Need help rebuilding my 2002 RM250

[pavelkod]

Can someone please give me a list on all the tools I need. I have the manual and it shows how to rebuild. Any tips, or warnngs before I attempt this myself? I have all the regular tools any special tools. Any tips on taking the circlip out? Piston rings, good piston brand? Thanks

 

[Faded]

Can be done with basic hand tools (metric wrenches). Clean the bike really good before you start. Just take your time, and be sure to cover the crank case with a rag once you get the jug off so you don't drop anything down there. Always had good luck with Wiseco pistons.

Try a search "top end" etc., you'll find a lot of good stuff.

 

[CRrider125]

make sure everything is spotless before you put it back together and clean the cylinder with dish soap...its supposed to do something but i'm not sure exactly what.

 

[Faded]

Clean w/dish soap if you hone (with a light oil). Helps to flush out the contaminates and break down the honing oil used. Be sure to take a rag and a lil oil and wipe the inside of the cyl. if you wash it with water. This will prevent it from rusting.

Read the tech tip at the top of this forum. It should help you along.

 

[a454elk]

If you have your manual, it gives you a great step by step process in there, mine does. Go slow and when you take it aprat, be ready to put it back together as soon as possible, the longer you wait, you tend to forget stuff. Make sure the gaskets are entirelly removed and cleaned off the base and jug. Clean out the power valve while you're at it, good time for it. Real easy process, no odd tools needed. Good luck and if you feel apprehensive, take some digital photos of the process along the way.;)

 

[kbob]

The one tip I have is be very careful with the little plastic clip that holds the rod for the powervalve rod in place it breaks easily. There is also a little allen screw in the powervalve.When reasembling make sure you get the screw in the slot cut in the shaft or your powervalve won't open and close the hole way.

 

[Joepro9]

I agree, wait until you have the new parts, so you can slap it back together asap. I took my cr (top end)apart after I ordereds the parts that were supoosed to be at my house the next day. Then I was suddenly informed that the gaskets were back ordered for 3 months...(weird huh) Well I had to cancel order and get the parts some where else. 5 days later I was really struggeling to remeber, for the honda maual lacks detail.

 

[factoryRM]

I just tear that little plastic peace off and buy a new one every time I rebiuld my motor. get a small 3/8 torc wrench anda swivle bolt extention and a veary long extention. you also want pliers with rubber tips to pull off the valve spring cover.

 

[bscottr]

There's some great info on Eric's site. Click here.

 

[mackay]

Two things from my experience...make sure the piston is facing foward (oriented correctly) and circlip orientation (12 o'clock or 6 o'clock) also go to Eric Gorrs site and check out the articles on top end rebuild.

 

[Erick82]

I just rebuilt my 02 RM 250 two months ago. It was pretty easy, it was my second top end job, I didn't even have the manual, but I did talk to the guy at the shop about the power valve release. The only thing that I didn't like was I had to pull the radiators to get the cylender off. Good luck and take your time. I try to keep everything realy clean when I am doing it, like my work area, bike everything. I also spray a little WD-40 in the cylender when I put it back together. I think it makes it a little easier to start and gives it a little lub when you are first kicking it over and it is cumbustible. Just something I do.