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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    Ok I removed the clutch actuator from the left case. I put a torch on it and I was able to tap the shaft and the bearing out.There wasn't a keeper or lock ring.

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    There was a hole in the top of the shaft about 6mm deep, It appears Suzuki had a special attachment for a slide hammer tool that fit into the hole, but I could not find it or a picture of it anywhere.

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  2. Hawaiidirtrider

    Hawaiidirtrider Major Contributor!

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    Hmm.. now to figure where to get that part.. or just refurb as good as can
     
  3. Moto7man

    Moto7man A level Member
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    I got a little bit done this weekend. I removed the bearings from both hubs.
    Here is the front hub.
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    Here is a partial shot of the rear hub, note the the nest.
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    Bearings came out of both hubs without a problem. The front hub looked like new inside.
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    The front and rear bearing spacers looked like new. I think these are the original spacers and bearings from the factory.

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    Then I pulled the bearings out of the swingarm. I used a Motion Pro Suspension Service Tool and once I broke the bearing loose, I used an Impact Wrench on the low power setting to spin the tool. It was fast work, 5 minutes each side and the bearings were out.
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    The bearings were not worn, but they were rusted very badly.
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    The interior of the swingarm looked fine, it just needs some cleanup.
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  4. Moto7man

    Moto7man A level Member
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    Sorry for the delay, I got busy at work. I have been making some progress.

    Do you think the chain guide block was worn out?[​IMG]

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    Another bolt was sheared in half by the chain.
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    Everything else looked good just a little dirty.

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  5. Moto7man

    Moto7man A level Member
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    The four rear suspension link spherical bearings were retained by steel circlips. They were very oxidized and difficult to remove. I had to compress the spherical bearing with a socket in a bench vice into one circlip to get enough clearance to remove the the circlip on the other side.

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    You need these to pry out the circlips.

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    There were eight of these circlips to remove.

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  6. Moto7man

    Moto7man A level Member
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    I just received a new oem Suzuki .025 piston and one of my crank bearings arrived as well.

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    Here is a pic of the rubber mounted triple clamps. The stock bars were original but had been tweaked hard. Anybody got a recommendation on a bar bend? Does anybody know what the renthal bar bend is on the new 2018 XC Gassers?

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  7. Moto7man

    Moto7man A level Member
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  8. Moto7man

    Moto7man A level Member
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    This is the top steering stem, is this a removable race or machined part of the frame. The multi piece bearing above(pictured in previous post) and below, fits this top of the steering stem.

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    This is what the top bearing looked like before I removed the it.
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    The bottom race is normal and I removed it without a problem.
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  9. Moto7man

    Moto7man A level Member
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    I left my parts with a local powdercoater and after two weeks of the continual run around I went and picked up my parts that were sitting in the same pile in the shop floor where I had left them two weeks ago.

    I am shipping my parts to my old powdercoater.He does a great job but the shipping is a little expensive.

    This is what a bike looks like in a box.
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    Engine cases bubble wrapped and boxed up.
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    Hubs, cylinder and other pieces.
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  10. Moto7man

    Moto7man A level Member
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    Here is a picture of the oem silencer. It was very oxidized, I cleaned it up a bit with a wire wheel. (Always wear respiratory protection) I am going to have it and the radiators anodized.

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    The 34 year old radiators don't look too bad.

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  11. Moto7man

    Moto7man A level Member
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    Some more parts coming in bit by bit.I picked up some used protapers.
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    The Oem triples are rubber mounted, and when I disassembled the triples the rubber cones looked like new.

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  12. Moto7man

    Moto7man A level Member
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    Is This Race Removable? Here is a better picture.

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  13. Moto7man

    Moto7man A level Member
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    The build is moving along. I ordered a suzuki oem top steering stem bearing so that is sorted.
     
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  14. Moto7man

    Moto7man A level Member
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    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.

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

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    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.

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

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    84 RM 250 peg and 98 RM 250 peg
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  15. Moto7man

    Moto7man A level Member
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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.
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    It took a while to get off all the rust
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    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!

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  16. Moto7man

    Moto7man A level Member
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    The new seat cover just arrived.

    [​IMG]
     
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  17. Moto7man

    Moto7man A level Member
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    Btw, I bought a small drill press and mounted it on the workbench last night. [​IMG]

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    It has a laser....
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  18. Moto7man

    Moto7man A level Member
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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.

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    Here is the outer basket.

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    Reverse side of the outer basket.

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  19. Moto7man

    Moto7man A level Member
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    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.
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    I disassembled the throttle and cleaned up the inside of the throttle tube with a dremel and a wire wheel.

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    I ran a tap through the pro tapers so I can can mount hand guards.
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    This is the throttle after cleanup with new Pro Grip Rally Grips mounted,glued and safety wired.

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    MSR Raptor Clutch lever.
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    __________________
     
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  20. Moto7man

    Moto7man A level Member
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    Finished throttle with new grip glued and safety wired with new assembly bolts.[​IMG]

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    Bars are ready to mount up.

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