The Rustoleum Rebuild...

[stever250r]

I spent some time after work this past week stripping down the 1988 I picked up for my Girlfriend...All was well except for the typical Frozen Swingarm Bolt... I finally had to break out the Sawzall. I got the Swingarm off, but I still have to deal with the getting the Needle Bearings Out...:mad:

Anyhow, with the frame stripped, Christy and I spend the weekend Cleaning, Inspecting, and Prepping Parts for Paint.. Since we are building the Quad to ride, with some apprehension we still chose to go the Rattle Can route and see how we could make it look... ( I dont want her cutting into my Laeger Funds... LOL) After a quick trip to Home Depot, we came home with a few rattle cans of each of the following colors...Rustoleum Brand... Primer Gray, Sunrise Red, Gloss Black, and Silver Metallic....

I did most of the wrench work, but Christy helped to clean, prep, and paint the parts so I could reinstall them...THe rattle cans did alot better than I anticipated and we are on our way to putting this one back together.

Here are a few pics of the progress we made this weekend. I will update this thread with new pictures as we continue to put this one back together....

BEFORE...
http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/1988Before.jpg

FRAME PREP
http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/198.jpg

FRAME PRIMER
http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/205.jpg

[stever250r]

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/231.jpg
http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/230.jpg
http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/229.jpg
http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/232.jpg
http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/226.jpg
http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/228.jpg

[wilkin250r]

Of course, everyone will tell you that "spray paint won't last, you should powdercoat it" Of course, they're right.

However, rattle can is easy easy touch-up. I would suggest skipping the gloss (and it sounds like you did) because it makes touch-up even that much easier. A little bit of sanding, a little bit of masking, and a quick shot of color, and you look good as new.

[Jesse1980]

Looks good, I know that swingarm bolt is is always a b:tch to get out. I dont like to cut mine unless I really have to or the bolt head is striped out because I am to cheap to buy new ones. As for the spray paint, it's not a show bike it is for one thing, to ride the sh*& out of!

[stever250r]

Originally posted by wilkin250r
Of course, everyone will tell you that "spray paint won't last, you should powdercoat it" Of course, they're right.

However, rattle can is easy easy touch-up. I would suggest skipping the gloss (and it sounds like you did) because it makes touch-up even that much easier. A little bit of sanding, a little bit of masking, and a quick shot of color, and you look good as new.

I know this and agree 100%. The Gloss was purchased in Black for some of the metal parts.. .ie footpegs.. I never had any intention of trying to cleacoat over anything.. We also picked up some Krylon Fusion for some of the plastic, such as the stock Shrouds and rockguard.. and some Heat Resistant Flat black for the Radiator..Cases.. etc...

This quad was basically an impulse purchase, with the intent to clean it up and get it back to running so that we could both have something to ride while I am working on my MX Build. We want it to look nice, and as close to original as possible, without investing the expense of a complete restoration and then having the fear of ever using it as it was intended and it turning into a garage Ornament that you never use...

In a nutshell, We want to have it look clean and original, keep it simple and cheap... and then ride the &*^% out of it!!
:D

[Ruf Racing]

Nice job. There are a lot of low budget paint jobs riding around. It will hold up, just fine. Enjoy the ride! :D

[89trx250r]

i think it looks great and the spray im sure will hold up just fine spray paint has come a long way

[SilverLake250R]

First 250R I built was similar, really cleaned up nice, and some new parts where necessary, and used a lot of spray paint! It held up for a few years, actually, when I tore it down it was because the frame was toast, not the paint. So take some pictures when you're done, then go ride the **** out of it!

[jcs003]

looks nice. if you wreck it you wont be too upset that you scraped $25 worth of paint. as wilkin said. being able to touch it up is nice.

[leager-n-ky]

I use to spray paint my race bikes every winter, they always held up fine. Lookin good, congrat's on finding someone that enjoys the " R " with you, will make life much calmer....lol

[CorvetteZ06]

stever250r -- it looks amazing. 10 years ago before I had a D.L. I rattle canned all my 250R's, as I couldnt bring my parts to a powder-coater. I actually used to get 2 or 3 seasons out of it too! yours looks amazing !! From the pictures, you cant really tell at all!

[leager-n-ky]

Originally posted by CorvetteZ06
stever250r -- it looks amazing. 10 years ago before I had a D.L. I rattle canned all my 250R's, as I couldnt bring my parts to a powder-coater. I actually used to get 2 or 3 seasons out of it too! yours looks amazing !! From the pictures, you cant really tell at all!

I am brain dead here, What is " D.L " ???

[etccb]

I believe he means his drivers license.

[leager-n-ky]

OK, Thanks.

[stever250r]

Thanks for the comments everyone. I have made a bit more progress on the bike, but not quite enough to make posting a new picture necessary.

I am STUCK at the moment with trying to remove the old Needle Bearings from the Swingarm....I HAVE DONE EVERYTHING... PB BLASTER, HEAT, SOAK IN DIESEL... These are the very worst I have ever seen.. I have managed to bust the inner races lose and remove all of the needle bearings, but the outer races are literally now part of the swingarm..... I believe I am going to have to take it to a machine shop and have them cut out somehow.. Either that, or try to find another swingarm... UGH :mad: I am open to any and all suggestions..I really cant do too much more with the Chassis until I get this swingarm issue resolved.

Guess I will pull the bottom end out tonight and start the teardown and disassembly on that. The Crank is literally rusted to the Case Half crank journals from where it was left sitting uncovered in the weather for so long....I'll get some close up pictures of that mess before I start to tear it apart..

