Motorcycle Repair: 250 2 stroke, metal shavings, clutch side


Question
I didnt put enogh oil in with the gas and it froze up. i plan on tearin it apart to find out how bad it is, ive never done it before, is there any thing special i should know before i start?

Answer
Clark, usually they just seize the piston first, but the metal shavings go all over inside the cases, so it all has to come apart. Don't know what flavor 2 stroke you are working on, but you may need some special tools to help split the cases. Varies with each application. The cases generally split vertically, so you will have to remove the clutch side stuff, first, then the generator/ignition side items, which sometimes requires a rotor puller tool. I woul definitely get a shop manual, some GOOD quality metric tools, an impact driver and a digital camera so you can track what goes where. Bag the small items that are associated together and mark them.
The crankshaft should be checked for debris in the bearings, either clean them or replace them, then put some new crankseals on both ends.. ignition side and transmission side, plus all the other seals for shift shaft, kickstart shaft, etc.  There are generally a lot of shims and washers that have to be placed back where they belong. You are going to have a bench full of bits, when it all comes apart. Take your time and/or have someone else do it for you. Even though there are very few parts on the top end, there are a lot of items inside the cases.
It will be a real education for you, if you tackle it!

Bill Silver