2004 Suzuki RM125 Build

Edited Date/Time 11/26/2022 2:07pm
Bought a 2004 RM125 in August 2021 with a “fresh top end,” which worked well for about 3 hours and then it fell on its face. Decided to tear down the bike entirely and do a full build on it, as it has been neglected and I’ve always wanted to do a bike build. Been working on it since November 2021 slowly, and figured I’d start a thread on it before I go too far in. As the bike sits right now it has had the engine fully rebuilt top and bottom, ported and cut head, and the frame, subframe, and swingarm are powder coated gloss black. Suspension will be sent out shortly for Kashima/TiNi/Ano coatings.



6
|
8/27/2022 6:20am
Love a Suzuki build. Excited to see that suspension.
1
10/12/2022 6:06pm Edited Date/Time 10/28/2022 11:31am
Been a little bit since I’ve made any progress on this bike, I don’t have very much time or money to work on it as I am in school most of the day. Sent my suspension to KB5 for coatings, might be back in November/December. Polished up engine cases because in my opinion it looks better than vapor blasting. Here is how it turned out:


I also tore apart the rear brake and started to polish that, but not very close to finished yet. I polished a few other pieces like my linkage, but will not be touching the front brake. I found a 280mm oversized front brake off one of R ‘s old RM250s, sold to me by a forum member. My current project is straightening my radiator fins with screwdrivers, as the radiators will be sent to ICW eventually for some mods.


Also, have any of you seen this pipe before? FMF hasn’t made the REV pipe for these old RMs for quite some time, to my understanding they helped with top end power, unlike the fattys they sell nowadays. Thought about repairing and polishing it, but I might just switch to pro circuit.
10
Hammer 663s
Posts
3087
Joined
6/2/2016
Location
Forest Grove, OR US
10/13/2022 8:44pm
Looks great. Here’s an 05 I finished a couple months ago.
22
10/15/2022 6:24pm
Nice build!

The Shop

Phillip_Lamb
Posts
2065
Joined
12/14/2010
Location
ORANGEVALE, CA US
10/16/2022 10:52pm
04 is a good year. I had one recently and raced one when they were new.

add v force, pipe silencer of your choice, upgrade the power valve mechanism to an 07
1
10/17/2022 12:27pm
04 is a good year. I had one recently and raced one when they were new. add v force, pipe silencer of your choice, upgrade the...
04 is a good year. I had one recently and raced one when they were new.

add v force, pipe silencer of your choice, upgrade the power valve mechanism to an 07
I have V Force 3 reeds installed on it already, as well as an R304 silencer, planning on getting a matching PC expansion chamber. I'll look into the powervalve swap as well.
rm449
Posts
92
Joined
8/19/2014
Location
Pittsburgh, PA US
10/25/2022 5:42pm
04 is a good year. I had one recently and raced one when they were new. add v force, pipe silencer of your choice, upgrade the...
04 is a good year. I had one recently and raced one when they were new.

add v force, pipe silencer of your choice, upgrade the power valve mechanism to an 07
Can you elaborate on this swap?
10/26/2022 6:54am
04 is a good year. I had one recently and raced one when they were new. add v force, pipe silencer of your choice, upgrade the...
04 is a good year. I had one recently and raced one when they were new.

add v force, pipe silencer of your choice, upgrade the power valve mechanism to an 07
rm449 wrote:
Can you elaborate on this swap?
From the looks of it, upgrading to a K5+ power valve system will require a K5+ cylinder. I wouldn’t pursue it especially since I already had to buy a new cylinder for my RM
Phillip_Lamb
Posts
2065
Joined
12/14/2010
Location
ORANGEVALE, CA US
10/28/2022 9:45pm
I was never told the exact details of the swap. When i was building my 04, someone commented that they had swapped the Governor assembly specifically (not the powervalve's) which improved the timing.
1
11/26/2022 2:07pm
Suspension is back from Japan getting coatings, should be arriving on Thursday potentially. I’ll have to get it revalved and resprung, then it can go back on the bike
12/4/2022 1:08pm

Almost forgot to post, suspension came back from KB5 and is now coated! I will be sending it out again at some point to get gold valves, then I will get triple clamps and bearings to install the forks, shock, and swingarm to the bike.

I went with Kashima on the fork uppers as well as shock body, had the fork lugs plus misc. shock pieces black ano, and the fork lowers and shock shaft are a blue fade TiNi.


8
Dave #125
Posts
251
Joined
5/31/2014
Location
Andrews Farm , SA AU
12/6/2022 1:51pm

Awesome build! 

 

Any chance your could measure fork guard holes for me? 

Front 2 holes - centre to centre? 

Length of guard top to bottom ? 

Side length of guard ? 

Iam hoping  RM guards will fit these forks I have 🙏🙏

spd47
Posts
88
Joined
12/17/2022
Location
Monterrey, N.L. MX
12/17/2022 3:54pm

We have few oem new parts for this bike, radiators, hubs, top end, carbon fiber clutch/stator cover, I believe we have apply triple clamps, and factory CDI use on Factory Suzuki/Bills Pipes AX Team RM125 

3
spd47
Posts
88
Joined
12/17/2022
Location
Monterrey, N.L. MX
12/19/2022 6:17pm

 

1
Phillip_Lamb
Posts
2065
Joined
12/14/2010
Location
ORANGEVALE, CA US
12/21/2022 6:40pm
spd47 wrote:
 

 

where were you when i built my 04 2 years ago??? 

