2002 service data.pdf

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2 STROKE

ITEM

Piston to cylinder clearance

Cylinder bore

SERVICE DATA

STANDARD

0.050 – 0.060

(0.0020 – 0.0024)

54.000 – 54.015

(2.1260 – 2.1266)

Measure 20 (0.79) from the top surface.

53.965 – 53.980

(2.1246 – 2.1252)

Measure 18 (0.71) from the skirt end.

———

4.5

Approx. (0.18)

0.45 – 0.60

(0.018 – 0.024)

0.020

(0.0008

15.000

(0.5906

– 0.060

– 0.0024)

– 15.006

– 0.5908)

Date: July 27, 2001

Model: RM125K2

Unit: mm (in)

LIMIT

0.120

(0.0047)

———

53.880

(2.1213)

0.05

(0.002)

0.05

(0.002)

3.6

(0.14)

0.80

(0.031)

———

15.030

(0.5917)

14.980

(0.5898)

Unit: mm (in)

CYLINDER + PISTON + PISTON RING

Piston diam.

Cylinder distortion

Cylinder head distortion

Piston ring free end gap

Piston ring end gap

Piston ring to groove clearance

Piston pin bore

Piston pin O.D.

14.995 – 15.000

(0.5904 – 0.5906)

CONROD + CRANKSHAFT

ITEM

Conrod small end I.D.

Conrod deflection

Crank web to web width

Crankshaft runout

STANDARD

19.003 – 19.011

(0.7481 – 0.7485)

———

54.0 ± 0.1

(2.126 ± 0.004)

———

LIMIT

19.040

(0.7496)

3.0

(0.12)

———

0.05

(0.002)

Unit: mm (in)

CLUTCH

ITEM

Clutch cable play

Drive plate thickness

Driven plate distortion

Clutch spring free length

STANDARD

10 – 15

(0.40 – 0.60)

2.72 – 2.88

(0.107 – 0.113)

———

39.8

(1.57)

LIMIT

———

2.42

(0.094)

0.10

(0.004)

37.8

(1.49)

Model: RM125K2

1/5

E-02, 03, 28

RADIATOR

ITEM

Radiator cap valve release

pressure

STANDARD

110 kPa (1.1 kgf/cm

, 16 psi)

LIMIT

———

Unit: mm (in) Except ratio

STANDARD

3.368 (64/19)

4.083 (49/12)

2.071 (29/14)

1.687 (27/16)

1.444 (26/18)

1.200 (24/20)

1.053 (20/19)

0.950 (19/20)

No.1, 2 & 3

0.05 – 0.25

(0.002 – 0.010)

4.95

(0.195

4.80

(0.190

–

5.05

0.200)

4.90

0.193)

LIMIT

———

0.45

(0.018)

———

Unit: mm (in)

Type

Links

20-pitch length

Drive chain slack

STANDARD

DAIDO: D.I.D 520DMA2

112

———

40 – 50

(1.6 – 2.0)

LIMIT

———

323.8

(12.75)

———

TRANSMISSION

ITEM

Primary reduction ratio

Final reduction ratio

Gear ratios

Low

2nd

3rd

4th

5th

Top

Shift fork to groove clearance

Shift fork groove width

Shift fork thickness

DRIVE CHAIN

ITEM

Drive chain

CARBURETOR

ITEM

Carburetor type

Bore size

I.D. No.

Float height

Main jet

Jet needle

Slow jet

Cut-away

Air screw

Throttle cable play

SPECIFICATION

TMX38S

38 mm

36F1

5 ± 1.0 mm (0.20 ± 0.04 in)

#460

6BGY27-77-3rd

#32.5

5.75

1�½ turns out

2 – 4 mm (0.08 – 0.16 in) at the throttle grip

(M.J.)

(J.N.)

(S.J.)

(C.A.)

(A.S.)

Model: RM125K2

2/5

E-02, 03, 28

ELECTRICAL

ITEM

Ignition timing

Spark plug

SPECIFICATION

5°±1° B.T.D.C. at 1 700 r/min.

NGK: R6918B-8

0.55 – 0.65

(0.022 – 0.026)

Over 8 (0.3) at 1 atm.

