1988 RM 250 build : Revisited and done

sandman768
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Edited Date/Time 2/21/2019 5:23am
just started restore of 88 rm 250. When I figure out how to get pho's off my phone, I will upload some. the fun has already started. Bike looked decent but the usual signs of neglect by former owners. the biggest issue is the fact that NO One ever greased anything on the bike! teardown was going well until swing arm bolt would not come out, eventually got it out, but after cleaning swing arm, noticed 2 cracks on both parts of swing arm where bearings go, cracks are almost entire length of bearing surface. Needless to say, I need a swing arm! Does anyone know if the 87 rm 250 arm fits the 88 250? cannot figure out how to decode suz part #'s...thanks...p.s also does anyone know what wide footpegs fit these bikes? cannot find any listings for wide pegs, most aftermarket pegs only go back to 1991 models.
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sandman768
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3/21/2014 6:08am
MXM
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3/21/2014 7:46am Edited Date/Time 3/21/2014 3:27pm
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MXM
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3/21/2014 7:46am Edited Date/Time 3/21/2014 3:27pm
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kevkx125
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3/21/2014 9:14am
Take swingarm to a competent welder they should be able to fix it.

The Shop

MXVet261
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3/21/2014 11:14am
MXM that is a 1986 RM250, not '87. 1987 RM250 had a rear disk brake and I believe it's the same swingarm as 1988 but I'm not 100%.

For wide pegs what I usually do is look for sets of pegs on Ebay from 1993-95 RMs. They have a slightly larger pin but you just drill out the frame to that size. They are nice and wide compared to those clothes-pins on the older RM's.

I have a brand new swingarm bearing kit for that bike if you need it. As stated previously, it can be welded. I've had a couple 80's RM's welded in that spot and a good welder will actually make it better than stock.
sandman768
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3/21/2014 1:26pm
Thanks for all who replied! appreciate any advice, always good to get 2nd opinions. MXM, that is an 86 model, which like you state is completely different. The 87 & 88's were to the best of my knowledge very similar, the swingarm & linkage kits state for 87 & 88 rm 250 only. I have been comparing pho's and they look the same. I know the 89 is completely different as well. I called my local Suzuki dealer & he stated he could not cross reference the parts! but all attatching parts are the same. I have no problem getting welded, but I figure 100.00 to weld & then at least another 50-75$ for machine shop to bore inner so bearings can be pressed in properly.I don't see how it can be welded without having machine shop bore inside, I'll post a photo. I have located a decent looking 1987 arm on ebay for 50.00$, I had already bought bearing kit, as I knew I would be replacing those. I may have to take a shop in the dark on the 87 arm fitting. Meanwhile I'll also post photo of an 84 rm 250 I just finished! I planned on picking up a 96 Honda cr 250 for next project, but I have a soft spot for old rm's, don't know why, I've been riding Honda's since 93!
sandman768
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3/21/2014 1:40pm






quicken
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3/21/2014 2:55pm


Great looking '84!! Would like to see some clearer pics of it.

If your frame lug on the '88 looks like this, '91-02 RM pegs will fit....... if you drill out the mount and get the bigger pins (as mentioned above)
MXM
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3/21/2014 3:27pm Edited Date/Time 3/21/2014 3:27pm
oops! I have been working on so many 87's I think everything is an 87! Ya it's a 86, please dis- regard my comments.
sandman768
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3/21/2014 4:15pm
Agree on photo's, guess I'll have to increase resolution. Thanks for the photo Quicken! that's what mine look like, I will pick up some pegs & then I can send frame & few other items to get powder coated, while I work through the swingarm issue. I have compared every part that bolts onto, into or through both 87 & 88 arms, the only parts that don't interchange as per Partszilla are the brake caliper mount brct & the brake hose guides, I guess that would be enough to make Suzuki say arms are not interchangeable. I will bite the bullet & try the ebay 87 arm. I will find out if they interchange just in case some fool like me on the other side of the world is wondering! Good story on the 84 rm. Bought from a kid who knew nothing about bike, kid just had bike long enough to suck dirt & ruin top end, because the original filter had dry rotted to nothing. When I looked at the bike the first time, it was dirty & looked like it was too far gone. I walked away, told the kid I was not looking for another basket case. 1 week later the kid called me & said come get it for what I had offered which was 1/2 of what he was asking. When I got home, I degreased & pressure washed it & whoa! under all that crust, was a mostly original bike, original chain & sprockets, front tire, all plastic ect. The bike had never been pressure washed, I did not have to replace 1 bearing on the whole chassis. the rims are cleaner than my 2013 crf 450 rims! I got lucky on that bike, appears luck ran out on this 88 rm ! ha,ha.
MXVet261
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3/21/2014 4:19pm
I have an '84 as well..

