Suzuki RMZ 250 EV Restomod

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Eastwood   10 kW

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Suzuki RMZ 250 EV Restomod

Post by Eastwood » May 06 2022 8:55am

Picked up this 2007 Suzuki Rmz 250 frame and swingarm. Also came with the triple clamp and rear shock.

First priority is to get this into a rolling chassis.
Will restore this frame before mounting the motor and figuring out which battery to build or buy. I’ve ordered the front fork tubes, rear suspension linkage and missing bolts. Also ordered new bearings for everything including the steering. This bike will be built for Enduro and trail riding.

I’ve started sanding the swingarm to remove all scratches and minor dents. The plan as of now is to polish the swingarm and frame and apply a lacquer coating to protect the polished finish. The frame is in good shape not that many scratches but the swingarm was pretty beat up cosmetically.

Motor wise I’m not sure yet. It will be either the QS180 or the QS138 90h.

1st option : QS180 with 21” front 18” rear - wheels
2nd option : QS138 with 19” front 16” rear - wheels
Will build the wheels using excel Takasago rims.
Leaning toward the first option with a 50kW set up :thumb:

I’ll post pictures as I make progress with the bike build. As mentioned I will restore this bike into a rolling chassis before I start any motor mounting, battery and controller. This build will take me a while. Stay tuned!
Attachments
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Disassembled and ready for a rebuild. I’ve ordered everything to rebuild this rear shock just waiting on the parts.
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This is the worst part of the swingarm the bottom of the chain side. Will sand out some of these dents but some of them are too deep and I don’t want to remove that much material. Plus it’s on the bottom side so it won’t be seen.
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Will fix the chain gouges
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:bolt: Suzuki Rmz 250 EV Restomod :bolt:
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skeetab5780   100 MW

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Re: Suzuki RMZ 250 EV Restomod

Post by skeetab5780 » May 06 2022 2:01pm

sub'd He's finally doing a dirt bike! GL man

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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » May 07 2022 9:39am

Thanks skeetab, this should be a nice journey getting this bike restored and converted :thumb:
:bolt: Suzuki Rmz 250 EV Restomod :bolt:
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:bolt: Enduro Frame build :bolt:
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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » May 07 2022 9:39am

Received the front fork tubes :thumb:
I have replacement bushings and seals from allballsracing.
The forks seem to be in good condition no pitting or rusting on the chrome. Will also refinish the outside but keeping the gold color. Probably just needs a good cleaning with some scotch bright but first remove the old stickers.
Attachments
BB44A7BE-50E4-42F6-B697-25A09B844E38.jpeg
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:bolt: Suzuki Rmz 250 EV Restomod :bolt:
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:bolt: Enduro Frame build :bolt:
viewtopic.php?f=6&t=113133

Scootdan   10 W

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Re: Suzuki RMZ 250 EV Restomod

Post by Scootdan » May 07 2022 1:09pm

Really appreciate your work sir. Your bike on here is so awesome. Are you serious with the quick connect swapable motors?! And the power looks so fun. I can only dream how tricked out you will make this sweet machine. Thank you brother. :thumb:

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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » May 10 2022 8:04am

Scootdan wrote:
May 07 2022 1:09pm
Really appreciate your work sir. Your bike on here is so awesome. Are you serious with the quick connect swapable motors?! And the power looks so fun. I can only dream how tricked out you will make this sweet machine. Thank you brother. :thumb:
Thanks for the support brother! The Enduro build has been fun, loving that bike. Now it’s time to make a full size dirtbike with big power 8)
:bolt: Suzuki Rmz 250 EV Restomod :bolt:
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SlowCo   10 MW

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Re: Suzuki RMZ 250 EV Restomod

Post by SlowCo » May 11 2022 2:26pm

Good luck building and enjoy the process :thumb:

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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » May 12 2022 11:09am

SlowCo wrote:
May 11 2022 2:26pm
Good luck building and enjoy the process :thumb:
Thanks! :wink:
gobi wrote:
Apr 27 2022 10:27am
Very very nice,
I read that suzuki factory forks rock too.

