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Suzuki RM 125 User Manual

Suzuki RM 125
233 pages
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Table of Contents

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Suzuki RM 125 Specifications

General IconGeneral
Front BrakeSingle disc
Rear BrakeSingle disc
IgnitionCDI
Final DriveChain
Front Tire80/100-21
Rear Tire100/90-19
Displacement124 cm3
Cooling SystemLiquid
Fuel SystemMikuni carburetor
Bore x Stroke54.0 mm x 54.0 mm
Width830 mm
Height1, 270 mm

Summary

Foreword

Safety Warnings and Notes

Explains the meaning of warning, caution, and note symbols used throughout the manual.

General Considerations

Riding Safety and Preparation

Covers essential safety gear, machine inspection before riding, and passenger policy.

Riding Techniques and Awareness

Provides advice on riding on level ground and understanding personal limits.

Serial Number Location

Warnings for Servicing

Precautions for Servicing

Servicing Precautions

General precautions and recommendations for performing maintenance tasks.

Replacement Parts Usage

Emphasizes the importance of using genuine or equivalent replacement parts.

Symbol Marks and Materials

General Instructions

Location of Parts

Diagrams identifying various parts of the motorcycle.

Fuel and Oil Recommendations

Specifies recommended fuel types, oil, and mixture ratios for the engine.

Operating Instructions

Guides on starting, stopping, and operating the motorcycle, including break-in procedures.

Transmission and Engine Part Replacement

Information on transmission operation and procedures when engine parts are replaced.

Periodic Maintenance

Inspection Before Practice and Race

Pre-ride checks and inspection procedures before competition.

Maintenance Schedule and Component Checks

Covers maintenance intervals, spark plug, air cleaner, fluids, cables, and major component checks.

Brake System Maintenance

Procedures for brake fluid, pads, and lever/pedal adjustments.

Suspension, Wheels, Tires, and Steering

Maintenance of front fork, rear suspension, wheels, tires, and steering system.

Troubleshooting

Engine Troubleshooting

Diagnosing and resolving common engine complaints and their causes.

Chassis Troubleshooting

Diagnosing and resolving common chassis-related issues and their causes.

Machine Tuning

Carburetor Tuning Principles

Understanding carburetor components and basic principles for tuning.

Carburetor Tuning Procedures

Practical steps for tuning the carburetor based on air/fuel mixture.

Suspension Tuning (Front and Rear)

Adjusting front fork and rear suspension settings for optimal performance.

Engine Removal and Installation

Exterior Parts Identification

Diagram showing exterior parts of the motorcycle for reference.

Engine Removal Procedure

Step-by-step instructions for safely removing the engine from the motorcycle.

Engine Installation Procedure

Step-by-step instructions for reinstalling the engine into the motorcycle.

Cylinder, Piston and Exhaust Valve

Construction and Component Overview

Exploded view and identification of cylinder, piston, and exhaust valve components.

Component Removal and Inspection

Step-by-step guides for removing and inspecting cylinder, piston, and exhaust valve components.

Component Reassembly and Governor Service

Instructions for reassembling piston rings, piston, cylinder, and exhaust valve systems.

Clutch

Construction and System Overview

Diagrams showing clutch construction and basic system overview.

Clutch Plate Service

Procedures for removing, inspecting, and reassembling clutch plates and springs.

Primary Driven Gear Service

Procedures for removing, inspecting, and reassembling the primary driven gear assembly.

Clutch Release Camshaft Service

Procedures for removing, inspecting, and installing the clutch release camshaft.

Kick Starter

Construction and System Overview

Diagrams showing kick starter construction and components.

Kick Starter Removal and Inspection

Step-by-step procedures for removing and inspecting kick starter components.

Kick Starter Reassembly

Step-by-step procedures for reassembling the kick starter mechanism.

Gearshifting

Gearshift Linkage Construction

Exploded view of the gearshift linkage components.

Gearshift Linkage Service

Procedures for removing, inspecting, and reassembling the gearshift linkage.

Transmission and Crankshaft

Construction and Component Identification

Exploded view of transmission and crankshaft components.

Engine Bottom Side Service

Procedures for removing primary drive gear, separating crankcase, and removing transmission/crankshaft.

Component Inspection

Inspecting transmission, crankshaft, oil seals, and bearings for wear and damage.

Component Installation and Reassembly

Procedures for installing crankshaft, reassembling transmission, crankcase, and primary drive gear.

Fuel System

Carburetor Service

Procedures for carburetor construction, removal, cleaning, inspection, and reassembly.

Reed Valve Service

Procedures for reed valve removal, inspection, and reassembly.

Cooling System

Construction and Engine Coolant

Diagram of cooling system construction and engine coolant replacement.

Radiator Service

Procedures for radiator inspection and removal/installation.

Water Pump Service

Procedures for water pump removal, inspection, and reassembly.

Electrical System

Construction and Electrical Circuit

Diagrams of electrical system construction and the main electrical circuit.

Ignition System Service and Inspection

Covers ignition system, peak voltage, ignition coil, CDI unit, and stator coil inspection.

Magneto Rotor and Stator Service

Procedures for removing and reassembling the magneto rotor and stator.

Front and Rear Wheels

Wheel Construction and Components

Exploded view of front and rear wheel assemblies.

Front Wheel Service

Procedures for front wheel removal, inspection, bearing replacement, and disc plate replacement.

Rear Wheel Service

Procedures for rear wheel removal, inspection, bearing replacement, and sprocket replacement.

Front and Rear Brakes

Brake System Construction and Fluid Service

Diagram of brake system construction and procedures for brake fluid service.

Brake Pad, Disc, and Caliper Service

Procedures for replacing brake pads, inspecting discs, and servicing calipers.

Master Cylinder and Brake Pedal Service

Procedures for master cylinder and brake pedal removal, inspection, and reassembly.

Front Fork and Steering

Construction and Handlebar Controls

Diagrams of front fork/steering construction and handlebar control components.

Front Fork Service

Procedures for front fork removal, disassembly, inspection, and reassembly.

Steering System Service

Procedures for steering system removal, bearing replacement, and installation.

Rear Suspension

Rear Suspension Construction

Exploded view of the rear suspension assembly.

Rear Shock Absorber Service

Procedures for rear shock absorber removal, oil replacement, and disassembly.

Swingarm Service

Procedures for swingarm removal, inspection, bearing replacement, and installation.

Rear Suspension Linkage Service

Procedures for linkage removal, inspection, bearing replacement, and reassembly.

Servicing Information

Service Data (Specifications)

Detailed service specifications for various motorcycle components.

Special Tools and Wiring Diagram

Lists special tools required and provides the wiring diagram.

Routing and Specifications

Information on wire/cable routing, general specifications, and fluid capacities.

Spare Parts List

List of available spare parts with part numbers and quantities.

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