2005 service data.pdf

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SERVICE DATA

2 STROKE

CYLINDER + PISTON + PISTON RING

ITEM

Piston to cylinder clearance

Cylinder bore

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.

Date: December 28, 2004

Model: RM125K5

Unit: mm (in)

LIMIT

0.120

(0.0047)

Nicks or

Scratches

53.880

(2.1213)

0.05

(0.002)

0.05

(0.002)

3.4

(0.13)

0.80

(0.031)

—

15.030

(0.5917)

14.980

(0.5898)

Unit: mm (in)

STANDARD

19.003 – 19.011

(0.7481 – 0.7485)

—

53.9 – 54.1

(2.12 – 2.13)

—

LIMIT

19.040

(0.7496)

3.0

(0.12)

1.0

—

0.05

(0.002)

STANDARD

0.030 – 0.040

(0.0012 – 0.0016)

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 19.57 (0.77) from the skirt end.

—

Approx. 4.3 (0.17)

0.45 – 0.60

(0.018 – 0.024)

0.020 – 0.060

(0.0008 – 0.0024)

15.002 – 15.008

(0.5905 – 0.5907)

14.995 – 15.000

(0.5904 – 0.5906)

CONROD + CRANKSHAFT

ITEM

Conrod small end I.D.

Conrod deflection

Conrod big end side clearance

Crank web to web width

Crankshaft runout

Model: RM125K5

1/6

E-03, 28

CLUTCH

ITEM

Clutch lever play

Drive plate thickness

Drive plate claw width

Driven plate distortion

Clutch spring free length

No. 1, 2

STANDARD

10 – 15

(0.40 – 0.60)

2.72 – 2.88

(0.107 – 0.113)

13.85 – 13.96

(0.545 – 0.550)

—

39.78

(1.57)

Unit: mm (in)

LIMIT

—

2.42

(0.094)

13.35

(0.526)

0.10

(0.004)

37.8

(1.50)

RADIATOR

ITEM

Radiator cap valve release

pressure

STANDARD

93.3 – 122.7 kPa

(0.95 – 1.25 kgf/cm

, 13.5 – 17.8 psi)

LIMIT

—

TRANSMISSION

ITEM

Primary reduction ratio

Final reduction ratio

Gear ratios

STANDARD

3.368 (64/19)

4.167 (50/12)

2.071 (29/14)

1.687 (27/16)

1.444 (26/18)

1.200 (24/20)

1.052 (20/19)

0.950 (19/20)

0.05 – 0.25

(0.002 – 0.010)

4.95 – 5.05

(0.195 – 0.200)

4.80 – 4.90

(0.190 – 0.193)

Unit: mm (in) Except ratio

LIMIT

—

0.45

(0.018)

—

Low

2nd

3rd

4th

5th

Top

Shift fork to groove clearance

Shift fork groove width

Shift fork thickness

No. 1, 2 & 3

DRIVE CHAIN

ITEM

Drive chain

Type

Links

20-pitch length

Drive chain slack

40 – 50

(1.6 – 2.0)

STANDARD

D.I.D 520DMA2

114

—

Unit: mm (in)

LIMIT

—

323.8

(12.7)

Model: RM125K5

2/6

E-03, 28

CARBURETOR

ITEM

Carburetor type

Bore size

I.D. No.

Float height

Main jet

Jet needle

Pilot jet

Cut-away

Air screw

Throttle cable play

SPECIFICATION

Unit: mm (in)

USA, 000

Others

TMX38SS

←

38 mm

←

36F6

36F7

8.7 ± 1.0 mm (0.34 ± 0.04 in)

←

#370

#390

6CHY17-64-3rd

6CHY17-64-4th

#42.5

5.0

2 turns out

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

Unit: mm (in)

SPECIFICATION

5° B.T.D.C. at 1 000 r/min.

NGK: R6918B-8

0.55 – 0.65 (0.022 – 0.026)

Over 8 (0.3) at 1 atm.

72 – 127

Ω

24 – 40

Ω

1.6 – 2.6

Ω

2 V and more

25 V and more

Primary

Secondary

8 V and more

0.17 – 0.70

Ω

13 – 20 kΩ

200 V and more

NOTE

(M.J.)

(J.N.)

(P.J.)

(C.A.)

(A.S.)

ELECTRICAL

ITEM

Ignition timing

Spark plug

Spark performance

Pick-up coil resistance

Exciter coil resistance

Charge coil resistance

Pick-up peak voltage

Exciter peak voltage

Charge peak voltage

Ignition coil resistance

Ignition coil primary peak voltage

Type

Gap

R–G

B/R – R/W

Y – B/W

R–

B/R –

R/W

Y –

B/W

W/Bl – B/W

Plug cap – W/Bl

B/W –

W/Bl

Model: RM125K5

3/6

E-03, 28

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

Brake fluid type

Wheel rim runout

STANDARD

11 – 15

(0.4 – 0.6)

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 – 12.743

(0.5000 – 0.5017)

10.957 – 10.984

(0.4314 – 0.4324)

12.657 – 12.684

(0.4983 – 0.4994)

27.000 – 27.050

(1.0630 – 1.0650)

27.000 – 27.050

(1.0630 – 1.0650)

26.900 – 26.950

(1.0591 – 1.0610)

26.900 – 26.950

(1.0598 – 1.0617)

DOT4

—

1.60

1.85

—

Unit: mm (in)

LIMIT

—

2.5

(0.10)

3.5

(0.14)

0.3

(0.012)

—

2.0

(0.08)

2.0

(0.08)

Axial

Radial

Wheel rim size

Wheel axle runout

Front

Rear

Front

Rear

0.25

(0.010)

0.25

(0.010)

Model: RM125K5

4/6

E-03, 28

SUSPENSION

ITEM

Front fork stroke

Front fork inner tube

O.D.

Front fork spring free

length

Front fork damping

force adjuster

STANDARD

310

(12.2)

47 mm

494 ± 2.5

(19.45 ± 0.10)

MAX-11 clicks

turn back

MAX-15 clicks

turn back

0 kPa

(0 kgf/cm

, 0 psi)

4.2 N/mm

(0.42 kgf/mm)

981 kPa

(9.8 kgf/cm

, 139.5 psi)

3.5 (0.138)

51 N/mm

(5.1 kgf/mm)

MAX-14 clicks

turn back

MAX-1

turn back

MAX-10 clicks

turn back

310

(12.6)

—

LIMIT

—

487 (19.17)

—

0.3

(0.01)

Unit: mm (in)

NOTE

Rebound

Compres-

sion

Front fork air pressure

Front fork spring rate

Rear shock absorber gas pressure

Rear shock absorber spring set

length

Rear shock absorber spring rate

Rear shock absorber

Rebound

damping force adjuster

Compres-

sion (High

speed)

Compres-

sion (Low

speed)

Rear wheel travel

Swingarm pivot shaft runout

3.5 mm compressed

from spring free length

TIRE

ITEM

Cold inflation tire pressure

Tire size

Tire type

Fron&Rear

Front

Rear

Front

(E-03)

Front

(The others)

Rear

Fron&Rear

STD/SPEC.

70 – 110 kPa

(0.7 – 1.1 kgf/cm

10 – 16 psi)

80/100-21 51M

100/90-19 57M

DUNLOP: SPORTS D742F

DUNLOP: SPORTS D756F

DUNLOP: SPORTS D756

—

LIMIT

—

4.0 mm (0.16 in)

Tire tread depth

(Recomend depth)

Model: RM125K5

5/6

E-03, 28

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