2 STROKE WORLD .net

The 2-Stroke Garage => Haus of Projects => Topic started by: busa1300 on November 21, 2025, 02:46:05 PM

Title: RS250 out of retirement, before retirement
Post by: busa1300 on November 21, 2025, 02:46:05 PM
18 years ago this Christmas, I bought myself a RS250 to do track days.
I knew how to go straight fast, but I wanted to learn how to drag my knee through the corners with ease. A TZ250 appeared to be too maintenance intense, and my RZ350 to old and slow....so a RS250 (which I drooled over when they were new and saw them at tracks a few years earlier) was the perfect ticket in my mind.

Went through the bike for the 2008 season, that winter, and repainted it as well. Spring came and I made my first track day without hurting myself or the bike. Then shit fell apart all around my world....as with many people in 2008-09.
Managed to keep the bike through it all, but it has never gone back to the track.

And I realized a few weeks back, that even if I'm too old to ride, I can still build bikes, but if I'm going to ever use this Aprilia, I better do it while I can still get on the bike.

First thing is to investigate the condition, and then I can go from there.

(https://advrider.com/f/attachments/img_8957-jpeg.7354463/)

(https://advrider.com/f/attachments/img_9005-jpeg.7373865/)
Title: Re: RS250 out of retirement, before retirement
Post by: busa1300 on November 23, 2025, 06:08:04 AM
Good compression, and held 5psi for well over an hour, so the engine itself is still in pretty good shape luckily.
Also forgot I had some worked over reed cages in this thing, which is a bonus.

(https://advrider.com/f/attachments/img_8990-jpeg.7373849/)

(https://advrider.com/f/attachments/img_8991-jpeg.7373867/)

(https://advrider.com/f/attachments/img_9041-jpeg.7388843/)

(https://advrider.com/f/attachments/img_9045-jpeg.7388847/)

(https://advrider.com/f/attachments/img_9064-jpeg.7400771/)

(https://advrider.com/f/attachments/img_9063-jpeg.7400769/)

Title: Re: RS250 out of retirement, before retirement
Post by: 85RZwade on November 23, 2025, 11:04:37 AM
Interested to see more! :pop:
Title: Re: RS250 out of retirement, before retirement
Post by: Simmons1 on November 23, 2025, 12:21:50 PM
 :clap:
Title: Re: RS250 out of retirement, before retirement
Post by: 38special on November 23, 2025, 12:25:40 PM
I like your method of holding the exhaust plugs in for the leakdown - very clever.
Title: Re: RS250 out of retirement, before retirement
Post by: busa1300 on November 24, 2025, 05:17:32 PM
:thumbs:

Bought some parts for this a few years back, when I was putting together a MK1 version for a Aprilia forum member. His bike ran so good after, I bought the same for mine.

Still sitting unused, but at least I beat the tariffs coming from Europe.
:cool:

Billet power valves, billet heads, billet power valve pulleys, Zeel ignition, pistons, pins, bearings, gaskets, and so on.

(https://advrider.com/f/attachments/img_8959-jpeg.7354467/)
Title: Re: RS250 out of retirement, before retirement
Post by: busa1300 on November 25, 2025, 03:40:53 PM
Cylinders look pretty good inside

(https://advrider.com/f/attachments/img_9080-jpeg.7407101/)

Bike was using a set of Suzuki SP straight plug heads already, so not sure how much help the billet ones will give

(https://advrider.com/f/attachments/img_9083-jpeg.7407105/)

Using a set of Suzuki SP cylinders as well when set up originally years back

(https://advrider.com/f/attachments/img_8995-jpeg.7373851/)

Also has Kit intakes that do not have the cross over mounting tubes, just rubber nubs

(https://advrider.com/f/attachments/img_9004-jpeg.7373863/)

I do have a few sets of Aprilia cylinders I might try using, if the cylinders on the bike now do not measure out good, when I pull them off for better inspection.

(https://advrider.com/f/attachments/img_8997-jpeg.7373857/)

Carbs are still spotless inside luckily

(https://advrider.com/f/attachments/img_9042-jpeg.7388845/)

Pipes just need a bit of cleaning up, and some new high heat black...

(https://advrider.com/f/attachments/img_9046-jpeg.7388851/)

Title: Re: RS250 out of retirement, before retirement
Post by: SoCal250 on November 25, 2025, 04:58:27 PM
:thumbs: :pop:
Title: Re: RS250 out of retirement, before retirement
Post by: busa1300 on November 26, 2025, 03:58:22 PM
Although the engine tested out really good....I can't leave well enough alone. I have all winter, so I might as well go a little deeper and make sure I don't have issues from long term neglect when I get to the track.

(https://advrider.com/f/attachments/img_9095-jpeg.7412519/)

(https://advrider.com/f/attachments/img_9096-jpeg.7412523/)

Found a nice set of Aprilia cylinders with good nikasil in a spares box, so I'll clean these up and probably use them with the new pistons I have.

(https://advrider.com/f/attachments/img_9098-jpeg.7412537/)

Title: Re: RS250 out of retirement, before retirement
Post by: busa1300 on November 27, 2025, 01:19:30 PM
Making sure I have all the parts I'll need for these Aprilia cylinders.
Will do a bit of soda blasting on them one more time, as I missed a few areas when I did them 10-15 plus years ago...

(https://advrider.com/f/attachments/img_9101-jpeg.7414453/)

The next thing I need to find is a MK2 oil tank, then I think I will have all the parts to go back to a pump.
...have pump, and cable, new hose and clamps, and have a spare powervalve motor with the oil pump over ride pulley and cable.

(https://advrider.com/f/attachments/img_9102-jpeg.7414477/)

After I get the clutch cover off I will see if all the internal gears are gone for the pump...I think I have some spares for that also somewhere.
But can't use any of it without that specific tank...