84 RM 250 E Ground UP Full Restoration
- Thread starter Moto7man
- Start date
Thanks! I am thinking about it.
Updates
I found an RM replacement shock and sent it to Drew at Works Enduro Rider. Drew is also going to install a set of Racetech Emulators in the forks. I had a big batch of OEM suzuki parts arrive and started getting them installed.
I pressed new bearings and seals into the upper full floater arm. Everything went together very nice and it was fairly easy to fit to the frame. Just make sure that you don't lose any needle bearings when install the long spacer and long pivot bolt.
This is what it looks like installed.That cad plated gold rod in the middle is actually a spacer and the pivot bolt goes through the center.
This is a shot from the side which show the pivot bolt and the new linkage arms bolted up with all new Oem Suzuki fasteners including new shock bolts.
View from the back, notice the new suzuki chain guard and bolt to the left.
New oem engine mount bolts and spacers.
New oem rear fender.
New oem front plate.
New oem fork boots
I found an RM replacement shock and sent it to Drew at Works Enduro Rider. Drew is also going to install a set of Racetech Emulators in the forks. I had a big batch of OEM suzuki parts arrive and started getting them installed.
I pressed new bearings and seals into the upper full floater arm. Everything went together very nice and it was fairly easy to fit to the frame. Just make sure that you don't lose any needle bearings when install the long spacer and long pivot bolt.
This is what it looks like installed.That cad plated gold rod in the middle is actually a spacer and the pivot bolt goes through the center.
This is a shot from the side which show the pivot bolt and the new linkage arms bolted up with all new Oem Suzuki fasteners including new shock bolts.
View from the back, notice the new suzuki chain guard and bolt to the left.
New oem engine mount bolts and spacers.
New oem rear fender.
New oem front plate.
New oem fork boots
Updates Continued
I had bought a new Renthal Ultra lite rear sprocket part number 123U. Package showed that it fit all the RM 250s to 2008. Wrong. I spoke to the Renthal rep and he said that the 84,85,86 RM 250 ran a different rear wheel that used Renthal sprocket number 125U. The Sunstar application chart confirms this is correct.After some more research its appears that the 84,85,86 RM 250s used the same rear wheel as the RM 465 and RM 500. After 86, Suzuki went back to the std RM 250 wheel that they used until like 2008.
New oem side panel.
These are the big wide 98 RM 250 footpegs.
New tank strap.
New CDI cushion
New CDI strap
Tank with new oem fuel valve and cad bolts.
New bearing and seal installed on clutch shaft.New main bearings installed into the cases.
Clutch cover with the new ceramic coolant seal.
I had bought a new Renthal Ultra lite rear sprocket part number 123U. Package showed that it fit all the RM 250s to 2008. Wrong. I spoke to the Renthal rep and he said that the 84,85,86 RM 250 ran a different rear wheel that used Renthal sprocket number 125U. The Sunstar application chart confirms this is correct.After some more research its appears that the 84,85,86 RM 250s used the same rear wheel as the RM 465 and RM 500. After 86, Suzuki went back to the std RM 250 wheel that they used until like 2008.
New oem side panel.
These are the big wide 98 RM 250 footpegs.
New tank strap.
New CDI cushion
New CDI strap
Tank with new oem fuel valve and cad bolts.
New bearing and seal installed on clutch shaft.New main bearings installed into the cases.
Clutch cover with the new ceramic coolant seal.
Water Pump
This is the water pump. I ordered new seals and bearings but upon closer inspection I am going to order a new impeller shaft. This shaft is too oxidized to use. This photo includes the new parts oriented on the old shaft that will be replaced.
This is the correct orientation of the ceramic seal for the water pump.
This is the water pump. I ordered new seals and bearings but upon closer inspection I am going to order a new impeller shaft. This shaft is too oxidized to use. This photo includes the new parts oriented on the old shaft that will be replaced.
This is the correct orientation of the ceramic seal for the water pump.
Thanks! Its getting there isn"t it?
Engine Build Started
I started on the engine build this past weekend. Here are the cases with the new Suzuki oem bearings installed in each new oem case.
Shift side case.
Brake side case.
The cases went together without a problem.
Everything rotates smooth without any binding, shifts nice.
I started on the engine build this past weekend. Here are the cases with the new Suzuki oem bearings installed in each new oem case.