Can you please weigh the bare frame with the swing arm as is now.
So I got the weight of the frame and swingarm. Figured I would reply to you here on the build thread for this bike. :thumb:
8 lbs - Swingarm
22 lbs - frame
Attachments
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Ordered the linkage from eBay. Pressed out the old bearings but on the linkage arm part there’s some scratches/gouges where the bearing seat. Considering getting a different one. New OEMs are around $350 so that’s out of the question lol. Paid 50 bucks for these used ones.
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Order the forks from eBay as well for $289. Not bad ;)
Will rebuild these soon.
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:bolt: Suzuki Rmz 250 EV Restomod :bolt:
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gobi   1 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by gobi » May 20 2022 11:05am

8 lbs - Swingarm
22 lbs - frame
1.1 lb - misc Fork parks
4.6 lbs - triple tree
20.7 lb - fork

50 lb Total, that is light,

Add seat, battery, motor, brake parts, wheel. I am guessing a bit over 100 lbs?

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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » May 20 2022 10:33pm

:pancake:
gobi wrote:
May 20 2022 11:05am
8 lbs - Swingarm
22 lbs - frame
1.1 lb - misc Fork parks
4.6 lbs - triple tree
20.7 lb - fork

50 lb Total, that is light,

Add seat, battery, motor, brake parts, wheel. I am guessing a bit over 100 lbs?
Yeah I was surprised of how light the frame is.
Still need to get the subframe, seat, plastics, handle bars, brakes and rotors. Plus build the wheels.

As far as weight I’m not sure yet but I’m actually leaning toward lifepo4 cells which are heavy. The battery would be a little over 100 pounds but I would have 90ah. lifepo4 are around 20% heavier but I like the safety factor. Still considering Molicel 21700 P42A as well.

So leaning toward 32s 6p of 33140 cells lifepo4. 3.2 nominal voltage - 5c discharge rate. Cells are 15ah so 75amp discharge per parallel group.
So nominal voltage of 102.4 with 450amp discharge equals
46,080KW and when fully charged at 115v = 51,750KW
:bolt: Suzuki Rmz 250 EV Restomod :bolt:
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gobi   1 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by gobi » May 21 2022 7:28pm

Maybe you can you look at LIPO pouch cells, A123 has good ones. Yeah, they are heavy, if you don't charge LIPO over 4.05 volts and check balance, you can see if cells are going cray cray.

I plan on building my FIRST lipo pack soon, BT JBD bms just to monitor the cells, for motor I plan on bypassing the bms.

Yeah, shockingly light frame, awesome piece of engineering.

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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » Jul 01 2022 4:08pm

It’s been a while since an update, just getting started back on this build as I moved recently.
Received the front rim today, 21”-1.6” excel takasago
The hubs and spokes will be here in couple weeks.
Rear rim should be next week, 18”- 2.15” excel takasago.

Also ordered the motor and went with the lighter option since this will be for trail riding and enduro. Went with the QS 138 70h. Was sold on the QS180 but with the QS138 it’s almost half the weight and the gear reduction is already built in so no welding the frame. Still leaving the option available to make this street legal so without making changes and welding the frame makes the process a lot easier.

Still contemplating the controller options but as of now I’m leaning toward ND721800 “far driver” or the ND721200. Those controllers are more than enough for this QS138 but I like the idea of using an oversize controller and not pushing it to the max for better efficiency and less heat.

Oh and I’ve scratched the idea of polishing the frame and will powder coat everything black. So all silver aluminum parts will be powder coated black, frame swingarm triple clamps etc.
Attachments
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0E649842-9562-43D6-A901-80CA28230D80.jpeg (251.17 KiB) Viewed 2865 times
:bolt: Suzuki Rmz 250 EV Restomod :bolt:
viewtopic.php?f=12&t=116038&p=1716022#top

:bolt: Enduro Frame build :bolt:
viewtopic.php?f=6&t=113133

Mivvi   1 µW

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Re: Suzuki RMZ 250 EV Restomod

Post by Mivvi » Jul 04 2022 4:44am

I'm loving this build, something along the lines of what I want to do. Will be following this closely. Good luck buddy!

