2005 Suzuki RM 250 Turbojez Rebuilding the old lady.

Turbojez
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Edited Date/Time 8/20/2019 10:51am
Here comes a rebuild on my old 250.
Unfortunately I do not have a lot of "before" pics.
I tore it apart to bits and pieces, simply because the crankshaft went out, and since I had it in boxes I figured, why not polish it up a little before putting it back together?

Parts list:
KYB SSS 48mm forks
X-trig clamps with PHDS
2016 RMZ KYB rear shock ( I hereby salute you Vital user Dizzzi2003)
Renthal Twinwall Bars
Renthal Kevlar grips
270mm Galfer front brake
2016 RMZ MC and Caliper
TiPegs
Polisport Restyled plastics
A bit of carbon fiber goodies

So here it goes, I just closed up the motor yesterday:



and got some bits and pieces delivered:





7
|
6/12/2019 6:15am
Those forks!!!!! Shocked

Definitely following this build. Those CF pieces look amazing
1
soggy
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6/12/2019 6:55am
:drooling:
1
Turbojez
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6/12/2019 6:55am
mattyhamz2 wrote:
Those forks!!!!! Shocked

Definitely following this build. Those CF pieces look amazing
Thanks Matty!
It won't be one of the ultra-polished builds, as unfortunately I cannot afford to spend long hours working the scotch brite and wd40 into all the bits. The weather is simply too good to let it sit in the boxes for too long, and I need to get the 250 back together before I blow up the 125 that I built for my lady to ride on Grinning
I did put the forks on a 125 to test fit and try out what they feel like, and other than being a bit too stiff, they work awesome.

1
r18b
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6/13/2019 3:38am
This is a trick part!


And ofcourse the forks!

The Shop

Turbojez
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6/14/2019 3:45pm
r18b wrote:
This is a trick part! [img]https://p.vitalmx.com/photos/forums/2019/06/13/353958/s1200_Screenshot_20190613_122848.jpg[/img] And ofcourse the forks!
This is a trick part!


And ofcourse the forks!
I actually have a couple sets of those if anyone's interested in pimping their RM's. This and a front hanger will come as a set, as it made more sense to have a couple of those made, instead of just one set. I was thinking 80$ would be a fair price? What do you think?
Zesiger 112
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6/14/2019 4:27pm Edited Date/Time 6/14/2019 4:28pm
Turbojez wrote:
Here comes a rebuild on my old 250. Unfortunately I do not have a lot of "before" pics. I tore it apart to bits and pieces...
Here comes a rebuild on my old 250.
Unfortunately I do not have a lot of "before" pics.
I tore it apart to bits and pieces, simply because the crankshaft went out, and since I had it in boxes I figured, why not polish it up a little before putting it back together?

Parts list:
KYB SSS 48mm forks
X-trig clamps with PHDS
2016 RMZ KYB rear shock ( I hereby salute you Vital user Dizzzi2003)
Renthal Twinwall Bars
Renthal Kevlar grips
270mm Galfer front brake
2016 RMZ MC and Caliper
TiPegs
Polisport Restyled plastics
A bit of carbon fiber goodies

So here it goes, I just closed up the motor yesterday:



and got some bits and pieces delivered:





I'll do the pipe hanger if it's close to yz. I need for my YZ!
1
Turbojez
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6/15/2019 2:47am
I'll do the pipe hanger if it's close to yz. I need for my YZ!
If you measure yours we can make sure it fits Wink
6/15/2019 5:16am
Ill measure my cr expansion pipe hanger and you Will get a pm! Just need to get home from roadracing vacation in Germany first.

Motor looks good!
1
Turbojez
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6/15/2019 2:46pm
Got the hubs painted (i planned something magnesium-like but they turned out to be more like "military appreciation hubs"). Will have to wait and see how will the paint hold up. Rim is what I had lying around for a good couple of years. I do have the itch to steal the gold excels, that I have on my RMZ. The Z is posted for sale and it's plenty of work to swap the rims, but I am still undecided.

As far as RM goes, I got every single bolt and axle from this bike zinc plated, bars re anodized (they were orange) and I am slowly putting it back together. Next stop, linkage bearings.




