Suzuki RM250 Project Bike

The 2002 Suzuki RM250 is one of our favorite machines in the Dirt Bike arsenal. The machine is super light, very flickable, it exudes immediate roll-on power and has one of the best cut-and-thrust mannerisms found in a motocross bike today. And this is in spite of fairly average suspension, a clutch that goes chattery in just a few weeks, a motor that demands race fuel and a powerband that needs to pull stronger out of the hole.
For the last three months we have been abusing this machine mercilessly and in the process have field-tested a host of mods that not only improve the RM 250 snort factor and handling prowess, but have enhanced the durability and life of the Suzook. We?ve tested pipes, silencers, aftermarket suspension, carb mods, ergonomic enhancers, protectors and gizmos; and in the end, what follows are the basics that will make your life with the RM 250 a better experience.?

Works Connection?s Pro Perch offers quality materials, on-the-fly adjustments and excellent leverage for a smooth pull. The 909 Velocity grip is one of our favorites for superior comfort in a half waffle design. Note here: certain lubes will blow these babies into shrapnel so use caution when installing.

A Tsubaki QR Pro-gold chain proved to be very strong and stretched almost not at all. The DSP chain guide is carbon fiber, very light and can take a licking.

Hidden under that ignition case is a 7-ounce Steely flywheel. This helped to control the hit and enhanced the tractability considerably.

The big news came in the Race Tech modified shock. They yanked the standard shim stack and replaced it with their own design, then resprung the machine to fit our needs and that of the new valving. The result? Better traction, improved bottoming resistance, and less of the track transmitted to the rider.

One of the keys to the RM?s newfound success came in the Hinson Clutch parts. A new basket, hub and pressure plate is almost mandatory on this machine and will outlast the stock stuff by eons.

Moto Tassinari?s V-Force Reed block requires you to modify the standard assembly (which is a pain) but the results were excellent. Increased flow translated into better roll-on power and a smooth, longer-pulling mid range.

The Bills Pipe helped the bottom power and midrange while peak power was adrenalized quite wonderfully. In moto applications we relished the increased hit and overrev.

Race Tech?s fork modification included all new valving to complement their Gold Valve, and new springs (stiffer) which make for a firmer, yet more supple ride. This sounds like a paradox, but the end result is excellent. Decal Works provided the Dirt Bike graphics while N-Style fronted the Gripper seat cover.

We run the chain back as far as possible, which helps with stability, and run 14/51 gearing (13/48 is stock). This helps give us a bit more usable ratios down low and has a good effect on the suspension when the chain torque works against the rollers. The MT450 Pirelli is one our favorites in the intermediate tire category. We plopped them on fore and aft, delighting in their stickiness in the semi loose and craving their longevity.

Works Connection provided the skid plate and frame guards. Their fit was spot-on. DSP?s factory footpegs are wonderful and come in two flavors; stainless and Titanium. They?re 12mm wider than stock and mirror the works pegs in design and stature.

Applied Racing?s top clamp gave us the ability to alter the ergos and place the bar more forward and higher. These mated to the Answer Pro Taper handlebar, which was chosen for its light weight and strength.

ARC?s front brake lever was chosen after we snapped our stocker off in a routine fall. The ARC is a little fat, but offers good adjustment and is designed to fold backwards, meaning that it can take a fall. We?ve yet to harm ours in spite of numerous flips.