86 250r project thread w/ pics- total basketcase

[jeopardy98]

So I picked up this 86 250r the other day for $500 because I wanted an "R" so badly. I was pretty content with my purchase even though I knew I probably didn't get a great deal and that I would need a lot of money and a lot of time to make this thing a rider. As I dug into it more today I kept finding things that made me realize I probably made a pretty terrible purchase but what is done is done so I'm jumping head first into getting her back running and running solid.

I pulled the engine today and found a few things that really concern me so I'm asking your opinion.
1. There are two studs missing for the cylinder. Are these replaceable or do I need a new case? Please say I can replace them.
2. There are two broken spots on the left side case for the piece that covers the front sprocket I assume. How big of a deal is this?
3. When I was pulling the engine I noticed that it is worn all the way down through the case where I can actually see the front mounting bolt. Does this area go all the way into the bottom end or is it drilled out just to house that bolt that attaches to the frame mounts? Am I still looking at a new case because of this?

On the upside I did find the carb and it appears to be in pristine condition. It looks like I'm going to need everything for this. Brakes for the front and rear, levers for the front and rear, twist throttle or thumb throttle etc. etc. I did get a seat in okay shape with this one but it will need recovered at the least and maybe new foam. I also got a tank that is in good shape but I didn't get any kind of fenders.

So for all you experts... Where do I start? How bad did I screw up? I'm still excited for this project but I guess I just need some encouragement as well as some realistic answers as to what I can expect with rebuilding this engine. Thanks in advance for any advice, gripes, or comments.

Here are some pictures:

[Jim mac]

I hate to say it, but I dont feel so bad about dragging my project home. this is what I dragged home a couple weeks ago. 85 250r the bucket of parts is the motor. it needs a piston, gaskets, and since its apart, probably a set of bearings.
Keep us posted on your project. I just got off the phone with a guy that offered me a 84 200X and a spare motor for my 200X that I was going to build into a 185 autoX. for my 250R. Im still on the fence about the trade, a running trike would be cool, but I really like bringing them back from the dead.
The last pic is the 200x im building into a auto X.

[PAPA250r]

picture 4 is ground down like that from the factory. cylinder studs are also removable . even if the threads are bad a new case is not needed .

as for the chain damage (no case saver ) it would be a shame to resurect the bike only to have the repair start to leak after you start ripping it down the trail it depends on the quality of the repair

[leviblue]

is that JB Weld around the clutch cable shaft???? if it is your in bad shape unless you can find one where the chain broke the case and cut the peice out. I might have a beat case to use for a patch but you gotta have a GREAT ALUM WELDER DO IT !!!!!! Not good but great......otherwise maybe $100 too much but I sometimes buy expensive sht too and it allways comes out looking good. My 85R that I race cost $1300 on ebay and $400 shipping. When I picked it up at the shipping depot I allmost cryed. It was not the bike I saw in the video. JB weld on everything. 2 of the 3 cases, the jug ( around the boot and head) an 84 tank, square back rims,no ft tire,cracked plastics and no exhaust. Like I said I wanted to cry but the laughter of the warehouse guys and my EX-GIRLFREINDS "I TOLD YOU SO" made me hold it in. PRIDE MAN PRIDE.....Now it's a year later and countless $$$ invested I'm happy as the 1st time I got layed !!!! Now I went all out and have 2 89 motors built for it. I've replaced everything except the frame and swinger. I could of done it on the cheap but I was pissed and went nuts. It took a few mths to find everyting , the motors (4 89) was the worst. But if I could do it so can you......and according to my Ex I'm a dumba$s

[ceaserthethird]

It's a project, Take your time ... It could take a year, by the Best Parts, SAVE & Buy make a pile of all the New Parts.

Don't Rush anything, You can get a New Case for $300, or buy a used eng. off e-bay with low hours

[jeopardy98]

Thanks for the replies so far. Is it true that you have to use matching cases on an engine? I always have but have never gotten a definitive answer as to if it is necessary or not. If not I'll start looking for a left side engine case. I think a year is very optimistic for this project lol. I'm thinking maybe 2 for me to save up the money I need to buy all the parts. Heck, I don't even know all the parts that I need. Oh well, slow and steady wins the race. It will all be worth it the first time I can kick that engine over and hear it roar to life.

[jeopardy98]

Well I have been slowly but surely acquiring some parts and tearing this thing down a little at a time. I'm in the process of looking for a good engine person to split my cases and replace my main bearings and seals. I'll have them hone or bore my cylinder and put a new piston/rings in it when they do so the engine is just sitting right now. I was going to do it but I'd rather spend the $200 in tools I need on getting the engine fixed or buying parts.

I tore down the rear end and will be rebuilding the forks next I think. All bearings will be getting replaced and some other things to make this thing solid but it won't be much of a looker. I did pick up a nice set of tires and an 85 with the engine in a box minus the left cover so I'm making some progress. I know you guys do much better work than I ever hope to but at least she will be dependable when I'm done.

[Jeepermc]

Looks like you're making good progress. Congrats!, Keep it up and you'll be ridin in no time....The experience you gain with this will be worth it's weight in gold. Keep doing it right and the trike will be good to you!

[jeopardy98]

Well I put in a few more hours today and I found out that both of my forks are tweaked AND I spent all day trying to remove the dang swingarm pivot bolt. It will not budge. I tried heat and pb blaster and an air chisel and every other thing I could think of. The PO put some kind of long rod with threads at the end in place of the original bolt and the dang rod doesn't have any kind of head on it. It is just a round cylinder. Strangest thing. I'm at my wits end. I guess I just have to cut it and find a new bolt. That really sucks. Oh well.

Here is where I am as of now.

[Dirtcrasher]

Grind it down till it's flush with the frame. Then I usually dremel out even more. At that point you can barely spread the frame and get the swinger out.

You may have to spread it out and sawzall it out of there, then deal with the swinger in a press...........

[Dammit!]

Get a bigger . A 12lb sledge will knock that bolt out. Mass is the key.

[jeopardy98]

I've already mushroomed the threads so bad I don't even think it will fit through there. I could just dremel off the mushroomed part and try a bigger . Maybe I'll do that. Either way I'm going to have to replace the bolt and all the bearings and seals. I'm just trying not to damage the swinger or the frame in the process.