1
johnk408
Posts
1085
Joined
1/20/2022
Location
Ft Mitchell, KY US
12/23/2022 7:09am
Dave #125 wrote:
Awesome build!    Any chance your could measure fork guard holes for me?  Front 2 holes - centre to centre?  Length of guard top to bottom...

Awesome build! 

 

Any chance your could measure fork guard holes for me? 

Front 2 holes - centre to centre? 

Length of guard top to bottom ? 

Side length of guard ? 

Iam hoping  RM guards will fit these forks I have 🙏🙏

If he doesn't, I have an 04 at home and will try to remember as well.

12/28/2023 8:53pm

IMG 7087 0
 

Been over a year since I’ve updated this thread, as I’ve had a lot of chaos taking me away from the build. I had some family stuff go on, moved houses, bought a WRX, and then traded that for a KX450. I’m still in school so I’ve had no money to set aside for this bike. Here’s how she currently sits in my room. I have big plans for it this summer, possibly selling my 450 to continue what I think will be one of the most built RM125s ever. I’m gonna be throwing on a Lectron Billetron Pro series, Vortex CDI, Factory 280mm front brake assembly, Excel A60s, and tons of carbon bits. It’ll just take some time

2
rm449
Posts
92
Joined
8/19/2014
Location
Pittsburgh, PA US
1/5/2024 6:47pm

Where are you getting the vortex cdi from.

romain524
Posts
754
Joined
1/14/2015
Location
Newport Coast, CA US
1/13/2024 10:41pm
  Been over a year since I’ve updated this thread, as I’ve had a lot of chaos taking me away from the build. I had some...

IMG 7087 0
 

Been over a year since I’ve updated this thread, as I’ve had a lot of chaos taking me away from the build. I had some family stuff go on, moved houses, bought a WRX, and then traded that for a KX450. I’m still in school so I’ve had no money to set aside for this bike. Here’s how she currently sits in my room. I have big plans for it this summer, possibly selling my 450 to continue what I think will be one of the most built RM125s ever. I’m gonna be throwing on a Lectron Billetron Pro series, Vortex CDI, Factory 280mm front brake assembly, Excel A60s, and tons of carbon bits. It’ll just take some time

You won’t use the Factory CDI from the AX team?

romain524
Posts
754
Joined
1/14/2015
Location
Newport Coast, CA US
5/31/2024 5:45pm

Any update?

6/1/2024 9:32am
rm449 wrote:

Where are you getting the vortex cdi from.

At the time I planned that they were still available, but now I am not sure how I’ll make that happen

6/1/2024 9:32am
  Been over a year since I’ve updated this thread, as I’ve had a lot of chaos taking me away from the build. I had some...

IMG 7087 0
 

Been over a year since I’ve updated this thread, as I’ve had a lot of chaos taking me away from the build. I had some family stuff go on, moved houses, bought a WRX, and then traded that for a KX450. I’m still in school so I’ve had no money to set aside for this bike. Here’s how she currently sits in my room. I have big plans for it this summer, possibly selling my 450 to continue what I think will be one of the most built RM125s ever. I’m gonna be throwing on a Lectron Billetron Pro series, Vortex CDI, Factory 280mm front brake assembly, Excel A60s, and tons of carbon bits. It’ll just take some time

romain524 wrote:

You won’t use the Factory CDI from the AX team?

That one was for a 2000 RM125, and will not fit my 2004

1
6/1/2024 9:34am
romain524 wrote:

Any update?

Unfortunately it has sat with almost nothing done to it for the past year or so, as I haven’t had much money to put into it. Since then I bought a WRX, sold that and got a KX450, and now I’m selling that to get a 150SX. I believe this summer I will be able to start making progress on the RM125 again 👍

1
8/27/2024 9:04pm

The original goal was to make this a replica of a ‘22 HEP Suzuki bike, but now I’m regaining interest in the build and I’m thinking about doing something more period correct. Anyone have any recommendations on graphics to give it that early 2000s look? If anyone has a red and white seat cover from a 2000s Suzuki amateur team bike I’d be interested in that too

1
2/14/2025 7:44pm

First progress update in 2 years! I plan to get RideNG triple clamps eventually, but for now I knocked the casting marks off the OEMs and cleaned them up a bit. Got a steering stem bearing kit as well so the front end is all torqued and assembled. Besides the front wheel spacers, I lost them so I’ll have to order more. I’m missing the swingarm bearings and rear axle nut which is all I need to make it a fully rolling bike, but I am going to replace linkage bearings while I’m at it. Just got some new plastics in today, I did not like the restyle kit at all. The bike won’t be done this summer, but I plan to make it good looking and rideable for an event at Meadow Valley this July. 

IMG 7048 1
Here’s how she sits as of today, I’m getting pretty motivated on this project again. The plan for graphics is to make them black/yellow with a similar theme to the old Motoworld bikes! Here’s my idea so far:

IMG 6011.jpeg?VersionId=CEpRlslQs15MIG2ue4MBXmKzdXQfBD
I’ve thought about doing small purple accents in the graphics and other parts of the bike, but not sure yet. Thoughts?

 

3
Vet57
Posts
2495
Joined
12/13/2010
Location
BRO Town, MA US
2/15/2025 1:23am

Chk out the latest issue of MXA

1
2/18/2025 11:29pm
Vet57 wrote:

Chk out the latest issue of MXA

Pretty sweet RM they have in that issue!

Post a reply to: 2004 Suzuki RM125 Build

The Latest