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 Post subject: Suzuki TDRGV 250
PostPosted: Sat Sep 16, 2017 5:05 am 
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To the on ramp
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
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.

I want the bike to run 17" wheels front and rear so I have a good choice of tyres, and lurking in the corner of the garage are these..........

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........a pair of NK42A Goose wheels that I originally purchased for my GT750 track bike. Single front disc fits the brief (and the forks too, although the spindle is a lot smaller in diameter than the RMZ spindle) but some top-hat bushes in the fork leg bottoms will sort that. The rear wheel will require similar bushes for the RMZ wheel adjusters, and needs metal removing from the cush drive to allow the wheel to centralize in the swing arm.

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 whole engine cradle unbolts to allow easy removal of the motor (not that it will be necessary - it's a Suzuki) :D

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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: Sat Sep 16, 2017 6:55 am 
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Novice racer

Joined: Tue Dec 16, 2008 11:37 am
Posts: 903
Location: Trowbridge UK
Country: UK
Bikes owned: T500R, SV1000S, TS125, Seeley T500
Wow, top project Garry :up: It will make for a hairy beast when it's finished :D

Cheers Geoff


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Sat Sep 16, 2017 8:57 am 
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World Superbike
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Joined: Thu Feb 16, 2012 11:50 am
Posts: 2153
Location: The Republic of South Yorkshire
Country: England
Bikes owned: GT550s GT750 GSX1400 and lots of spares
Another excellent project. All straightforward as usual, eh Garry! :lol:


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Sun Sep 17, 2017 7:33 am 
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To the on ramp
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Joined: Wed Apr 11, 2012 7:17 pm
Posts: 288
Location: Northern Indiana
Country: USA
Bikes owned: RGV RGV RGV RGV ......
This is a far out idea, and looks like the best idea yet for a Suzuki supermoto...!!!!
But then again....I love anything RGV :mrgreen:

_________________
MY TWO STROKE ADDICTION

RS 250 Cup bike
RGV VJ21 L
RGV VJ22 FL
RGV VJ22 N
RGV VJ23 T
RZ 350
GT 750 J....sold.....
GT 750 long term cafe project
SX-R 800
KD 80
RZV500R....in my garage by mid February :)


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Sun Sep 17, 2017 8:01 am 
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Moto GP
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Joined: Fri Oct 24, 2008 5:55 pm
Posts: 3972
Location: Lancaster Pa.
Country: US
Bikes owned: GT750 x2 97 -1200 Bandit 86 GSXR1100
I really like how you think about something and go for it :up: too bad we arnt neighbors :mrgreen:

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the older i get the faster i was


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Mon Sep 18, 2017 5:34 am 
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To the on ramp
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
Suzukidave wrote:
too bad we arnt neighbors :mrgreen:


it is Dave - if we were, you could finish them all for me ! :up:

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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: Tue Sep 26, 2017 5:53 am 
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To the on ramp
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
the rear wheel is in...........

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had to machine 9mm off the sprocket mountings, recess the outer bearing 4mm, remove the rear caliper locating lug and drill the arm for a peg to be welded in to replace it.
Good news is that it is all in line now, and although the sprocket does run very close to the swing arm, I am having a 1-off rear sprocket made that will allow me to use counter-sunk bolts to secure the sprocket to the cush drive.

Front wheel next................ :up:

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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: Tue Sep 26, 2017 2:18 pm 
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To the on ramp
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
trying to maintain a "factory built" standard, I took a punt on some DRZ-400SM parts on everyone's favourite auction site.
To my surprise, the headlamp brackets were the correct diameter to fit the RMZ forks, but are a bit short in length between the triple trees...........

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the DRZ headlamp unit bolted straight in..........

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and the fairing likewise..........

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I'll lengthen the brackets so as they fit snugly between the trees, then good to go

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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: Wed Sep 27, 2017 2:50 pm 
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To the on ramp

Joined: Fri Aug 11, 2017 7:09 am
Posts: 281
Country: england
Bikes owned: several gt250 ramairs
why is it garry, every time i think up a project you come up with something better? :D
my ts250 vic camp replica is looking very mild now :oops:
bet if we got our heads together we could REALLY come up with something outrageous :D
cheers, dd.

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GTS250 road registered. TS250 engine, Ramair frame.
GT250 big bang road registered. Both pistons fire the same time. USD forks.
GT285 road registered. Overbored - 58mm and TS125 +2 pistons fitted.
GT10 road registered. '65 T10 engine, GT250 frame.


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Thu Sep 28, 2017 5:33 am 
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To the on ramp
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
it's no better, and hopefully no worse, than any of your projects.

we just have a different train of thought to each other.

I enjoy putting motors in frames they weren't designed for :up:

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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: Mon Oct 23, 2017 10:32 am 
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To the on ramp
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
rolling, rolling, rolling..................

Image

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next time you see it, the front wheel will have been fitted the other way round so the spoke patterns match.......... :oops:

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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: Mon Oct 23, 2017 7:08 pm 
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To the on ramp
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Joined: Wed Apr 11, 2012 7:17 pm
Posts: 288
Location: Northern Indiana
Country: USA
Bikes owned: RGV RGV RGV RGV ......
Progress looks good.
Whats the plan for chambers on it...run them up high like a TDR, or low like a RGV?

_________________
MY TWO STROKE ADDICTION

RS 250 Cup bike
RGV VJ21 L
RGV VJ22 FL
RGV VJ22 N
RGV VJ23 T
RZ 350
GT 750 J....sold.....
GT 750 long term cafe project
SX-R 800
KD 80
RZV500R....in my garage by mid February :)


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Tue Oct 24, 2017 2:42 am 
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To the on ramp
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Joined: Wed Jan 01, 2014 2:04 pm
Posts: 479
Country: UK
Bikes owned: GT750 hybrids (x2) VJ23A RGV500 TS185 R250
looking at 1 up / 1 down - right side chamber up and over, left side low. But subject to change of mind.

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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: Sat Oct 28, 2017 4:41 pm 
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Moto GP
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Joined: Fri Oct 24, 2008 5:55 pm
Posts: 3972
Location: Lancaster Pa.
Country: US
Bikes owned: GT750 x2 97 -1200 Bandit 86 GSXR1100
:up:

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the older i get the faster i was


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 Post subject: Re: Suzuki TDRGV 250
PostPosted: Sat Oct 28, 2017 6:53 pm 
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Joined: Sun Feb 21, 2016 8:32 pm
Posts: 303
Location: Pisgah Forest, N.C. USA
Country: USA
Bikes owned: GT500 T500 GT750
That thing is going to be a turd. KIDDING! Cool project!!!!! Keep up the genius work.


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