2
sandman768
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3/21/2014 4:56pm
Love the gold wheels! if my stockers were not so clean I would have laced up some gold one's. have you ever thought about bolting on 84-88 rm 125 gas tank? much smaller & more compact. I have yet to try it, I don't think it requires much..
3/21/2014 6:18pm
MXVet261 wrote:
MXM that is a 1986 RM250, not '87. 1987 RM250 had a rear disk brake and I believe it's the same swingarm as 1988 but I'm...
MXM that is a 1986 RM250, not '87. 1987 RM250 had a rear disk brake and I believe it's the same swingarm as 1988 but I'm not 100%.

For wide pegs what I usually do is look for sets of pegs on Ebay from 1993-95 RMs. They have a slightly larger pin but you just drill out the frame to that size. They are nice and wide compared to those clothes-pins on the older RM's.

I have a brand new swingarm bearing kit for that bike if you need it. As stated previously, it can be welded. I've had a couple 80's RM's welded in that spot and a good welder will actually make it better than stock.
You are wrong. The '86 RM250 had a rear drum brake.
3/21/2014 6:20pm
Ya'll all wrong LOL. That is not a 1986. Op's bike has a rear disk. '86 had a rear drum.

3/21/2014 6:24pm Edited Date/Time 3/21/2014 6:25pm
I'd Order an 87 swingarm bolt first and see If it's the same length and whether it'll go through the mount in the engine cases. If it matches the 88, the the swingarm should fit fine. Might need an 87 rear axle as well if the bearing sizes in the hub changed.
3/21/2014 6:25pm
1987:


1988:


and finally, the most awesome RM250 of the 80s...
1989:
1
3/21/2014 6:28pm
It's good to look at linkage parts on ebay from different years to see if they mount the same as well. I almost ordered 1998 linkage parts for my 97 rm250 but a look at ebay showed that the linkage mounted way different and wouldn't have worked.
quicken
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3/21/2014 6:59pm
MXVet261 wrote:
MXM that is a 1986 RM250, not '87. 1987 RM250 had a rear disk brake and I believe it's the same swingarm as 1988 but I'm...
MXM that is a 1986 RM250, not '87. 1987 RM250 had a rear disk brake and I believe it's the same swingarm as 1988 but I'm not 100%.

For wide pegs what I usually do is look for sets of pegs on Ebay from 1993-95 RMs. They have a slightly larger pin but you just drill out the frame to that size. They are nice and wide compared to those clothes-pins on the older RM's.

