Hey guys, Foxracing500r here. I am usually making GTA videos on YouTube but I decided to get a bike again after years. I have 2 little girls and a great fiance that doesn't mind my stupid decisions sometimes . I have some time to rebuild, maybe a couple hours a week. But I plan on making this a Winter build, and break it in, in spring.

Little back story. My previous bikes have been more utility bikes. I had an TRX125 when I was wee little, then a Lt300 Suzuki, Lakota Sport, Grizzly 600 and had a buddies RM125 while he was in Iraq.

I started taking apart and building 2 strokes around 11 years old, so that aspect I am  not too new lol.


Anyways. I came across a 92 lt250r for $500. It has a seized piston. The guy I bought it from told me he had it for 5 years, beat the crap out of it and it was a really good bike. He said when it seized, the bike died, he hit the clutch and drifted a good ways. He said he tried pop starting it once and realized it was done.

The bike sat for 2 months and as of yesterday it is sitting in the back of my Tahoe (Yes it fits, barely lol).


So, I am cleaning the shed today, and moving all the kids stuff around to make room for my newest project.

I want to stop by the cycle shop today and get a Clymer manual. So that way I learn a little. Any tips or heads up I should need? I live in good old WV with one cycle shop. So Ebay, Craigslist and online parts will most likely be my source.


Edit: Btw, the pic is not at my place of the bike. It is at his. I plan on snapping a few later once I clean it up some.

Thanks man!

I would do the swap except for the money. I just want something to screw around with. Once in a while speed it down the street or something. My **** riding days are over, I am mainly going just for a toy.

I want to deck it out a little though. I need a new throttle cable, so I was thinking of replacing the whole assembly.

I give you guys credit on the 500r swap though. Everyone I have known to own a QuadZilla has sold them out of fear lol. I just figure a fun little 250r.


Does it sound typical to just rebuild the motor after it seized? Or do you think honing, or possibly boring will come into play?

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Thanks man. My Clymer manual will be here via UPS in a few. I am excited to start catching up on these. I figure later when the lady gets home I am gonna start some tear down.

I am really hoping I can get by with just a cylinder hone and a rebuild kit, but we will see.

Anyone know of any catalogs you can get in the mail for these anymore?


I swear, 2003 was a different time for these thing. Dennis Kirk, White Brothers, and Parts Unlimited used to have a ton of parts and now they are rare.

So far besides a brand new FMF fatty, and a used DG silencer are all I am finding for exhaust.


Did 2 strokes really get shunned this bad since 06?

Well I got all the plastic and the front bumper off. Also the gas tank. When draining tank I saw no blue tint. I almost feel he ran the wrong gas can in it. I also went and washed the fenders at the car wash. 

I have pics of how far I can move the kickstart. It's nowhere really.

I also got my clymer book today. I am liking the challenge ahead. My only concern with engine tear down is space. I literally have just enough room in the shed for the quad. So when it comes time to pull engine I dont know how I will do it.

there is only 3 moving parts concerning the engine.  the transmission is completly seperate.

the power valve is probly fine but will need a good cleaning.   so far you know you need a top end rebuild.
 

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a good full on engine rebuild  would need
- crank bearings and wrist bearing
-a new rod on the crank
-crank seals
-piston kit
- piston wrist spacers.
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pull the cylinder up and take a picture. maybe you will be lucky and be able to remove the wrist pin ok. 
-you can test the crank a little if you get the piston off.

Why not jump in with both feet and swap out that 250 motor with a 500?

Tons on info on the site about how to make a hybrid.

Either way, great buy for $500!  Make a rebuild thread and take lots of pics.  We like pics.

 

Q2W, he came from a Lakota & a Grizzly. We don't want to kill the new guy! lol

Great buy for $500. Welcome to the forum. Pull the exhaust & the head off to give you a better view of any obvious problems.

So more clues to the puzzle lol.

I pulled the carb, reeds, and exhaust. The exhaust was totally not for this quad. Maybe different year but nothing matched up, and over 30 mins was spent getting it off and unwrapped from the frame.


Anyways. I found a bolt was broken from the intake tube and reed cage. I think maybe a little more into the leaning it out thing.

I looked into exhaust port and saw piston. I looked into reed port and it looks like the skirt may have chipped. So we will see.

I ran out of light and the progress ends today.

Any thoughts?

that bolt should come out easy.
-i wouldnt worry about the pipe but post a picture if you dont know what it is.

the head looks ok. 
looks like you need a new connecting rod after all. its full rebuild time. refer to the list above.  let us know if you need something.

well cause the piston wont come off. look the rod is aluminum so its the first item to wear out concerning the upper wrist pin.

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Here is the cylinder