Two Stroke Motocross

Two Stroke Motocross Forum => Vintage Two Strokes => Topic started by: MotoDave721 on December 30, 2012, 03:12:42 PM

Title: PROJECT: 1986 RM250
Post by: MotoDave721 on December 30, 2012, 03:12:42 PM: New to the forum, I am presently rebuilding a 1986 RM250. A Craigslist find for under $300, I may have overpaid... . Anyhoo, the bike has been a challange due to abuse, neglect, and copious amounts of rattle can repair. From an ignition rotor that was welded to the crankshaft (true), to an airbox painted black and then safety orange (why paint a black airbox black?), it has been a journey.

I am making the bike over in a more modern look; stripped aluminum hubs, engine cases, cylinder, etc., and a black frame. I hope not to get the Suzuki purists mad by moving away from traditional blue frames and engines! The plastics have been equally abused, painted and then stripped with a body grinder, so lots of time sanding and scraping to get down to good, clean, yellow plastic. I will try and post pics later, having some difficulties earlier.

I am in need of an air filter cage if anyone has one to sell, please message me!

Here are some before pics:

http://i1338.photobucket.com/albums/o695/motoxgarage721/IMG_0317_zpseb5fe3e2.jpg

http://i1338.photobucket.com/albums/o695/motoxgarage721/IMG_0308_zps679fb9f3.jpg

http://i1338.photobucket.com/albums/o695/motoxgarage721/IMG_0316_zps5f3aec55.jpg

http://i1338.photobucket.com/albums/o695/motoxgarage721/IMG_0307_zps496115a4.jpg
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on December 30, 2012, 04:20:29 PM: Here are some in process:

Rolling chassis http://i1338.photobucket.com/albums/o695/motoxgarage721/Picture010_zpsd995dc8f.jpg

Closeup of the rear suspension http://i1338.photobucket.com/albums/o695/motoxgarage721/Picture012_zpsd8e9be2e.jpg

And footpeg area http://i1338.photobucket.com/albums/o695/motoxgarage721/Picture013_zps0ed67a8d.jpg
Title: PROJECT: 1986 RM250
Post by: SachsGS on December 30, 2012, 04:29:48 PM: As a friend would say, a nicely "farmerized" bike. Some people shouldn't have welders.
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on December 30, 2012, 04:42:45 PM: "Farmerized" is being too kind, but for the money I cannot complain too lowdly.

Once I straighten out the crankshaft ordeal, it should come together after that. Lots of elbow grease, straightening, painting cleaning, wire brushing, and powdercoating!
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on January 06, 2013, 12:28:08 AM: Spent some time on the Bridgeport, and was able to straighten some crankcase issues. Seems whoever worked on this engine hammered a bunch of the sealing surfaces and such, so I milled them all square again. The area where the mag cover bolts on was damaged the most, so I removed around .040" from there:

http://i1338.photobucket.com/albums/o695/motoxgarage721/bradspics064_zps55070489.jpg

Then I had to remachine the drain plug and tap out the hole to 16 x 1.5mm threading. Luckily, the oil screen drain from a 2009 RMZ250 has just the same thread:

http://i1338.photobucket.com/albums/o695/motoxgarage721/bradspics066_zps4d232deb.jpg

http://i1338.photobucket.com/albums/o695/motoxgarage721/bradspics067_zps9d3fa616.jpg

Lastly, I had to fabricate new seat mounts since nearly every Suzuki from this era suffers from the plastic seat mounts breaking or wallowing out. Before:

http://i1338.photobucket.com/albums/o695/motoxgarage721/bradspics069_zps2d63e12d.jpg

And after:

http://i1338.photobucket.com/albums/o695/motoxgarage721/bradspics071_zps0bc95b38.jpg

http://i1338.photobucket.com/albums/o695/motoxgarage721/bradspics072_zps8346a343.jpg

Project moves onward. I have equally challanging issues rebuilding the crankshaft...
Title: PROJECT: 1986 RM250
Post by: evo550 on January 06, 2013, 12:50:03 AM: Hi Moto,
Looks like you have your work cut out, I'd have to say this era of racer would have to be the most challenging (expensive/drawn out) era of vintage bike to restore. I did a 1987 cr250 recently and never again. Good luck hope all goes well.
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on January 06, 2013, 12:57:37 AM: SWEET RIDE!

