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  #71  
Old 02-27-2019, 06:41 AM
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Quote:
Originally Posted by dogger315 View Post
84 and 85 are direct swaps and 86 and early 87 will bolt on with modifications. Late 87 went to a one piece design.

You are probably going to have to restore what you have because any used shock that shows up will have the same problems or worse.

Looking at the parts fiche, it looks like a straight forward resto and most of the internals are still available OEM and aftermarket.

Your only other option would be trying to find an Ohlins or some other brand, but that is likely to be pricey.
Thanks Dogger! I was quoted $1250.00 for a new Ohlins. I have a couple of leads on a replacement.I will post updates. Thanks for responding!👍
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  #72  
Old 02-28-2019, 01:01 PM
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Default 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




---------- Post added at 01:01 PM ---------- Previous post was at 12:40 PM ----------

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.
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  #73  
Old 02-28-2019, 01:08 PM
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Default 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.
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  #74  
Old 03-04-2019, 01:47 PM
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Default Engine Build Begins

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.

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  #75  
Old 03-12-2019, 12:03 PM
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Default 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 trust 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.




---------- Post added at 10:03 AM ---------- Previous post was at 09:45 AM ----------

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.


Last edited by Moto7man; 03-18-2019 at 09:53 PM. Reason: Updated Technical data.
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  #76  
Old 03-13-2019, 09:36 AM
cowboyona426's Avatar
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You're almost in the home stretch now!
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  #77  
Old 03-14-2019, 08:07 AM
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The shock bodies on those RM's from that era are notorious for wearing out. So much so that in the MXA shootout from 1984 they reported that they needed to replace the shock on the RM250 more than once due to excessive wear. I have restored two 1984 RM125's, and am also finishing a 1984 RM250. I had Race Tech hard anodize the bodies on them as luckily all three of my bikes still had decent servicable shocks. That will go a long way to helping preserve them. If Drew has a source to hard anodize the body, (and I assume he would) that's a worth while investment. Very nice job on the build and thread.
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  #78  
Old 03-16-2019, 10:14 PM
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Quote:
Originally Posted by Greg376 View Post
The shock bodies on those RM's from that era are notorious for wearing out. So much so that in the MXA shootout from 1984 they reported that they needed to replace the shock on the RM250 more than once due to excessive wear. I have restored two 1984 RM125's, and am also finishing a 1984 RM250. I had Race Tech hard anodize the bodies on them as luckily all three of my bikes still had decent servicable shocks. That will go a long way to helping preserve them. If Drew has a source to hard anodize the body, (and I assume he would) that's a worth while investment. Very nice job on the build and thread.
Thanks for the compliment! Drew hard anodized the suspension on my 94 CR 250 and I asked him to the same thing on the RM. It was a real pain finding a replacement shock. Drew is still working on everything and I will post updates on the progress when I know more. I ordered an oem wrist pin bearing, it got here yesterday and it was mislabeled and it would not fit,so I had to stop the engine build until the replacement arrives. Can you add some pictures of your bikes to this thread? I am not hijack sensitive.🤪
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  #79  
Old 03-19-2019, 02:31 PM
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I am waiting for some of engine parts to arrive and my suspension is inbound from Works Enduro Rider. I tried to get some other things knocked out.

I put two oem orings into my brake pedal and a oem new spring and oem spacer on the folding end.








In 1984 this is how you put the "whoa" on your runaway motocrosser.



Thats right, just a single wire, no casing nothing else. Just a single pin connecting it to the rear brake pedal.



I installed the radiator mounts, three on each side.




New rear Sprocket arrived.




---------- Post added at 12:31 PM ---------- Previous post was at 12:22 PM ----------

Some medium strength lock tight.




Suzuki manual calls for 24 to 30 foot pounds, I set them at 26 foot pounds.




I snapped the new louvres onto the metal radiator guards.

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  #80  
Old 03-24-2019, 10:46 PM
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Default Closer to Finishing

The wristpin bearing finally arrived, I used an 18mm BuxTool to install the circlips, it took about 30 seconds to install each circlip. I coated the wristpin and bearing in two stroke oil. I installed a new oem Suzuki base gasket. I lightly wiped the sealing surfaces with lacquer thinner to remove debris and oil. I installed 4 new oem case studs, unlike my CR250, the rounded portion of the studs face up not down and I torqued them to 9 foot pounds. Also, these four case studs are all different with different part numbers and are position specific and two of the studs have dowels.



The cylinder was ported at Pro Circuit and the they milled the head to run on pump gas.This is a Wossner forged piston and it has a marking pointing to the exhaust side. I set the ring end gap at .4mm.








I installed a new oem suzuki head gasket. The must be installed with the 'EX" mark facing up and pointed to the exhaust side of the cylinder. I torqued all the cylinder studs to 9 foot pounds.


Exhaust port.


I am waiting on a few more parts before I can do my leak down test but I decided to install the motor, It went in very easy, the big open frame gives you plenty of access.all new oem motor mount bolts.







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