Edited Date/Time
6/21/2022 12:26pm
I’m almost finished with my AF conversion and thought I’d start sharing photos and knowledge along the way. Bottom line is that the conversion is much more involved than the original SwapMotoLive article stating the engine drops in with minor motor mount relocation. I started with a JGR 250 frame/swingarm, newer 49mm Showa A-kit, and stock hubs cerakoted by me laced up to new yellow Excels.
Next, I borrowed my 04 RM144 engine out of my steel frame for the mock up.
Next, I borrowed my 04 RM144 engine out of my steel frame for the mock up.
After the mock-ups, the headstay was welded in place
New Scalvini cone pipe had to have the rear mount moved and one of the spring tabs tacked over a bit.
The Shop
DeCal Works Huge Plastic Inventory of UFO and Polisport kits.
Free shipping: VITALMX
Luxon 4-Post Bar Mounts
$189.95 - $239.95
CDI unit was relocated behind the fuel tank and under the seat
Another big roadblock is the countershaft sprocket alignment. I believe it is off 3.5mm in stock form. Exactly half the thickness of a new Renthal sprocket. The alignment is too far in so there isn’t enough material to machine a standard sprocket and add a spacer. We’re having custom offset 12T sprockets made and hardened right now. I think it’s going to cost $100-150 because of the small batch.
Another issue is finding a longer shifter. The distance from center of footpeg to center of shift tip is an inch shorter than my steel frame RM250. I wear size 11 boots so I’m playing with different shifters. I wish Hammerhead had a RM125 shifter with a +20mm tip.
If you are going to have some of the offset countershaft sprockets made I would be interested in buying 3 or 4 of them if that helps with the costs.
What radiators are you using? it would be great if you have additional details & pictures of them and the rest of your build. Are you using an A-Kit shock and was there any clearance issues with the air boot? I had purchased an Suzuki OEM (Y) branch to use for the radiators if you wanted the part number along with an OEM air boot.
Good luck with the project and keep us updated on your progress and first ride.
I see no rubbing on the shock from the airboot. I used the stock Mikuni TMX for the mock up but I have a new Lectron HV38 that I’ve been debating on using. I’m pretty sure I’ll stick with the TMX because the jetting was spot on for the 144 kit. Bruce372 knows how to jet a 125/144.
I’ll check with my machinist on the progress of the sprockets. I ordered 2 for myself and I think M-Worx will have a few as well. I can tell him to do more if your interested.
I still need to find an RMZ250 left hand radiator as I did not have them to start with. I can not find any aftermarket radiators for the RMZ250 but they are available for the RMZ450 and I bought a set of them. The right hand side is the same between the 250 & 450, just the left hand side is different.
Here are a few shots of the starting points for our build:
Pit Row
Here's a little clip of it, I haven't really looked to much into it
I worked at TUF Racing through high school and after doing parts and wrenching. I followed Andy Stacy around to a few other dealerships until the whole empire collapsed around 2007-2009.
I never made it up there when I lived back in the Midwest, but hoping for a road trip this summer
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