2-Stroke Tuesday is all about supporting premix burning machines previous and current, this week we take an in-depth have a look at our 2003 Suzuki RM250 undertaking that we added some Sean Hamblin flare for a bit tribute to his time with the manufacturing unit staff. Reading like a who’s who of motocross historical past, Suzuki-supported riders within the early ‘2000s like Pastrana, Tortelli, Roncada and Hamblin—and that’s simply within the 250cc class alone—tried to step up into that prime spot. This is the place our inspiration for a 2003 RM250 rebuild got here from. So, with the scent of premix and race fuel burnt into our brains, we began spinning wrenches.

BUILDING OLD YELLOW
The better part about going again and rebuilding a 14-year-old motorbike is the facility of creativeness. With this construct, we determined so as to add a modern-day twist with an old-school look. When beginning a construct like this, there are a number of requirements one should possess. Patience is an important, as these builds are time-consuming and by no means go as deliberate, in addition to be versatile, prepared to alter instructions at any time and have a alternative bolt equipment from Specbolt or Tusk Racing, as a result of they’re lifesavers.
Unlike most rebuilds, our RM250 was really intact and in semi-working situation. We finally discovered that doesn’t at all times imply it’s going to make it any simpler. After a whole tear-down, we acquired to see what actually wanted to be performed, and belief us after we say it virtually stopped there. The bike was held along with mismatched {hardware}, JB Weld and a ton of what superglue. The full engine was shipped to Matt at L.A. Sleeve, and whereas he was disassembling it, he discovered all kinds of surprises.

Bottom line: the highest and backside ends of the engine wanted some TLC. On a great word, the transmission appeared okay, minus the clutch, which was hammered. The crank was rebuilt in-house utilizing a ProX OEM alternative rod equipment. The coating contained in the cylinder was half gone, so it was fastened with an L.A. Sleeve cylinder rebuild equipment. Each equipment incorporates a sleeve, LAPC piston with rings, clips and wrist pin, together with a brand new wrist-pin bearing and top-end gasket equipment. As we talked about, the clutch wanted some consideration, so we changed it with a ProX basket, inside hub and clutch-plate equipment that additionally consists of springs.
With all the most important engine work accomplished at L.A. Sleeve, we determined to incorporate some aftermarket components from Boyesen. The ignition and clutch cowl gave the RM a cool manufacturing unit look, whereas the Supercooler elevated coolant circulate, and the Rad Valve consumption would assist total engine efficiency.

Pepping up the engine efficiency can be a Bill’s Pipes exhaust system, and we added some cool manufacturing unit bling with a cone-look end on the enlargement chamber. This is a service that may be added to any Bill’s Works two-stroke pipes on the time of buy for an additional price of $125. The Keihin carburetor was rebuilt utilizing a equipment from All Balls. The equipment included every thing wanted to return the setting again to OEM specs.
Once the chassis was uncovered, identical to the engine it wanted a variety of work. Every bearing on the body, linkage and swingarm was changed utilizing All Balls’ equipment. Some of the outdated bearings have been so rusted that they needed to be heated and beat out with a punch. Some even required Dremel-tool consideration and knowledgeable mechanic expertise. It’s wonderful what a bit upkeep and a few grease may have prevented.
Suspension was one other attention-grabbing space on this construct. We thought the engine and chassis have been unhealthy, however the suspension was worse! It was so unhealthy that it couldn’t be saved. It was both hunt one thing down on eBay or go to the dealership and throw down a great deal of money.

Last 12 months WP North America launched the Cone Valve fork and Trax shock kits for newer Japanese bikes, so we determined to offer them a name. The Dirt Candy Suzuki staff really ran WP suspension elements on their bikes all final 12 months. Turns out that decision would change our route of the general construct. With using newer 450 triple clamps, we have been capable of bolt on a whole front-end. The forks slide proper within the clamps. We simply needed to run the entrance wheel with spacers off a more recent 250/450, together with a whole front-brake system off a more recent bike that we added an outsized Moto Master rotor equipment to. The Trax shock would require some modifications, making it shorter than the WP, however then would bolt as much as a inventory 2003 Suzuki RM250 linkage.
With all the most important work completed, we centered on the look. Sean Hamblin was a neighborhood SoCal child with tons of expertise that had scored a manufacturing unit Suzuki trip as a fill-in rider and proved himself worthy of a full-time trip. He really ran #33 in 2003, however we appreciated the look of the 2004 manufacturing unit bikes higher, so we morphed the 2 along with the assistance of Red Label Graphics.

The hubs are literally inventory. Faster USA cleaned them up, changed the bearings and laced up a set of Excel gold rims to prime off the manufacturing unit look. This is a service they provide to everybody for about half the price of a brand new wheelset. Bling with out an enormous price ticket? Now that’s our sort of deal. Instead of going with an all-black seat just like the manufacturing unit bikes, Jeff over at SDG added some shade with a yellow, black and pink customized gripper design.

GOOD AS NEW?
You know what we mentioned at first about endurance? On some builds, simply while you suppose all of the work is completed, it has solely simply begun! This is a kind of builds. Once the bike was accomplished, we began the method of getting the jetting dialed in. On older bikes this may be very difficult, and our RM250 proved to be simply that. After hours of various mixtures that at occasions bordered on downright madness, all the workers have been scratching their heads in confusion. So what does any good motohead do? Steal the carb of his buddy’s completely working RM250 when he’s at work in fact. With a few minor changes, it labored nice.
Sometimes, irrespective of what number of occasions you rebuild it, issues simply put on out and have to be changed, and that was undoubtedly true on this case. Once formally accomplished with a brand new carb, our RM250 was a blast to trip and turned heads in all places it went. Besides the time spent wrenching with buddies and a way of accomplishment when it’s all performed, the most effective half about builds like this one is having that feeling of wanting ahead to the weekend and the prospect to trip! Time to discover a new undertaking.