Aprilia RS250 top end rebuild - Auckland mechanic recommendation?

**BuzzbomB** · 22nd July 2010, 18:18

Hi, I posted this over in the bike mechanics forum but haven't had any responses so I thought I'd try here.

Its time for a top-end rebuild for my 97 RS250. Does anyone have recommendations for a good and experienced RS250 (or RGV250) mechanic in the Auckland area? I'm also interested in recomendations for a good suspension mechanic that can do something to improve on the front suspension (Showa??) and get things set up to match my weight, etc.

Thanks,
Greg

**imdying** · 23rd July 2010, 14:40

The top end you can probably manage yourself if you have a few clues. You can get the parts you require from The Tuning Works in the UK. The dollar is pretty good against the GBP at the moment, so now is the time to buy.

Even if you're getting somebody else to reassemble it, you will still want to strip the motor down first to confirm that you don't require any replacement barrels etc before you start. The more painless you make it for them, the cheaper it will be. Stop if you come to something you can't figure out how to dissassemble, and then post on rgv250.co.uk; those guys there have a vast range of knowledge, and will be able to advise you on anything you can't figure out yourself.

You will also want to closely inspect the centre retaining pin on the power valves, and the area around it (ok, inspect the whole valve of course) for any signs of cracking. They have replacement OEM power valves, rebuild kits for OEM valves, and CNC machined billet replacement valves. Power valve failure is a killer of RGV motors because it drops the power valve blade against the piston side, which basically rapes it.

Robert Taylor (a member of this site) can rebuild the front suspension for you. The 97 was the first model of RS250 with half decent forks apparently, so he should be able to sort them out for you.

It's a very basic motor, it shouldn't give you much trouble, and any tools you need to buy (a torque wrench, a basic socket set, etc) you will still have for the next time it goes bang

**Expert** · 2nd August 2010, 11:44

I've done a few of these and they're as easy as any two stroke, powervalve pins can wear and let them touch the pistons but it really rattles when it does this and it's the sort of noise that stops you riding. It only seems to happen on the top barrel, the bottom barrel having the valve fall away from the piston if the pin breaks.
The gudgeon pin holds the thrust washers that control the side play on the conrod, not the crankpin as in every other 2t engine, so be careful not to lose those into the motor when you pull the pin out. Should really pack the crankcase mouth with rag first.
Barrels wear and it's the bottom barrel that suffers first, i imagine because the piston is sliding along it sideways. 300cc kits are about $750 if you need new barrels, cheaper than a replate and that includes the pistons!

Forks are marzocci and have a spring in one side only which can be a bit of a suprise when you take them off.

Otherwise, if you divide running costs by fun, the RS250 is a bargain to run. That rhymes!

If you need someone to do it, pm me.

**imdying** · 2nd August 2010, 12:34

Originally Posted by Expert

300cc kits are about $750 if you need new barrels, cheaper than a replate and that includes the pistons!

Do tell us more! Where can we order those from?

**Expert** · 2nd August 2010, 16:12

Originally Posted by imdying

Do tell us more! Where can we order those from?

Oops, sorry. i've just realised i've put dollars when i was thinking in pounds.

When i was in the uk i got stan stevens to overbore the barrels, a stage 3 tune and wiseco pistons for 750 quid all in. But like the op said, good time to buy from the uk at the moment.

I've just found stans site and he's put the price up but still good, it's $650 a barrel to get them plated elsewhere so it puts it into perspective.

http://www.stanstephens.com/rgv.htm

Or these might work;

http://cgi.ebay.co.uk/Suzuki-RGV250-...item439c25af1c