Other than that, I am still in need of the rear Brake Caliper Mount, the Overflow Bottle, and a Stock Exhaust and Silencer....Hit me up, if you can offer me better prices than the Buy It Now Prices I am seeing on Ebay... sroarksr@gmail.com

[Fear250r]

Originally posted by stever250r

I am STUCK at the moment with trying to remove the old Needle Bearings from the Swingarm....I HAVE DONE EVERYTHING... PB BLASTER, HEAT, SOAK IN DIESEL... These are the very worst I have ever seen.. I have managed to bust the inner races lose and remove all of the needle bearings, but the outer races are literally now part of the swingarm..... I believe I am going to have to take it to a machine shop and have them cut out somehow.. Either that, or try to find another swingarm... UGH :mad: I am open to any and all suggestions..I really cant do too much more with the Chassis until I get this swingarm issue resolved.



That's exactly what happened to me. I ended up buying another swinger. I've put the other one aside hoping to have it machined out at some point.

[250Renvy]

It's a bit extreme but it does work if you can make sure not to mess it up.

I've had a weld built up inside on the race, then you just pound the living snot out of it until it's loose. The weld gives you material to latch on to.

[etccb]

You might try a mini hack saw to weaken the outer race with some cuts in a few places before getting another one.

[89rwfo]

Originally posted by 250Renvy
It's a bit extreme but it does work if you can make sure not to mess it up.

I've had a weld built up inside on the race, then you just pound the living snot out of it until it's loose. The weld gives you material to latch on to.

This is the only way I have ever gotton them out. Works like a charm.

[stever250r]

Originally posted by 250Renvy
It's a bit extreme but it does work if you can make sure not to mess it up.

I've had a weld built up inside on the race, then you just pound the living snot out of it until it's loose. The weld gives you material to latch on to.

Thats an idea.... Thank you for the suggestion... I will see about trying that...

[destey]

A press is the probably the only thing that will get it out other than slicing it

[profab250R]

instead of building up a weld just take a piece of scrap metal and weld it on both sides of the race 9like a slash through a 0) then you have a nice solid piece to bang on.

[stever250r]

I am going to swing by a place I know of tomorrow and try the weld tactic on the swingarm bearings.

I spent a few hours this afternoon tearing into the bottom end, and splitting the cases. I was really shocked by the overall condition of the bottom internals. It all looked to have extremely low hours on it to be 23 years old, and I actually believe that I am the first person to ever take off the covers and split the cases. Everything is OEM, and you can tell by the lack of grooves on the clutch basket how little use this engine actually had on it. Besides the Crank Bearings and Crank, everything else is still in excellent condition. :cool:

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/IMAG0003.jpg


http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/IMAG0002.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/IMAG0006.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/IMAG0005.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/IMAG0009-1.jpg

[CorvetteZ06]

wow, besides the crank, those internals look great! any luck on the swing-arm bearings? i myself have gotten so pissed in the past at stuck bearings, that i just went out and purchased another swing-arm... lol....

[stever250r]

Well, I finally got those Swingarm Bearings out!! The Welding tip above was the trick that worked... We took a long bolt and slid it through the swingarm opening and welded the head of the bolt to the inner race of the opposing needle bearing. Then whacked the crap out of it with a BFH and they popped right out. Thank you so much for that information... I really thought I was going to have to scrap that swingarm...

Anyhow, with that done, Christy and I have continued to clean, paint, and reinstall the parts we have. I mounted the wheels and tires I had in the garage, but we intend to replace the tires as we get closer to the end..

I did get a nice OEM Cylinder and Piston in the mail today that is ready to bolt on as soon as I get the bottom end back together. I also have a taillight and a few other small OEM parts on the way. I am still looking for the OEM exhaust, lower fender brackets, rear brake caliper mount. I am sure we will find them eventually..

I guess the weekend will be spent trying to clean up the plastics and seat. Anyone know of a good cleaning product for the vinyl seat?

Here are a few photos of how it's sitting right now... More to come as we piece it back together...

NEEDLE BEARING REMOVAL TRICK

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/IMAG0011.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/IMAG0013.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/IMAG0014.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/IMAG0020.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/IMAG0018.jpg

[stever250r]

I have made a little more progress over the weekend, and this week...... I have a new hood, stock exhaust, resevoir bottle, and top end gaskets on the way. I should have the top end installed sometime early next week if all goes well and then I can see if this thing is going to have any spark...Fingers are crossed!!

I still need to get some plastic renew and work with the tank and a few spots on the plastic. I am still looking for the lower fender brackets, rear brake caliper mount, and a few small odds and ends like OEM clutch lever with Parking Brake, etc.

Here are the latest pictures....

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/088.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/091.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/089.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/090.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/087.jpg

[slamdak8782]

It looks great. Doing a nice job

[stever250r]

Well.... It looks like this build is mostly complete... I was shocked that we didn't encounter any electrical problems, and after getting the cylinder on this thing fired right up... I took it for a spin down the street and it felt really good.

We replaced the decals, headlight, and a few other parts, but the biggest thing was getting it running again. We have the OEM case saver and sprocket cover on the way, and plan on replacing the rear tires soon.

We finished this one up just in time... I picked my Laeger parts up from the Powder Coater today, so now its time to start on mine.. Christy is happy with hers and is cheesing big...

Here are the finished pictures, and a short video of this one running

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/055-1.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/060.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/064.jpg

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/069.jpg

VIDEO

http://i152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/th_071.jpg (http://s152.photobucket.com/albums/s178/SteveR250R/The%20Rustoleum%20Rebuild/?action=view&current=071.mp4)

[DoonRider]

Good job, that's nice.:D