1982 RM250 Winter Project

Bent206
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Bent206 1/7/2018 5:39pm
1/7/2018 5:39pm
Dekon wrote:
I'd go with the Allen kit because I hate dealing with Philips heads for the cases. But, there are also those who like to keep a...
I'd go with the Allen kit because I hate dealing with Philips heads for the cases. But, there are also those who like to keep a bike stock. Who are you going to have do your crank?

BTW, I've never seen a clutch plate do that.
I’ll bring it to Ken O’Connor Racing. I had him rebuild the crank in my ‘86 CR250 and he did an excellent job.
sandman768
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sandman768 1/7/2018 6:45pm
1/7/2018 6:45pm Edited Date/Time 1/7/2018 6:49pm
Suzuki has never had durable clutch components. Overheating can cause cork plates to break, I have broke plates in Hondas from overheating them. Basket looks pretty grooved up...Honda CR 8mm headed case bolts work nice to replace the Phillip head torture devices
MaxPower
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MaxPower 1/7/2018 7:01pm
1/7/2018 7:01pm Edited Date/Time 1/7/2018 7:03pm
I agree with Sandman. It's a effort to get the right sizes but it's worth it . Replace the engine bolts with flange 8mm head bolts. Allen heads look cheesy and they fill with dirt . 8mm head bolts are easier to get a torque wrench on than Phillips screws
Dekon
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Dekon 1/8/2018 5:10am
1/8/2018 5:10am
Dekon wrote:
I'd go with the Allen kit because I hate dealing with Philips heads for the cases. But, there are also those who like to keep a...
I'd go with the Allen kit because I hate dealing with Philips heads for the cases. But, there are also those who like to keep a bike stock. Who are you going to have do your crank?

BTW, I've never seen a clutch plate do that.
Bent206 wrote:
I’ll bring it to Ken O’Connor Racing. I had him rebuild the crank in my ‘86 CR250 and he did an excellent job.
Ken does great work. Had him do my '89 YZ125 crank. Dropped it off on Thursday morning, got a call Friday morning it was done. Runout was better than OEM spec.

The Shop

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Bent206
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Bent206 1/9/2018 9:38am
1/9/2018 9:38am
Does 020 on the Wiseco piston mean it's .020 = .50mm or does it mean 2.0mm over standard bore?
I haven't measured it yet but thought I'd ask.




Bent206
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Bent206 1/11/2018 3:07pm
1/11/2018 3:07pm
Handlebars stripped and painted. I think they had about 20 layers off paint on them. I saw black, white and gold in multiple layers. I’m happy with the finish. They are straight and have a good old school look to them.
I’m surprised how straight they are considering the rest of the bike!






Bent206
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Bent206 1/31/2018 6:06pm
1/31/2018 6:06pm Edited Date/Time 1/31/2018 6:08pm
I finally started back on this project. Here’s a quick update.
I had Ken O’Connor look at the crank and cylinder.
Good news: the crank is within spec and doesn’t need a rebuild.
Bad news: the cylinder is junk. Missing the intake bridge and has a repair on the bottom skirt.
I found another cylinder on eBay that’s in great shape. I’m waiting for the piston kit to finish up the bore job. Also found replacement for the worn clutch basket. I’ll post some pictures when that arrives.
Struts are finished. Stripped and powder coated.
The axle blocks are done.
Looks like I received a 125 head gasket. Weird, it has the 250 part number on it.






sandman768
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sandman768 2/1/2018 5:24am
2/1/2018 5:24am
Keep at it, it will be nice when you are done.
Bent206
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Bent206 2/1/2018 10:55am
2/1/2018 10:55am
sandman768 wrote:
Keep at it, it will be nice when you are done.
I took a break to work on my modern bike. I greased all of the bearings and gave everything a good cleaning. It's ready for another season of riding. Now I can devote all of my attention to the RM.