White/Blue – Black/White

0.15 – 0.45

Ω

Plug cap – Black/White

12 – 21 kΩ

75 – 125

Ω

18 – 30

Ω

Unit: mm (in)

NOTE

Type

Gap

Spark performance

Ignition coil resistance

Primary

Secondary

Magneto coil resistance

R–G

R/W – B/R

Unit: mm (in)

BRAKE + WHEEL

ITEM

Brake lever adjuster length

Rear brake pedal height

Brake disc thickness

Front

Rear

Brake disc runout

Master cylinder bore

Front &

Rear

Front

Rear

Master cylinder piston diam.

Front

Rear

Brake caliper cylinder bore

Front

Rear

Brake caliper piston diam.

Front

Rear

STANDARD

2.3 – 2.8

(0.09 – 0.11)

0 – 10

(0 – 0.4)

3.0 ± 0.2

(0.118 ± 0.008)

4.0 ± 0.2

(0.157 ± 0.008)

———

11.000 – 11.043

(0.4331 – 0.4348)

12.700

(0.5000

10.957

(0.4314

12.657

(0.4983

27.000

(1.0630

27.000

(1.0630

26.900

(1.0591

–

12.743

0.5017)

10.984

0.4324)

12.684

0.4994)

27.050

1.0650)

27.050

1.0650)

26.950

1.0610)

LIMIT

———

2.5

(0.10)

3.5

(0.14)

0.30

(0.01)

———

26.900 – 26.950

(1.0591 – 1.0610)

Model: RM125K2

3/5

E-02, 03, 28

ITEM

Wheel rim runout

STANDARD

Axial

Radial

———

80/100-21 51M

100/90-19 57M

LIMIT

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

———

Unit: mm (in)

Wheel axle runout

Front

Rear

Tire size

Front

Rear

SUSPENSION

ITEM

Front fork stroke

Front fork spring free length

Front fork spring rate

Rear shock absorber gas

pressure

Rear shock absorber spring

set length

Rear shock absorber spring rate

Rear wheel travel

Swingarm pivot shaft runout

STANDARD

310

(12.2)

———

4.0 N/mm

(0.40 kgf/mm)

1 200 kPa

(12 kgf/cm

, 170 psi)

8.5

(0.33)

48 N/mm

(4.8 kgf/mm)

320

(12.6)

———

LIMIT

———

466.5

(18.37)

———

0.3

(0.01)

NOTE

8.5 mm compressed

from spring free length

TIRE PRESSURE

Front

Rear

(

70 – 110 kPa

0.7 – 1.1 kgf/cm

10 – 16 psi

)

Model: RM125K2

4/5

E-02, 03, 28

FUEL + OIL + COOLANT

ITEM

Fuel type

SPECIFICATION

Use only unleaded gasoline of at least 90 pump

octane (

R 2 M

method).

Use only unleaded gasoline of at least 95 octane.

(Research method)

Fuel tank capacity

Engine oil type

8.0 L

(2.1/1.8 US/Imp gal)

SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRICANT

or equivalent Two Cycle Racing Lubricant

MOTUL 800 2T

or equivalent Two Cycle Racing Lubricant

Fuel and engine oil mixture ratio

Transmission oil type

Transmission oil capacity

Change

Overhaul

Front fork oil type

Front fork oil capacity

(each leg)

32:1

SAE 10W/40

750 ml

(0.8/0.7 US/Imp qt)

800 ml

(0.9/0.8 US/Imp qt)

Outer tube oil

quantity

Damper rod

oil quantity

NOTE

For USA and

Canada

For other

countries

For USA

For other

countries

SUZUKI fork oil SS-05 or an equivalent fork oil

380 ml

(12.8/13.4 US/Imp oz)

180 ml

(6.1/6.3 US/lmp oz)

Engine coolant type

Use an anti-freeze&summer engine coolant

compatible with aluminum radiator, mixed with

distilled water only, at the ratio of 50:50.

970 ml

(1.0/0.9 US/Imp qt)

SUZUKI rear suspension oil SS-25

or an equivalent suspension oil

380 ml

(12.8/13.4 US/Imp oz)

DOT 4

Engine coolant

Rear shock absorber oil type

Rear shock absorber oil capacity

Brake fluid type

Model: RM125K2

5/5

E-02, 03, 28

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