I have a brand new swingarm bearing kit for that bike if you need it. As stated previously, it can be welded. I've had a couple 80's RM's welded in that spot and a good welder will actually make it better than stock.
You are wrong. The '86 RM250 had a rear drum brake.
They're talking about a pic MXM had up ....not the OP's pic
MXVet261
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3/22/2014 5:15am Edited Date/Time 3/22/2014 5:16am
Queen of Spodes, you are not reading some of our posts correctly. We are saying the exact same thing as you. MXM realized his mistake and deleted his incorrect info.
MXM
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3/22/2014 6:31am Edited Date/Time 3/22/2014 6:37am
My bad! I was confused after watching 2 weeks of "airplane" wreckage recovery on tv and almost put a photo up of the boeing 777 instead...lol Please lay all the blame at my eye weary brain.
kevkx125
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3/22/2014 8:35am
If those are pics of your swing arm, the cracks can be repaired. Grind small v in crack and weld & grind.
sandman768
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3/22/2014 10:31am
I agree kevkx125, I'm sure it can be welded, in my area, it will be min. 75-100$, then the issue of clearance for pressing bearings back in, inside bearing surface area may need to be bored or grinded. I have since found ebay 88 arm, does not appear as clean as mine was, but I planned on media blasting the arm anyway. Believe me, a collection of rm swingarms was not my intention! Maybe I'll take mine to the welder just for giggles...seems like no one in my area moves too fast unless 100.00 bill is under their nose!
sandman768
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3/22/2014 10:59am
I should have started this thred/build with proper photo's. These are when I just arrived home, thinking I had another good score! Not sure if I incl'd, but 1 photo I tried to show the mice living in the airbox! At least I had enough brains to take the seat off at the previous owners house, the family of mice ran back into his shed. The previous owner wanted to try & start it, I said, don't bother, good thing, the mice had eaten the filter and the engine would have sucked a bunch of engine destroying acorns! amazingly the top end looks decent, but I already have engine out & torn down. 1 thing I learned doing these old bikes, I go through and replace every part I can get, if I'm going to do it, I'm doing it right!







sandman768
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3/25/2014 1:22am
I think I have determined what makes 87 swingarm different from the 88. the chain adjuster setup was changed in 88 to a less complicated system, without those large adjuster nuts that had to be loose b4 adjusting chain, the 88 does not have the big adjuster nuts 32mm? I compared photos & appears the holes, where the adjusters and axle come through in the swingarm are smaller on the 88. Axle & bearings all the same. Appears if the 87 chain adjuster setup is used than the 87 arm can be used. I think I'll visit my local welder & see what he thinks about welding my arm. My arm has some cosmetic scrapes ect. but no dents or deep gouges. Mean while, a mistake I made on my last restore was to not have the suspension done in time, so I had a frame & engine, that was not ez to move around the shop, I like to at least have a roller so I can move it around. So I thought I would focus on wheels. Brake rotors have rusty bolts & could use a media blast, easy right? I was only able to get 2 rotor screws out, all the other screws are seized in the hub! I tried pb blaster, then heat, not coming out! Tried impact screw driver, but tangs for hubs look fragile, did not want to break hubs. Out comes the drill, now I have to drop them of to a machine shop for removal....So, I'm stalled out on the swing arm, wheels and cant send frame out for powder coating until foot pegs & skid plate get here for fit. This is the point where you start to wonder: what the hell am I doing?
MT MX
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3/25/2014 8:12am
1987: [img]https://farm8.staticflickr.com/7121/7664623312_b054ccf74b_o.jpg[/img] 1988: [img]https://farm6.staticflickr.com/5542/10652659025_0cc5e718e6_o.jpg[/img] and finally, the most awesome RM250 of the 80s... 1989: [img]https://p.vitalmx.com/photos/forums/2012/07/27/1990_suzuki_rm250_852551.jpg[/img]
1987:


1988:


and finally, the most awesome RM250 of the 80s...
1989:
I think the bottom photo is the 1990, not the 1989. The '89 versions graphics said RM horizontally, not vertically
Glen
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3/25/2014 4:48pm
wow, look at that plastic clutch lever and (I think) old-ass Sunline brake lever with the bend in the middle. Talk about old school
barkhard696
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3/25/2014 6:44pm Edited Date/Time 3/25/2014 6:45pm
>I'd Order an 87 swingarm bolt first and see If it's the same length and whether it'll go through the mount in the engine cases. If it matches the 88

Just join FullFloater.com on Facebook. Ed Tajikian (SP?) is on there all the time. He'll know for sure. Also, Dave Dixon is usually a big RM465/500 guy-- but he's restored about 6 of the '88 RM250s. I've done business with both, and both really know their stuff. I'm sure you'd get a lot of your questions answered there.

