84 RM 250 E Ground UP Full Restoration

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

  1. Moto7man

    Moto7man A level Member
    Thread Starter

    Messages:
    117
    Likes Received:
    55
    Trophy Points:
    28
    Mastercross Italy Watercooled RM 500 1985

    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.
    http://www.mastercross.net/index_eng.html
    Suzuki NOS Louvers

    [​IMG]

    Like this water cooled 1985 RM 500
    http://www.mastercross.net/index_eng.html

    [​IMG]
     
    mtdirtbag likes this.
  2. Moto7man

    Moto7man A level Member
    Thread Starter

    Messages:
    117
    Likes Received:
    55
    Trophy Points:
    28
    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.[​IMG]

    I did receive some stuff that the average young rider has never seen.

    RM 250 EBC Grooved brake shoes!
    [​IMG]
    [​IMG]
    [​IMG]

    The grooves are supposed to channel any water or debris out of the shoes.
    [​IMG]

    [​IMG]
     
  3. Moto7man

    Moto7man A level Member
    Thread Starter

    Messages:
    117
    Likes Received:
    55
    Trophy Points:
    28
    A few more items just arrived.[​IMG][​IMG][​IMG][​IMG]

    [​IMG]

    New front brake perch with shorty lever. I am gonna replace those phillips screws with allen bolts.

    [​IMG]

    This is actually a Oem NOS KX stop switch, but it mounts right up with the RM harness.

    [​IMG]

    Motion Pro front brake cable.

    [​IMG]

    Motion Pro throttle cable.

    [​IMG]
     
  4. Moto7man

    Moto7man A level Member
    Thread Starter

    Messages:
    117
    Likes Received:
    55
    Trophy Points:
    28
    Frame.

    [​IMG]

    Brake Pedal and Footpegs.

    [​IMG]
     
    mtdirtbag likes this.
  5. Moto7man

    Moto7man A level Member
    Thread Starter

    Messages:
    117
    Likes Received:
    55
    Trophy Points:
    28
    Here are some more photos from the powdercoater.

    Barrel, engine case and clutch cover.
    [​IMG]

    Suspension Parts Triples and silencer
    [​IMG]

    Head, magnesium ignition cover and water pump cover.
    [​IMG]

    Rear hub and magnesium backing plate.
    [​IMG]

    Swingarm and suspension linkage
    [​IMG]
     
    mtdirtbag likes this.
  6. Moto7man

    Moto7man A level Member
    Thread Starter

    Messages:
    117
    Likes Received:
    55
    Trophy Points:
    28
    Reassembly Begins!

    The powdercoated parts just arrived last night. So, assembly will begin this week.

    Here is the frame.
    [​IMG]

    Rear brake lever.
    [​IMG]

    Cylinder and head.
    [​IMG]

    Head again.
    [​IMG]

    Rear brake drum and backing plate.

    [​IMG]

    Wheels and engine cases.
    [​IMG]

    Triples and rear suspension components.
    [​IMG]

    Radiator guards.
    [​IMG]
     
  7. Moto7man

    Moto7man A level Member
    Thread Starter

    Messages:
    117
    Likes Received:
    55
    Trophy Points:
    28
    Front hub and backing plate.

    [​IMG]

    Foot pegs, stock and upgraded.

    [​IMG]

    Swingarm

    [​IMG]

    Another shot of the brake pedal with the folding tip.
    [​IMG]

    Silencer soon to be modified into a spark arrestor.
    [​IMG]

    Triples again with rear brake arm and rad guards.
    [​IMG]

    Cylinder head with water pump and outlet.
    [​IMG]
     
  8. Moto7man

    Moto7man A level Member
    Thread Starter

    Messages:
    117
    Likes Received:
    55
    Trophy Points:
    28
    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.
    [​IMG]

    CDI and Coil mounted up.Just waiting for a oem protector and mount for the CDI.

    [​IMG]

    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.

    [​IMG]

    I think the frame turned out nice. Here are some shots of the frame.
    [​IMG]

    [​IMG]
     
  9. Moto7man

    Moto7man A level Member
    Thread Starter

    Messages:
    117
    Likes Received:
    55
    Trophy Points:
    28
    Tank mounted, just waiting on some bolts.

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]
     
    mtdirtbag likes this.
  10. Moto7man

    Moto7man A level Member
    Thread Starter

    Messages:
    117
    Likes Received:
    55
    Trophy Points:
    28
    [​IMG]

    [​IMG]

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

    [​IMG]
     
    mtdirtbag likes this.
  11. Moto7man

    Moto7man A level Member
    Thread Starter

    Messages:
    117
    Likes Received:
    55
    Trophy Points:
    28
    I decided to go to the bigger bars on the RM. I was able to find ProTaper Mounts with Pro Taper Replacement Cone Kit.

    [​IMG]

    [​IMG]

    Pro Taper Bar Pad

    [​IMG]


    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.
    [​IMG]

    Top
    [​IMG]

    Bottom
    [​IMG]

    Partially bolted up with new throttle, clutch and front brake cables.

    [​IMG]

    [​IMG]
     

Share This Page