Shift side case.
Brake side case.
The cases went together without a problem.
Everything rotates smooth without any binding, shifts nice.
Engine Build Continues
New Mitaka Alloy basket with oem Suzuki Ring Gear installed.Thrust washer to the right.
This is the spacer with the two piece bearing in place. This spacer is a little different than a gasser, which has a thrust washer behind the basket and a spacer and bearing inside the basket. This suzuki spacer is really a combination thrust washer and spacer in one with a two piece bearing that fits onto the spacer. if you look closely at the photo you will see the bearing is a two piece design.
This is the main seal installed.If you look closely at the main seal you will see how the water pump bearing housing covers part of the main seal. You must install this main seal from the inside and before you install the main bearing. My Suzuki manual and my Clymer manual did not mention this procedure.
Back to the clutch.Basket mounted right up with thrust washer in place.
Nut and washer in place. New pushrod and ball.
New clutch pack installed with new oem springs.These clutches only have 5 fibers and 4 steels. On the later RMX models, these fiber plates interchange but the RMXs have 8 fibers and 7 steels.
Fitted the stator cover, new oem shifter and chain cover and oem case saver.
New Mitaka Alloy basket with oem Suzuki Ring Gear installed.Thrust washer to the right.
This is the spacer with the two piece bearing in place. This spacer is a little different than a gasser, which has a thrust washer behind the basket and a spacer and bearing inside the basket. This suzuki spacer is really a combination thrust washer and spacer in one with a two piece bearing that fits onto the spacer. if you look closely at the photo you will see the bearing is a two piece design.
This is the main seal installed.If you look closely at the main seal you will see how the water pump bearing housing covers part of the main seal. You must install this main seal from the inside and before you install the main bearing. My Suzuki manual and my Clymer manual did not mention this procedure.
Back to the clutch.Basket mounted right up with thrust washer in place.
Nut and washer in place. New pushrod and ball.
New clutch pack installed with new oem springs.These clutches only have 5 fibers and 4 steels. On the later RMX models, these fiber plates interchange but the RMXs have 8 fibers and 7 steels.
Fitted the stator cover, new oem shifter and chain cover and oem case saver.
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Waiting on a Wrist Pin Bearing and a Primary Gear
One shot of the engine without the chain cover and case saver installed. The new studs and dowels went in fine. Note, all four of these case studs are different and they are position specific.(check the suzuki fiche). I used assembly lube and I carefully torqued them in three steps with a 1/4 drive torque wrench. That is a new renthal sprocket.
One interesting issue. I had to order a new primary gear and crankshaft woodruff key. The 81 to 84 250 cranks interchange but the 83 and 84 have a different primary gear. (The 85 crank does NOT interchange because the rod is about 8mm longer.) My crank was a new 82 crank so I had to use a new primary gear but the water pump drive gear is the same.
One shot of the engine without the chain cover and case saver installed. The new studs and dowels went in fine. Note, all four of these case studs are different and they are position specific.(check the suzuki fiche). I used assembly lube and I carefully torqued them in three steps with a 1/4 drive torque wrench. That is a new renthal sprocket.
One interesting issue. I had to order a new primary gear and crankshaft woodruff key. The 81 to 84 250 cranks interchange but the 83 and 84 have a different primary gear. (The 85 crank does NOT interchange because the rod is about 8mm longer.) My crank was a new 82 crank so I had to use a new primary gear but the water pump drive gear is the same.
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Stand
That is what I am looking for in a stand. Some mobility and not being hunched over for hours at a time.
That is what I am looking for in a stand. Some mobility and not being hunched over for hours at a time.
Those Princess Auto scissor lifts are just the usual made in China garbage. The quality of the welds is poor. Sometimes you get one that's OK, sometimes not.
One of the welds on mine failed and I had to redo it. No problem if you have a welder, but a pain for the regular guy without a welder.
Also the hydraulic circuit is meager and sometimes the lift won't go up. The fix is to increase the spring pressure on the bypass valve. Wait for a sale to buy one, they're barely worth that price.
One of the welds on mine failed and I had to redo it. No problem if you have a welder, but a pain for the regular guy without a welder.
Also the hydraulic circuit is meager and sometimes the lift won't go up. The fix is to increase the spring pressure on the bypass valve. Wait for a sale to buy one, they're barely worth that price.