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RM125
Suzuki RM125 User Manual
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9
GEARSHIFTING 9-1
CONTENTS
GEARSHIFTING
CONSTRUCTION .........................................
............................................... 9- 2
REMOVAL ............................
..............................................
......................... 9- 3
INSPECTION ............................................
....................................
............... 9- 5
REASSEMBLY .............................................
............................................... 9- 6
103
105
Table of Contents
General Information 1
10
Serial Number Location
5
Replacement Parts
7
Table of Contents
10
Location of Parts
11
General Information
11
Fuel and Oil Recommendation
12
Operating Instructions
13
Starting the Engine
13
Stopping the Engine
13
Transmission
14
Break-In (Running-In)
14
When the Motorcycle Is New
14
When Engine Parts Are Replaced
14
Periodic Maintenance 2
16
Periodic Maintenance
18
Inspection before Practice
18
INSPECTION before RACE (All Items of Inspection before Practice above Plus)
18
Periodic Maintenance Chart
19
Spark Plug
21
Air Cleaner
22
Air Cleaner Element Removal
22
Washing
22
Installation
22
Transmission Oil
23
Transmission Oil Level Inspection and Replenishment
24
Transmission Oil Change
24
Engine Coolant
25
Engine Coolant Level Check
25
Engine Coolant Replenishment
26
Cooling System Inspection
26
Clutch Cable
27
Major Adjustment
27
Minor Adjustment
27
Throttle Cable
27
Fuel Hose
28
Fuel Valve
28
Cylinder Head, Cylinder and Piston
29
Cylinder Head
29
Cylinder
29
Piston
29
Exhaust Valve
30
Exhaust Silencer
30
Silencer Inspection and Replacement
30
Silencer Reassembly
30
2-16 Periodic Maintenance
31
Sprocket Inspection
32
Drive Chain Guide, Buffer, Tensioner Roller
32
Drive Chain Guide
32
Drive Chain Guide Buffer
33
Drive Chain Tensioner Roller
33
Brakes
33
Brake Fluid Level
33
Brake Pad
34
Front Brake Lever Adjustment
34
Brake Pedal Height Adjustment
34
Front Fork
35
Rear Suspension
35
Wheels and Tires
35
Wheel Rim
35
Spoke Nipple and Rim Lock
36
Tire Pressure
36
Steering
37
Lubrication
38
Troubleshooting
40
Troubleshooting
41
Drive Chain and Sprockets
31
Drive Chain Slack
31
Drive Chain Adjustment
31
20Th Pitch Length
31
Drive Chain Lubrication
31
Machine Tuning
46
Carburetor Tuning
47
Carburetor Components and Functions
47
Principles of Carburetor Tuning
47
Carburetor Tuning in Practice
51
Front Fork Tuning
54
Compression Damping Force Adjustment
54
Rebound Damping Force Adjustment
54
Oil Quantity Minor Adjustment
55
OIL CHANGE (Only for Outer Tube Oil Chamber)
56
Spring Change
58
Front Fork Tuning Procedure
60
Rear Suspension Tuning
61
Compression Damping Force Adjustment
61
Rebound Damping Force Adjustment
61
Spring Pre-Load Adjustment
62
Rear Suspension Tuning Procedure
63
Suspension Balance
65
Balance Test
65
Balancing Tips
65
Engine Removal and Installation
66
Exterior Parts
67
Engine Removal and Installation
68
Removal
68
Installation
72
Cylinder, Piston and Exhaust Valve
74
Construction
75
Engine Top End
76
Cylinder Head Removal
76
Cylinder Removal
76
Piston Removal
77
Exhaust Valve Removal
78
Cylinder Head Inspection
79
Cylinder Inspection
79
Piston and Piston Ring Inspection
80
Exhaust Valve Inspection
81
Conrod Inspection
81
Piston Ring and Piston Reassembly
82
Exhaust Valve Reassembly
82
Cylinder Reassembly
83
Exhaust Valve Governor Removal and Disassembly
85
Exhaust Valve Governor Inspection
86
Exhaust Valve Governor Reassembly and Installation
86
Clutch
88
Construction
89
Clutch Plate
90
Removal
90
Inspection
91
Reassembly
92
Primary Driven Gear and Clutch Sleeve Hub
93
Removal
93
Kick Starter
93
Inspection
94
Reassembly
94
Clutch Release Camshaft
96
Removal
96
Inspection
96
Installation
96
Kick Starter
98
Construction
99
Removal
100
Inspection
101
Oil Seal
101
Kick Starter
101
Kick Starter Idle Gear
101
Reassembly
102
Inspection after Reassembly
