It's time to revive an old favorite – the Suzuki RM250. There's nothing like the simplicity and excitement of a 2-stroke dirt bike. Known for being easy to maintain and repair, these bikes offer a budget-friendly alternative with cheaper parts and lower upkeep costs. But the real draw? The pure fun of whipping around on a 2-stroke, with that unmistakable sound and the nostalgic smell of Caster 927 oil mixed with race gas. If you're ready to relive the golden days of dirt biking, the Suzuki RM250 is your ticket to adventure!
Reviving the 2003-2005 Suzuki RM250: How to Bring Your Bike Back to Life
If you're ready to bring your 2003-2005 Suzuki RM250 back to its former glory, let's start by tackling the heart of the bike – the engine. When the motor is worn and doesn’t sound right, it's likely time for a complete rebuild. For this, we’ll rely on the Vertex Complete Engine Rebuild Kit. This all-in-one kit includes everything you need to restore your RM250's engine - Vertex Complete Engine rebuild Kit - WR101-063:
- OEM replacement crankshaft
- Fresh Vertex piston
- All new main bearings and seals
- Transmission bearing set
- Complete gasket set
With this kit, you'll have all the essentials to give your bike the overhaul it needs, restoring its performance and reliability.
Now, let’s move on to the intake. Upon inspection, the reed petals are gapped and chipped, which means they need to be replaced. Why not upgrade to the New VForce3 Reed Cage V307A? This will boost power across the entire powerband, giving your RM250 a significant performance upgrade. It’s a win-win for you rebuild!
- V-Force3 Reed Valve System increases torque and increases horsepower over the entire powerband.
- V-Force3 Reed Valve System incorporates the industry's first and only patented snap-together reed valve design. The entire assembly is completely screwed free, meaning that when reed petals need changing the job is now literally a "SNAP".
- (The VForce3 the cage also firs the YZ250)
Time to Rebuild the Carburetor
Since the RM250 has been sitting for a long time, this is the perfect opportunity to completely disassemble it and give it a thorough cleaning. The best method would be to soak the parts in an ultrasonic cleaner to remove all debris and buildup. After cleaning, you can install a fresh rebuild kit from Moose Racing (Part number 1003-0737) to ensure your bike is restored to peak performance.
After rebuilding the carb and installing a new reed cage, it's time to put in a fresh air filter. We've been using the FunnelWeb Pro Line Filters recently, and they offer significantly more surface area to keep the bike breathing freely for longer. These filters are reusable and feature FunnelWeb’s unique pyramid-profiled foam, designed to improve dirt-holding capacity while still delivering optimal airflow.
All FunnelWeb Filters use advanced open-cell polyurethane foam profiling, which dramatically increases the filter’s surface area. This allows it to trap more dirt on the outside, preventing harmful dust from entering the engine.
Fitment: FWF PRO 7550 - Suzuki RM125 / RM250 (2003-2008)
Now that the Suzuki RM250 is running great, let’s make sure all that power gets to the ground efficiently. Why run a fresh motor with an old clutch? We recommend the EBC Dirt Racer Clutch Kit. It's built to be extremely durable and uses heavy-duty components, ensuring your bike hooks up properly and delivers maximum performance.
Key Features of the EBC Dirt Racer Clutch Kit DRC161 - 2003-2005 Suzuki RM250:
- Superior Performance: Designed for competitive riders, delivering reliable and smooth clutch engagement.
- Complete Kit: Includes friction plates, driven plates, and heavy-duty clutch springs.
- Durable Materials: Utilizes anti-swelling, alloy-impregnated, cork-based facings for enhanced durability and smooth take-up.
- Long-Lasting Reliability: Built for long-term use, even in demanding off-road conditions.
The last step is upgrading the exhaust. It's time to replace that old, rusty, and dented stock pipe with a fresh, shiny nickel-plated one. We recommend the Pro Circuit Platinum Pipe - PS04250P for a durable, high-performance upgrade that will give your Suzuki RM250 a new edge.
Key Features of the Pro Circuit Platinum Pipe - PS04250P:
Electroless Nickel Plating: Extends part life 2-10x longer for increased durability.
High-Quality Materials: Made from stamped AKDQ carbon steel for strength and performance.
Hand-Welded Seams: Hand-pounded and welded seams ensure precision and reliability.
Key Features of the Pro Circuit Platinum Pipe - PS04250P:
- Electroless Nickel Plating: Extends part life 2-10x longer for increased durability.
- High-Quality Materials: Made from stamped AKDQ carbon steel for strength and performance.
- Hand-Welded Seams: Hand-pounded and welded seams ensure precision and reliability.
For riders looking for even more power, pairing the R-304 silencer with the Pro Circuit Platinum Pipe creates the ultimate power combo for competitive edge and peak performance.
Pro Circuit R-304 (Shorty) Silencer - Key Features:
- High-Performance Design: Full-race two-stroke silencer optimized for maximum performance gains; ideal for closed-course racing.
- Fully Rebuildable: Easy to maintain with hex head screws securing the inlet cap for quick re-packing and extended silencer life.
- Durable Construction: Built with a 304 stainless steel intake tube and double-walled mounting brackets, TIG and MIG welded for long-lasting strength.
- Made in the USA: Crafted with precision and quality materials, proudly manufactured in the USA.
The reassembly of the RM250 is now complete, and after all the effort spent getting it back in top shape, it's time to have some fun! Fill it up with 2-stroke fuel and let it rip—time to hit the track and enjoy the ride!
Suzuki RM250 Performance Parts Collection at Moto-House MX
Keep in mind that everything we’ve done to this bike can be applied to any 2-stroke, whether it’s a 125, 250, 85, or even a 65. Of course, each bike is different, and how well it was maintained previously may affect the process. We’re assuming you’re starting with a solid cylinder and a sturdy chassis, along with good suspension and all bearings tight in good condition. With a good foundation, you can achieve great results!