Factory RM250 RC4 replica Update (Hinson works cover, carbon disc guard arrived)

Jacko986
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Jacko986
Edited Date/Time 2/5/2021 6:47am
The bike I’m starting with is a very little use, very low hour 2008 RM250 I’ve owned since 2013. I purchased it off the original owner who purchased it new in 2012 (in Australia these were sold until 2012) and put a measly 7 hrs on the bike. I rode it on and off for a few years and now it’s time to pull it down and make it into a bit of a show piece.

The bike I’m planning on replicating is either the 2004 RM250 US open bike or of coarse the 2005 makita bike. Even know it’s been done a hundred times, I’m leaning more towards the makita bike as I remember that bike so well and how RC won the SX title against the newer tech 4 strokes.
Outline for the build is simple, make it as close as possible to the one RC rode without going too crazy with budget.

Parts And plans:
-Rmz A kit rear shock
-Dsp carbon ignition cover or coated original
-lightspeed carbon glide plate, rear caliper guard, rear chain guide
-period spec braking rear rotor
-factory Suzuki 270mm braking front rotor
-correct one ind seat cover
-pro circuit rear suspension link
-pro circuit exhaust with ti2 carbon muffler
-Hinson clutch cover
-Motostuff billet caliper (very close to the factory nissin caliper)
-cerakoted oem hubs with excel yellow wheels
-titanium bolts where possible and if budget allows
-kashima coated suspension
Plus various other little parts I’ve acquired in preparation




Bike has been stripped and frame has had mounts welded for the lightspeed carbon glide plate so I can do away with little alloy hooks.



Frame was then powder coated gloss black. I put bolts in all the threads to save myself half a day of tapping out the powder coat

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Headling
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Headling 3/21/2019 6:38am
3/21/2019 6:38am
Looking forward to the updates on this one, good luck with the build
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Jacko986
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Jacko986 3/21/2019 7:13am
3/21/2019 7:13am
Fitted up the glide plate with some titanium counter sunk bolts and fitted some titanium pro circuit pegs with new springs and pins


9
cesar_rc4
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cesar_rc4 3/21/2019 1:42pm
3/21/2019 1:42pm
I vote for US open bike! When i did my rm rebuild i almost did it but finally did a custom graphics...
Nice work so far, can wait to see the final work

The Shop

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Wilkinson81 3/22/2019 12:37am
3/22/2019 12:37am
I have this sweet pro Circuit exhaust off Carmichael’s 2005 bike. Not for sale though sorry nice build so far.

N
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Jacko986
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Jacko986 3/22/2019 12:38am
3/22/2019 12:38am
cesar_rc4 wrote:
I vote for US open bike! When i did my rm rebuild i almost did it but finally did a custom graphics... Nice work so far...
I vote for US open bike! When i did my rm rebuild i almost did it but finally did a custom graphics...
Nice work so far, can wait to see the final work
I like the US open bike as it had similar colors to the 2004 factory bike which looked brilliant. But I’ve got a soft spot for the makita bike
Jacko986
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Jacko986 3/22/2019 12:41am
3/22/2019 12:41am
Wilkinson81 wrote:
I have this sweet pro Circuit exhaust off Carmichael’s 2005 bike. Not for sale though sorry nice build so far. [img]https://p.vitalmx.com/photos/forums/2019/03/22/333482/s1200_30CBB522_1BB6_44AE_A499_0AAE6F4BE879.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2019/03/22/333481/s1200_B6EDB250_D17D_42AB_A3FA_D0BC235A847D.jpg[/img] N
I have this sweet pro Circuit exhaust off Carmichael’s 2005 bike. Not for sale though sorry nice build so far.

N
What a find! If you ever want to offload it let me know that would be the cherry on the cake ??
Thankyou for the comments
Jacko986
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Jacko986 3/22/2019 12:48am
3/22/2019 12:48am
Had some titanium arrive today and got a little bit of work done. Engine and swingarm mounted.


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Jacko986
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Jacko986 3/22/2019 6:53am
3/22/2019 6:53am
RONJ OSE wrote:
where are you getting all your carbon and TI
Carbon glide plate is lightspeed, carbon ignition cover was a NOS DSP item. The case saver I made myself. TI pegs I’ve had for year still brand new in the packaging ready for this build. Bolts of got from a couple of different suppliers in Australia (pro-bolt and racebolts), both have been very good quality so far

