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Thread: 250ES Big Red Rebuild

  1. 03-03-2009, 10:10 PM #1
    rebel33382
    rebel33382 is offline At The Back Of The Pack Arm chair racerFirst time rider
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    250ES Big Red Rebuild

    Well, I took my cylinder head and jug and piston to machine to asses the damage of the $200 dollar complete '85 big red I bought. Come to find out the marks in the piston, which I thought the valves did due to the worn out timing chain, are suppose to be there, go figure! So its already bored .40, he put the micrometer to everthing and said I just need to resurface valves, new stem seals, and a good professional jug honing; piston and rings are fine. So that was some $$$ relief, just ordered a timing chain, gasket set, steering stem bearings (not BB's!) Airfilter, front brake cable and shoes (back cable and springs and adjuster, and foot lever are missing) , left brake lever for reverse cable, and a new folding shift lever. Hopefully everything will be in by saturday and I can be riding on SUNDAY! I just cleaned all the clutch plates and centrifugal with brake cleaner, miked them, and resoaked them in oil. If anyone has any trade secrets of putting this thing back together, I'll take some advice.
    Thanks!
    Jay
    1984 200ES first Shaft driven big red with reverse!
    85 Big Red 250ES with a rebuilt top end!
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  2. 03-04-2009, 08:48 AM #2
    Taiser's Avatar
    Taiser
    Taiser is offline Just Too Addicted Arm chair racerJust too addicted
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    May 2008
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    Since you have it apart I'd probably replace the rings anyways, not expensive and could save you some headaches, especially if you're going to hone the cylinder. Seems like your already going to lap the valves and replace the seals so I'd say your looking good to go. Use a torque wrench (especially on the head) and you'll be good to go
    My Trikes...

    -1985 Big Red


    -1986 250r


    -1984 200x


    -1980 110


    -1980 ATC 185
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  3. 03-04-2009, 02:40 PM #3
    rebel33382
    rebel33382 is offline At The Back Of The Pack Arm chair racerFirst time rider
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    I dont like torque wrenches, have had some bad luck with them, I just remember how hard it was to take off, then tighten from there...I know it sounds stupid
    1984 200ES first Shaft driven big red with reverse!
    85 Big Red 250ES with a rebuilt top end!
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  4. 03-04-2009, 03:24 PM #4
    Taiser's Avatar
    Taiser
    Taiser is offline Just Too Addicted Arm chair racerJust too addicted
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    They were probably rusted on, they don't get torqued down that heavy. You won't have a problem putting them back on. I've actually had an idiot put locktight on head bolts, if you can believe that, then asked me to take them off...now that was tight!! :-o

    If you don't torque the head down properly and in the right order, you'll have a leaking gasket real quick, mostly just a pain but makes the head look like crap and any leak robs you of power.
    My Trikes...

    -1985 Big Red


    -1986 250r


    -1984 200x


    -1980 110


    -1980 ATC 185
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  5. 03-05-2009, 01:27 AM #5
    threewheelin-feelin's Avatar
    threewheelin-feelin
    threewheelin-feelin is offline Power User Teaching quads a lesson
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    yes do it right have a manual and torque everything right...bad things can happen if you dont
    current rides
    82' ATC110
    85' ATC310R
    85' ATC250R
    85' ATC250ES
    16' brute force 750
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