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Few people realize how much time and effort these projects take unless you've done a few yourself.

After a couple light figure eights on my surface board Little more time on the board And a few more figure eights, gets it flat, matched and hopefully air & coolant leak free

Wheel bearings are tight, chain buffer & rear guide still a lot of life left in them...even has the original lower chain roller! And what is this? An air filter....Shocking!

It will need a full engine rebuild...no coolant in the radiators....the P.O. Had the radiator overflow tube connected to the cylinder Powervalve vent! Genius!

Your doing some nice work Brian. It’s a lot of work I know, but we’ll worth it in the end. I’m following. Keep it up it’s going to be an awesome machine when your done. Put the finishing touches on mine and jetted it properly. Like I said... these old bikes are worth your time.

no, don't do it.... those forks sucked ass in comparison to the 86 cartridge forks.

sweet wr i have one havnt ridden it yet i put forks on everything, but i get the whole front end, then i have a machine shop make a steering pin like the stock one that fits the nnew clamps its more expensive but simple when you think about it, heres my wr with 95 yz 250 forks

This cylinder has already been sleeved. I personally would get a new cylinder with Nicasil plating right away. Get a quality piston like Vertex or Wössner at 0,05mm of play and off you go. On HPP engines one good upgrade is to get the HPP valves & guides off the 98/99 model. These seal better than all previous HPP valves. Here's a pic from the exhaust side: left is 98/99 valve....to the right it's the 90-97 valve. You can clearly see the blow-by when closed which is what makes them less effective. Even more impressive is the view from...

That cylinder has a steel sleeve in it. Previous owner probably blew it up and had it sleeved. Rear skirt of cylinder was ground off which is a popular mod. I'd have it bored and a new piston fit.

It appears it has worn through the nikasil coating. You can't bore it, it must be sent in and recoated. Some will say sleeve it but I would stick with the nikasil. Millennium Technologies can fix you up.

I’m definitely not an expert...but I just ran into this exact thing on some old KTM 125 head gaskets. Turns out the one that seemed to be missing the holes was intended to direct water better...to get the cooled water to the hottest area first (exhaust port). Possible that Suzuki figured something like that out and updated the gasket with the superseded number.

i had 95 yz 250 whole front end and it went rite on my wr