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Thread: My 87 Lt250r restoration

  1. #51
    Join Date
    Jan 2010
    Location
    Jonesboro, TN
    Posts
    169
    Got the wheels powder coated gold today. Here is a pic of one hanging to cool down.

    aa0a0003.jpg

    Hopefully get tires mounted and get them back on bike this afternoon. I can't wait to see how they look installed.
    '03 z400, '87 Lt250R Quadracer, '01 Lt80, '96 Lt80

  2. #52
    Join Date
    Jan 2010
    Location
    Jonesboro, TN
    Posts
    169
    '03 z400, '87 Lt250R Quadracer, '01 Lt80, '96 Lt80

  3. #53
    Join Date
    Jan 2010
    Location
    Jonesboro, TN
    Posts
    169
    I ran into a problem last night building the engine. Got the bottom end assembled and sealed up, then started on piston and jug. The ATC 72mm piston I'm planning on using is a bit too narrow inside where the rod sides into it. It doesn't allow room for the thrust washers. It will fit and work fine if I leave them out but I'm not sure about doing that. Gotta call Allen at CT to find out what he thinks or if that was something he overlooked.

    My plan is to take piston to machine shop to open it up to Suzuki specs but I'll wait and see what he says.
    '03 z400, '87 Lt250R Quadracer, '01 Lt80, '96 Lt80

  4. #54
    Join Date
    Jan 2010
    Location
    Jonesboro, TN
    Posts
    169
    I did a little research, the '87 Lt250r wrist pin bearing is 18x23x24mm and it's too wide to fit into the ATC Honda piston with the thrust washers. I cant just use a Honda wrist pin bearing because it measures 18x22x23mm so even though it's shorter, it's too small to fit Lt250 rod.

    Like I posted earlier, was planning on just taking piston to machine shop to mill it out a little but that would make it more complicated to freshen up with new piston in future if need be. So I think I found an easy alternative. A wrist pin bearing For a 77-99 RM250 measures 18x23x22mm so it's correct size for rod and it's 2mm shorter so it should allow enough room for the 2 thrust washers and proper tolerance.

    My local Atv shop had one in stock so I picked it up but haven't had time to install it yet. I hope it works and I'll keep you updated.
    '03 z400, '87 Lt250R Quadracer, '01 Lt80, '96 Lt80

  5. #55
    Join Date
    Nov 2008
    Location
    hawaii
    Posts
    258
    LT is coming along great! Good luck with the top end. Issues like these sure do suck but it is sure worth it in the end.

  6. #56
    Join Date
    Jan 2010
    Location
    Jonesboro, TN
    Posts
    169
    Thanks for the encouragement. I got the engine sealed up finally. Now I can actually feel what 13.5/1 compression is gonna be like. (I'm parking this thing on a hill as much as possible)

    39cc0870.jpg

    Then ran into a minor problem of a bearing missing from the power valve assembly. I had to order it this after and wait, yet again, on shipping. That's what happens though when you've had a project torn down for this long and had it at 2 different shops over time.

    It's slowly but surely coming to life though.
    '03 z400, '87 Lt250R Quadracer, '01 Lt80, '96 Lt80

  7. #57
    Join Date
    Jan 2010
    Location
    Jonesboro, TN
    Posts
    169
    2882cb4c.jpg

    final assembly of everything.
    '03 z400, '87 Lt250R Quadracer, '01 Lt80, '96 Lt80

  8. #58
    Join Date
    Jan 2010
    Location
    Jonesboro, TN
    Posts
    169
    New ARP head studs installed

    612e0490.jpg

    Engine bolted down in frame

    ba4adf4e.jpg
    '03 z400, '87 Lt250R Quadracer, '01 Lt80, '96 Lt80

  9. #59
    Join Date
    Jan 2010
    Location
    Jonesboro, TN
    Posts
    169
    My bike has been setting for so long, I just had to order front and rear master cylinder rebuild kits
    '03 z400, '87 Lt250R Quadracer, '01 Lt80, '96 Lt80

  10. #60
    Join Date
    Jan 2010
    Location
    Jonesboro, TN
    Posts
    169
    fec5f93f.JPG

    I was just looking around at the local Atv salvage yard today and ran across a factory ignition key switch for this bike. I can't wait to get it installed.

    I can't believe how hard this bike pulls high in the rpm range. I'm so happy it's finally running.



    short clip I took right after first start-upVideo
    '03 z400, '87 Lt250R Quadracer, '01 Lt80, '96 Lt80

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