Building a 1988 Suzuki RM250 engine

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We just received a 1988 RM250 that we are going to most likely do a full rebuild on.
First things first, let's give it a good washing before disassembly.

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There is nothing worse then dropping dirt, sand, grease, and grim into a motor.
Regardless if we are going to clean it all up later, we want to keep it as nice as possible...
Who knows, at this point, it may not be worth rebuilding...

Here is what we are starting with..

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At first glance it does not look too bad..
But a closer inspection reveals a few things..
Missing carb cap..

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Broken right side exhaust valve cover

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Broken exhaust flange

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The drain plug has been repaired.
Externally it looks good but we won't know until we get it apart and inspect it.

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Some buggered up parts.
We might be able to clean them up and polish them out a bit..

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Broken shift shaft spacer..

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And heavy wear around the engine case..

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Yes, it is repairable but it may be cheaper to get a new case...
We will see

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Clutch basket is REALLY worn..

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More disassembly..

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AH HA!
Found the transmission problem...
Rounded dog ears..
The big question is, can we find replacements that are better?

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Cylinder issues....
Look at the sleeve.... and cracks in the bridges.

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It should look more like this:

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And when we are done it will be better

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We have parts from 4 different engines to help us in getting the best parts available.
Keeping things organized becomes a priority...

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And how can you decide which part to use unless you have clean parts to inspect?

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I think Jason is OCD sometimes