Many of you have been following my progress on my subframe and plastics swap from 1998 style to 2001+ RM250.

The step by step link:

http://www.thumperta...ad.php?t=825826

I think I'm the first to do this swap on this model/year(s) bike. I want to thank Cammeddr-z for help and some pics on his previous swaps... Plus, for kinda giving me the confidence to try it myself!!

I knew if I wanted the new style RM250 plastics on my 1998 RM250, I'd have to swap subframes. I bought a used 2001 tank, new shrouds, new rear number plates, new rear fender, used 2001 seat, and a used 2003 subframe and airbox/boot.

The above link will show step by step progress, but I did encounter some pitfalls if you read it. Basically, to make a 2001+ rear subframe fit the 1996-2000 bikes, you need to relocate the lower left side bracket - It needs to move up about an inch. The main center point under the tank needs to be moved as well. I wound up welding threaded tabs onto the old location where the bolt went through - This really is the best way I could come up with to do this because relocating the tub for the bolt and using the factory style attachment wasn't an option due to the rear shock mount.

Next mounting the tank was fairly easy - Thanks to the idea from Cammeddr-z, I made some tabs that bolted to my tank, and then bolted to the frame - They didn't quite line up w/o them. Had to do the same type of thing with the lower radiator attachment point for the shrouds.

The only other thing was the airBOOT. I bought a used airbox/airboot assembly. The new airBOOT was a tad too deep, meaning when I bolted everything down, it was very squished in the frame. The solution was simply to use the 96-00 airBOOT, which was a direct swap from the new one.

I'm sure I'm missing something, but everything else was pretty much putting the plastics on. Aside from some welding (thanks to my awesome neighbor who builds hotrods), this is a fairly easy swap. I'm REALLY pleased with the results - I have a killer graphics kit that I still need to put on, but that will wait a little while longer, until I get a warm enough day.

Here it is: My 1998 RM250 with 2001+ tank and plastics. (I will be swapping the front number plate when I get my new forks to go with my new clamps.)

Here's a before and after:



Here are some others:



















WHATCHA THINK??

looks pretty good..you getting some graphics for it?

Yup -I have this kit:

Very cool!

What forks are you installing?

does look good...post some pics when you get the graphics on

zig06 said:

Whichever I can find - Hoping for some 04+ Showas, but at this point, I'dbe happy with some 01-03 KYB's.

You could consider a set off of a '99 or 2000, those were inverted too. And then you should be able to use your '98's front wheel, brake and axle.

zig06 said:

I had thought that the 98 wheel would work with the newer stuff. If not, I'll go newer - I need to be able to use a 2001+ clamp to correctly use the new number plate.

Unless, the 99-00 forks will fit one of the newer years triple clamps.....???

the conventional forks wont fit the new tripple clamps for the upside down shocks, but i would consider leaving the forks the 98 conventional duel cartrige forks are way better than the newr kayabas and IMHO better than the new showas if there valved right, if your gonna shich out the clamps i would go for a ohlins set up or something realy trick otherwise your just spinng your wheels for astetic reasons yeah the number plate will look cool but your suspension will suck. Its a toss up, but your bike looks sweet i am thinking aboute doing the same i got a set ot tripple from a 07 rmz 250 with mx tech built shocks so i may swich my bike up some did it take alot of modification to fit the sub frame air box and boot on?? or did it all pretty much line up??

98rm250_90cr500 said:

To mount the subframe, the main attachment point above the top rear shock mount needs to be modified. I cut my factory mount down and welded threaded tabs on to the ends of the old mount:







The other main modification was the left lower mount. I cut the mount off at the original location and welded it up about an inch:





Aside from that, the only other modification to make the subframe and the subframe-mounted plastics work is the airboot. You have to use the new style airbox, but use the 96-00 airboot.

Thats basically it on the subframe... :thumbsup:

Good job Dante! looks sweet!

Any decisions on the forks yet? I've heard some folks on here are using RM-Z450 triples on their 47mm Showa RM250s. Perhaps someone more knowledgeable (I've seen Cammer's name attached to a few posts on that)

Well, it really depends on what I can find. I've heard the stockers are great, but this begs the question, Why does NO ONE (mfg'rs) run this style anymore??

I made a mistake by cutting off the lower fork guard from my stock number plate - I really didn't think it made that big of a difference - WELL, it does... My forks didn't leak at all, and shortly after removing the guards and getting the forks muddy, the seals began to leak... If there was a way to protect the seals (w/ a guard) and use a modern number plate, I'd probably stick with 'em. Being that I don't think there's a good solution, I'll probably switch to something inverted.

It just sucks that its gonna take another $300 to get something that will work. It'll probably be a little bit before I can find a good deal on some forks/clamps, so who knows....

Seal savers! they're cheap, and do what they're named for!

The conventional forks flex more. It would be a simpler fix than all this machining holes in your triple trees, but everyone's of the opinion that inverted is the way to go. Truthfully, I like any forks I can get set up to the action I like, and I loved the 02 vintage KTM WP forks that everyone else hates.

Just keep your eyes on every classified you can get your grubby paws on, and get your name out there on forums, some forks will find you. Who knows, some one might even wanna trade! (No, not me). I actually picked up a set of KLX400 forks for my 98 in trade for some vintage parts I had taking up room in my garage, straight across. I think he got screwed, but then again, he thinks I got screwed prolly :p

500XC said:

Intriguing - Never heard of SealSavers; but - I just did some checking on them - They seem pretty easy to me - I'd need to clean my seals/wipers first, but I bet that'd do the trick... hmmmmm....

What size are the factory conventional Showas on the 98 bikes?? Any ideaS?

they're 49mm. Use Race Tech's product search to figure out sizes for years, they make their money on accuracy.

Nice Job!
Just out of curiosity..... How much did this run you so far?

mihylo33 said:

Altogether - I could have bought a 2001+ RM250 by now...

For the plastics/parts alone for the swap:

Tank $22
Shrouds & Plates: $50
Subframe: $75
Rear Fenders (Black & Yellow ones): $26
Seat: $17
Airbox/boot: $15

I bought the 2001+ tank rubber mounts, but they were the exact same size as the 98's.

Oh well - I've had fun, and thats really all that matters I suppose - Plus, if it didn't, I'd be crying!

:thumbsup:

order dr-z400 fork boots they are the exact same forks as a 1998 rm250 which is 49mm showa conventional forks, and the clamps that hold them on so that you can run a newer style front number plate


500xc didn't you swap dr-z forks onto your 1998 a while back? they had the boots on them right? the only difference between the two is the dr-z forks are sprung to .440 kg/nm and the 1998rm250 is sprung to .420 kg/mm

cammeddr-z said:

Very interesting - Although a quick check of ebay revealed no clamps under $125. If I'm spending that kind of $ on the clamps, I might as well go newer inverted, right?

Definitely have to do something - Even if I stuck with my current forks and just adapted the newer plate, you'd still see at least 2 of the old mounting holes on the lower clamp... ugh.

no i meant the plastic hose-type clamps that hold the boots onto the forks like $4 new from the dealer
also i have a set of 45mm showa inverted forks/clamps and a set of 47mm showa inverteds/clamps kicking around........