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 The RL250 was imported into the U.S.
only for the two model years, 1974-75. The
differences between the two models were few and generally quite insignificant.
In many cases, a revised part number was just a hardware callout; longer screw
or larger diameter washer. Other differences involved a change in
materials, such as steel from aluminum.
In all cases except one, any RL250 part will fit either model. The exception
is that the early '74 models had a 4.16:1 primary gear ratio (75Tx18T) and the
later '74 and '75' models had a 4.23:1 ratio (72Tx17T). The gears for the two
ratios cannot be mixed.
According to Suzuki, the serial number break between models is as follows:
 | 1974 RL250L - Frame - RL250-10001, Engine - RL250-10001 |
| 1975 RL250M - Frame - RL250-18199, Engine - RL250-18223 |
Some differences between models are:
| Fuel tanks - changed to steel from aluminum in '74 |
| Kick starter crank lever - identical except for plating, chrome for
'74, silver cadmium for '75. |
| Tank decals - orange with white trim for aluminum tanks, gold with
black trim for steel tanks |
| Control lever perch clamp hardware - Phillips head screw for '74,
hex head bolt for '75 |
| Rear shock springs - early '74 not progressive wound |
| Clutch Cover Case -
three part numbers listed, two for '74, one for
'75 with different quantities and filler plug types |
| Primary drive ratio - these are the gears on the right side
crankshaft end and the clutch basket. |
| Chain guards - aluminum for '74, steel for late '74 and '75 |
| Lower fork outer tubes - drain screw location; on the bottom early
'74, aft facing on late '74 and '75. |
| Rear brake cable - from RL specific cable to the same used on the
TM400 and other bikes |
It is impossible to distinguish when the more significant changes actually
began to appear on new production bikes. Suzuki, like most manufacturers, will
use up their old stocks before bringing in the newest part. That will not
necessarily be coincident with a new model introduction. The '74 model appeared
in late winter/early spring of 1974. From an engineering viewpoint, changes were
being made even before the first bikes hit the showroom.
Suzuki designers were tasked with the mandate that the bike had to weigh in
under 200 lbs. It is interesting to consider that the aluminum tanks and chain
guards may have been incorporated just to make the target weight as they were
quickly phased out after production began.
Please ask if you have any questions about part applicability.
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