83 250R - what to do??

[red_ryder]

Here's the skinny: Rode the 83 250R all day long with no problems. End of the day, it won't shift down into first. I pulled the clutch out and the pawls look to be fine, so I'm guessing the shift fork is the problem. From what I've read so far, this is gonna be a case splitter and the part is discontinued. So... I found me a complete used bottom end. Unsure of it's condition, but I was told it was in the process of getting a top end job and never got finished.. I don't know where it's been at, for how long, or anything like that. It does seem to shift fine on my workbench, but that's about all I've done with it so far.

I was thinking, pull the top end off of mine then slap it onto this bottom end (moving the piston as well because the one in the new bottom end doesn't look so great). Could it be that easy or am I missing something? Now the deepest I've ever gotten into a motor is pulling a clutch out of one the other night. Wasn't hard, I have a manual, but I'll admit cracking a case open scares me. I know new gaskets are needed and everything needs to be clean. I am worried about a couple spots on the bottom end. It looks like someone used a screwdriver to get the jug off (see pictures). Is this repairable? If so, my next question would be about how to clean or flush out the bottom end before installation. I have no idea what could have fallen inside the case during it's storage, but it's not the cleanest looking. Any tips on flushing out the case? Thanks for any help you can shoot my way.

http://farm5.static.flickr.com/4016/4354857091_bd3b309804_b.jpg

http://farm3.static.flickr.com/2793/4354857321_9f14b322ef_b.jpg

http://farm5.static.flickr.com/4014/4355602578_617f18fa0d_b.jpg

http://farm5.static.flickr.com/4041/4354856911_c696386b17_b.jpg

[Brockey]

Well, I split the cases on my 81 and it scared me aswell. That being said I took the laptop into the garage and tore my two motors down and carefully placed stuff in the order it was removed. Then I followed the manual that I got on the computer and it worked out perfect. As for the other bottom end, you could use a bit of gasket silicone as well as the paper gasket to allow for them gouges or take it too a machine shop and have him build up the area if thats possible.

[RodKnockRacing]

the way i see it as long as you use a manual u should be fine dont let it scare you its how u learn by doing

[torker]

If you have a bit of mechanical skill and knowledge, by all means, Do It. Just make sure you have a munual handy. Also, take it apart carefully and have a big, clean bench with a big towel and put everything just the way they come out. Watch for shims that you may miss because sometimes, they will fall or stay "glued" with the oil and then fall while you're working on the engine and you absolutely need those shims back where they where. Most assembblys come out complete (like the crank & rod, gear shafts etc).
Have fun.

TORKER.

[red_ryder]

Thanks for the input guys, I think I will go ahead and get my hands dirty. I DO NEED to learn this, and feel I'm mechanically inclined enough to handle it... and of course I have you all here to help me if I hit any snags, so there is a bit of a comfort level there. I need to get my hands on a torque wrench, and other than that I have just the basic set of tools (wrenches, sockets, hammers, screwdrivers, and vice on my bench). Are there any special tools I may need to get ahold of and if there's any tips that the manual may have left out, I'm all ears. Thanks again.

[beets442]

Take lots of pics as you dissasemble. I've rebuilt a few engines. Kinda hillbilly but when I absolutely need a tool, I went as far as buying it(check return policy) and return it when I'm done. Whatever it takes to get the job done with little $.....Good luck Beets

[200XMichigan]

The guy definitely messed up the mating surface. Use the paper gasket with this on the bad side.

http://www.permatex.com/products/Automotive/automotive_gasketing/gasket_makers/auto_Permatex_the_Right_Stuff_Gasket_Maker.htm

It cures in 1 minute, since I can never wait over night to start an engine I got back together, like most other RTV silicone says to. We used this sealing jet pumps to the hull on jet skis. So one side was submerged underwater, and the other side had two stroke oil and whatever else people spilled in the hull. The stuff works great. They make a caulk gun style tube, costs more the the aerosol style like this dried up after a year. I used most of it.

It doesn't peel off as easy as RTV but it can be used immediately.

Beets is right, when I've been broke I've bought a torque wrench and returned it. Now I finally own 2.