Bent206
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Bent206 2/1/2018 2:27pm
2/1/2018 2:27pm
This clutch basket makes me happy! It looks like it may have been touched up with a file but not much, if at all. Hard to tell. It’s out a a 1985 so I had to buy the primary gear to match. Hopefully the piston kit will arrive tomorrow.

Also received the correct head gasket. I was going to ask which side faces the exhaust port.........until I noticed the EX stamped into it. Ha ha






Bent206
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Bent206 2/3/2018 1:07pm
2/3/2018 1:07pm
Rear brake pedal is ready for paint. I reamed the bushing to the next size and welded on a matching shaft. Everything is nice and tight again.






Bent206
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Bent206 2/7/2018 6:07am
2/7/2018 6:07am
I picked up my cylinder from Ken O'Connor Racing. Fresh bore and chamfered ports. He does great work.
I need to double check my parts list but I think I'm almost ready to start assembling the engine.

Bent206
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Bent206 2/18/2018 11:42am
2/18/2018 11:42am
Replaced all off the crankcase and side case fasteners with Honda hardware. All but one fastener arrived with a chrome finish! Figures....ha ha

kruspy378
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kruspy378 2/24/2018 10:49am
2/24/2018 10:49am
Bent206 wrote:
I finally started back on this project. Here’s a quick update. I had Ken O’Connor look at the crank and cylinder. Good news: the crank is...
I finally started back on this project. Here’s a quick update.
I had Ken O’Connor look at the crank and cylinder.
Good news: the crank is within spec and doesn’t need a rebuild.
Bad news: the cylinder is junk. Missing the intake bridge and has a repair on the bottom skirt.
I found another cylinder on eBay that’s in great shape. I’m waiting for the piston kit to finish up the bore job. Also found replacement for the worn clutch basket. I’ll post some pictures when that arrives.
Struts are finished. Stripped and powder coated.
The axle blocks are done.
Looks like I received a 125 head gasket. Weird, it has the 250 part number on it.






Nice bike there! Just a silly question because i have not done much bottom end stuff, How is the crank pin / connecting rod big end needle bearing ? Without separating the crank halves does one just go by "feel" with respect to the lateral and radial play of the connecting rod? Just curious because i have two RM125s, an 81 and an 85 that i did top ends on but did not split cases, yet...Hope i dont have to anytime soon as both appeared good to me with just a "slop" test... I would love to get my hands on a 250. Keep up the nice work ☺Sorry for the long post btw...
Bent206
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Bent206 2/25/2018 6:48am
2/25/2018 6:48am
Bent206 wrote:
I finally started back on this project. Here’s a quick update. I had Ken O’Connor look at the crank and cylinder. Good news: the crank is...
I finally started back on this project. Here’s a quick update.
I had Ken O’Connor look at the crank and cylinder.
Good news: the crank is within spec and doesn’t need a rebuild.
Bad news: the cylinder is junk. Missing the intake bridge and has a repair on the bottom skirt.
I found another cylinder on eBay that’s in great shape. I’m waiting for the piston kit to finish up the bore job. Also found replacement for the worn clutch basket. I’ll post some pictures when that arrives.
Struts are finished. Stripped and powder coated.
The axle blocks are done.
Looks like I received a 125 head gasket. Weird, it has the 250 part number on it.