103
Gearshifting
104
Construction
105
Removal
106
Inspection
108
Reassembly
109
Transmission and Crankshaft
112
Construction
113
Engine Bottom End
114
Primary Drive Gear Removal
114
Crankcase Separation
115
Transmission Removal
115
Crankshaft Removal
116
Transmission Inspection
116
Crankshaft Inspection
117
Crankshaft Runout
118
Oil Seal Inspection, Removal and Installation
118
Bearing Inspection, Removal and Installation
120
Crankshaft Installation
121
Transmission Reassembly
122
Crankcase Reassembly
123
Primary Drive Gear Installation
124
Fuel System
126
Carburetor
127
Construction
127
Removal and Disassembly
128
Cleaning
132
Inspection
132
Reassembly and Remounting
133
Carburetor Solenoid
135
Removal and Inspection
135
Reassembly
135
Throttle Position Sensor
136
Inspection
136
Reed Valve
137
Removal
137
Inspection
137
Reassembly
137
Cooling System
138
Construction
139
Cooling Circuit
140
Inspection
140
Engine Coolant
140
Replacement
140
Radiator
141
Removal
141
Inspection
141
Installation
141
Water Pump
142
Removal
142
Inspection
142
Reassembly
143
Electrical System
146
Cautions in Servicing
147
Connector
147
Coupler
147
Semi-Conductor Equipped Part
147
Using the Multi-Circuit Tester
147
Switch
147
Location of Electrical Components
148
Construction
149
Electrical Circuit
149
TROUBLESHOOTING (no Spark or Poor Spark)
150
Ignition System
151
Ignition System Peak Voltage Inspection
151
Ignition Coil Inspection
152
Stator Coil Inspection
152
Magneto Rotor and Stator Removal
153
Magneto Rotor and Stator Reassembly
154
Front and Rear Wheels
156
Construction
157
Front Wheel
158
Removal
158
Inspection
158
Bearing Replacement
159
Disc Plate Replacement
160
Installation
160
Rear Wheel
161
Removal
161
Inspection
161
Bearing Replacement
162
Disc Plate Replacement
162
Rear Sprocket Replacement
163
Installation
163
Front and Rear Brakes
164
Construction
165
Brake Fluid Air Bleeding
166
Brake Fluid Replacement
167
Brake Pads Replacement
168
Front Brake Pads
168
Rear Brake Pads
168
Brake Disc Inspection
170
Caliper
170
Front Caliper Removal and Disassembly
171
Rear Caliper Removal and Disassembly
172
Caliper Inspection
173
Caliper Cleaning
174
Front Caliper Reassembly
174
Rear Caliper Reassembly
175
Master Cylinder
176
Front Master Cylinder Removal and Disassembly
176
Rear Master Cylinder Removal and Disassembly
177
Master Cylinder Inspection
178
Master Cylinder Cleaning
178
Front Master Cylinder Reassembly
178
Rear Master Cylinder Reassembly
179
Brake Lever
180
Removal
180
Installation
180
Brake Pedal
181
Removal
181
Reassembly
181
Front Fork and Steering
182
Construction
183
Front Fork, Steering
183
Handlebar Controls
184
Removal
185
Disassembly
186
Inspection
190
Reassembly
192
Installation
198
Steering
199
Removal
199
Inspection
201
Bearing Replacement
201
Installation
202
Rear Suspension
206
Construction
207
Rear Suspension
207
Rear Shock Absorber
208
Removal
208
Spring Replacement
209
Inspection
210
Bearing Replacement
210
Oil Replacement
211
Disassembly and Inspection
214
Reassembly
216
Installation
216
Disposal
217
Swingarm
218
Removal
218
Inspection
219
Bearing Replacement
220
Installation
221
Rear Suspension Linkage
222
Removal
222
Inspection
223
Bearing Replacement
223
Reassembly
224
Servicing Information
228
Service Data
229
Cylinder + Piston + Piston Ring
229
Conrod + Crankshaft
229
Clutch
229
Radiator
230
Transmission
230
Drive Chain
230
Carburetor
230
Electrical
231
Brake + Wheel
231
Suspension
232
Tire
233
Fuel + Oil + Coolant
233
TIRE Service Data
233
Tightening Torque
234
Special Tools
236
Wiring Diagram
238
Wire, Cable and Hose Routing
239
Specifications
247
Dimensions and Dry Mass
247
Engine
247
Transmission
247
Chassis
248
Electrical
248
Capacities
248
Optional Parts
249
Spare Parts List
249
Setting Data
250
4
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Suzuki RM125 Specifications
General
Brand
Suzuki
Model
RM125
Category
Motorcycle
Language
English
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