Suzuki Rm125 Dirt Bike 2 Stroke Full Service Repair Manual 1996 – 2007 – PDF DOWNLOAD

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Suzuki Rm125 Dirt Bike 2 Stroke Full Service Repair Manual 1996 – 2007

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LANGUAGE:ENGLISH
PAGES:164
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SUZUKI RM125 DIRT BIKE 2 STROKE FULL SERVICE REPAIR MANUAL 1996 – 2007 – PDF DOWNLOAD:

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Suzuki Rm125 Dirt Bike 2 Stroke Full Service Repair Manual 1996 – 2007

FOREWORD:

This manual is presented as a means whereby you can maintain your RM125 in top working condition at all times . Your riding skill and the maintenance steps outlined in this manual will assure you of top performance from your machine under any type of competition . We sincerely wish you and your Suzuki motorcycle a successful partnership for many years of happy riding. All information . illustration, photographs and specifications contained in the manual are based on the latest product information available at the time of publication . Due to improvements or other changes , there may be some discrepancies in this manual. Suzuki reserves the right to make production changes at any time, without notice and without incurring any obligation to make the same or similar changes to vehicles previous built or sold. Suzuki Motor Corporation believes in conservation and protection of Earth’s natural resources. To that end , we encourage every vehicle owner to recycle, trade in, or properly dispose of. as appropriate, used motor oil, engine coolant, and other fruid, and tires.

TABLE OF CONTENTS:

Suzuki Rm125 Dirt Bike 2 Stroke Full Service Repair Manual 1996 – 2007

1996 SUZUKI RM125 2-STROKE MOTORCYCLES.....................  1
	FOREWORD...............................................  3
	WARNING/CAUTION/NOTE...................................  3
	WARNINGS FOR SERVICING.................................  6
	SYMBOL MARKS AND MATERIALS.............................  8
	TABLE OF CONTENTS...................................... 11
	GENERAL INSTRUCTIONS................................... 12
		Location of Parts.................................. 12
		Fuel............................................... 13
		Operating Instuctions.............................. 14
		Transmission....................................... 15
		Break-In........................................... 15
	PERIODIC MAINTENANCE................................... 16
		Inspection Before Practice......................... 16
		Inspection Before Race............................. 16
		Periodic Maintenance Chart......................... 17
		Spark Plug......................................... 18
		Air Cleaner........................................ 18
		Transmission Oil................................... 20
		Engine Coolant..................................... 20
		Clutch............................................. 22
		Throttle Cable..................................... 22
		Fuel Hose.......................................... 22
		Cylinder Head, Cylinder and Piston................. 23
		Exhaust Valve...................................... 23
		Exhaust Silencer................................... 23
		Drive Chain and Sprockets.......................... 24
		Drive Chain Guide, Buffer, Tensioner Roller........ 25
		Brakes............................................. 26
		Front Fork......................................... 28
		Rear Suspension.................................... 28
		Wheels and Tires................................... 28
		Steering........................................... 28
		Lubrication........................................ 29
		Tightening Torque.................................. 30
	TROUBLESHOOTING........................................ 32
		Engine............................................. 32
		Chassis............................................ 35
	MACHINE TUNING......................................... 36
		Carburetor......................................... 36
		Principles of Carburetor Tuning.................... 36
		Carburetor Tuning in Practice...................... 39
		Front Fork......................................... 42
		Rear Suspension.................................... 47
		Suspension Balance................................. 50
		Riding Position.................................... 51
	ENGINE DISMOUNTING AND MOUNTING........................ 52
		Dismounting........................................ 52
		Engine Mounting.................................... 53
	CYLINDER, PISTON AND EXHAUST VALVE..................... 55
		Cylider Head Removal............................... 56
		Cylinder Removal................................... 56
		Piston Removal..................................... 56
		Exhaust Valve Removasl............................. 57
		Cylinder Head Inspection........................... 57
		Cylinder Inspection................................ 57
		Piston and Piston Ring Inspection.................. 58
		Conrod Inspection.................................. 59
		Piston Ring and Piston Reassembling................ 60
		Exhaust Valve Reassembling......................... 60
		Cylinder Reassembling.............................. 60
	CLUTCH................................................. 63
		Clutch Plate Removal............................... 64
		Clutch Plate Inspection............................ 64
		Rack and Pinion Inspection......................... 65
		Clutch Plate Reassembling.......................... 65
		Primary Driven Gear Assembly Removal............... 65
		Inspection......................................... 66
	KICK STARTER........................................... 69
		Kick Starter Removal............................... 70
		Kick Starter Inspection............................ 70
		Kick Starter Reassembly............................ 71
	TRANSMISSION AND CRANKSHAFT............................ 73
		Gearshift Linkage Removal.......................... 74
		Primary Drive Gear Removal......................... 74
		Crankcase Separation............................... 74
		Transmission Removal............................... 75
		Crankshaft Removal................................. 75
		Gearshift Linkage Inspection....................... 75
		Transmission Inspection............................ 76
		Crankshaft Inspection.............................. 77
		Oil Seal Inspection, Removal and Installation...... 77
		Bearing Inspection, Removal and Installation....... 78
		Crankshaft Installation............................ 79
		Transmission Reassembly............................ 79
		Crankcase Reassembly............................... 80
		Primary Drive Gear Reassembly...................... 80
		Gearshift Linkage Reassembly....................... 81
	FUEL SYSTEM............................................ 83
		Carburetor......................................... 84
		Reed Valve......................................... 85
	COOLING SYSTEM......................................... 87
		Engine Coolant Replacement......................... 88
		Radiator Cap Inspection............................ 88
		Radiator........................................... 88
		Water Pump......................................... 89
	ELECTRICAL SYSTEM...................................... 91
		Electrical Circuit................................. 92
		Ignition Coil Inspection........................... 92
		CDI Unit Inspection................................ 93
		Stator Coil Inspection............................. 94
		Magneto Rotor and Stator Removal and Reassembly.... 94
	FRONT AND REAR WHEELS.................................. 97
		Front Wheel Disassembly and Reassembly............. 98
		Rear Wheel Removal and Reassembly.................. 98
		Front and Rear Wheel Inspection.................... 98
		Wheel Bearing Removal and Reassembly............... 99
		Disc Plate Replacement.............................100
		Rear Sprocket Replacement..........................100
	FRONT AND REAR BRAKES..................................101
		Brake Fluid Air Bleeding...........................102
		Brake Fluid Replacement............................103
		Brake Pad Replacement..............................103
		Brake Disc Inspection..............................104
		Caliper............................................104
		Master Cylinder....................................108
		Brake Pedal Removal and Reassembly.................111
	FRONT FORK AND STEERING................................113
		Front Fork.........................................114
		Steering...........................................123
	REAR SUSPENSION........................................127
		Rear Shock Absorber................................128
		Oil Replacement Procedure..........................130
		Swingarm...........................................135
		Rear Suspension Linkage............................137
	SERVICE DATA...........................................141
		Cylinder + Piston + Piston Ring....................141
		Conrod + Crankshaft................................141
		Clutch.............................................141
		Radiator...........................................142
		Transmission.......................................142
		Drive Chain........................................142
		Carburetor.........................................142
		Electrical.........................................143
		Brake + Wheel......................................143
		Suspension.........................................144
		Tire Pressure......................................144
		Fuel + Oil + Coolant...............................145
	SPECIAL TOOLS..........................................146
	WIRE. CABLE AND HOSE ROUTING...........................148
	SPECIFICATIONS.........................................157
		Dimensions and Dry Mass............................157
		Engine.............................................157
		Transmission.......................................157
		Chassis............................................158
		Electrical.........................................158
		Capacities.........................................158
		Spare Parts List...................................159
	INDEX..................................................160

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]