Basket case 2003 RM250 Build

slick james187
Edited Date/Time 5/9/2014 12:51am
Hello all, I've been lurking the site for a while but I'm new to posting.
I got this build on another site but I'd like to share it here as well.

I want to share with everyone why some people shouldn't own bikes.
I picked up this filthy 03 RM250, worst kind of shape you could imagine.
Plastics all held on with bailing wire, both seat bolt holes trashed.
Shock linkage seized, both forks completely blown and one took a bad hit.
Piston is in peices, somehow to bore only has one small gouge.
Kid rode it without the rear wheel spacer between the wheel and the caliper, beat up the swingarm a bit.

I'll update with photos as I go!

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JM485
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JM485 5/2/2014 9:00pm
5/2/2014 9:00pm
Damn man, thank you for rescuing that thing! I hate to see a bike like that, especially a late model Suzuki. I have an 06 and love it, so I'm sure you will be happy with that thing once it's done. Good luck with the build!
slick james187 5/2/2014 9:16pm
5/2/2014 9:16pm
I couldn't let it rot away. Dumb kid was asking 900 bucks or trade.
I gave him an old crappy but running 1980 Honda xl185 for it.
Kinda kick myself in the ass, but this is ten times the bike.

So I understand that the 03 was a bastard year, I'm curious as to what all year forks and wheels will fit.
I have the chance to pick up some used black excels with tires, front and rear brake setups, a swingarm,
and a set of 49mm showas off a 99 RM125 all for $100. I'm mainly curious if the forks and clamps will work.
I'm not sure to buy the stuff or not.
JM485
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JM485 5/2/2014 11:04pm
5/2/2014 11:04pm
slick james187 wrote:
I couldn't let it rot away. Dumb kid was asking 900 bucks or trade. I gave him an old crappy but running 1980 Honda xl185 for...
I couldn't let it rot away. Dumb kid was asking 900 bucks or trade.
I gave him an old crappy but running 1980 Honda xl185 for it.
Kinda kick myself in the ass, but this is ten times the bike.

So I understand that the 03 was a bastard year, I'm curious as to what all year forks and wheels will fit.
I have the chance to pick up some used black excels with tires, front and rear brake setups, a swingarm,
and a set of 49mm showas off a 99 RM125 all for $100. I'm mainly curious if the forks and clamps will work.
I'm not sure to buy the stuff or not.
I just took some wheels off a 2000 and they fit my 06, so those 99 wheels should fit your 03. As for the forks, assuming they are the same as the 2000 donor bike I had, they will work if you run the 99 clamps. The older forks were about 2mm larger in diameter than the ones on my 06 were, so I wasn't able to use my forks with those clamps. I don't know if the 03 had the newer, smaller diameter forks or not. The older clamps also looked like they had more offset than mine which is why I wanted to try them in the first place, which may or may not work well on the newer bikes.
slick james187 5/3/2014 12:04am
5/3/2014 12:04am
Thats just what I needed to hear!
I just hope I can get to sac before someone else scores the goods.
Thanks for the tips man, much appreciated!

The Shop

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scooter5002
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scooter5002 5/3/2014 1:43am
5/3/2014 1:43am
Seems to me the 03's had trans issues, maybe 3rd was weak? Have a look inside before you get to carried away with just doing a top end and riding off into the sunset. I'm assuming you were going to split the cases anyway, looking at that pic.
slick james187 5/3/2014 1:57am
5/3/2014 1:57am
Already have the bike torn down to frame, painted, linkage rebuilt and have the cases split.
Tranny is nice and smooth shifting, and someone even put brand new clutch plates and springs in it for me!
Will post pics tomorrow!
slick james187 5/3/2014 2:23am
5/3/2014 2:23am
Ok, here is a little carnage.

This is from riding without a wheel spacer, caliper beat the crap out of it.


Fork took a hard hit, gotta replace


Whats left of the seat mounts



And of course this


Got the cases split, not too bad.



And here is the frame after I stripped to metal for inspection and hit it with fresh paint
JM485
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JM485 5/3/2014 8:26am
5/3/2014 8:26am
slick james187 wrote:
Thats just what I needed to hear! I just hope I can get to sac before someone else scores the goods. Thanks for the tips man...
Thats just what I needed to hear!
I just hope I can get to sac before someone else scores the goods.
Thanks for the tips man, much appreciated!
Just to be sure they will work before you make the drive, maybe go onto Motosport.com or something and match up the oem part numbers for the hubs. I would assume 99 and 00 would be the same but I don't want you to get all the way down there and be screwed.
slick james187 5/3/2014 9:51am
5/3/2014 9:51am
Yeah, I was thinking about that. Decided i wanna score some 04 + showas if I can.
If anyone has spare parts for this bike let me know, I need a few things!
For now, I'm off to ebay.
Benton713
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Benton713 5/4/2014 8:07pm
5/4/2014 8:07pm
slick james187 wrote:
Yeah, I was thinking about that. Decided i wanna score some 04 + showas if I can. If anyone has spare parts for this bike let...
Yeah, I was thinking about that. Decided i wanna score some 04 + showas if I can.
If anyone has spare parts for this bike let me know, I need a few things!
For now, I'm off to ebay.
What do you need sir I have a few things that I can part ways with check out my build also
slick james187 5/5/2014 9:37am
5/5/2014 9:37am
I actually read your build last night. Thats some good work! I wish I had that clean of a bike to start with... I have a total of 10-12 hours just cleaning, the pressure washer wouldn't touch 5 or more years of clay and gunk. Had to scrape and scrub!

Ok, as for parts i need here we go:
Airbox, got one but it's a little busted up
Forks, or 03 upper tubes as the ones I got took a hit
Wheels, will probably get new
Head pipe, i do have a Pro Circuit 304 silencer
Maybe a swingarm if I can't repair the caliper rail
Plastic, not opposed to used if it's still nice

There is probably more I'm forgetting, but thats the main stuff i'm after.
suzook241
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suzook241 5/5/2014 12:19pm
5/5/2014 12:19pm Edited Date/Time 5/5/2014 12:21pm
I have a stock 03 pipe, possibly a sub frame, front wheel, full set of triple clamps, used plastic galore, stock reed cage, many seat covers, seat pans,

I may have more, will have to check out the garage later... I also have a full set of suspension off a 2006 that was freshened up by Factory connection and never ridden on.
garagedog 5/5/2014 1:49pm
5/5/2014 1:49pm
Dang, that is nasty. Woohoo Good luck man.!

DPR250R
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DPR250R 5/5/2014 4:41pm
5/5/2014 4:41pm
That might not be an 03. I had an 03 and don't remember the discs being slotted in that pattern. I would double check the VIN.

Anyway... keep posting pics... really want to see how this turns out!!
slick james187 5/5/2014 8:47pm
5/5/2014 8:47pm
I was kinda wondering that myself. The frame has to be a replacement frame, no vin or tool marks from removing one.
I ran the engine numbers and It's apparently a 2002. Fortunately the 03 linkage stuff all worked!
But now I have a full Cometic top and bottom end gasket set for a 2003 I don't need :-(
slick james187 5/8/2014 1:00pm
5/8/2014 1:00pm
Ok fellas, I'm thinking that this bike may be more work than it's really worth. What do you guys think?

Pit Row

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smoothies862 5/8/2014 6:49pm
5/8/2014 6:49pm
i dont think youll make money on it,if thats what you mean. if you plan on keeping it and just enjoy building it when time and cash allow.then thats different. keep us posted.
Benton713
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Benton713 5/9/2014 12:51am
5/9/2014 12:51am
I agree with smoothies keep us posted

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