84 RM 250 E Ground UP Full Restoration

[Moto7man]

Trying to resolve a few things while I am waiting on parts to arrive.

I cleaned up the clutch and it doesn't look too bad now. It definitely needs new fibers because of spots of rust, even though the fibers, steels and springs were all well within spec, almost at the spec for new items.

Here is the outer basket.

Reverse side of the outer basket.

 

[Moto7man]

Pro Grip Rally Grips and Other Stuff

Still waiting on powdercoater and new parts, so I tried to finish up a few other things.

Cut the old scott gripe off the throttle.

I disassembled the throttle and cleaned up the inside of the throttle tube with a dremel and a wire wheel.

I ran a tap through the pro tapers so I can can mount hand guards.

This is the throttle after cleanup ready for new Pro Grip Rally Grips to be mounted,glued and safety wired.

MSR Raptor Clutch lever.

 

[Moto7man]

Finished throttle with new grip glued and safety wired with new assembly bolts.

Bars are ready to mount up.

 

[Moto7man]

Mastercross Parts/Motos Italy-Watercooled RM 500

Just got these Oem nos radiator louvers yesterday. I have been looking for these everywhere. I found these in Italy of all places. His name is Tiziana and speaks ok English. I had my parts in 14 days. He has vintage works parts, he builds aluminum tanks and he has a bunch of bikes for sale.

Suzuki NOS Louvers

Like this water cooled 1985 RM 500

http://www.mastercross.net/index_eng.html
Click the flag at the bottom and his page will load in English.

 

[Moto7man]

EBC Grooved Brake Shoes have Arrived

I just contacted my powdercoater, he is a great guy and he is covered up with work so it will be two more weeks before he has my frame, engine, triples, hubs etc finished. I don't mind waiting because he does it the right way the first time.

I did receive some stuff that the average young rider has never seen.

RM 250 EBC Grooved brake shoes!

The grooves are supposed to channel any water or debris out of the shoes.

 

[Moto7man]

More Stuff

A few more items just arrived.

New front brake perch with shorty lever. I am gonna replace those phillips screws with allen bolts.

This is actually a Oem NOS KX stop switch, but it mounts right up with the RM harness.

Motion Pro front brake cable.

Motion Pro throttle cable.

 

[(F5)]

That RM. I've watercooled a couple of aircooled bikes, but I haven't seen one direct drive off the flywheel before, except by belt. That's a lot cleaner than I would have expected.

 

[Moto7man]

That RM. I've watercooled a couple of aircooled bikes, but I haven't seen one direct drive off the flywheel before, except by belt. That's a lot cleaner than I would have expected.

It’s kinda cool, isn?t it?

 

[Moto7man]

First Pictures From the Powdercoater!

Frame.

Brake Pedal and Footpegs.

 

[Moto7man]

Powder Coated Parts Should Arrive this Weekend

Here are some more photos from the powdercoater.

Barrel, engine case and clutch cover.

Suspension Parts Triples and silencer

Head, magnesium ignition cover and water pump cover.

Rear hub and magnesium backing plate.

Swingarm and suspension linkage

 

[Moto7man]

Reassembly Begins!

The powdercoated parts just arrived last night. So, assembly will begin this week.

Here is the frame.

Rear brake lever.

Cylinder and head.

Head again.

Rear brake drum and backing plate.

Wheels and engine cases.

Triples and rear suspension components.

Radiator guards.

 

[Moto7man]

Front hub and backing plate.

Foot pegs, stock and upgraded.

Swingarm

Another shot of the brake pedal with the folding tip.

Silencer soon to be modified into a spark arrestor.

Triples again with rear brake arm and rad guards.

Cylinder head with water pump and outlet.

 

[(F5)]

Looking forward to seeing the result.

 

[Moto7man]

I am looking forward to that too.

 

[Moto7man]

More Progress

Almost done with the seat. I have two bolts to install under the seat, then I can stretch the cover tight and it will be ready.

CDI and Coil mounted up.Just waiting for a oem protector and mount for the CDI.

New steering head bearings installed with the triples. Bottom bearing is a tapered bearing and top bearing is a older design roller bearing, but the top bearing mounted up tight with low drag and smooth action. There is a kit to covert the top bearing to a tapered bearing but it requires machining the stem slightly. The oem design seems very strong so I decided to go with it. I know this bearing is used on several other suzuki models. The design is a little strange and the inside machining inside the top of the steering head looks two races but they are not removable races just machined surfaces into which the new races(roller ball or tapered) are inserted.

I think the frame turned out nice. Here are some shots of the frame.

 

[Moto7man]

Tank mounted, just waiting on some bolts.

 

[Moto7man]

Triples

The top triples have rubber mounts. I ordered some Protaper replacement rubber bar mounts that should be here tomorrow.

 

[Jakobi]

She's coming up a treat mate! Love following threads like this.

 

[Moto7man]

She's coming up a treat mate! Love following threads like this.

Thanks! After I get this one done, I think I am going to do what you did and buy a new gasser in the spring.

 

[Moto7man]

New Pro Taper Rubber Mounts

I decided to go to the bigger bars on the RM. I was able to find ProTaper Mounts with Pro Taper Replacement Cone Kit.

Pro Taper Bar Pad

Everything bolted right up and I torqued the bolts to 27 foot pounds per the protaper instructions. The suzuki manual has a spread of torque values that are acceptable to adjust the feel of the rubber cones. I will post an update later.

Top

Bottom

Partially bolted up with new throttle, clutch and front brake cables.