RM250 Coach Project 96 RM250

[Nighthawk016]

Coach's project continues!

I pulled the factory pj38 carb, just couldn't get it idling and running right. I swapped in a pwk38 and used some jetting specs from a person who has done this swap before. 52 pilot, dgk needle on the 3rd clip, and 172 main. I am very happy with the outcome, the bike idles now, and it's a little fat up top. I think I either drop the needle 1 clip position or drop the main to a 170.

 

[Nighthawk016]

1996 Suzuki RM250 with pwk carb

Swapped the stock keihin pj carb for a keihin pwk 38mm carb. Bike runs much better.

youtu.be

The bike still stalls pretty easy when the rpms coming down and slowing down, I think it part of it is my clutch is dragging even when the clutch lever is completely pulled. More to come!

 

[Nighthawk016]

Tuning is much closer now! Dropped the main one size and installed different bars and hand guards.

 

[2strokesteve89]

Tuning is much closer now! Dropped the main one size and installed different bars and hand guards.

Nice hand guards, if you spend anytime in the woods, they are a must imo.

 

[Nighthawk016]

Watch me struggle in the sand at the mx track!

sunset mx on a Suzuki rm250

Riding at Sunset mx in North Judson IN on a 1996 Suzuki RM250

youtu.be

 

[Nighthawk016]

Nice hand guards, if you spend anytime in the woods, they are a must imo.

Yeah most of my time is gonna be woods riding.

 

[Nighthawk016]

The bike appears to be running really well from the plug, but the silencer says differently! And I got my hinson basket installed today too!

 

[Nighthawk016]

So I dropped my pilot as it's been warming up here finally. The jetting is pretty close, but I still can't quite get the bike to consistently idle. It's loading up a bit, but under load it clears up almost immediately. I've been messing with my mix screw and kind of adjusting my idle up and down but I can't quite seem to get it. My digital tach that I've got installed now says in hovers around 2k rpms for a few seconds, then slowly idles down and stalls. Any recommendations?

April 30, 2024

youtube.com

 

[Nighthawk016]

So, I have to admit, I cheated a little on my last upgrade to the bike...

In all seriousness, the bike is running better than ever. I also retarded my ignition timing to lessen the hit a little. It is just a beast in the woods with the lectron and the 12oz fww. I wish I would have done it sooner.

1996 Suzuki RM250 Lectron h series carburetor

First ride with the lectron h series carb. No tuning done.

youtu.be

 

[Nighthawk016]

Today is maintenance day! Repacked the silencer, adjusted my carb, lubed my chain, and did a detailed look over the bike for loose bolts or anything like that. The packing in the silencer was long over due

 

[Nighthawk016]

Big update. Waterpump seal decided to check out. Engine has approximately 20hrs on the top end, crank has no play in the big end bearing, and deflection on the rod is about 1.5mm. Cylinder and piston look good, reeds are wore out, so I replaced those. I split the bottom end and did a thorough inspection. Upon inspection all of the bearings were marginal or ready to be replaced. I figured out everything in the bottom end is original, I am the first person to split the cases. So I decided to just replace everything. Got half of the bearings installed, still waiting on the rest.

 

[SRAD97750]

Fresh.
Always good to get in and inspect!
-BIG DAN

 

[2strokesteve89]

They don’t make em like that anymore, gotta keep them ole girls goin’

 

[Nighthawk016]

Another big day! Got the rest of my bearings installed and reassembled the engine. I realized that I forgot to order an output shaft seal. So that will be here mid next week. Other than that it was a successful day.

 

[Nighthawk016]

Okay hopefully final update on this portion of my process. Got the bike back together, all new bearings, new water pump and seal, new reeds and one repair set of threads.