1981 rm 250 slow build thread...completed..

sandman768
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sandman768 7/1/2017 6:30am
7/1/2017 6:30am
chuckie108 wrote:
Looking good so far!
Thanks, chuckie108....I"m planning on the reassembly during winter, when I have more spare time. Still gathering up a few parts & flirting with fitting a 1985 rm 250 rear shock.

The Shop

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OW38B
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OW38B 7/29/2017 12:58am
7/29/2017 12:58am
Holy Smokes!

Doing a great job so far Sandman. Looking forward to seeing it completed.

I did a 77 Suzuki RM250 two years ago and for sure, was a labor of love. Cool
sandman768
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sandman768 9/7/2017 12:18pm
9/7/2017 12:18pm
Well, all the practice tracks are closed due to the non stop rain......so...good time to clean & reseal the most over engineered airbox of all time....



carbon fiber wrap on the airbox covers....
sandman768
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sandman768 9/7/2017 12:21pm
9/7/2017 12:21pm
OW38B wrote:
Holy Smokes! Doing a great job so far Sandman. Looking forward to seeing it completed. I did a 77 Suzuki RM250 two years ago and for...
Holy Smokes!

Doing a great job so far Sandman. Looking forward to seeing it completed.

I did a 77 Suzuki RM250 two years ago and for sure, was a labor of love. Cool
Thanks Ow38b....I love the old air cooled RM"s.... Did you post up your build?
sandman768
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sandman768 10/3/2017 9:46am
10/3/2017 9:46am








Frame back from PowderTech, a few weeks ago. Finally got a few hrs to play with it this morning.
sandman768
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sandman768 10/17/2017 2:07pm
10/17/2017 2:07pm
Oem pipe, dents removed the best I could, sandblasted, sanded down, blued welds, high temp clear coat paint. Been putting time into the gas tank, wet sanding with various grades, still have long way to go on the tank, graphics will cover most of the tank ...until they bubble back off...





sandman768
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sandman768 10/17/2017 2:14pm
10/17/2017 2:14pm
Popped in the last few case bearings today, bottom end all prepped for paint..







cvm
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cvm 10/18/2017 1:13am
10/18/2017 1:13am
sandman768 wrote:
Popped in the last few case bearings today, bottom end all prepped for paint..[img]https://p.vitalmx.com/photos/forums/2017/10/17/220543/s1200_image.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2017/10/17/220544/s1200_image.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2017/10/17/220545/s1200_image.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2017/10/17/220546/s1200_image.jpg[/img]
Popped in the last few case bearings today, bottom end all prepped for paint..







"Paint" your seals / filler plug / etc, w/vasoline and a Q-tip so paint doesn't stick. Unless you're a step ahead of me & they are all donor pieces Smile

Fantastic bike thx for sharing.
sandman768
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sandman768 10/18/2017 4:14am
10/18/2017 4:14am
Thanks for the tip Cvm....the seals, screws, filler plug are all old parts just used for refinishing....in another lifetime I was a pretty good automotive painter....trying not to get too carried away with this build...but I do have a good amount of time into prepping these cases! Should be able to get them refinished today, yesterday temps were a little too cool for the PJ1 case paint. Just ordered Race Tech shock rebuild internals for the rear shock, was hoping the 85 resevoir with adjustable compression & bladder would fit the 81 shock.... Thread pitch is different ...just going to go with the stock 81 resevoir.
450exc115
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450exc115 10/18/2017 6:16am
10/18/2017 6:16am
Bring both hoses to a Parker hydraulic hose shop and have them make up one for you. Cost me about $25-35 to make up one for my YZ
sandman768
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sandman768 10/20/2017 11:43am
10/20/2017 11:43am
450exc115 wrote:
Bring both hoses to a Parker hydraulic hose shop and have them make up one for you. Cost me about $25-35 to make up one for...
Bring both hoses to a Parker hydraulic hose shop and have them make up one for you. Cost me about $25-35 to make up one for my YZ
Thanks, I"ll look into that....
sandman768
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sandman768 10/25/2017 4:34pm
10/25/2017 4:34pm
Assembled most of the bottom end today....all new Seals, bearings, shift forks & a couple nos gears. I had a spare bottom end to use a few better looking gears from, this model is 1 year only on a lot of engine parts. Went together really nice.



sandman768
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sandman768 10/25/2017 4:51pm
10/25/2017 4:51pm
Dropped shock off today to be rebuilt, shop not sure if he can save it, the upper mount that holds the compression adjuster is loose on the shock shaft & leaking oil. I may have to go with the complete 85 shock, which will need a shaft & hose, along with a full rebuild.
sandman768
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sandman768 10/30/2017 4:43pm
10/30/2017 4:43pm
Decided to go with the 85 shock, have some parts coming to rebuild it....went about as far as I could until the shock is done...this bike did come with a lot of spares & a full set of Nos plastics, got everything test fitted & all new hardware sorted for it...have to get down to my brothers work shop to glass bead the cylinder, shock spring & retainer....the wheels are solid and in good condition, I will just sodablast them to clean up the spoke & nipples.















sandman768
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sandman768 11/1/2017 12:29pm
11/1/2017 12:29pm
Swingarm done...had the normal gouges & scratches..bearings were good, had everything else replated, swing arm chain buffer still has life in it, replaced the chain guide lower pad. New decals....