6
Jacko986
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Jacko986 3/24/2019 1:36am
3/24/2019 1:36am
Cooper 688 wrote:
Wow, this is going to be good! Already is ??
Thanks mate, it’s a tedious task assembling a bike but very rewarding. Have you still got your rm250? I remember following the built a couple of years ago
Cooper 688 3/24/2019 4:34am
3/24/2019 4:34am
Yep I’ve still got the RM, it’s a keeper for sure. Mine was just an RC theme but yours is looking more factory legit than mine. Looking forward to your updates here mate
Jacko986
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Jacko986 3/24/2019 11:14am
3/24/2019 11:14am
Cooper 688 wrote:
Yep I’ve still got the RM, it’s a keeper for sure. Mine was just an RC theme but yours is looking more factory legit than mine...
Yep I’ve still got the RM, it’s a keeper for sure. Mine was just an RC theme but yours is looking more factory legit than mine. Looking forward to your updates here mate
Good to here it’s still in your possession. This bike will stay will be a keeper also. I’ll try to keep it as up to date as possible, I’ve got a few cool parts that I’ve acquired over the years going onto it so it should turn out fairly neat
Jacko986
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Jacko986 3/26/2019 5:30am
3/26/2019 5:30am
These are the wheel set that going on the bike, consists of standard second hand hubs that have been cleaned up on a lathe just to remove all the little dints and marks. They were then cerakoted burnt bronze to replicate the factory magnesium rear hub that came on the factory 04-05 bikes. They were then build up with stainless spokes and yellow excel rims. Tyres are Bridgestone x20/30



Also cleaned up the cast marks and lines on the rear suspension linkage knuckle



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Jacko986
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Jacko986 3/27/2019 2:38am
3/27/2019 2:38am
Picked up a few parts from getting cerakoted today, quite happy with the results. Power valve covers and water pump cover are in a champagne color and the rear brake caliper carrier is burnt bronze to match the hubs. The water pump cover started out as a boyensen super cooler unit, ended up filing down the lettering and cast marks/humps to get the desired look. The rear brake carrier also had some mods, removed the brake disc mounts as they won’t be needed and smoothed it out prior to cerakoting. Still waiting on titanium bolts for power valve covers









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nascarnate326 3/27/2019 4:32am
3/27/2019 4:32am
Wow this bike is going to look amazing when done. Are you doing the cerakote yourself?
Jacko986
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Jacko986 3/27/2019 5:35am
3/27/2019 5:35am
nascarnate326 wrote:
Wow this bike is going to look amazing when done. Are you doing the cerakote yourself?
No I’m not equipped to do cerakoting but I know someone who is who has done it all on this bike. Seems to be of really good quality, nice uniform finish
Jacko986
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Jacko986 3/28/2019 8:59am
3/28/2019 8:59am
I hadn’t had any luck finding a factory Suzuki gear shifter so I modified a hammerhead shifter to get the desired look. I sandblasted the shifter to remove the original coating, polished and brushed the main part of the shifter. I then had a mate turn up a small billet alloy button on the lathe to fit snug in the end of the tip.



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Jacko986
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Jacko986 4/1/2019 5:36am
4/1/2019 5:36am
Had some time today to clean up the stock triple clamps. I purchased a set of rg3 clamps for this build but they were too neat to strip down to look like the factory clamps so decided to keep them for a future 125 build.


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motofool
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motofool 4/1/2019 11:51am
4/1/2019 11:51am
Jacko986 wrote:
Had some time today to clean up the stock triple clamps. I purchased a set of rg3 clamps for this build but they were too neat...
Had some time today to clean up the stock triple clamps. I purchased a set of rg3 clamps for this build but they were too neat to strip down to look like the factory clamps so decided to keep them for a future 125 build.


Clamps look great, I recently did the same with my 06 clamps. Lots of work but looks fantastic when it's done. Shifter turned out so good I'm a bit jealous!
Jacko986
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Jacko986 4/6/2019 5:03am
4/6/2019 5:03am
Jacko986 wrote:
Had some time today to clean up the stock triple clamps. I purchased a set of rg3 clamps for this build but they were too neat...
Had some time today to clean up the stock triple clamps. I purchased a set of rg3 clamps for this build but they were too neat to strip down to look like the factory clamps so decided to keep them for a future 125 build.


motofool wrote:
Clamps look great, I recently did the same with my 06 clamps. Lots of work but looks fantastic when it's done. Shifter turned out so good...
Clamps look great, I recently did the same with my 06 clamps. Lots of work but looks fantastic when it's done. Shifter turned out so good I'm a bit jealous!
Yeah it takes so much time and effort but it’s worth it for the finished product. Your clamps came up real nice mate ??
Jacko986
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Jacko986 4/6/2019 5:43am
4/6/2019 5:43am
Bit of progress, tidied up my front brake carrier which I’d been using when the bike was riden. I mounted it up with the new motostuff works billet caliper. The carrier is braking brand as is the front disc which is an ex factory Suzuki 270mm rotor with very little use from the 04-05 era. Fitted the rotor with titanium bolts aswell


Also got the rear brake caliper and rear master cylinder rebuilt and cleaned up. Fitted the caliper the carrier and fitted the master cylinder with titanium hardware. Fitted the rear disc and period tag sprocket to the hub also




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