Suzuki 2 Strokes

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.........





........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..........



........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........


















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

Wow, top project Garry It will make for a hairy beast when it's finished

Cheers Geoff

Another excellent project. All straightforward as usual, eh Garry!

This is a far out idea, and looks like the best idea yet for a Suzuki supermoto...!!!!
But then again....I love anything RGV

I really like how you think about something and go for it too bad we arnt neighbors

Suzukidave wrote: too bad we arnt neighbors

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

the rear wheel is in...........





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................

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...........



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



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





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

why is it garry, every time i think up a project you come up with something better?
my ts250 vic camp replica is looking very mild now
bet if we got our heads together we could REALLY come up with something outrageous
cheers, dd.

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

rolling, rolling, rolling..................





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

Progress looks good.
Whats the plan for chambers on it...run them up high like a TDR, or low like a RGV?

looking at 1 up / 1 down - right side chamber up and over, left side low. But subject to change of mind.

That thing is going to be a turd. KIDDING! Cool project!!!!! Keep up the genius work.