2002 RM 250 Factory/replica TP199

Edited Date/Time 12/28/2025 3:33pm

Here is my 2002 RM250 that I’m trying to build to be a TP199 bike. As close to genuine as possible. But technically a replica as I know it will be near impossible to source every part to be correct as used in 02.

I have an 02 frame and wiring loom that was used in 02 as it still has the tech inspection sticker and Suzuki identification plate. It’s no longer legible unfortunately. It has the works skid plate weld on brackets. I have not managed to source the skid plate yet. 

The engine I’m unsure what’s inside but I bought it as a complete unit with what I believe is a factory cylinder, head and pipe. All with matching etching (SRT #2) there is a full ti engine bolt kit on this along with DSP Carbon ignition cover and chain guide. The clutch cover is a MAG sand cast piece as used on the factory bikes. The gear lever is a factory lever to the same spec pastrana used. 

The suspension is Showa A Kit. Unfortunately I couldn’t source Rm forks. But I managed to pick up some RMZ forks and they have been coated to look similar to the factory suspension of that era. The shock is an 07 A kit piece as the clevis is shorter on the 02 than the 04-08 bike I have had a clevis manufactured and the shock matched to a 2002 a kit rear shock. Just with an 18mm shaft.

The rear linkage is a factory billet knuckle with OEM link arms that have been cerakoted to look similar to the works pull rods. Almost picked up and RG3 linkage like they used in 2002 but unfortunately missed out on that one.

The wheels are a bit of a mismatch. As I have fitted RMZ A Kit the front wheels of the rm are not compatible. Which is unfortunate as they are just turned stock hubs which I had done before picking them up. But since having the A kit I sourced a factory RMZ front wheels with an unused works 280mm disk. I had to pick up a KXF 280mm brake Hanger as they are the same spec as RM But no one has made any bigger than a 270mm oversize kit for RM/RMZ. The rear is a hub that came from Rockstar Suzuki when they did a 2 stroke build so unfortunately not the correct mag hub but defo a cool piece turned down and coated in the mag colours.

I have sourced a works rear axle spindle that should be on its way to go with the works axle blocks and matching TI bolts with with indent to slot into the blocks (like rocking horse shit).

Not sure if I’ve missed anything, I also have an almost complete works clutch lever assembly (without a lever, pinch bolt and bar clamp) so if anyone has those bits or anything that I could purchase to contribute towards the build would be greatly appreciated.

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bestmx
Posts
239
Joined
11/17/2014
Location
Ware GB
12/29/2025 2:31am

Epic starting point!

2
1/7/2026 12:37pm

Turns out the works rear axle runs a different size but, haven’t managed to source a factory one but did work out it’s the same as YZ so picked up a wob rear nut. Looks pretty sweet. Yes I know there is only one bolt in the rear disk haha.

IMG 8495 2

3

The Shop

1/7/2026 11:12pm

Great job so far mate! Lots of cool parts on this…keep at it

1

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