Said I wasn't going, but.... 1982 RM250 rebuild

Racerx930
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Edited Date/Time 11/27/2020 8:09pm
Well last year I pretty much sold off all my Maicos and Bultacos when I opened my track here in Oklahoma. I talked myself out of going to Diamond Dons this year but Coop has talked me back into it. I'm going to race his Penton 400 on Saturday and purchased a 1982 RM250 yesterday that's going to need quite a bit.

When I got it home today I noticed some things that just weren't typical of your roached CL bike. It appeared someone had just pulled it down to the frame and painted the frame, It also had new chain sliders, chain rollers, new coil, and a few other new goodies. He even gave me a brand new clymer manual with the bike. I didn't do a compression test right away but I decided to pull the cylinder off and see what she looked like. To my surprise the cylinder looked great and had a brand new OEM .25 over piston installed, you could tell this bikes never been ran since the piston was put in.


The bike still doesn't even try to pop off, I can see that the ignition wire plugs are missing and they've clamped them together. To the naked eye it looks to me like the bike sometimes fires and sometimes doesn't. Even when it does I'm not convinced it's firing well. If I was 100$ convinced that would get this motor going for Diamond Dons I would probably just buy a PVL, but I'm not. Times an issue with it so I don't see me doing a full rebuild on the motor, basicly freshening up the suspension, replacing some linkage bushings and bearings, etc.

Anyone happen to have a spare ignition setup for one of these? It would be nice to have something known good to test with.
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lostboy819
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3/13/2014 4:41pm Edited Date/Time 3/13/2014 4:43pm
Post up some pictures of it. Where did you find it and does it have a twin air single sided airbox on it and blue frame? It could be my old RM and it made the rounds to Ponca and then Shidler etc
Racerx930
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3/13/2014 5:03pm
I can't believe I forgot to grab pics.
It has the OEM air box but will get the DC repop single sided if I get it running.

I was actually in Wichita picking up an XR200 for the cross country (Nothing funner than the 200cc cross country race).

I looked on the Topeka Craigslist and found this thing for $200 bucks but told myself it was just too far. I sent the ad to Coop and he told me I was crazy if I didn't go get, so here I am. He actually raced an 82 last year at DD and told me it was the best "vintage" bike he's ever raced.
lostboy819
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3/13/2014 5:08pm
Best bike ever and even better for vintage. Jorski even has one still.

The Shop

Racerx930
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3/13/2014 5:15pm
My 83 maico 250 I raced the last 2 years was unbelievably fast. I had 3 bike lengths on everybody going into the fist corner at DD's last year. I miss it but it's setting in a museum now.
Racerx930
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3/13/2014 5:17pm
I can't figure this one out. I'm convinced it has igniton problems, just not enough to go buy an ignition lol. I will do a compression test tomorrow, it feels slightly low to me but has a brand new piston in it. So unless it doesn't match the bore...
Jack mehoff
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3/13/2014 5:32pm
Or the ring is only partially seated and is in the process off slipping off
3/13/2014 5:37pm
What shape is the carb in? Remove the plug and put a thimble of pre-mix in the cylinder and then see what you have.
Racerx930
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3/13/2014 5:44pm
Tried that wrench, never pops or anything.
Racerx930
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3/13/2014 5:45pm
The most I've seen out of it is a little smoke out of the exhaust (some times). I really feel like some times it sparks some times it doesn't. The ignition plugs are cut off and hard wired into the CDI wires.
downard254
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3/13/2014 6:24pm
lostboy819 wrote:
[img]https://p.vitalmx.com/photos/forums/2014/03/13/48272/s1200_381855_337150246301509_2063434713_n.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2014/03/13/48273/s1200_388635_337150212968179_1072233032_n.jpg[/img]


It appears to have 1983 tank stickers. Always had hard on for RM's, not sure why. I've owned and raced a bunch of 250's, air cooled '81, '83, '85 (my favorite), '90, and now I have an '06. I never had the pleasure of riding the '82, but I've heard so much about them. A works motor in a stock frame.
3/13/2014 6:59pm
Racerx930 wrote:
The most I've seen out of it is a little smoke out of the exhaust (some times). I really feel like some times it sparks some...
The most I've seen out of it is a little smoke out of the exhaust (some times). I really feel like some times it sparks some times it doesn't. The ignition plugs are cut off and hard wired into the CDI wires.
Disconnect the kill button 1st, Then remove the spark plug cap, check the wires to make sure they aren't cross wired, you can also check the stator and pickups for rust.
Racerx930
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3/13/2014 7:07pm
Kill switch was the first thing I did. Stator area looks really dirty and possibly a partial broken wire on it.

