To go along with the 2002 TM build, also have this 1999 which starts out in much better shape than the 2002. It still needs torn down and refreshed. It's been sitting for 6-7 years but does run and has a semi fresh engine build. The 99's did not come with Ohlins forks and were not an upgrade option like they had for the 02/03's but they are the same forks from a 2002 or 2003. Some odd spacing going on with the front caliper and front axle. Axle isn't quite long enough so it must be for the stock Paioli forks. Front rim is surprisingly tru but the rear is not. Dealing with wheels on these TM's is not as simple as the other brands since TM uses a much smaller diameter spoke/nipple so the rims are unique to TM.
I'll add what a stock one looks like. I've already been able to source new stock graphics, seat cover, and plastics.
Subscribed and looking forward to this build. We should keep close tabs, as I'm working on a 2001 TM 250 MX and a 2002 TM 250 MX. Interesting the changes they make each year. My 01 has Paioli forks and the 02 has Ohlins forks for starters, different brakes also.
The changes from year to year is interesting. What's your plan for wheels?
I just ordered some nipples that hopefully work with the oem TM spokes and a standard aftermarket rim.
Alex Puzar was so fast on the 98& 99. Entering, threw & exiting corners , he does it perfect.
Thought about doing a replica.
The Shop
DeCal Works Huge Plastic Inventory of UFO and Polisport kits.
Free shipping: VITALMX
Luxon 4-Post Bar Mounts
$189.95 - $239.95
Was planning on ordering Excel Takasago rims from RMATV when the time comes. Didn't know the rims/spoke nipple were different? Please be sure to share more info as your build progresses.
it's very hard to find concrete data for some reason on this but as far as I know at this point and
TM front nipple diameter of ~.260"
TM Rear nipple diameter of ~.280"
Nearly all other brands use a nipple diameter of .300-.320. When the nipples I ordered come in, ill know for sure. But the TM nipples in a standard rim are nowhere close to a large enough diameter, that much I do know as i've already tried it.
Plastic came in. UFO still makes some of the plastic which saves a ton of money from ordering straight from TM (if it's even available). They had blue side plates but couldn't get the blue rear fender so I just got them in black, it's the shares tail/side plates with 94-98 KX. Still need the front fender which UFO has, I just forgot to add it to my cart when ordering :/
Got the forks and shock apart. As in my 02 TM build thread, you can use 46mm KYB seals/bushings.
That bumper tho ..
I also picked up an Ohlins shock from a 99 enduro model which I don't have apart yet but interested to see the difference in piston and shim stack.
Where did you source the UFO plastics from? I've been getting mine thru TM. The plastics are the most expensive part of the build!
Also, would you mind posting a picture of your handlebar clamp setup? On my 'show-room' model, the top mount is a one-piece 7/8" mount. I've been trying to source original bar clamps for it. Yours look like 1 and 1/8". I also have 1 and 1/8" upper triple clamps from Applied racing and Emig racing that came with my bikes.
Same, I went with '02 KX rear fender in white and '03+ KX side number plates. Trying to source the front shrouds and fender in blue. UFO europe site had decent pricing but wouldn't let me check out. US site doesn't list TM parts?? Been quoted $74CAD each for shrouds up here...
The only "TM" part they really have are the shrouds. Front number plate and fork guards are Honda. The rear fender, front fender, side plates are all 94-98 kawasaki. But do have them in TM Blue except the rear fender is the incorrect year. They had the blue rear fender listed for 97-99 TMs, but its really for the 00-03
The 00-03 TM uses 99-02 KX rear fender so I got one of those for my 02 TM. But sadly all the rest needs purchased from TM which is crazy $$.
The UFO TM plastic doesn't ship from the US, they come from Italy.
My 99 is 7/8" and one piece.
My 02 has 1-1/8" from factory.
