Suzuki RL250 Mania

[Westy]

Thanks Stork. I'll leave the coils separate. Thanks again for the information regarding sprockets. I'll check things out this week.

I have been busy playing with my left hand cover. It looks better than before.

[Westy]

Hey Hey. I got a nice orange polyurethane colour on my parts today. Next comes silver and then clear and then it's time to make some moulds. Looking good? What do ya think?

I got a refund for that dodgey cable.

I spoke to B & J Racing this morning. Bob's sending my order out today! Woo hoo!

[Westy]

Restoration update.

I went into the bike shop that sold me the wrong pitch sprocket. They are cool with me returning it. BUT! I asked if they make an alloy TT500 sprocket for a '79. YES they do! So I am going to exchange my steel 520 sprocket for an alloy one. Funnily enough, it's the same sprocket used on an early model YZ. How's that? ... and it has a great tooth selection from 42 to 55. I have decided that I am going to keep the 520 pitch transmission system and make my own front sprockets.

From this I have an idea for a great chain tensioner that doesn't use a block of plastic that eventually wears out.

As you may have seen in some previous photographs that my stop lamp is very bright but the tail lamp can't even be seen. Especially when the lens reflector is in line with the filament. I have a plan to rectify this dull problem. Just this afternoon I purchased a little back of engineering tricks that I am going to assemble. When I am finished, the dull tail lamp will be bright as bright can be.

I also bought some fuel hose.

Does anyone have any colour schemes that they can suggest the for an RL other than original?

[David Lahey]

This one looks pretty cool

[David Lahey]

Restoration update.

I went into the bike shop that sold me the wrong pitch sprocket. They are cool with me returning it. BUT! I asked if they make an alloy TT500 sprocket for a '79. YES they do! So I am going to exchange my steel 520 sprocket for an alloy one. Funnily enough, it's the same sprocket used on an early model YZ. How's that?

It's because Yamaha like many other manufacturers likes to use parts from an existing model when they make a new model!
The forks and wheels (and many other parts) on the first model TT500 were a direct lift from the YZ range and other model Yamahas.

[Westy]

It's pretty handy Dave. Just like the TS and RL swap over. My favourite is the DT200 with the YZ frame.
I need to know where the clutch cover came from on that RL you posted on this thread?
If it lightens my clutch I want one!

[David Lahey]

I'm no Suzuki expert but I do remember that in about 1976 or 1977 the TS250 motor (and a few other TS motors) started using a clutch cover that looked like that.

[Stork955]

Gday, I think the PE 250's (B, C, N) used a 520 sprocket that will fit the RL. They have a raised face on one side so you would need to fit it "backwards" to make it work. Easier than getting one made. Cheaper too. Have a look on the JT Sprockets website, they have dimensions etc on there, the RL has an unusual spline size, 5 mm pitch IIRC.

Cheers,

Stork

[Scorps]

Howdy Y'all,

Pipoca, that yellow and silver RL is my Dad's bike, the clutch cover came on the bike when we bought. The cover though, is off a 73/74/75 TM250 or a 76 TS250. Check Ebay USA there is one on there now:

http://cgi.ebay.com/ebaymotors/SUZUKI-TM-250-TM250-1974-CLUTCH-ENGINE-COVER-AHRMA-MX_W0QQcmdZViewItemQQ_trksidZp3286Q2em20Q2el1116QQhashZitem483036f5a4QQitemZ310046553508QQptZMotorcyclesQ5fPartsQ5fAccessories

If you want a lighter clutch though, just take out 3 of the clutch springs (every second one of course!). Dad's RL is running only 3 std springs and it didn't slip once during the Brooweena trial.

Cheers,
Your friendly neighbourhood ScorpaMan,
Scorps

[Westy]

Thanks for the model number and the link Scorps! My original clutch cover has a patch on it. I have been searching all over for one and could only find junk on ebay. Tonight I put in TM250 and TS250 and I found about eight of the buggers. One of them is NOS. So, I have bid on two cheapies and bought one out-right off a 1972 TS250.
I have a belly full of spaghetti and a spare clutch cover on the way. I'll sleep well tonight.

I have a question for everyone. If a 520 chain has an inside width of 0.25" and the recommended sprocket thickness is 0.227" (found on the net). Would you say that using a sprocket 0.236" thick would cause me much problems? In metric terms I would be decreasing the clearance from 600 micron to 355 micron.

Westy