kruspy378 wrote:
Nice bike there! Just a silly question because i have not done much bottom end stuff, How is the crank pin / connecting rod big end...
Nice bike there! Just a silly question because i have not done much bottom end stuff, How is the crank pin / connecting rod big end needle bearing ? Without separating the crank halves does one just go by "feel" with respect to the lateral and radial play of the connecting rod? Just curious because i have two RM125s, an 81 and an 85 that i did top ends on but did not split cases, yet...Hope i dont have to anytime soon as both appeared good to me with just a "slop" test... I would love to get my hands on a 250. Keep up the nice work ☺Sorry for the long post btw...
I had KOR check the crank. He measured it using dial gauges and by feel. I trust his judgment.
I usually like to have the connecting rod replaced when I rebuild a bike. It gives me piece of mind and most bikes of this vintage are usually shot. It looks like the crank in this bike was rebuilt at some point in its life.
kruspy378
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kruspy378 2/25/2018 7:03am
2/25/2018 7:03am
Bent206 wrote:
I finally started back on this project. Here’s a quick update. I had Ken O’Connor look at the crank and cylinder. Good news: the crank is...
I finally started back on this project. Here’s a quick update.
I had Ken O’Connor look at the crank and cylinder.
Good news: the crank is within spec and doesn’t need a rebuild.
Bad news: the cylinder is junk. Missing the intake bridge and has a repair on the bottom skirt.
I found another cylinder on eBay that’s in great shape. I’m waiting for the piston kit to finish up the bore job. Also found replacement for the worn clutch basket. I’ll post some pictures when that arrives.
Struts are finished. Stripped and powder coated.
The axle blocks are done.
Looks like I received a 125 head gasket. Weird, it has the 250 part number on it.






kruspy378 wrote:
Nice bike there! Just a silly question because i have not done much bottom end stuff, How is the crank pin / connecting rod big end...
Nice bike there! Just a silly question because i have not done much bottom end stuff, How is the crank pin / connecting rod big end needle bearing ? Without separating the crank halves does one just go by "feel" with respect to the lateral and radial play of the connecting rod? Just curious because i have two RM125s, an 81 and an 85 that i did top ends on but did not split cases, yet...Hope i dont have to anytime soon as both appeared good to me with just a "slop" test... I would love to get my hands on a 250. Keep up the nice work ☺Sorry for the long post btw...
Bent206 wrote:
I had KOR check the crank. He measured it using dial gauges and by feel. I trust his judgment. I usually like to have the connecting...
I had KOR check the crank. He measured it using dial gauges and by feel. I trust his judgment.
I usually like to have the connecting rod replaced when I rebuild a bike. It gives me piece of mind and most bikes of this vintage are usually shot. It looks like the crank in this bike was rebuilt at some point in its life.
Gotcha. Good luck with the project. Nice ride!
Bent206
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Bent206 2/25/2018 9:35am
2/25/2018 9:35am
kruspy378 wrote:
Nice bike there! Just a silly question because i have not done much bottom end stuff, How is the crank pin / connecting rod big end...
Nice bike there! Just a silly question because i have not done much bottom end stuff, How is the crank pin / connecting rod big end needle bearing ? Without separating the crank halves does one just go by "feel" with respect to the lateral and radial play of the connecting rod? Just curious because i have two RM125s, an 81 and an 85 that i did top ends on but did not split cases, yet...Hope i dont have to anytime soon as both appeared good to me with just a "slop" test... I would love to get my hands on a 250. Keep up the nice work ☺Sorry for the long post btw...
Bent206 wrote:
I had KOR check the crank. He measured it using dial gauges and by feel. I trust his judgment. I usually like to have the connecting...
I had KOR check the crank. He measured it using dial gauges and by feel. I trust his judgment.
I usually like to have the connecting rod replaced when I rebuild a bike. It gives me piece of mind and most bikes of this vintage are usually shot. It looks like the crank in this bike was rebuilt at some point in its life.
kruspy378 wrote:
Gotcha. Good luck with the project. Nice ride!
Thanks!
Post some pictures of your RM’s.
kruspy378
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kruspy378 2/25/2018 12:28pm
2/25/2018 12:28pm
Bent206 wrote:
I had KOR check the crank. He measured it using dial gauges and by feel. I trust his judgment. I usually like to have the connecting...
I had KOR check the crank. He measured it using dial gauges and by feel. I trust his judgment.
I usually like to have the connecting rod replaced when I rebuild a bike. It gives me piece of mind and most bikes of this vintage are usually shot. It looks like the crank in this bike was rebuilt at some point in its life.
kruspy378 wrote:
Gotcha. Good luck with the project. Nice ride!
Bent206 wrote:
Thanks!
Post some pictures of your RM’s.
I have some pics og the 85 under Old School Moto 1985 RM125 brought back to life. I'll get some of the 81 up soon..

