2004 RM250 fork Help

TPMX #8

TPMX #8

PR Addict
We set out today to rebuild the forks on a 2004 rm250
Ussing a Pivot Works full kit we ran into an issue
The kit doesn't come with bushings for the lower end of the Damper tube plus the bottom guide bushing in the kit is the correct
diameter but almost 1/4 inch wider than the stock bushings
I rebuilt the forks on my 04 years ago but didn't run into this issue
You Suzuki guys ever have this issue?
 
Yes I've had issues with varying quality of aftermarket kits. End up using OEM parts whenever I can.
 
OEM doesn't even list a bushing for that position on the damper tube
Doesn't look like you can buy it
going to a dealer today see what to do
Thanks Vet261
 
Action Sport Cycles in Alliance. helped with this problem
They figured out a kit from a 250f had in it what we needed
Honda offered the two bushing that Suzuki doesn't plus two other bushings that where wrong in the Suzuki kit was correct in the Honda kit
They just happened to have an opened kit for the Honda
 
Still ca not find the correct bushings for this bike
we have ordered the oem bushings for a couple models and cant come up with the correct bushings
diameters are correct but the width is wrong
the bushings we need are 51x47x12 mm wide
any we order or come in kits are 15mm wide
any ideas?
 
where on the forks are these bushings? Got any pics? Maybe call RaceTech.

I've never had any problems rebuilding RM forks, but it sounds like you might be replacing parts I've never replaced.
 
Vet261
I have done many Suzuki forks and never ran into this
Its the slider bushing that goes in the counterbore in the fork tube
I believe they are the outer slider bushing by name, on an oem microfiche its #6 reference
I talked to FCR today and he usually stocks the size needed and he should have them back
in stock late week
Hope those work
I just don't understand why this set of forks is a problem
Race tech does list them also #FMBO 47122 P
Which is 47mmX12mm wide x 2mm wall which makes the od 51mm
They just don't have them in stock either
their has to be an gem set also I just don't know where to look anymore
thank you
 
Did somebody frankenbike up the forks or something? Those are typical, normal bushings that I replace all the time. Keep us posted.
 
that's pretty much my thoughts at this point
my son just bought this bike because. he like these years RMs
who knows what the previous owner did
there's some real hacks out there
Nothing from Suzuki seems to fit
all the forks I've done I've never ran into this and ive had Suzukis since 1977
 
finally figured out this fork mess
01-06 rm125 k2 and k3 forks used these bushings
no longer available oem but found some old stock on eBay
 
Wow, weird. Wonder how this 2004 RM250 ended up with forks or at least parts of forks from an 02/03 RM125?
 
my son purchased the bike used so who knows what has been changed
I hate seeing a bike that even has a bolt that has been replaced with the wrong bolt
 
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