I have an '82 RM250 with a set of Simons UDX-60s. Marc Shade built that and several other bikes for me. Marc runs FullFloater.com, try it-- and say hello to him for me. Those are all good folks.
sandman768
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3/26/2014 3:23am
I was going to reuse those levers! just kidding, but will sell them! Thanks, Barkhard, I'm going to visit my welder to see what he thinks of arm, If I could find a clean, non dented arm on ebay , for an 88,I would buy it. Sometimes I get impatient on these builds & often buy more than I really need. I have plenty of other issues to address on the build so, I think I'll weigh my options for a while on the arm dilemma. I will reach out to those guy's as you suggested, sounds like they know their stuff. Not a member of facebook, maybe it's time ? Here are some photo's of the clutch cover repairs. the prior owner had it repaired, actually a good weld job, but, they failed to grind down the excess weld material. The clutch pressure plate & basket end were actually rubbing on the weld! must have made noises but must have been too much work to take the cover off again & grind it down correctly. I spent 2 hrs with a die grinder then file. came out nice, I will finish outside case with a product called "all metal". It is an aluminum enriched body filler that can handle heat/oil & gas exposure. I grew up working in a body shop & was painting cars when I was 14 years old, so this is right up wheelhouse! I've restored a few cars in my day, if you think bikes are a pain, do an old car!
sandman768
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4/8/2014 1:45pm






Some updates: After some helpful responses from you guy's, I went ahead & ordered foot pegs for 96-02 rm's. Found a nice set of what appears to be pro Circuit pegs for 20.00$, ordered 96-02 pins & springs & drilled pin holes in frame larger, they fit great! I also ordered a skid plate and clutch side case guard from long time sponsor: Works Connection. They do not list a skid plate for an 88 rm, so I asked them what may be close & the owner knew that 89 rmx was similar. the plate fits good, just had to bend out front tab to clear engine mounts & slightly modify rear brcts, lastly, I also had works connection send a case guard for a newer year rm 250, I selected guard based off photo only. surprise, it will fit nicely & protects the clutch case & lower water pump as designed. This bike had a damaged clutch case & I have seen many others with damage clutch cases, appears they stick out farther, maybe due to Suzuki adding 2 clutch plates in 88. Now I can send frame to welder to have cobby Suzuki welds redone and case guard brcts welded. While at the welder I'll see what he says about the swing arm.
sandman768
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4/30/2014 3:24am






While waiting for the swingarm & frame to come back from the welding shop, I replaced all bearings & seals in the linkage rocker & wheels. I picked up an ebay swingarm, but found cracks very similar to mine & mine was much cleaner, so off to the alum. welder to get mine repaired. I have an extra linkage assy if anyone needs one, needs all new bearings of course! cylinder is at Powerseal getting plated & bottom end is getting a new rod kit, all engine bearings & seals & tranny gears inspected. Once I get the frame back I can refinish that & really start to build it. I'm just hoping to get this bike rolling b4 summer actually starts in NY...A local bike salvage shop had a going out of business sale, he was a KTM dealer, but I stopped in anyway. I went through a bunch of old boxes & found a brand new frnt sprocket, frnt brake levr & rear brake pads! for the RM. I then walked out back to see if they had any parts bikes & there stood an 87 rm 250! Realy the only bike that has Some interchangeable parts. Motor was gone & bike sat out in the elements, swingarm was cracked just like mine! I was able to get a part that was missing off my bike, the airbox lid. the seat base was decent, but I have already repaired mine, so I did not take it. Although I wish I had, I later found out the new rear caliper piston I ordered from R/mountain was discontinued, I was able to pick up an ebay caliper for 20.00$. this build is turning out to be a little problematic but some of that is due too my mechanical ability!

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