Suzuki RM125 - Service Data; Cylinder + Piston + Piston Ring; Conrod + Crankshaft; Clutch

18-2 SERVICING INFORMATION
SERVICE DATA
CYLINDER + PISTON + PISTON RING Unit: mm (in)
CONROD + CRANKSHAFT Unit: mm (in)
CLUTCH Unit: mm (in)
ITEM STANDARD LIMIT
Piston to cylinder clearance 0.030 – 0.040
(0.0012 – 0.0016)
0.120
(0.0047)
Cylinder bore 54.000 – 54.015
(2.1260 – 2.1266)
Measure 20 (0.79) from the top surface.
Nicks or
Scratches
Piston diam. 53.965 – 53.980
(2.1246 – 2.1252)
Measure 19 (0.75) from the skirt end.
53.880
(2.1213)
Cylinder distortion
—
0.05
(0.002)
Cylinder head distortion
—
0.05
(0.002)
Piston ring free end gap
Approx. 4.3 (0.17)
3.4
(0.13)
Piston ring end gap 0.45 – 0.60
(0.018 – 0.024)
0.80
(0.031)
Piston ring to groove clearance 0.020 – 0.060
(0.0008 – 0.0024)
—
Piston pin bore 15.002 – 15.008
(0.5905 – 0.5907)
15.030
(0.5917)
Piston pin O.D. 14.995 – 15.000
(0.5904 – 0.5906)
14.980
(0.5898)
ITEM STANDARD LIMIT
Conrod small end I.D. 19.003 – 19.011
(0.7481 – 0.7485)
19.040
(0.7496)
Conrod deflection
—
3.0
(0.12)
Conrod big end side clearance — 1.0 (0.04)
Crank web to web width 53.9 – 54.1
(2.12 – 2.13)
—
Crankshaft runout
—
0.05
(0.002)
ITEM STANDARD LIMIT
Clutch lever play 10 – 15
(0.40 – 0.60)
—
Drive plate thickness
No. 1, 2
2.72 – 2.88
(0.107 – 0.113)
2.42
(0.094)
Drive plate claw width
No. 1, 2
13.85 – 13.96
(0.545 – 0.550)
13.35
(0.526)
Driven plate distortion
—
0.10
(0.004)
Clutch spring free length 39.78
(1.57)
37.8
(1.50)