84 RM 250 E Ground UP Full Restoration

Discussion in 'Suzuki' started by Moto7man, Mar 16, 2018.

  1. Moto7man

    Moto7man A level Member
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    Here I go again with another restoration. I always liked the Suzuki RA and RH Works bikes and the 1984/1985 RMs were the production copy of those bikes.

    I just had this 84 shipped in last night. This bike was parked in a garage in 1991 and never touched for 26 years! Besides the surface rust, she is an original stock bike. This will be a slow build.

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  2. Moto7man

    Moto7man A level Member
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    Piston rings are stuck in the cylinder. Look at the wild design of the frame tubes.[​IMG]
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    Original old school Fox and Cycle News stickers.[​IMG]
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  3. Moto7man

    Moto7man A level Member
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    Last night, I pulled the tank and seat off.
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    Look what I found under the tank....
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    It seems she really has been sitting for a LONG TIME.
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  4. Moto7man

    Moto7man A level Member
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    Ok, back to the inspection. The seems to be very original. There doesn't to be anything missing or anything fouled up by screwball maintenance. Its simply neglect.
    The floater linkage is complete, intact, very smooth and works very nice.
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  5. Moto7man

    Moto7man A level Member
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    Original pipe, it doesn't seem to have any damage.
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    The piston is stuck. I drained the coolant, it was very clean and the rads were full, no oil and no leaks. Rads look good too. Tonight I am going to remove the head and put some Kano Aerokroil Penetrating Oil in the intake and exhaust ports and the piston. I looked at the piston through the exhaust port, it looks good,no damage, just a dusting of a small amount of rust.
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    Here is what I am finding on most of the bike, there is a mixture of red clay and rust on the exposed bolts but the inner parts of the bolts look new.
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  6. Hawaiidirtrider

    Hawaiidirtrider Major Contributor!

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    Awesome.. Its like an archeological find. . I never rode these year bikes. It makes me wonder how these are. I rode a late 70s 125 rm. That’s it till around 2001 rm 250 or so. Nice pics!
     
  7. Moto7man

    Moto7man A level Member
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    Thanks for the compliment! This RM is from a lost era with a different design approach. Its more simple in design and its a lighter machine.
     
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  8. Moto7man

    Moto7man A level Member
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    Ok, I got the piston unstuck from the cylinder after letting the cylinder soak in PB Blaster and Kano Aerokroil Penetrating Oil for about a week.
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    The piston was stuck at almost TDC. The head, and the piston looked good but there was surface rust on the lower cylinder skirts.
     
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  9. Moto7man

    Moto7man A level Member
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    Barrel
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    The piston didn't look too bad at all.
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    There was a lot of carbon on the piston and in the exhaust port.
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    After a quick cleanup, this is what the piston looked like,
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  10. Moto7man

    Moto7man A level Member
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    Intake
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    Reeds looked great, some oxidation on the cage.
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    Another shot after unsticking the cylinder.
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    Stator
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  11. Moto7man

    Moto7man A level Member
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    I could not find direct damage from engine failure or even wear, just neglect from sitting since 1991. I drained the oil and it was debris free just very old. Ok, here is the bad news.
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    The rod and main bearings are stuck too. But no sign of apparent direct damage or wear.

    I decided to pull the motor for a full rebuild. I pulled the swingarm shaft 3/4 of the way out and removed all the engine mounts except the bottom one which the nut came off the bolt but the bolt would not move. I turned the bike upside down and hit the bolt with PB Blaster and some heat, then my impact wrench, the bolt turns freely now but the bolt still will not back out. I am going to let it soak for a few days.
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  12. Moto7man

    Moto7man A level Member
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    Some interesting things.....

    Good sealing side access airbox that completely comes off with 3 bolts and an original Klotz sticker.
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    Full floating rear brake.
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    Dual arm front brake. front forks have compression adjusters on the bottom.
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    Like a time capsule, a Sunstar sprocket logo that I haven't seen since I was 17 years old.
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  13. Moto7man

    Moto7man A level Member
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    Well things are moving along. the bottom motor bolt was tough to take off. I had to put the torch on it twice and pound it out with a mini sledge. It was very rusted and bent.
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    Here is the bottom end on the workbench.
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    The water pump cover came off without a problem. It looks like new inside.
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    The impeller looks perfect as well.
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    I don't think the clutch cover has ever been off the bike. small dent in lower cover, looks like from the rear brake pedal when someone tipped over.
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    Some sludge in the bottom of the clutch cover, I rinsed this all out with some brake cleaner.
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  14. Moto7man

    Moto7man A level Member
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    The clutch basket and plates look original and the clutch basket has never been off the bike.
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    just a very small amount of grooving on the clutch basket.
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    But the steel plates have rusted into the fiber plates.
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  15. Moto7man

    Moto7man A level Member
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    I need help on two problems. I can't get the primary gear nut on the crank loose. I read some threads that said Suzuki put a high strength locker on this nut and it was only removable with heat. Some thought the bolt was a left hand thread because it was so hard to remove, but other said it was right hand thread but it took a lot of heat. I put PB blaster and the torch on the nut, then put my 1200 pound Milwaukee Impact Wrench on it, it didn't move the nut at all and it rounded the edge of the nut but I stopped immediately and I straightened the damage with a file.

    I could use my 3/4 breaker bar with a 3/4 inch 19mm socket.
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    And the nut came right off the stator. I have 6 flywheel pullers and none of them fit this design which has the two locations to thread into the bolt holes.

    Any body have specific puller model to recommend?
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  16. Moto7man

    Moto7man A level Member
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    The clutch basket looks fabulous with no indication that it has ever been removed from the bike.
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  17. Hawaiidirtrider

    Hawaiidirtrider Major Contributor!

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    Wow.. awesome adventure.. are you knowing where to get gaskets and parts for this ? or is it sort of sifting through the used market and ebay etc sifting for what you can find. I got my 82 husky 430 cr but there's everything for those. It's like looking for parts for a 55-57 chevy or a jeep. Got aftermarket stuff for everything for certain years of Husky. My project husky is just sitting. I'm fooling with upgrading my 300rr Beta now. just got an RK head.. got 5 bikes and all need to be addressed. Too many projects!!!
    Thanks for posting! great pictures too!
    Here's my Husky.. Someone put some time into it setting up for vintage racing. I bought it from a navy guy for $400 bucks.. It's got trick parts on it too.. It was missing some parts so started collecting on ebay and got links to sources from the vintage section of cafe husky. Got some vintage dirt bike groups on facebook too. I'm surprised at what's available.
    I raced one of these in the early 80's. I always wanted another one.. The one I had was an xc though.. black tank.. white fenders.. gold fork legs.. Great bike. I rode hard core trail races and raced mx and whatever with it.. awesome bike. I'm sure when I ride it again I will vibrate to death. It's different when you are in your early 20's and pushing 60.

     
  18. Hawaiidirtrider

    Hawaiidirtrider Major Contributor!

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    The one I had was like this.. xc.. not cr..

     
  19. Moto7man

    Moto7man A level Member
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    Actually I was looking for a late 70s early 80s Husky open bike when I bought this bike. I like the red tank and cool rear shocks on your 430, that is a nice bike!
     
  20. Moto7man

    Moto7man A level Member
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    Does anyone know the original blue paint code or the blue powdercoat code for the frame on the 84 RM 125/250?
     

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