Garage Build
Garage Build 2003 SUZUKIRM250
Garage Build 2003 SUZUKIRM250
Garage Build
2003 SUZUKIRM250
BIKE BUILD BY JAY CLARK // www.jayclarkent.com
WORDS: DAVID PINGREE
PHOTOS: SIMON CUDBY
This RM250 looked like it was in amazing shape for a bike over 15 years old, so we just wanted to make sure everything was good inside. While we had it apart, we decided to add a little horsepower.
WRENCH RABBIT
Hot Rods Top End Bearings,Vertex Piston
wrenchrabbit.com
TOM MORGAN RACING
Cylinder Porting and Head Mod
tommorganracing1.com
FMF RACING
Fatty Exhaust, Shorty Silencer
fmfracing.com
COMETIC GASKET
Top End Gaskets
cometic.com
SUPERSPROX
Front and Rear Sprocket, MX Chain
supersproxusa.com
ALL BALLS
Carb Rebuild Kit, Throttle Cable, Clutch Cable, Front and Rear Caliper and Master Cylinder Brake Rebuilds and Brake Pins
allballsracing.com
FASTER USA
Stock Hubs Treated and Rebuilt With New Spokes and Excel Rims, Cerakote of the Brake Master Cylinders and Calipers
fasterusa.com
UNI FILTER
Two-Stage Air Filter
unifilter.com
MOTO TASSINARI
V-Force Reed Cage
mototassinari.com
UFO PLASTIC
Full Plastic Kit RM250 (2018 RM-Z250 Front End Pieces), Custom Side Number Plates
ufoplasticusa.com
FACTORY CONNECTION
Suspension Rebuild and Service
factoryconnection.com
WORKS CONNECTION
Front and Rear Brake Cap, Rotating Bar Mount Front Brake, Hour Meter and Mount, Stand, Clutch Perch Assembly, Front Brake Lever, Engine Oil Fill Cap
worksconnection.com
DECAL WORKS
Semi-Custom Graphics Kit, Preprinted Number Plate Backgrounds
decalmx.com
RAPTOR
2015 KTM Ti Footpegs
raptortitanium.com
APPLIED RACING
Custom Triple Clamp, Number Plate
appliedrace.com
ICW
Radiator Straightening and Bracing
icwbikestands.com
TM DESIGNWORKS
Rear Chain Guide, Chain/Swing Slider
tmdesignworks.com
This RM250 looked like it was in amazing shape for a bike over 15 years old, so we just wanted to make sure everything was good inside. While we had it apart, we decided to add a little horsepower.
WRENCH RABBIT
Hot Rods Top End Bearings,Vertex Piston
wrenchrabbit.com
TOM MORGAN RACING
Cylinder Porting and Head Mod
tommorganracing1.com
FMF RACING
Fatty Exhaust, Shorty Silencer
fmfracing.com
COMETIC GASKET
Top End Gaskets
cometic.com
SUPERSPROX
Front and Rear Sprocket, MX Chain
supersproxusa.com
ALL BALLS
Carb Rebuild Kit, Throttle Cable, Clutch Cable, Front and Rear Caliper and Master Cylinder Brake Rebuilds and Brake Pins
allballsracing.com
FASTER USA
Stock Hubs Treated and Rebuilt With New Spokes and Excel Rims, Cerakote of the Brake Master Cylinders and Calipers
fasterusa.com
UNI FILTER
Two-Stage Air Filter
unifilter.com
MOTO TASSINARI
V-Force Reed Cage
mototassinari.com
UFO PLASTIC
Full Plastic Kit RM250 (2018 RM-Z250 Front End Pieces), Custom Side Number Plates
ufoplasticusa.com
FACTORY CONNECTION
Suspension Rebuild and Service
factoryconnection.com
WORKS CONNECTION
Front and Rear Brake Cap, Rotating Bar Mount Front Brake, Hour Meter and Mount, Stand, Clutch Perch Assembly, Front Brake Lever, Engine Oil Fill Cap
worksconnection.com
DECAL WORKS
Semi-Custom Graphics Kit, Preprinted Number Plate Backgrounds
decalmx.com
RAPTOR
2015 KTM Ti Footpegs
raptortitanium.com
APPLIED RACING
Custom Triple Clamp, Number Plate
appliedrace.com
ICW
Radiator Straightening and Bracing
icwbikestands.com
TM DESIGNWORKS
Rear Chain Guide, Chain/Swing Slider
tmdesignworks.com
2003 SUZUKI RM250 close up
2003 SUZUKI RM250 close up view
2003 SUZUKI RM125
W

e powder coated the frame and replaced just a few bearings and seals with Pivot Works kits. We went with All Balls for the cables, and we also utilized their full rebuild kits for the brakes. With the rebuild and the Cerakote from Faster USA, our brakes looked full factory and were finished with Tusk steel braided lines.

On the older RM250, the front brake line wrapped under the fork. To update this, we used a current RM-Z line and a newer RM-Z fork guard with a little modifying. We also modified the rear master cylinder reservoir with an updated RM250 version, which required some custom welding by Metaltek. Our carburetor jetting was taken from the Pro Circuit website and was as follows: stock needle #2 162 main jet and 48 pilot—what we had backed it over to the PC jetting.

On the track, you could tell this bike didn’t have much time on it. The whole bike felt brand-new, and even a little tight at first. Once it had a heat cycle on it, the whole thing really started to come together and I remembered how good these bikes were. The turning on the Suzukis has always been incredible; not only did it turn on a dime, but you could maneuver the bike in the air easily, or change directions as you entered or exited a turn with almost no effort.

The motor was crisp, strong, and broad, with just enough power to keep it exciting. The brakes were powerful, and all the controls were comfortable and consistent. This bike was an absolute pleasure to ride.

2003 SUZUKI RM250 on track
2003 SUZUKI RM250 wheel close up
2003 SUZUKI RM250 peg close up
2003 SUZUKI RM250 wheel close up
1986 Honda CR250R