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OFF-ROAD TEST
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Giving an RM250 an off-road
offf road attitude
The late ’90s to mid-2000s Suzuki take us very long to find
> RM250 two-strokes might just be the
best used motorcycles out there. They
feature a strong engine and a great handling
package that makes the bikes fun to ride. This
is probably why we don’t come across many
out what was wrong with
the engine. The piston
had broken into pieces,
sending shrapnel down
into the lower end. Even though
the rod and bottom-end bearings seemed to
for sale; the people who have them want to
keep them. Thankfully, we met Ross Summers, be fine, we decided to tear it down completely
a farmer from Tremonton, Utah, who had been and rebuild it. It’s almost impossible to get all
able to purchase a 2004 Suzuki RM250 and the broken pieces of a piston out of the bottom
was interested in doing a rebuild. end, and even if you do, the damage may have
Of course, he knew the machine had some already been done. Better safe than sorry.
issues; what else would you expect from an Ross just happens to have a really good friend
almost 20-year-old piece of machinery? Since who works at Syndicate Development, so he
this was going to be an off-road build, reliability took care of all the engine details. A Wrench
and function were at the top of the list. It didn’t Rabbit kit, featuring a full Hot Rods bottom
50 www.dirtbikemagazine.com SEPTEMBER 2020 / DIRT BIKE 51
PROJECT: 2004 SUZUKI RM250
0
Syndicate Development in Utah took
care of our RM250 engine with some
help from industry-leading companies.
end, gaskets, bearings, piston, rings, recommend using more than what is
wrist pin and circlips, was used to supplied.
rebuild the engine. While the engine The stock Suzuki wheels had
cases were split, the transmission seen better days and needed some
was ISF polished for smoother shifting attention. Collin and the crew at
characteristics. Once the engine was Faster USA removed the old spokes,
reassembled, Syndicate Development rims and bearings, leaving only the
also dyno-tuned the engine, installing OEM hub. The hub was cleaned
a complete JD Jetting kit in the up in a blast machine, and then a
carburetor. multi-layer bronze Cerakote finish
The chassis was in slightly better the chassis bearings were replaced was applied. Once the Cerakote was
shape than the engine, but it was far using bearing and seal kits from All heated and cured, new bearings were
from what we would be comfortable Balls. These kits come complete installed in the hub. The refurbished
throwing a leg over. The main frame with bearings, seals and races when hubs were attached to a set of bright,
was sent off to be stripped down and needed. Although each kit comes Suzuki-yellow Excel rims (18 inches
powdercoated for a clean look. All with a small tube of grease, we in the rear for off-road use, of course)
52 www.dirtbikemagazine.com
via stainless steel spokes, bringing During the reassembly phase, we its rear-brake clevis, wraparound items that we used on this RM250 Decal Works topped off the build. the feeling the owner gets being on
the wheels back to life. really got to see our off-road vision handguards with replaceable plastic project. Trust us when we say a With the build complete, it was the bike. If smiles and bench-racing
Race Tech tackled our suspension take shape. An IMS, natural-colored deflector shields and Flexx bars. To kickstand is a great addition to any time for our favorite part—the trail material are the result, then it is a
needs. We have to admit, this RM250 oversized tank was installed for run the oversized Flexx bars, we used off-road build. It will come in handy testing. With these types of off-road successful project in our books. Ross
had seen better days and showed increased fuel capacity, which equals a set of Applied Racing handlebar way more often than you think. two-stroke rebuilds, it’s not about Summers’ 2004 RM250 is a blast to
signs of neglect, but the Race Tech more trail time. Larger IMS mounts instead of replacing the Naturally, the RM250 didn’t come comparing them to new- ride, with great handling and power
crew commented that they had seen Super Stock pegs replaced entire top triple clamp. stock with this option back in 2004, model off-road bikes, that is easy to use. Everything you
way worse. With this being an off- the 15-year-old OEM When preparing a bike for but Pro Moto Billet makes a version although they are need to spend a long day having fun
road build, they went slightly softer units. We used a few off-road use, protection is key. that bolts right on and tucks up probably in the same on the trail is included on this RM250.
overall with spring rate and valving products from P3 Carbon, Topar Racing, out of the way. A complete UFO ballpark. These builds We are just sad to see the bike leave
specs for comfort. They also replaced Fasst Company, TM Designworks and Works plastics kit wrapped in custom- are all about the our possession and start its journey
all the seals, bushings and oil. including Connection all make bolt-on designed graphics from Nic at process and back to Utah where Ross lives. ❏
The build
The custom process was
graphics from long but well
Decal Works made worth it when the
this build literally finished product
sparkle. Look close looks and runs like
and you will see what our RM250 does.
we are talking about.
PROJECT: 2004 SUZUKI RM250
MOST POWERFUL E-BIKE
WITH TORQUE SENSOR, 120 NM
GERMAN TQ-MOTOR
en.m1-sporttechnik.de
Bobby Root Industries US DISTRIBUTOR
62100 Pinion Drive Tel: +1 760-218-4533
CA-92561 Mountain Center Bobbyroot@hotmail.com
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