1969? TC250 the novice rebuild

BadWolf · Posted: Thu Jan 14, 2010 9:24 am Post subject: 1969? TC250 the novice rebuild

Ok So i got this bike via some horse trading with a friend. I wasnt sure how rare or difficult this bike was to rebuild just new that a 6 Speed 60's 2 stroke sounded cool. Ive rebuilt Vespa and Lambretta Scooters so i figured piece of cake. Right off the rip Im Missing left side body cover and the left side engine cover. I've done the research and Paul miller Vintage seems the place for any hope of finding parts. ( Should be posed as a question?) Any ways heres where im starting.
Engine Siezed and all around a mess. So before i get ahead of myself ( i already asked about paint codes Embarassed

)

Got it Soaking in some PB Blaster and crossing my fingers. The cover im missing is the stator side that covers the Stator.

BadWolf · Posted: Thu Jan 14, 2010 5:48 pm Post subject:

ok got the cylinders off wasnt near as bad as i figured. The pistons and cylinders dont look bad at all just some rust on the inside to the cylinder gonna hone emm out and Mic emm. So heres the question to crack the case or not to crack the case? i mean it would be a great learning experiance to crack emm and make sure everything looks great.

jayel · Posted: Thu Jan 14, 2010 5:53 pm Post subject:

check for parts availiblity first but usually when a two-stroke twin like what you have has set a long time the center seal between the combustion chambers needs replaced, dries out and has compression leakdown problems good time to check the trans gears are in good shape too

AnKhe105 · Posted: Thu Jan 14, 2010 5:58 pm Post subject:

Hey Badwolf, here's a website dedicated to 2 strokes. Lots of good help on here and you'll need it!
http://www.motorcycleracer.net/phpBB2/index.php

BadWolf · Posted: Fri Jan 15, 2010 9:13 am Post subject:

I decided to pull the cases apart. There is a problem with the shifter as well as the kick starter. I just hope that there isn't anything wrong that means i have to buy a whole parts bike. Also not being familiar with these bikes the engine is stamped T20 is that common in Suzukis?

RJRamso · Posted: Fri Jan 15, 2010 10:11 am Post subject:

Hi!
I would highly recommend rebuilding your crankshaft. As Jayel said, the seals would be dried out. Cross your fingers and start looking for the center seals. Also change the center bearing while your at it!
It's not a long time since AnKhe105 rebuilt his crankshaft.
The T20 and the T20 has almost evrything in common. The engine is also the same, except other heads and a little difference on the gears in the transmission (you can gear down from 2nd to 1st without stopping in Neutral with the TC250)
What's the problem with the shifter and the kick starter?

BadWolf · Posted: Fri Jan 15, 2010 11:05 am Post subject:

Both Shafts splines are completely non existant. I only noticed this after throwing the motor in the parts washer. Ive never dealt with a Horizontal split motor. The only motors ive ever rebuilt were Lambretta motors which in the scheme of things are simple. I want to keep this build thread active but dont want to sound like a turd posting every 5 seconds on the progress.

KirkN · Posted: Fri Jan 15, 2010 11:53 am Post subject:

Post away, Wolfie, post away!! And by all means, post pictures of every little step.

btw, where abouts in Cleveland are you? I was born and raised just south of there in Richfield. We moved down to FL back in '79.

Kirk

BadWolf · Posted: Fri Jan 15, 2010 12:10 pm Post subject:

Im in Cleveland Proper on the Westside in Westpark. ok good i just know most everyone here is experienced builders and dont need to see pics of a motor rebuild. But i am really getting into this cant wait to get off work to spend a nice relaxing friday cussing at an inanimate object and scratching my head.

KirkN · Posted: Fri Jan 15, 2010 12:16 pm Post subject:

Rizingson · Posted: Fri Jan 15, 2010 1:19 pm Post subject:

RJRamso I didn't know that the T20 had a positive stop down through neutral, I just that the tranny on my T20 was sticking when I came to a stop sign. My old honda C100's have a positive neutral stop both directions if I recall. Well I guess you can learn something everyday if you read these forums.

BadWolf · Posted: Sat Jan 16, 2010 9:51 am Post subject:

Ok so Last night the plan was to split the cases and have a look inside. Took the Primary Cover off and just sitting in there were a snap ring and a thrust washer. I identified these as coming off the Idler gear ( gear behind the clutch in picture one?) After that i tried taking one of the counter cunk screws out which there are plenty of and quickly realized i didnt have the tool for the job. I needed an Impact driver . By far the best tool i ever bought. but i still have one screw that i made into swiss cheese. Movement is slow but id rather take my time and do it right then rush and lose one of the little springs or something so im doing about an hour or 2 a day.

BadWolf · Posted: Sun Jan 17, 2010 9:08 am Post subject:

Ok I split the cases. I must say horizontal split cases rule. Everything looks great I
gonna try and source as many new bearings and seals as I can since I'm in there. Now I also am looking at this crank and wondering how big of a job a rebuild on the crank is? I know it was posted someone just rebuilt one. Other the the snapped off screw I have to drill out I think the motor is gonna be the easy part of this rebuild. Pics when I go back to work .

dorT500 · Posted: Sun Jan 17, 2010 10:37 am Post subject:

AnKhe105 · Posted: Sun Jan 17, 2010 2:50 pm Post subject:

It was posted that I had mine rebuilt on my TC250 but that is incorrect. Mostly because I could not locate center seals or outer bearings, I made the determination after close inspection that I would close it up and go with it. Bearings and seals seemed good to my eye and feel so perhaps they had been done before. So far, so good with the crank. Time will tell when riding season arrives here in the north. Haven't really had a chance to test it out.
One of the MANY times I had mine apart, I noticed the thrust washer and clip off also. Put them back on and came off again so installed a new circlip via Paul Miller I think it was. Perhaps pinching the clip together a bit with a pliers would be just as good.
By all means, Bill Bune is the man I'm told for crank work but I think you will have to find the parts first. Takes time so I hope you're not in a hurry. As a novice myself, I found it quite a task and lots of learning along the way. If the splines are shot on those shafts, you'll likely have to replace those. Parts bike would be nice but I've been looking for one of those for quite some time with no luck. These T20's and TC250's are getting very scarce and....not many differences between the 2. Mostly the exhaust. Engines, electrical, headlight bucket, fuel tank, etc all the same to my knowledge.
As Kirk says....PICTURES!!! All the bikes these folks have on here are different but many of the basics the same. For the best hope of help from others, pictures! Have fun, take your time, get the proper manuals, and ask away. We'll help if we can. Good luck, Doug
BTW: ebay, ebay, ebay or google the part number. (Sometimes that brings something up)

PS: GTReiner1 [at] aol [dot] com is a German guy who has lots of stuff. Email him and he will send you a list via PDF of what's available. Have dealt with him twice and have been happy about it.