics are from @evomxgraphics . #suzuki #2stroke #dirtbike #restorationvideos
I rebuilt these forks as part of my #RM250 restoration using @racetechinc Gold Valves. The outer tubes were in rough shape. I stripped off the anodizing, removed the lugs, polished them and anodized them gold to match the rims. Don't they look brand new now? #suzuki #2stroke #dirtbikes
I was able to save this rare @answerracing carbon fiber CF.2 #2stroke silencer that came on my 1996 #RM250 I just finished restoring. @evomxgraphics did an unbelievable job replicating the logo (along with all the graphics for the bike + the seat cover). #suzuki #dirtbike
