Project Suzuki 1984 RG250 part 4 BRUNO BARES ALL!
Classic Motorcycle Mechanics|September 2021
This month, while we wait for backorder engine parts, we strip the chassis back to the bare frame, assess what is needed and plan the reassembly…
JEFF WARE

G’day. I’m not sure what part of the year you’ll read this over in Pom land, but it’s been freezing in the shed lately and I’ve had to run two heaters! I know it’s probably a laugh to you guys (a bit like when you say 35 degrees C is hot when to us that’s a nice mild day) but temperatures of between eight and 15 degrees C with chilly westerly winds is a bit much for us Aussies to deal with!

I was hoping to have a complete rebuilt motor by now but finding parts for the 1984 RG has proven harder than I imagined. In fact, there are less bits around than there were for the RZV500R or RG500, or even the TZR250 3MA! There is almost nothing left these days here in Australia and very little I can find overseas.

I’ve managed to get a mate on to it, Steve Cutting, of Steve Cutting Motorcycles, and he has managed to find most of what I need via Suzuki dealerships or in aftermarket version, but it’s been a six-week period of chasing parts. Crazy! Anyway, the cylinders are off getting rebored and the rest of the engine parts are on order so rather than sit around with the flies I decided to strip the rest of Bruno’s chassis.

This bike really has surprised me. It has big mileage on it but is also very original and stripping the roller down proved I really have scored a good project here. Nothing is missing. In fact, my list of OEM chassis parts required remains blank. All black plastic frame plugs were there; all wiring harness clips and original straps in place; the wiring plugs and connector rubber boots all still there; the plastic rings that sit under the triple-clamp to route cables and wires through are still intact (amazing); the headlight adjustment knob is still on the light! All fasteners are original, no rubber trims missing, and even the plastic guard around the shock is there and amazingly, the shock still has the original warning sticker on it. The grips and levers are OEM as well. After 37 years, I find this all amazing, particularly considering the bike was in a sorry state when I got it and had definitely been stored outside for a period of time in the elements, possibly without shade or shelter. Having all of these little parts makes the job so much easier. I remember it did my head in finding all of these details for my two 1985 GSX-R750F projects a few years ago, not to mention the expense was horrendous…

Stripping the RG was easy and was a one-day job. No seized or stuck fasteners; not even the swingarm pivot was jammed. The rust on the fork inner tubes meant getting them through the triple-clamps required some WD-40 and a flat-bladed screwdriver to prise the clamps open a little, but aside from that, it was all smooth sailing.

Continue reading your story on the app

Continue reading your story in the magazine

MORE STORIES FROM CLASSIC MOTORCYCLE MECHANICSView All

Honda VFR750R - RC30

If there’s a more worshipped V4 out there, we’ve yet to see it: welcome to our reboot of the awesome VFR750R RC30…

2 mins read
Classic Motorcycle Mechanics
September 2021

Mountain tension!

Award-winning motorcycle engineer!

5 mins read
Classic Motorcycle Mechanics
September 2021

Fazer set to STUN!

What do you get when you mix CRK’s lovely café racer kit to Yamaha’s budget middleweight and the recently-retired Martin Fox? Well, one helluva foxy Fazer!

6 mins read
Classic Motorcycle Mechanics
September 2021

Project Suzuki 1984 RG250 part 4 BRUNO BARES ALL!

This month, while we wait for backorder engine parts, we strip the chassis back to the bare frame, assess what is needed and plan the reassembly…

6 mins read
Classic Motorcycle Mechanics
September 2021

Project Kawasaki Z900 Stocker part 2 Ralph has a blast!

For the best finish on his Z900’s motor Ralph wants the best, so he visits Stephen Smethurst Casting Renovation to find out how it’s done properly.

10 mins read
Classic Motorcycle Mechanics
September 2021

Project Suzuki TS400 Part 8 Loom with a view!

We’re getting down into the nitty-gritty this time with component testing and loom building. What could go wrong?

6 mins read
Classic Motorcycle Mechanics
September 2021

Project Yamaha TX750 Part 12 A question of balance…

Only The Beach Boys had good vibrations… so what’s Mark been up to, to sort out the bad ones coming from his TX750?

6 mins read
Classic Motorcycle Mechanics
September 2021

Splitting links

Ralph Ferrand works with tools all day long – he sells them too at bikerstoolbox.co.uk so he knows what works.

4 mins read
Classic Motorcycle Mechanics
September 2021

STAVROS: PRINCE OF PRANKSTERS!

It’s probably fair to say that Stephen JamesParrish’s persona and overall levity throughout his life have muddied the waters as to just how good a bike racer he was back in the day.

1 min read
Classic Motorcycle Mechanics
September 2021

Metal magic!

Ralph Ferrand works with tools all day long – he sells them too at bikerstoolbox co uk so he knows what works.. .

3 mins read
Classic Motorcycle Mechanics
July 2021
RELATED STORIES

THE SUZUKI HAYABUSA

Suzuki said the first Hayabusa invented a new category called Ultimate Sport. We said, “Yeah, right,”…until we rode it.

5 mins read
Cycle World
Issue 4 - 2020

FORBIDDEN FRUIT

WITH CLASSIC 4X4 DESIGN CUES AND AN OLD-SCHOOL 4X4 DRIVELINE IN A PINT-SIZE PACKAGE, IT’S LIKE DRIVING THE JEEP WRANGLER’S LITTLE BROTHER. BUT IT’S NOT FOR SALE HERE.

5 mins read
Motor Trend
January 2021

MASTER BARTON BOEHM'S PATH TO PEACE

THERE’S MORE TO MARTIAL ARTS THAN KICKS AND STRIKES.

6 mins read
American Survival Guide
September 2020

Radical Rerun

Going under the sword with the 2020 Suzuki Katana

9 mins read
Cycle World
Issue 2 - 2020

DESIGN MACHT MUT(H)

How a German designer came to forge Suzuki’s sharpest sword

5 mins read
Cycle World
Issue 2 - 2020

One Hell of A Week Hellas Rally Raid, Greece

I started riding motorcycles some six years ago in Peru, and it wasn’t because I was always a die-hard moto fan or knew anything about bikes.

10 mins read
Adventure Motorcycle (ADVMoto)
November-December 2020

Toyota, Suzuki Partnering In Self-driving Car Technology

Japan’s top automaker, Toyota, and smaller rival Suzuki are partnering in the development of self-driving car technology, as manufacturers around the world grapple with innovations in the industry.

1 min read
AppleMagazine
August 30, 2019

Suzuki Unveils All-New S-Cross Model For Global Markets

Suzuki Motor Corporation has unveiled the all-new S-Cross model for the European market. The model will eventually make its way into India in 2022. The new S-Cross makes a strong statement with bold, dynamic SUV styling complemented with a spacious and versatile interior and 48V mild hybrid technology.

2 mins read
Motown India
December 2021

MARUTI SUZUKI CELERIO

Now in its second-generation, and more spacious than the Wagon R, does the Celerio have what it takes to climb back up the sales charts?

6 mins read
Overdrive
November 2021

Sorry I hit your car but it's s*** so I'm not leaving my details!

A MUM says she's baffled by a note left on her car from a rude driver.

1 min read
Manchester Evening News
December 16, 2021