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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Sun Jun 21, 2020 11:37 pm 
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World Superbike
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Joined: Thu Feb 16, 2012 11:50 am
Posts: 2350
Location: The Republic of South Yorkshire
Country: England
Suzuki 2-Strokes: 2 x GT550s GT750, T200, TC200
June onwards ok for me.

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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Wed Jun 24, 2020 4:05 pm 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 574
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
bucking the trend - instead of wrapping my exhausts, I've wrapped my induction hoses........

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Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Thu Jun 25, 2020 8:32 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 574
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
As Tinypic folded and removed all the previous photo's, here's a recap of how it all started...............

A Suzuki TDRGV?

well Suzuki never built one, so I thought, why not?

Having spent a long time looking for a suitable donor bike, I snapped up this ebay bargain.........

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........a 2005 Suzuki RMZ250 motocrosser, complete bar it's (4-stroke) motor. Once home, I stripped it down and proceeded to sell-off all the parts that I don't need (most of the bike, actually!) For this project I only need the frame, swing arm, shock and linkages and the front forks. So the wheels (with Talon hubs), the carb and other sundry items have found new homes, which has helped to recoup almost all of the purchase price of the rolling chassis.
My original intention was to fit a parallel-twin motor from an RG250, so as to mimick the original TDR250, but knowing how crap these motors are, I decided to use one of the RGV250 motors I have in stock.

First job was to decide how to fit the RGV motor into the RMZ frame. And this is how to do it........

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the RMZ's front down tube and engine cradle were removed and a new, removable cradle constructed around a "mule" RGV250 motor so we could get all the dimensions right. A new upper and lower rear engine mounting bracket was also fabricated.
A pair of 17" Suzuki Goose wheels were fitted - the rear had to have 9mm shaved off the sprocket mounting flanges and the left side bearing recessed by 4mm to get it to fit.
The get the spoke pattern of the front wheel to match the rear, the fork legs had to swap sides, as the RMZ has it's front caliper on the left side, and the Goose on the right.
A new caliper bracket was fabricated and welded in place, supporting a 4 piston Brembo Gold Line caliper which in turn bites on a custom one-off front disc, made for me by ISR.

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Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Thu Jun 25, 2020 10:44 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 574
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
now a rolling chassis, a (very) long kick stand was added to support it, along with a cut down RMZ front mudguard, a DRZ400 front head lamp unit and fairing and a standard RMZ rear mudguard with an enduro bike tool kit bag attached.

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Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Thu Jun 25, 2020 11:01 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 574
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
With the mule motor installed, it was sent to have it's exhausts fabricated and fitted...........

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_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Thu Jun 25, 2020 11:06 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 574
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
power valve motor and throttle cable junction box mounted on the right hand side...........

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only the oil pump control cable and the small cable from the junction box to the p/v pulley are original RGV cables - the 4 p/v operating cables, both carb cables and the throttle grip tojunction box cable had to be made from scratch.

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Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Thu Jun 25, 2020 11:16 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 574
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
with the RGV 250 thermostat housing on the other side..........

Image

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Thu Jun 25, 2020 11:25 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 574
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
where to put the oil tank? And which tank will fit?

A lightly modified Yamaha DT125 oil tank support bracket.........

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a few home made fittings to attach it...........

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and the DT125 oil tank attached.........

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and hidden from view..........

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_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Thu Jun 25, 2020 11:27 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 574
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
folding foot rest to allow use of the kick start lever and the matching, extended rear brake pedal.......

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_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Thu Jun 25, 2020 11:32 am 
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Yeah Man, the Interstate
User avatar

Joined: Wed Jan 01, 2014 2:04 pm
Posts: 574
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
the re-positioned clutch adjuster and "long" actuator arm that allow the front pipe to tuck in closer to the bike.....

Image

the original adjuster is to the back of the water pump housing.

_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Thu Jun 25, 2020 11:36 am 
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Yeah Man, the Interstate
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 574
Country: UK
Suzuki 2-Strokes: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
and the enduro tail pack. All is not what it seems..............

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there is a severe shortage of space on a moto cross bike to house all the bits that a road bike needs to function correctly. So, time to get creative...........

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_________________
Garry


I'm addicted to brake fluid, but I can stop anytime.


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Thu Jun 25, 2020 1:05 pm 
Online
World Superbike
User avatar

Joined: Thu Feb 16, 2012 11:50 am
Posts: 2350
Location: The Republic of South Yorkshire
Country: England
Suzuki 2-Strokes: 2 x GT550s GT750, T200, TC200
That's going to surprise one or two when it's finished.
Very nice project, and as usual 'mad as a hatter' bike.
Lovely.

_________________
Think of how stupid the average person is, then realise that half of them are more stupid than that.


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