I do need to make sure he's gone wire to wire correctly. It has me wondering why though? As if maybe it's not the correct CDI for this Stator.

Another strange thing is the rebuild kit for this stator is the same kit for a late model RM85. I have a few late model rm85 cdi's laying around.........
lostboy819
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3/13/2014 7:53pm Edited Date/Time 3/13/2014 7:55pm
lostboy819 wrote:
[img]https://p.vitalmx.com/photos/forums/2014/03/13/48272/s1200_381855_337150246301509_2063434713_n.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2014/03/13/48273/s1200_388635_337150212968179_1072233032_n.jpg[/img]


downard254 wrote:
It appears to have 1983 tank stickers. Always had hard on for RM's, not sure why. I've owned and raced a bunch of 250's, air cooled...
It appears to have 1983 tank stickers. Always had hard on for RM's, not sure why. I've owned and raced a bunch of 250's, air cooled '81, '83, '85 (my favorite), '90, and now I have an '06. I never had the pleasure of riding the '82, but I've heard so much about them. A works motor in a stock frame.
That is a tank cover that has the 83 graphics on it, for some reason they never did the cover with the correct 82 graphics. A works motor is right!! and the rear suspension was great the only weal link was the front forks but you could fix them.
Racerx930
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3/14/2014 4:02pm
I'm the worlds worst at remembering to take pictures.

Lots of work and 0 progress today, I took the shock apart thinking I would have the correct seals to rebuild the seal head, I did not.

The reeds were not fully closing so I installed a new set, still doesn't even try to pop off. Tested the compression at 160 psi..


Got my manual out and the color wires I have on my stator only show up on the 81 model stator. The CDI box on this bike and stator are hard wired together. It does produce spark but I just can't help but think I have some kind of ignition issue here. Again we're bypassing fuel issues and spraying fuel straight into the back of the carb just trying to get it to do something.

I'm literally at a loss when I have fuel, fire, and compression and it won't do anything.
vet323
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3/14/2014 4:18pm
Racerx930 wrote:
I'm the worlds worst at remembering to take pictures. Lots of work and 0 progress today, I took the shock apart thinking I would have the...
I'm the worlds worst at remembering to take pictures.

Lots of work and 0 progress today, I took the shock apart thinking I would have the correct seals to rebuild the seal head, I did not.

The reeds were not fully closing so I installed a new set, still doesn't even try to pop off. Tested the compression at 160 psi..


Got my manual out and the color wires I have on my stator only show up on the 81 model stator. The CDI box on this bike and stator are hard wired together. It does produce spark but I just can't help but think I have some kind of ignition issue here. Again we're bypassing fuel issues and spraying fuel straight into the back of the carb just trying to get it to do something.

I'm literally at a loss when I have fuel, fire, and compression and it won't do anything.
Is the spark coming at the right time? Flywheel key missing/broke? I had that happen to a CR500 once and wasted an hour looking at things that were already working.
lostboy819
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3/14/2014 6:48pm
Racerx930 wrote:
I'm the worlds worst at remembering to take pictures. Lots of work and 0 progress today, I took the shock apart thinking I would have the...
I'm the worlds worst at remembering to take pictures.

Lots of work and 0 progress today, I took the shock apart thinking I would have the correct seals to rebuild the seal head, I did not.

The reeds were not fully closing so I installed a new set, still doesn't even try to pop off. Tested the compression at 160 psi..


Got my manual out and the color wires I have on my stator only show up on the 81 model stator. The CDI box on this bike and stator are hard wired together. It does produce spark but I just can't help but think I have some kind of ignition issue here. Again we're bypassing fuel issues and spraying fuel straight into the back of the carb just trying to get it to do something.

