RG250 Mark 1 Dual Sport

[JonW]

Good to hear mate, excited to see this one when finished as youre not that far from me

[Pezz]

Ok, dust has settled and I am back at it again!!!

Now working on the front end and will get back to the swing arm a little later.

Just pressed the stem out of the DR600 triples and about to start measuring up to make a new stem. I will lower the bottom triple clamp about 20mm to clear the radiator and give more steering lock.

Question is what are the steering head bearing numbers for the RG250?

I will run the same bearings but need the lower bearing dimensions.

Looking at the DRZ400 front wheel hub and it looks identical to the DR600 so hopefully I will mean just a change of wheel bearings . . . . .

[JonW]

this may help

http://www.rzrd500.com/phpBB3/viewtopic ... 21&t=10509

[Pezz]

Thanks JonW

I have done a few of these conversions now, but will be reading that with interest

Just removed the steering head bearings from the RG

Top E32005J 25mm ID
Bottom E32006J 30mm ID

[JonW]

No worries, Ive spent hours studying that info as well, its amazing what you can find to make work like that... like, KX500 lower bearing race fits the XT and is 2mm deeper, every little helps when adding different forks...

[Pezz]

Just picked up some 4140 - 38.1mm x 400mm ready to start machining the steering stem. Cost $22.60

Here is the stem design i have come up with

[JonW]

sounds good value. I created a similar stem when I put KTM forks on my XT, but I cut down the old KTM stem rather than start from scratch, tho at that money it would have made more sense LOL!

[Pezz]

Had a productive afternoon roughing out the new steering stem to within about 1mm of desired diameter.

The old lathe took a bit of fettling to stop the chattering, and I was cutting it a bit slowly to start with.

Now the slow and time consuming part as clearances will need to be spot on.

[Pezz]

Well it's getting a little more exciting, now just need to make a spacer for below the bottom bearing and all will be ready to fit the DR600 front end on. Took a little bit to sort this out and I must thank my friend Malcolm, a retired toolmaker for his help with this. I have so much to learn when it comes to machining. Having a great mentor is always a big advantage. If I may offer advice, just keep asking lots of questions, 'cause the skills of these old tradesmen are disappearing these days.

New bits sitting together ready to reassemble



the 2 stems side by side

[Pezz]

Spacer ring on, probably should have cleaned it first



triples back on, next is insert the forks legs



On the crate, waiting for some more loving

[JonW]

Very similar to how I did KTM WP forks on my XT500, nice work!

[JonW]

Met up with Pezz today and saw this project. To be honest while he has a fair bit of work to do, its tantalisingly close to looking like a goer, and its a very cool project. Lovin it!

Thanks for the coffee Pezz, was great to catch up m8!

[Pezz]

Again Im sorry about the poor phone pics, Canon camera has died

Well I got the forks on and then jacked the bike up and sat the swingarm in for a check and look and see.

Realy quite impressed how it is coming together. The swingarm is too long and I have been given another swing arm by JonW, which looks like it will fit the bill nicely.



I will try to take some decnt pics over the weekend, as I look at ways to get the rear suspension working.

[JonW]

Thats looks the part mate! good work.

[BRG1200]

its really starting to get a consolidated TransAlp look going on. I don't mean that in a bad way BTW. The little Suzuki has some nice lines to start with. Keep going