Pit Row

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Shredder
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Shredder 11/2/2017 11:20am
11/2/2017 11:20am
Please tell me you're not leaving the forks yellow and you're not going to leave that front fender on it. That bad boy is screaming for silver forks and a Tony D fender! This is my fave vintage bike of all time from my youth as a grom jonesing for my big bro's bikes.Looks great though, can't wait to see the end result.
sandman768
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sandman768 11/2/2017 6:12pm
11/2/2017 6:12pm Edited Date/Time 11/2/2017 6:14pm
Shredder wrote:
Please tell me you're not leaving the forks yellow and you're not going to leave that front fender on it. That bad boy is screaming for...
Please tell me you're not leaving the forks yellow and you're not going to leave that front fender on it. That bad boy is screaming for silver forks and a Tony D fender! This is my fave vintage bike of all time from my youth as a grom jonesing for my big bro's bikes.Looks great though, can't wait to see the end result.
Not diggin the platipus front fender? ....I know it's not correct for the year, I"m just test fitting some stuff, I do have a Tony D front fender or Preston petty? ...the forks...they are staying on...I have the original 38 mm"s actually in very good condition, but the yellow forks are a complete front end from an 83 which are 43 mm forks, they also accept the dls front brake setup that I"m using. wait until u see my metal milisha graphics & pink spoke wraps!
sandman768
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sandman768 11/6/2017 4:04pm
11/6/2017 4:04pm
Nos 84-85 shock internals showed up today...Thanks, Leeroy....

sandman768
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sandman768 11/11/2017 4:27pm
11/11/2017 4:27pm
Got the shock body ready for reassembly. Found out the shock I have is an 83-84 rm 500 shock, not an 85 250 shock, hopefully the 84-85 piston assembly works! Got a new braided hose made up by a local company., They had it done in 1 day.



sandman768
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sandman768 11/11/2017 4:34pm
11/11/2017 4:34pm
Sent cylinder to Powersealusa to get fitted to next size piston & have Oem intake boot on order from RMC. Ordered tank & side plate decals from Evo-MX , within a few weeks this project should be wrapping up..
sandman768
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sandman768 11/16/2017 1:24pm
11/16/2017 1:24pm
Made some progress today ...was glad the 84 shock internals worked with what I think is an 83-84 rm 500 shock.....mounted up really nice to swingarm & modified upper rocker



All new seals, shock bearings, spacers ect.



sandman768
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sandman768 11/16/2017 1:39pm
11/16/2017 1:39pm
Shock resevoir is larger & has external adjuster, I"m going to have to fab up new mounts for the resevoir.







Period correct aluminum adjustable struts, may be the 125? I have a what I think is a 125 rocker that they fit better?





I must have about 4 hrs into getting this front brake to work correctly ! When I pull the brakes on they stick...everything is new or refurbished...the brake pads are sticking in the hub....aftermarket brake pads came with bike look new, I have heard Oem pads work the best?
sandman768
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sandman768 12/1/2017 3:57pm
12/1/2017 3:57pm
New nos intake manifold

Evo -MX to the rescue!

Made a lot of progress today.....cylinder back from Powersealusa, top end done today....





sandman768
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sandman768 12/1/2017 4:03pm
12/1/2017 4:03pm




Tank graphIcs are top notch, or course they did not cover up a spot I had hoped, have to come up with another decal for that spot.

Kick start rebuilt, new nos rubber cover
sandman768
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sandman768 12/2/2017 4:46pm
12/2/2017 4:46pm










Moving along pretty fast now ...not going to be a rider so I just threw on some decent Dunlop 756"s I had laying around. The shock action feels nice, the adjusters work & you can feel them effect the shock compression & rebound, I still have to make a resevoir bracket, but everything needs to be test fitted before I make the bracket. After spending a few hours playing with the aftermarket aluminum strut rods, I decided to use the OEM rods for now, I had all new seals, bushings for the rods anyway. These aluminum strut rods must have come with a hardware kit as they need spacers to fit the upper rocker arm, they could be easily made...likely going to fire this up soon!
sandman768
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sandman768 12/4/2017 11:08am
12/4/2017 11:08am


Slight problem with the dg silencer.....side plate mount is off 1/2 inch, noticed the p.o. Had a cob job brct connecting the 2, that's not going to work for me, I have to take silencer to the welder to get tab extended...also still have to figure a good way to mount the larger shock reservoir...otherwise pretty much done










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