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  #41  
Old 07-06-2018, 12:07 PM
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Join Date: Dec 2015
Last Online: Yesterday 01:19 PM
Location: Murfreesboro,TN
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The build is moving along. I ordered a suzuki oem top steering stem bearing so that is sorted.

---------- Post added at 11:07 AM ---------- Previous post was at 10:38 AM ----------

I saw this listed on another forum without much detail so I though I would see if it would work because the stock 84 footpegs are very narrow. So, I pulled my frame out of my shipping box so I could drill out the peg mount holes before having the frame powder coated.

These are the stock pegs.



These are the 98 RM 250 pegs with pins and springs.



The pins are bigger on the 98 so you have to drill out the holes on the frame to 9.5mm which is a 3/8 inch drill bit. I used carbide bit and a Milwaukee hammer drill at super slow speed. You have to maintain pressure on the drill but barely rotate the bit, as long as you are getting long chunks of metal you are doing fine but if you are just getting metal dust, you are going too fast and you will ruin the bit.

It took me about 6 minutes per each peg mount. Afterwards, the pins fit perfectly.





Pegs bolted right up but I did have to file the brake side a little to clear a frame weld.



84 RM 250 peg and 98 RM 250 peg
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  #42  
Old 07-21-2018, 07:45 PM
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Join Date: Dec 2015
Last Online: Yesterday 01:19 PM
Location: Murfreesboro,TN
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Big stuff is still at the powdercoaters. I just cleaned up some stuff to have it cad plated.

Here is the stuff after cleanup waiting to be cad plated.


It took a while to get off all the rust




I had to use a mini sledge to get the rear axle out. I thought it was impossible to clean up the threads. I bought a Snap On Thread Chaser RD7-18 which is a M16-1.50 thread pitch. It worked!









---------- Post added at 06:36 PM ---------- Previous post was at 06:34 PM ----------

The new seat cover just arrived.



---------- Post added at 06:45 PM ---------- Previous post was at 06:36 PM ----------

Btw, I bought a small drill press and mounted it on the workbench last night.









It has a laser....


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  #43  
Old 07-23-2018, 02:44 PM
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Join Date: Dec 2015
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Location: Murfreesboro,TN
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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.





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  #44  
Old 07-29-2018, 11:40 AM
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Join Date: Dec 2015
Last Online: Yesterday 01:19 PM
Location: Murfreesboro,TN
Posts: 227
Default 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 with new Pro Grip Rally Grips mounted,glued and safety wired.




MSR Raptor Clutch lever.




---------- Post added at 10:40 AM ---------- Previous post was at 10:31 AM ----------

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



Bars are ready to mount up.


Last edited by Moto7man; 07-29-2018 at 11:34 AM. Reason: grammer
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  #45  
Old 07-31-2018, 10:30 PM
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Location: Murfreesboro,TN
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Default 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



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

Last edited by Moto7man; 07-31-2018 at 10:35 PM. Reason: add link
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  #46  
Old 08-03-2018, 12:29 PM
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Location: Murfreesboro,TN
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Default 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.

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  #47  
Old 08-03-2018, 04:20 PM
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Location: Murfreesboro,TN
Posts: 227
Default More Stuff

A few more items just arrived.:r ockout



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.

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  #48  
Old 08-16-2018, 04:39 PM
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Location: Murfreesboro,TN
Posts: 227
Default First Pictures From the Powdercoater!

Frame.



Brake Pedal and Footpegs.

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  #49  
Old 08-22-2018, 01:57 PM
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Location: Murfreesboro,TN
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Default 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 links
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  #50  
Old 08-28-2018, 02:03 PM
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Location: Murfreesboro,TN
Posts: 227
Default 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.


---------- Post added at 01:03 PM ---------- Previous post was at 12:53 PM ----------

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.
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  #51  
Old 09-08-2018, 11:57 AM
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Location: Murfreesboro,TN
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Default 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 like 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.




---------- Post added at 10:48 AM ---------- Previous post was at 10:37 AM ----------

Tank mounted, just waiting on some bolts.

















---------- Post added at 10:57 AM ---------- Previous post was at 10:48 AM ----------





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

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  #52  
Old Yesterday, 01:19 PM
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Location: Murfreesboro,TN
Posts: 227
Default Rubber Bar 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.



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