Here is UFO link for shrouds.
https://us.ufoplast.com/replica-plastics/9094-radiator-covers-blue-091-…
Awesome thanks! When you say you can use 46mm KYB rebuild parts, does that apply to the Ohlins shock as well?
Mine has the Paioli's upfront, which also takes the 46mm KYB's apparently.
Love these bikes, should have never sold my 03, it was clean, this 01 I have is rough.
Sadly, its not the same luck with the shock.
Piston band is 8mm, KYB's are taller.
The seal head could potentially use the KYB seal head if its thin enough. A lot of them are a good 10-20mm taller than the ohlins.
Small update.
Frame and subframe back from getting powdercoated. New bearings in swingarm, linkage, and steering head. Triple clamps cleaned up with Titanium tapered socket cap bolts added. Forks rebuilt. Shock you see is from an enduro model, I have not rebuilt the shock for this bike yet. Wheels have yet to be touched. Just wanted to see it rolling. OEM graphics and seat cover should be here soon. The seat needs new foam, which won't be hard to source has it shares that with the 94-98 KX125/250.
Looks sweet!!
I didn’t know it was that complicated to find plastics for TM.
how is it to find engine parts for those years? You should get the engine done.
It would be cool to see more people restoring older TM.
it makes me want to watch some motovision now. Those years were pretty good with Puzar, Chiodi, Vuillemin, Brown, Federicci?
Looking good! I just ordered new seat foam from Guts Racing for mine. Use code "pulpmx2023" to save 20%!
Poke for update...
Pit Row
Sadly no real updates besides bars graphics and seat cover. Been occupied working on road race stuff.
Carb has been sent through sonic cleaner and rebuilt.
Need to rip the wheels and finish cleaning the engine.
Doing some tube fitting tests. The first one is about how the factory does it including the race bikes. The 2nd version is how i've seen a few TM's have them routed and the last is the common way all other manufactures do it. Will most likely go with the TM way, waiting on the vent hose bracket that mounts to the bowl screw to get the final fitment.
Will source a black fuel line, bit too much pink going on.
When i first posted, you can see the front caliper set up was wonky with bunch of washers. Somehow, I did not notice, but these are not the same ohlins forks that are on the 2002 TM. The fork lug is different. Someone drilled and tapped the caliper bracket to make it work with these forks. These look like the forks that came on Canondale MX400s. Either way, going to roll the dice and get a KTM caliper bracket from early 2000s, the spacing should be the same. OR the other option would be to get a set of original Paioli forks which wouldn't be as cool,
02 Caliper on the right is after going through the sonic cleaner.
KTM front caliper bracket is a no go. Need one that's 102mm spacing. Search continues.
Got some Pirelli's mounted. Front wheel is for the 2002, did not buy an excel for this 99 yet.
Looking good!
Hi,
Sorry for the off.
I'm building a 2005 TM 450 SMR and I have the same style of Öhlins shock as you. How does the shock "end cap" come out? I've seen a couple Öhlins shocks before but none of them were this style of cap. With three grooves... Is it a threaded part? Or do I need to ply it off?
Thanks a lot in advance!
Your bike looks fantastic, can't wait for the outcome.
Its not threaded, you Tap it out like you would a KYB or Showa shock.
Thank you!!
What size front axle are you running in the Ohlins forks
It's the stock 1999 TM Axle. Identical to the one on my 2002 as well
Have you ever compared the 46mm TM triple clamps to a set of 46MM Yamaha Triple clamps by chance? I have a 2000EN that came with conventional 50mm Marzocchi forks that are a pain to get parts for. I have a spare set of 46mm KYB forks and clamps that I was considering modifying to use on mine. Much easier than finding a set of 46mm TM clamps.
Based on some internet sleuthing, I believe the offset is pretty close, within 1-2mm at least for YZ triples. The fork lug and axles you may need to play with. But if you have the parts just test fit it. You many also need to swap the steering tube into the other clamps.
Yeah when I have the chance I'll put the triples off of this bike. It's blue plated
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