Drawn out, maybe so far. Not like a newer bike where I can get every part easily. I have been forced to troll eBay, and not every seller knows the years properly. I have been led astray on a couple items...amazing how many incorrect parts are out there, buyer beware.

Cost has not been out of hand yet, I will say I am still on budget. But I will not venture into plastics and bodywork yet, which is where it might get costly! Luckily I have access to machining, welding, sand blasting, etc., which helps a ton

Still fun, and now I want to go find the bike I really want and do this again! Glutton for punishment!
Title: PROJECT: 1986 RM250
Post by: TMKIWI on January 06, 2013, 07:50:53 AM: Cool project.
I am in the process of getting a '85 RM250 to go with my 125.
We are only allowed up to 1985 in VMX here.
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on January 20, 2013, 02:05:58 PM: Made some progress this weekend on the project, the engine is now mostly together and back in the frame. As I started to sort the buggered electrics, I discovered (suspected as such...) the CDI is shot. I jerry rigged the wiring to another CDI from another bike, and was able to see spark (!), so I know now that there is life in there!

Anywho, here is the engine going together:

http://i1338.photobucket.com/albums/o695/motoxgarage721/Picture019_zps5cb8f16d.jpg

http://i1338.photobucket.com/albums/o695/motoxgarage721/Picture020_zps527d7157.jpg

And several hours later:

http://i1338.photobucket.com/albums/o695/motoxgarage721/Picture023_zpsc49769f1.jpg

http://i1338.photobucket.com/albums/o695/motoxgarage721/Picture021_zps5304bf06.jpg
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on January 20, 2013, 02:11:38 PM: And finally:

http://i1338.photobucket.com/albums/o695/motoxgarage721/Picture025_zps1c91a42f.jpg

http://i1338.photobucket.com/albums/o695/motoxgarage721/Picture024_zpsee7a275d.jpg

So lots to still sort out, but happy to see it rolling and I can sit on it and bounce the suspension ...and go vroom vroom!
Title: PROJECT: 1986 RM250
Post by: nnudy34 on January 21, 2013, 12:40:54 AM: Looking great! You do top notch work
Title: PROJECT: 1986 RM250
Post by: motoxr377 on January 21, 2013, 03:33:16 AM: How'd you get the tank so perfect???!
Title: PROJECT: 1986 RM250
Post by: TMKIWI on January 21, 2013, 06:21:20 AM: Nice.
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on January 21, 2013, 04:41:47 PM: Thanks guys, it is a work in progress. The tank is really not yet that good, I was able to sand it down, and use the scraping technique to get it closer to normal. I have to really work at it, the previous owner took a body grinder to the tank and plastics to remove black paint!

You can kind of see the damage in this pic:

http://i1338.photobucket.com/albums/o695/motoxgarage721/IMG_0317_zpseb5fe3e2.jpg

More work ahead, but I want to sort the mechanical and electrical problems first. I am Ok with a little patina on the looks, so we will sort this stuff last. Still haven't ordered a seat cover!
Title: PROJECT: 1986 RM250
Post by: SachsGS on January 22, 2013, 03:15:32 PM: Garage queen or is she hitting the dirt?
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on January 22, 2013, 04:06:27 PM: Quote from: SachsGS on January 22, 2013, 11:15:32 PM
Garage queen or is she hitting the dirt?

No way, this one is a rider all the way

After all the sweat equity, I need to earn some back by wailing on her
Title: PROJECT: 1986 RM250
Post by: Chad_Bakken on January 24, 2013, 06:21:06 PM: That looks great!!! I have always loved mid-late 80's bikes
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on March 19, 2013, 05:50:55 PM: Ok, so some small progress on this beast. I still am sorting the electronics, trying to find a decent CDI from the mid-eighties Suzuzki's is kind of tough

Since winter is still here, I am not too worried about it anyway...so I busied myself with the cosmetic side just to get that out of the way:

http://i1338.photobucket.com/albums/o695/motoxgarage721/Picture001_zps4c1e5375.jpg

http://i1338.photobucket.com/albums/o695/motoxgarage721/Picture003_zpsdcd47f00.jpg

http://i1338.photobucket.com/albums/o695/motoxgarage721/Picture002_zps98303955.jpg