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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » Jul 06 2022 2:50pm

Mivvi wrote:
Jul 04 2022 4:44am
I'm loving this build, something along the lines of what I want to do. Will be following this closely. Good luck buddy!
Thanks! I’ll be giving more updates frequently as I have more parts on the way :thumb:
Need to get this frame swingarm etc. out to the powder coater since I have the bearings removed.
:bolt: Suzuki Rmz 250 EV Restomod :bolt:
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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » Jul 06 2022 2:51pm

Received the front and rear hubs today :thumb:
I have to say, this gold finish is beautiful!
Got the rear spokes in but still waiting on the nipples and spokes for the front wheel. The hubs are forged aluminum, much beefier than the stock hubs.

The rear excel rim should be here today
Attachments
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The seller sent me some extra spokes and nipples for the front and rear. Still waiting on the actual nipples as it’s from a different warehouse. Excited to get these built!
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I’m really loving those excel rims with the gold hubs
65E9049D-C8C9-4F11-8456-4D387F8BD330.jpeg (2.82 MiB) Viewed 2732 times
:bolt: Suzuki Rmz 250 EV Restomod :bolt:
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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » Jul 11 2022 12:53pm

Got the motor today! QS138 70H
Motor weight 27lbs, not bad especially since this will be for Trail/enduro use, the lighter the better :thumb:

Also Received the rear rim 18” and the rest of the spokes and nipples.

Hopefully I can drop off my frame swing arm etc. to the powder coater sometime this week but I need to receive the subframe first.
Attachments
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:bolt: Suzuki Rmz 250 EV Restomod :bolt:
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:bolt: Enduro Frame build :bolt:
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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » Jul 15 2022 10:07pm

Just laced up the rear wheel this evening :thumb:

Dropped off the frame, swing arm, triple clamps, etc. to the powder coater today :thumb:
Went with satin black, black jack
Should have everything back in about a week-ish.
Attachments
223B286B-E76B-4865-9E83-948CA3478ED5.jpeg
Everything I dropped off today at the powder coater
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Used some anti-seize on the spoke threads
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:bolt: Suzuki Rmz 250 EV Restomod :bolt:
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:bolt: Enduro Frame build :bolt:
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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » Jul 16 2022 1:30pm

Just laced up the front wheel. I’ll wait to fully tighten and true the wheels once I have them on the bike, that’s my truing stand :wink:
Attachments
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:bolt: Suzuki Rmz 250 EV Restomod :bolt:
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:bolt: Enduro Frame build :bolt:
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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » Jul 27 2022 8:55am

Got all the parts back from the powder coater :thumb:
I really like this satin black/Black jack. I almost went high gloss but I’m glad I didn’t.

Was able to install new bearings in the swingarm using the motion pro bearing installer.
Attachments
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:bolt: Suzuki Rmz 250 EV Restomod :bolt:
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j bjork   1 MW

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Re: Suzuki RMZ 250 EV Restomod

Post by j bjork » Jul 27 2022 11:49am

Sure looks nice :)
But were you already finished with fitting points and brackets for everything?

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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » Jul 27 2022 7:17pm

Thanks!

Well technically no I haven’t fabricated the final motor mounts but I’ve messed around with motor positioning and I’m able to actually use all the factory engine mounting points so no welding with this build. Got 3 solid factory engine mouning points for the new motor and possibly a few other spots for additional support if needed. Also considering I’m using the QS 138V3 I don’t have to mess with welding mounting points for the jack shaft/gear reduction :wink:

But yeah once I fabricate the motor mounts will have those powder coated as well but will probably do lots of testing to make sure all is good before having the mounts/brackets powder coated.
:bolt: Suzuki Rmz 250 EV Restomod :bolt:
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MDG   1 W

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Re: Suzuki RMZ 250 EV Restomod

Post by MDG » Aug 20 2022 1:47pm

This is going to be rad!!! 8)

speedy1984   100 W

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Re: Suzuki RMZ 250 EV Restomod