I'm literally at a loss when I have fuel, fire, and compression and it won't do anything.
I had the end of the crank with the rotor on it break in half and shear off the key way but you could not tell until you pulled the rotor. Pull it off and see if it sheared the keyway
3/14/2014 7:51pm
If the frame was just painted make sure you have a bare metal ground somewhere. I have acquired project bikes that someone painted and forgot to give the engine a bare ground to the frame (painted engine, frame, mounts, and all bolts were corroded). You can chase your tail until it has a good ground. Same thing with the stator. Pull it and make sure you are metal to metal. Then make sure you still have a magnetized rotor that is rust free.

Vintage is lots of fun. Most of it is figuring out the "fixes" that have been done in the previous 30 years.
lostboy819
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3/14/2014 8:03pm
Racerx930 wrote:
I'm the worlds worst at remembering to take pictures. Lots of work and 0 progress today, I took the shock apart thinking I would have the...
I'm the worlds worst at remembering to take pictures.

Lots of work and 0 progress today, I took the shock apart thinking I would have the correct seals to rebuild the seal head, I did not.

The reeds were not fully closing so I installed a new set, still doesn't even try to pop off. Tested the compression at 160 psi..


Got my manual out and the color wires I have on my stator only show up on the 81 model stator. The CDI box on this bike and stator are hard wired together. It does produce spark but I just can't help but think I have some kind of ignition issue here. Again we're bypassing fuel issues and spraying fuel straight into the back of the carb just trying to get it to do something.

I'm literally at a loss when I have fuel, fire, and compression and it won't do anything.
Is yours worse than this ?
3/15/2014 6:13am
Take one of your "late model " RM 85's, and pull the complete ignition off of a known runner. See if it will fit the 250.

I used a complete '87 YZ80 system on my old '79 YZ250. Taper of the crank ends were the same, rotor / flywheel slid right on.
Racerx930
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3/15/2014 10:39am
Thank you all for the good advice, I'm taking it all into consideration. I think I may have just came up with something here though. I ordered a new stator yesterday, the first year I went to Diamond Dons I burnt one up on an elsinore so I said why not. I got to looking at CDI's on ebay, keep in mind I said mine was hard wired in to the stator.


Look at this photo, see the wire that appears to go to a ground? (Has the round end). This was the wire that he ran into the kill switch. Now that I've disconnected the kill switch it's not hooked up to anything. I am still getting fire though but..................
Craze
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3/15/2014 1:22pm
I had a similar problem...Thought it was electrical, turn out to be the carb....Installed a new one...problem solved.
Racerx930
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3/15/2014 1:53pm
I'm bypassing carb issues by shooting fuel straight into it, it should do something.


As an update I went and messed with this today and it still did nothing. However I did have a complete stator and cdi from an rm85 and it bolted right up. Finally I have bright blue spark! Now it's popping and backfiring as if firing at the wrong time. I just came home from the shop and got to thinking, I put the entire RM85 setup on other than the flywheel, I probably should have put that flywheel on also.
Racerx930
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3/16/2014 5:59pm
I changed the flywheel today to the 03 RM85 flywheel, I now have a complete 03 RM85 ignition system.

The bike fired up on the very first kick and runs awesome! Pics to come as I start the "rebuild".
Racerx930
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3/16/2014 6:00pm
Needing a lower shock res mount. Anyone?
lostboy819
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3/16/2014 10:26pm
I got new ones from midwest action cycle a few years ago.
MaxPower
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3/17/2014 5:53am
OLd RMs had the worst stators. In 82 I though my RM was slow. Had it ported. Still slow. Ran the entire season till 2 races to go and it quit running. Put a new stator on and it was rocket fast. The entire season I thought it was supposed to run like a1980 Kx125. No, it was a fast bike.
My 79 was idling on the stand. It started to sound funny when it was previously running perfect while I was getting googles on. I took off and was unridable by popping. New stator next week and I was back in business. I'm just saying there's different degrees of a bum stator
Racerx930
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3/17/2014 4:35pm
Waiting on parts, pretty boring at this point...


When I took the rear wheel off of this thing it seemed like the swingarm spread apart when I loosened the nut. The reason was because there was no brake side outer spacer. This is another part that is no longer available. I was hoping someone could help me out with the thickness of this spacer? I have the means to fab one if I knew how thick to make it.

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