So the journey continues, if anyone knows of a decent CDI from a 1985 - 1987 RM250 for a fair price, let me know!
Title: PROJECT: 1986 RM250
Post by: lauterbacher on March 19, 2013, 07:00:04 PM: Really nice bike, Is there anyone who can repair the CDI unit?
Title: PROJECT: 1986 RM250
Post by: SachsGS on March 20, 2013, 12:56:27 AM: I've seen guys McGyver cheap Chinese CDI's to work in the Japanese stuff.
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on March 20, 2013, 05:09:12 PM: I found a CDI from another bike (unknown, but suspect an RM80), and was able to wire it into the harness which was simple. The RM has a simple three phaze stator, and really just goes to the CDI, and then the CDI feeds the coil.

I was able to get a weak spark out of it, but it not putting out enough. I also suspect the rotor magnets are also weak, I may replace that. The stator is new, as is the coil.

My worry with another CDI is simply that the ignition curve would not be correct, possibly hurting the engine. I have a bead on a few fleebay CDI's, so I may just go that route
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on July 14, 2013, 09:22:04 PM: My CDI trials and tribulations continue, still not running. Everything else, except finalizing the silencer connection, is ready to go.

Has anyone used these and been happy with the result? Should I step up and spend nearly what I paid for the scooter and buy PVL?

http://www.ebay.com/itm/NEW-OEM-STATOR-KIT-CDI-SUZUKI-RM-250-74-86-/251249486685?pt=Motorcycles_Parts_Accessories&hash=item3a7fa2eb5d&vxp=mtr#ht_2703wt_1063

Thanks for the feedback!
Title: PROJECT: 1986 RM250
Post by: TMKIWI on July 15, 2013, 08:40:53 AM: Its a small world.
I have just been looking at that for my '85.
His dimensions are slightly wrong on the plate mounting holes and rotor boss, so waiting on a reply back.
Will let you know how I get on.
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on July 15, 2013, 05:31:32 PM: Thanks TM, I would like to hear how well these work. The price is good, so it makes me worry if this is too good....and the PVL I think would be the premium set up. I can normally do some adapting if needed, that seems to be the case with some of these older bikes.

I will keep my eyes open for a used one at Vintage Days this weekend, I hope to be able to get to the swap meet in time to pick up some odds and ends. I am under orders not to bring another one home...
Title: PROJECT: 1986 RM250
Post by: TMKIWI on July 16, 2013, 08:21:57 AM: The guy got back to me and said it "should" fit.
I will pass at this stage.
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on July 20, 2013, 11:02:33 PM: I hear ya, I would run the other way with my wallet too

Vintage Days was a bust for parts, so back to square one
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on July 24, 2013, 05:39:19 PM: Well, picked up a used CDI and flywheel off eBay, so better days ahead. Should start to finally come together and run again, so I will hopefully post a video with sound soon!

Cheers!
Title: PROJECT: 1986 RM250
Post by: scotty dog on August 02, 2013, 03:04:18 PM: Nice work MotoDave I love the 80's bikes
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on September 12, 2013, 03:07:07 PM: Well, 98% there still dealing with the electrics. Seems this is can be the main issue with older bikes if you by one with questionable electronics. So I am working on generating some cash to just purchase the PVL and be done with it...

Here is the finished bike, looking forward to riding it!

http://i1338.photobucket.com/albums/o695/motoxgarage721/RM250011_zps0571eff0.jpg

http://i1338.photobucket.com/albums/o695/motoxgarage721/RM250010_zps91af4b27.jpg
Title: PROJECT: 1986 RM250
Post by: rlaj1004 on September 12, 2013, 04:21:34 PM: Damn, very nice. Thats pretty enough to park in the living room.

But it will look even better covered with mud
Title: PROJECT: 1986 RM250
Post by: Stusmoke on September 13, 2013, 04:19:18 AM: Just started reading this thread now... A welded ignition to crank? Thats upsetting. Heartbreaking in fact, that I belong to a race that could be so stupid.
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on September 15, 2013, 08:40:32 PM: You know it, that was only the beginning on this bike. My personal favorite was the layers of rattle can paint...the black plastic airbox was painted safetly orange, then black again over that

It took several applications of paint remover to get to the bottom of that problem. Thankfully the airbox was pretty decently protected under all that paint.

