2007 RMZ 250 Complete engine rebuild

This bike was brought to me with the cases split and all parts in a boxes.  From the beginning, I had my doubts about being able to safely put it all back together since I was not present for the disassembly.  It took a long time and a lot of replacement parts, but it finally started to take shape.  I had to start with the service manual and follow it step by step while taking notes.  Fortunately, Suzuki service manuals are in my opinion some of the best manuals out there and fairly easy to follow.

The major parts replaced included:

  • Cylinder
  • Valves
  • Cam Journal repair
  • Crankshaft
  • Crank Bearings
  • Replacement 1st and 2nd gears
  • Various thread repairs

The 07-09 RMZ 250 had problems with the transmisison, and this one was no exception.  There were worn gears that had to be replaced.  The gears were worn in the areas where the shift cog slides over to engage the gear.  It was concluded that without replacing the gears, the customer could experience false neutrals and jumping out of gear. Read more about it here:


All in all, it was a tremendously grueling rebuild to take on, but in the end I feel it was well worth the experience.  The owner has approximately 12 hrs on the bike since rebuild and everything seems to be holding up well.

Author: joedean

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