Post by speedy1984 » Aug 20 2022 3:51pm

img_1141-600x450_10 rmz.jpg
img_1141-600x450_10 rmz.jpg (30.24 KiB) Viewed 1926 times
I run this motor mount on my crf conversion.I did not want the battery mount at the front so they knocked the price right down for me.So currently only using two mounting points that includes the swing arm axle bolt and its more than strong enough as is.Buy, fit and forget is what i wanted even after making my own mounts.I was worried i would throw the chain on my first ride on my diy mounts an scrape my mint build up,so thought better of it :thumb:

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Dui, ni shuo de dui   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Dui, ni shuo de dui » Aug 23 2022 4:23am

Looks like it will be a great build!
I wouldn't have the balls to powder coat the frame before making everything fit before, would be too afraid of ruining it or to have to modify it in some way for stuff to fit. I sure hope you won't have to.

Anyway, keep up the good work! I'm very interested to see how this bike will turn out, I wish to have the opportunity to build a dirt bike someday, looks like a lot of fun!
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Eastwood   10 kW

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Re: Suzuki RMZ 250 EV Restomod

Post by Eastwood » Oct 04 2022 12:06pm

So I’ve been away for a while haven’t had much time to work on the bike. I’ve installed all the bearings now including the swingarm and headset bearings. Also rebuilt the rear suspension. I had quite a few spots to clean up powder coating as They did a horrible job with prepping To keep the powder coat out of the areas where the bearings are installed. The actual powder coat finish looks great tho. I will start assembling the bike later this week but still need to sort out making or purchasing some motor mounts. Stay tuned 8)




MDG wrote:
Aug 20 2022 1:47pm
This is going to be rad!!! 8)
Thanks! 8)
speedy1984 wrote:
Aug 20 2022 3:51pm
img_1141-600x450_10 rmz.jpg

I run this motor mount on my crf conversion.I did not want the battery mount at the front so they knocked the price right down for me.So currently only using two mounting points that includes the swing arm axle bolt and its more than strong enough as is.Buy, fit and forget is what i wanted even after making my own mounts.I was worried i would throw the chain on my first ride on my diy mounts an scrape my mint build up,so thought better of it :thumb:
Nice, thanks for sharing the pic!
So are you saying that you purchased those motor mounts, if so where? I planned on making my own but if there’s options for these mounts to be purchased I would definitely consider that.
Dui, ni shuo de dui wrote:
Aug 23 2022 4:23am
Looks like it will be a great build!
I wouldn't have the balls to powder coat the frame before making everything fit before, would be too afraid of ruining it or to have to modify it in some way for stuff to fit. I sure hope you won't have to.

Anyway, keep up the good work! I'm very interested to see how this bike will turn out, I wish to have the opportunity to build a dirt bike someday, looks like a lot of fun!
Thank you! :thumb:
Yes I thought about this long and hard about Powdercoating before or after. In my state if you make any changes to the frame it’s a lot harder to make something street legal. So no modifications to the frame whatsoever on this build. Also considering I don’t have to build a jack shaft/gear reduction which would’ve been the only modifications. This build is for Trail/Enduro use but I’m sure I will eventually like to build some super Moto wheels so I can hit the streets every once in a while.
Attachments
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Resurfaced the piston for the rear suspension.
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This was loosely put together just wanted to see what it’s going to look like.
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Look at the horrible job they did prepping where the headset bearings are Installed! So annoying when you pay people to do something to save you time it ends up taking more time removing the damn overspray. Used a strong gasket remover with lots of elbow grease was able to get out all the overspray. Thankfully!
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There’s the brand gasket remover I used. This stuff works great for a removing powder coat! Also you can see the rear suspension reassembled. Still need to stop by a motorcycle dealership to get some nitrous added to the rear shock
53BE0D2B-11FC-4185-8059-8E0481D433DD.jpeg (2.45 MiB) Viewed 1434 times
:bolt: Suzuki Rmz 250 EV Restomod :bolt:
viewtopic.php?f=12&t=116038&p=1716022#top

:bolt: Enduro Frame build :bolt:
viewtopic.php?f=6&t=113133

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