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Thread: My Topend rebuild

  1. #1
    apriliaforum prov-nov
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    My Topend rebuild

    98 model imported from Germany( wich is the only country that required a catalytic converter for the RS250 to be road legal), only did 160km/100miles last year and it did go perfect.. I wanted to be on the safe side, so I ordered a top end kit from TTW, last week I took the engine out, to get the job done. Taking the right hand exhaust off the bike it had a rattle and out came some of the cat... not good. Removing the right hand cylinder head confirmed my fear, nikasil was damaged on the exhaust side. Haven’t checked the left hand yet. Is it be the broken catalytic that has done the damage?

    will keep you updated when time allows..

    new rubber for the oil tank has arrived
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  2. #2
    apriliaforum expert grendels_arm's Avatar
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    This is why cats are horrible. This crap happened to my car when the cats went bad. Because of how the emissions worked pieces of the cats got sucked back into the cylinders, scoring them. There's no Check Engine light I don't think to warn you when emissions goes bad like on cars.

    Good luck man.
    Sam

    USGPRU #98
    1998 Honda RS125
    1998 Aprilia RS250 Cup bike

  3. #3
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    Cylinders and pistons are off, right hand cylinder and piston has some damage, left was like new. Will probably send both cylinders for replating at TTW. Click image for larger version. 

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  5. #5
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    I’m thinking about replacing the reed valves to new oem ones. Are there no gasket between engine block and reed block?

    Does anyone have the suzuki part number for the reed valves?

  6. #6
    apriliaforum Member Kusti59's Avatar
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    Suzuki OEM Part Code:

    13153-12C10

    https://www.cmsnl.com/suzuki-rgv250-...ed_1315312c10/

    Cheers

  7. #7
    apriliaforum prov-nov
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    Many Thanks.

    1- How to remove this tiny jet?

    2- is the pin that holds the float bowl press fit?




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  8. #8
    apriliaforum prov-nov
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    This cable seems to be too long when the carbs were still in the bike, is this normal?


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  9. #9
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    The surface treatment in the slides in carbs seems to come off? Anyone seen this before?


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  10. #10
    apriliaforum Junkie
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    The pin what holds the float is kind of press fit. Slightly larger at the end but will push in by hand. And will push out from other side with a punch or one of the auto punches

  11. #11
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    Quote Originally Posted by AllanRS250 View Post


    The surface treatment in the slides in carbs seems to come off? Anyone seen this before?


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    I have never seen that before. I have some carbs where it has worn off. Just sand it off I don't think it would cause you any issues. You could get it re coated if you was that bothered.

  12. #12
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    Quote Originally Posted by AllanRS250 View Post


    This cable seems to be too long when the carbs were still in the bike, is this normal?


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    Yeah normal it's just a age thing if you get a new one it will bend better

  13. #13
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    Leave it in just make sure it's not blocked when cleaning the carburettors

  14. #14
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    Quote Originally Posted by AllanRS250 View Post
    I’m thinking about replacing the reed valves to new oem ones. Are there no gasket between engine block and reed block?

    Does anyone have the suzuki part number for the reed valves?
    No gasket it has a rubber seal around them. If they leak gasket sealent will be OK. I bought new ones but they are expensive for what they are

  15. #15
    apriliaforum prov-nov
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    Thanks for the info james.

    1/2 Hour in the ultrasonic cleaner and the carbs are like new. I was expecting a lot more fuel-slime in the carb bowl, after all those years and few kilometers, but there was very little. New jets in the “full power”/ “no-cat“ sizes are used to reassemble carbs. O-8 Needle jets are no longer available, but TTW still managed to find new ones for me. There are problably no noticable difference between the 0-9 and 0-8 but I still like that its the way it was from factory. The cat exhausts are now in the bin and hopefully a set of jollys’ will finds its ways to my RS next year.


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