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Bent206
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Bent206 2/28/2018 4:52pm
2/28/2018 4:52pm
I’ve been on hold until I could find another LH case half. Finding a good one took a while but it had to be done.
PO had welded the broken clutch arm boss. I could live with that but I found the case cracked next to the ignition. Not the end of the world but the ignition cover threads had been tapped for English threads. To many things wrong with it.
The replacement (bottom case in picture) looks to be in good condition (besides the ugly paint). I’ll clean it up and paint it with the rest of the engine.
In the meantime I’ve just been working on the small details. Modified the top chain roller mount to accept a modern style sealed bearing roller.



Falcon
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Falcon 3/1/2018 5:05pm
3/1/2018 5:05pm
Nice bike, man. BTW, my '82 RM80 broke the clutch plates just like yours shortly after I learned how to use the clutch.
Bent206
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Bent206 3/9/2018 3:32pm
3/9/2018 3:32pm
1 steps forward 2 steps back.....
The cases are painted, the crank and bearings are in. Looking at the old stock top end kit I purchased and it doesn’t have a wristpin! How did I miss this? The circlips aren’t correct either. At least the piston and ring are right! Haha
I’m digging the black cases with the Honda case bolts.
I’ll assemble the right side tomorrow and post some pictures. I had planned on finishing the motor but that will have to wait for the additional parts.


kruspy378
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kruspy378 3/9/2018 3:38pm
3/9/2018 3:38pm
Circlips and wristpin, part of reciprocating parts... GOTTA wait. The excitement, the anticipation, the "Where the ph you see Kay R my partz? " I feel for that...
kruspy378
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kruspy378 3/9/2018 3:39pm
3/9/2018 3:39pm
Looks nice too btw
Bent206
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Bent206 3/9/2018 6:39pm
3/9/2018 6:39pm
kruspy378 wrote:
Looks nice too btw
Thanks!
It’s getting there.
Bent206
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Bent206 3/10/2018 10:39am
3/10/2018 10:39am
Bottom end is done. I ordered the wristpin and clips. I’ll button up the top end when they arrive.
Looks way better than the day I got it!




Dekon
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Dekon 3/11/2018 6:31am
3/11/2018 6:31am
Engine looks better than the day it left the factory.
Bent206
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Bent206 3/28/2018 8:52am
3/28/2018 8:52am
I figured I'd post an update.
3-weeks later and still waiting for wristpin & clips!! USPS tracking information is terrible. It was supposed to be delivered on March 16th.



I'm just trying to work on the other details while I wait for those.
I installed the rear wheel to sort out the spacers and discovered the backing plate for the rear brake is incorrect. Bummer, as the one on the bike is in great condition. The eBay search continues!
I did rebuild the shock. Some forward progress!! Ha Ha It is ready for nitrogen.


kruspy378
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kruspy378 3/28/2018 9:33am
3/28/2018 9:33am
Shipping is taking way to long imho... Looking nice. How was the shock body? Did you do the piston band, o-ring, and seal head? What viscosity fluid did you use? Good weather is comming soon and cant wait to ride...☺
Bent206
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Bent206 3/29/2018 1:32pm
3/29/2018 1:32pm
F is for F*cking slow! It actually says First Class!!
It took 16 days for the USPS to walk this from Illinois to Rhode Island. There has to be a better transportation system.





kruspy378
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kruspy378 3/29/2018 1:49pm
3/29/2018 1:49pm
Tell me about it... Im waiting for fork springs from Finland. Its been since early March, like the 4th im thinking. Heikki himself, on some Husqvarna or Yamaha... up through the north, cross alaska, into canada then into USA and off east to PA. Probably faster shipping.

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