It is highly unlikely the gearbox will mount in a 2003 frame without modifications. The crankcase part number for the '94 is 43860. The '03 number is 36890. Nine years is a wide span and many changes have taken place. Sorry.
the way you explain this, the fuel and air mix is wrong, is the spark plug wet, if it is check the carb air mix screw. remove the mix screw and use a can of air and blow it out. before doing this remove the air filter and the spark plug then spray some wd (brand name) in hole and do again with the air can. then screw back in. leave the air filter off. and put spark plug back in and start the engine you will need to adjust the screw until you can get it to start. when it does give it a few good revs and keep it running for a bit. replace the filter and start engine and you will need to adjust the air screw till the engine sounds right again.
replace the rings as they have lost their tension
make sure that they are free to move in the grooves as to score a cylinder normally results on the ring lands closing up on the rings and jamming them
Hey Anon,
First, make sure the clutch is adjusted correctly..This video is a basic tutorial.. use it for a guide BUT DO the steps as I TELL YOU..
1. Loose the cable adjuster at the handle bar.. run the adjuster in - (give it as much slack as you can)
2. The clutch actuator lever on the engine case should be able to move about 8mm (.325") before it starts to disengage (gets hard to move)..
3. Adjust the cable at the bottom adjustment to take up any slack at this point.. ..you MIGHT/should be able to feel some (NOT FULL TENSION) clutch disengagement in the handle bar (clutch) lever at this point.. IF YOU CAN'T - tighten the cable at the bottom adjustment ONE round at a time until you can feel (a small amount) tension and have at least/about 12mm (.48") max. of play in the lever (BETWEEN THE LEVER AND THE MOUNT when YOU START TO FEEL TENSION... - NOW - in the clutch lever (handle bar).. when you can feel tension in the lever... >> you should start adjusting the lever to have (at least) approximately 1/8" - (3mm) of play (gap) between the lever and mount.. when you have this set correctly, the clutch adjustment question is eliminated. If the adjustment has not helped and you had to do A LOT of adjusting. you need to replace the clutch cable.. and do this adjustment process again. NOW adjustment is NOT part of your problem. If this fixes your problem GREAT!!
.. If not.. now.. we have to move internally..The next issue will be grooves worn into the arms of the clutch basket be the fiber clutch plate ears..(see picture) (the ones that keep the plates stationary when you shift to help disengage the clutch). Also check the actuator arm (see picture below) for wear..
. How to Adjust Clutch
Ok.. if you have gotten this far and everything seems good, reinstall AFTER YOU HAVE METICULOUSLY CLEANED THE BASKET!! The clutch should be working now.
Congrats!! If you need professional port work contact me..
Suzuki RM80 250 89 95
Make sure you have ignition spark and just wer yhe tip of the plug with gas. Puttting gas in the cylinder is too rich and will add to you problem. Good Luck
Ok.. if you have gotten this far and everything seems good, reinstall AFTER YOU HAVE METICULOUSLY CLEANED THE BASKET!! The clutch should be working now.
Congrats!! If you need professional port work contact me..
Suzuki RM80 250 89 95
