Suzuki RG250 HB Replica: Yellow Terror Part 2

Words & Pics: Jeff Ware

Two years after taking delivery of Bruno, an original but rough RG250HB replica, Jeff finally hits the hills!

G’day,

Well, in the end I did a complete nut and bolt resto on the RG. I built the engine using the original cases but adding the best of the gearbox and clutch components I had among my RG spares, plus a good top-end using new rings. All seals and bearings were replaced aside from the centre main bearing and seal, as the crank I used I deemed good enough for the job.

Final inspection before the bodywork covers up that gorgeous two-stroke powerplant.

I hand polished the frame and swingarm, along with all other bare alloy parts (thanks to Todd for the help), then had the forks re-chromed. All black bracketry was resprayed, the exhausts de-coked and resprayed and Todd rebuilt the stinger mufflers and polished them to a mirror finish. He also restored the dash to new conditions.

Lining up the bellypan and the brackets. 

Josh from Gibson Automotive gave the RG a pass! 

Every chassis bearing was replaced, the wheels stripped and painted, new Bridgestone BT46 tyres fitted, and the brakes completely rebuilt and painted by Todd, with new custom made Hel brake lines from Hel Australia in Brisbane. The last big job was completely rebuilding the wiring loom to original shape and spec, that was a big job.

Easy does it with the fasteners. I used plenty of plastic washers to protect the clear coat.

The final steps getting the RG sorted were relatively easy. All I had to do was fit the screen and indicators to the front fairing and get that on, then the rest of the bodywork lined up perfectly. Some sections were a bit fiddly, like the six brackets that hold on the bellypan and the lower frame mounted stays that brace the bottom of the bellypan… But it all went smoothly, and the shiny new fasteners look mint…

The bike ready to take off the bench.

The very first ride was a short run to see Josh at Gibson Automotive in Woy Woy, NSW, to get a ‘Historic Vehicle Inspection’ done for the historic registration. You must join a club… I am in the VJMC.

I thought about a single seat cowl but I’m still unsure of whether I should bother or not. The red seats look OK.

Bruno passed Josh’s test with flying colours, and we headed off to service NSW to sort the paperwork and get a numberplate. The short ride gave me a chance to assess the bike and as soon as I got home, I added some fork oil and had a play with the shock, but I am now on the lookout for a new aftermarket one as the original is stuffed… Aside from that, Bruno ran like a new bike. I was stoked.

Partly dressed, ready for the main fairings. 

The first longer ride was great. Of course, I had to add the bike to my Shannons Insurance account (I have all my vehicles and trailers insured under the one policy with Shannons), then I was on my way. The bike runs very sweetly, is super well carburetted, has strong power and a smooth clutch and gearbox.

Suzuki Australia have been following the build and sent me a Suzuki shirt, cap, and jacket! This shot was taken when I got home from the first run. 

All the lights work, there are no nasty vibes, and it feels like it just rolled off the showroom floor aside from the shock. It’s comfy, fun, fast and makes me feel young again particularly riding it around my home area where I grew up riding 250 two-strokes in the early 1990s… I can’t wait to do a big ride soon…

Fanging through the hills with a huge smile on my face. 

Protect your motorbike. Call Shannons Insurance on 13 46 46 to get a quote today.