2003 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.

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 18 (0.71) from the skirt end.

—

4.3

Approx. (0.17)

0.45 – 0.60

(0.018 – 0.024)

0.020 – 0.060

(0.0008 – 0.0024)

15.002 – 15.008

(0.5906 – 0.5909)

14.995 – 15.000

(0.5904 – 0.5906)

Date: May 31, 2002

Model: RM125K3

Unit: mm (in)

LIMIT

0.120

(0.0047)

—

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)

—

0.05

(0.002)

Unit: mm (in)

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)

CONROD + CRANKSHAFT

ITEM

Conrod small end I.D.

Conrod deflection

Crank web to web width

Crankshaft runout

CLUTCH

ITEM

Clutch cable play

Drive plate thickness

Driven plate distortion

Clutch spring free length

RADIATOR

ITEM

Radiator cap valve release

pressure

STANDARD

110 kPa (1.1 kgf/cm

, 16 psi)

LIMIT

—

Model: RM125K3

1/5

E-03, 28

TRANSMISSION

ITEM

Primary reduction ratio

Final reduction ratio

Gear ratios

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)

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)

—

Unit: mm (in)

Type

Links

20-pitch length

STANDARD

DAIDO: D.I.D 520DMA2

112

—

40 – 50

(1.6 – 2.0)

LIMIT

—

323.8

(12.75)

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

Drive chain slack

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

USA

Others

←

TMX38S

38 mm

←

36F2

36F3

←

8.7 ± 1.0 mm (0.34 ± 0.04 in)

#460

#560

6BGY27-77-3rd

6BGY28-77-4th

#40

5.0

1�½ turns out

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

(M.J.)

(J.N.)

(P.J.)

(C.A.)

(A.S.)

Model: RM125K3

2/5

E-03, 28

ELECTRICAL

ITEM

Ignition timing

Spark plug

SPECIFICATION

5°±1° B.T.D.C. at 1 700 r/min.

Type

NGK: R6918B-8

0.55 – 0.65

Gap

(0.022 – 0.026)

Over 8 (0.3) at 1 atm.

White/Blue – Black/White

Primary

0.15 – 0.45

Ω

Plug cap – Black/White

Secondary

12 – 21 kΩ

Ω

75 – 125

Ω

18 – 30

Ω

Unit: mm (in)

NOTE

Spark performance

Ignition coil resistance

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

Wheel rim runout

Axial

Radial

Wheel axle runout

Front

Rear

Tire size

Front

Rear

STANDARD

2.3 – 2.8

(0.09 – 0.11)

5 – 15

(0.2 – 0.6)

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)

26.918 – 26.968

(1.0598 – 1.0617)

—

80/100-21 51M

100/90-19 57M

LIMIT

—

2.5

(0.10)

3.5

(0.14)

0.30

(0.01)

—

2.0

(0.08)

2.0

(0.08)

0.25

(0.010)

0.25

(0.010)

—

Model: RM125K3

3/5

E-03, 28

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)

—

4.2 N/mm

(0.42 kgf/mm)

1 000 kPa

(10 kgf/cm

, 142 psi)

9.7

(0.38)

49 N/mm

(4.9 kgf/mm)

320

(12.6)

—

LIMIT

—

466.5

(18.37)

—

0.3

(0.01)

Unit: mm (in)

NOTE

9.7 mm compressed

from spring free length

TIRE PRESSURE

Front

Rear

70 – 110 kPa

(0.7 – 1.1 kgf/cm

10 – 16 psi)

Model: RM125K3

4/5

E-03, 28

FUEL + OIL + COOLANT

ITEM

Fuel type

SPECIFICATION

Use only unleaded gasoline of at least 90 pump

octane (

R + M

method).

Use only unleaded gasoline of at least 95 octane.

(Research method)

8.0 L

(2.1/1.8 US/Imp gal)

SUZUKI CCI SUPER 2-CYCLE MOTOR LUBRI-

CANT or equivalent Two Cycle Racing Lubricant

MOTUL 800 2T

or equivalent Two Cycle Racing Lubricant

30:1

SAE 10W – 40

750 ml

Change

(0.8/0.7 US/Imp qt)

800 ml

Overhaul

(0.9/0.8 US/Imp qt)

SUZUKI fork oil SS-05 or an equivalent fork oil

365 ml

(12.34/12.85 US/Imp oz)

177.5 ml

(6.00/6.25 US/lmp oz)

Use an anti-freeze&summer engine coolant

compatible with aluminum radiator, mixed with

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

1 100 ml

(1.2/1.0 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

NOTE

For USA and

Canada

For other

countries

Fuel tank capacity

Engine oil type

For USA

For other

countries

Fuel and engine oil mixture ratio

Transmission oil type

Transmission oil capacity

Front fork oil type

Front fork oil capacity

(each leg)

Outer tube oil

quantity

Damper rod

oil quantity

Engine coolant type

Engine coolant

Rear shock absorber oil type

Rear shock absorber oil capacity

Brake fluid type

Model: RM125K3

5/5

E-03, 28

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