1
Headling
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6/16/2019 2:40am
Looking good Jez, what pegs are they??
Turbojez
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6/16/2019 4:47am
Headling wrote:
Looking good Jez, what pegs are they??
Twenty Tipegs, got them as black friday deal last year, they were crazy cheap, and look very good. They also keep me focused when I walk around the garage, with those teeth waiting to get a piece of my shin. Grinning
1
Headling
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6/16/2019 12:22pm
Headling wrote:
Looking good Jez, what pegs are they??
Turbojez wrote:
Twenty Tipegs, got them as black friday deal last year, they were crazy cheap, and look very good. They also keep me focused when I walk...
Twenty Tipegs, got them as black friday deal last year, they were crazy cheap, and look very good. They also keep me focused when I walk around the garage, with those teeth waiting to get a piece of my shin. Grinning
Thanks mate, I’ll see if I can find a set for my 125, if not read 13-15 ktm pegs fit
1
Turbojez
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6/16/2019 12:46pm
Headling wrote:
Thanks mate, I’ll see if I can find a set for my 125, if not read 13-15 ktm pegs fit
Those are KTM pegs, I forgot to mention that! I believe it's 2010-2016.
You will need to grind the bottom part (where it rests on the frame) a bit, other than that they fit perfect.
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Headling
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6/16/2019 1:53pm
Ok cool, Thanks again Jez 👍🏻
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Bruce372
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6/17/2019 1:06am
Looks nice so far mate
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Zesiger 112
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6/17/2019 6:19am
Sent you a fb message about the pipe hanger.
Turbojez
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6/19/2019 2:50am
Putting the front end together.
I should have sent the Xtrigs for anodising, guess it's a little too late now Grinning

Don't mind the mess, there's a reason half the time I spend in the garage is looking for my tools.

3
jeffro503
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6/19/2019 9:12am
Looking great so far Turbo! And like what other's said.....those damn forks! Freakin' drool worthy!
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mxb2
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6/19/2019 9:32am
Badazz build.
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Turbojez
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6/22/2019 9:25am
Thanks for the kind words!

Here is how she sits now.
This is NOT finished, as I will be using the restyle plastics, but I am waiting for the graphics kit.
The wheels were also not ready yet, so I took those off a 125, and put them on a 250 just so that I can spin some laps on it this weekend.
Scored a PC pipe a couple of days back, and that's what I'll be using, but it's still in US, so it's gonna take a while to get it down here.

Temporary look:




6
Turbojez
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6/25/2019 1:20am
When rebuilding I put the Pro Circuit recommended jetting and needle into the carburetor.
This thing is now faster than ever, and as snappy as they come, especially after spending a couple of last months on a 125.
As a matter of fact it was so snappy, that it no longer has a rear fender or silencer, so I need to get back to work on this bike, straighten the silencer, weld the silencer bracket back to the subframe and replace the broken plastics.
Of course it happened on lap one.
I felt like crying when I was laying on the track and saw the bike cart wheeling into the sunset.
3
Turbojez
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7/2/2019 2:40am
Transmission shat itself on my second ride. It's a love-hate relationship, I'm in the 'hate' stage now.
2
JMX82
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7/2/2019 1:15pm
Turbojez wrote:
Transmission shat itself on my second ride. It's a love-hate relationship, I'm in the 'hate' stage now.
I know what you going trough. My KTM 150SX did the same thing at first proper riding session after full rebuild. Now it's just waiting in my garage for me to get inspired to rebuild the bike again
Turbojez
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7/2/2019 2:16pm
JMX82 wrote:
I know what you going trough. My KTM 150SX did the same thing at first proper riding session after full rebuild. Now it's just waiting in...
I know what you going trough. My KTM 150SX did the same thing at first proper riding session after full rebuild. Now it's just waiting in my garage for me to get inspired to rebuild the bike again
That sucks big time man, I am tearing it apart once again, but I can't help with the quiet voice in my head that keeps talking about a new or barely used TC 250...
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Bruce372
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7/2/2019 2:18pm
Jez, Langham mx has a bunch of transmission parts new for sale
1
Turbojez
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7/2/2019 3:26pm
Bruce372 wrote:
Jez, Langham mx has a bunch of transmission parts new for sale
Thanks Bruce!
Turbojez
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7/3/2019 3:05pm
After opening the motor it turned out the crankshaft was toast, ot snapped, so the ignition side wos no longer connected with the clutch side. Need to get another one and she'll be good to go.
pedromfr
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7/4/2019 1:22am
Turbojez wrote:
Putting the front end together. I should have sent the Xtrigs for anodising, guess it's a little too late now :lol: Don't mind the mess, there's...
Putting the front end together.
I should have sent the Xtrigs for anodising, guess it's a little too late now Grinning

Don't mind the mess, there's a reason half the time I spend in the garage is looking for my tools.

Hi

From what bike you take the clamps?

RGD
Turbojez
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7/4/2019 1:41am
pedromfr wrote:
Hi

From what bike you take the clamps?

RGD
Hey Pedro, 2016 RMZ 450, but it is not a direct swap. You will need some spacers made (if you look closely between the upper clamp and the upper stem bearing, there is an aluminum spacer, the RMZ stem is longer then RM stem) and fabricate the steering stops, either on the frame or by modifying the triple clamps.
7/4/2019 5:15am
Looking good, Turbro. Sorry about the transmission.

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