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Author Topic: PROJECT: 1986 RM250  (Read 15062 times)

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Offline MotoDave721

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PROJECT: 1986 RM250
« 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... ;D. 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
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline MotoDave721

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PROJECT: 1986 RM250
« Reply #1 on: December 30, 2012, 04:20:29 PM »
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline SachsGS

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PROJECT: 1986 RM250
« Reply #2 on: December 30, 2012, 04:29:48 PM »
As a friend would say, a nicely "farmerized" bike. Some people shouldn't have welders.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline MotoDave721

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PROJECT: 1986 RM250
« Reply #3 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!
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline MotoDave721

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PROJECT: 1986 RM250
« Reply #4 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...
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline evo550

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PROJECT: 1986 RM250
« Reply #5 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.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline MotoDave721

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PROJECT: 1986 RM250
« Reply #6 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  8)

Still fun, and now I want to go find the bike I really want and do this again! Glutton for punishment!
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline TMKIWI

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PROJECT: 1986 RM250
« Reply #7 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.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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If you don't fall off you are not going hard enough

Offline MotoDave721

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PROJECT: 1986 RM250
« Reply #8 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



« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline MotoDave721

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PROJECT: 1986 RM250
« Reply #9 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  8)...and go vroom vroom!
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline nnudy34

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PROJECT: 1986 RM250
« Reply #10 on: January 21, 2013, 12:40:54 AM »
Looking great! You do top notch work
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline motoxr377

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PROJECT: 1986 RM250
« Reply #11 on: January 21, 2013, 03:33:16 AM »
How'd you get the tank so perfect???!
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline TMKIWI

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PROJECT: 1986 RM250
« Reply #12 on: January 21, 2013, 06:21:20 AM »
Nice.
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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If you don't fall off you are not going hard enough

Offline MotoDave721

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PROJECT: 1986 RM250
« Reply #13 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!
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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Offline SachsGS

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PROJECT: 1986 RM250
« Reply #14 on: January 22, 2013, 03:15:32 PM »
Garage queen or is she hitting the dirt?
« Last Edit: December 31, 1969, 04:00:00 PM by ' »
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