Funny stuff, some people have no appreciation for things mechanical
Title: PROJECT: 1986 RM250
Post by: KDXGarage on December 17, 2013, 08:01:54 AM: WOW! You did a TERRIFIC job!

Congratulations on your abilities.
Title: PROJECT: 1986 RM250
Post by: blbiker56 on May 27, 2014, 10:17:53 PM: Hey Moto Dave, Love your bike, I am starting a similar one. The little brother to yours 1986 rm125 that I have began building up. I was hoping to get some of the yellow fork guards that you did on your bike, where did you get them? are they just yellow background decals? also the carbon fiber frame sliders are awesome as well!
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on June 27, 2014, 12:55:48 PM: Yup, just yellow background decal for the fork guards, I have been looking out for the real plastic version and will add them at some point. These projects never end!
Title: PROJECT: 1986 RM250
Post by: blbiker56 on June 27, 2014, 03:56:06 PM: Yeah I know, Always an on-going process. Thank you for the advice, I will grab some yellow backgrounds to use on the forks. Very impressed with your build. How does she ride?
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on June 28, 2014, 12:30:40 PM: Well best intentions were to be riding it by now...still looking for a good CDI in my price range. As priorities go, the modern bikes are getting more attention these days (and the money), and I have two sons that ride. So I am hopeful to either trip over a new CDI somewhere like eBay, swap meets, etc...I keep looking. I should just get the PVL but $400 can buy a few sets of tires and weekends of riding!

I will be heading down to Vintage Days at Mid-Ohio with the goal of coming up with something, or another whole bike! I have to jump in to the deep end of the vintage pool, I feel like I am missing out when my bud's talk about the racing the old bikes. For now I get to walk by her in the garage as a reminder to get this project done...
Title: PROJECT: 1986 RM250
Post by: blbiker56 on June 28, 2014, 03:55:11 PM: Is The cdi The same for The 125 and The 250. There are a ton of 125 cdi's on eBay and a couple of 250's for around $75. I would definitely check them out cause a couple look like they are in good shape. You can also get a new coil for about $30.
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on June 29, 2014, 12:34:35 PM: Cool, I didn't know the 125 and 250 shared a CDI, I thought the connectors (male/female) were reversed?

I have a new coil and mag, so this should be one of the final pieces. OK, now I am juiced again to get it going.

And then I picked up another project, a 1953 Cushman Eagle that is a frame up job. Because I need more projects...ugh!
Title: PROJECT: 1986 RM250
Post by: blbiker56 on June 30, 2014, 05:40:34 AM: Quote from: MotoDave721 on June 29, 2014, 07:34:35 PM
Cool, I didn't know the 125 and 250 shared a CDI, I thought the connectors (male/female) were reversed?

I have a new coil and mag, so this should be one of the final pieces. OK, now I am juiced again to get it going.

And then I picked up another project, a 1953 Cushman Eagle that is a frame up job. Because I need more projects...ugh!

I hope you didnt buy a rm125 CDi cause im not sure if they are the same. I was asking, But if you did, I guess you could flip flop the connectors between the one you have and the new one. This is just a though, but I am totally unaware if this would work.
Title: PROJECT: 1986 RM250
Post by: blbiker56 on June 30, 2014, 06:03:29 AM: Here is a picture of my 1986 rm125 CDI Connection.

The coming from the CDI is on the Left and comming from the stator is on the right.
Title: PROJECT: 1986 RM250
Post by: TMKIWI on June 30, 2014, 09:23:23 AM: The CDI plug wiring on my 85' RM 125 & 250 are both different.
Title: PROJECT: 1986 RM250
Post by: MotoDave721 on June 30, 2014, 07:38:39 PM: Thanks for the pic's guys, my plug is inverted from that from the stator. I will keep looking, and hopefully be up and riding sooner rather than later.

I picked up a brand new 2002 RM250 last fall and have been spending weekends getting my moto on, what a great bike! Rare to find too, so I had to jump on the deal, so the real vintage RM250 sits and waits...