2004 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 19 (0.75) from the skirt end.

—

Approx. 4.3 (0.17)

0.45 – 0.60

(0.018 – 0.024)

0.045 – 0.060

(0.0018 – 0.0024)

15.002 – 15.008

(0.5905 – 0.5907)

14.995 – 15.000

(0.5904 – 0.5906)

Date: June 25, 2003

Model: RM125K4

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)

CONROD + CRANKSHAFT

ITEM

Conrod small end I.D.

Conrod deflection

Conrod big end side clearance

Crank web to web width

Crankshaft runout

STANDARD

19.003 – 19.011

(0.7481 – 0.7485)

—

0.3 – 0.8

(0.0118 – 0.0315)

53.9 – 54.1

(2.12 – 2.13)

—

LIMIT

19.040

(0.7496)

3.0

(0.12)

1.0

—

0.05

(0.002)

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)

LIMIT

—

2.42

(0.094)

13.05

(0.514)

0.15

(0.006)

37.8

(1.49)

Model: RM125K4

1/5

000, E-03, 28

RADIATOR

ITEM

Radiator cap valve release

pressure

STANDARD

95 – 125 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)

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

—

LIMIT

—

323.8

(12.7)

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, 000

Others

TMX38S

←

38 mm

←

36F4

36F5

8.7 ± 1.0 mm (0.34 ± 0.04 in)

←

#390

#460

6CHY16-62-3rd

6CHY17-62-4th

#42.5

5.0

1 and 1/2 turns out

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

(M.J.)

(J.N.)

.J.)

(C.A.)

(A.S.)

Model: RM125K4

2/5

000, E-03, 28

ELECTRICAL

ITEM

Ignition timing

Spark plug

Type

Gap

Spark performance

Pick-up coil resistance

Pick-up peak voltage

Exciter peak voltage

Ignition coil resistance

Ignition coil primary peak voltage

Exciter coil resistance

Primary

Secondary

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.

75 – 125

Ω

3 V and more

30 V and more

0.15 – 0.45

Ω

12 – 21 kΩ

210 V and more

18 – 30

Ω

NOTE

R–G

G–

R/W –

B/R

W/Bl – B/W

Plug cap – W/Bl

B/W –

W/Bl

R/W – B/R

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

—

LIMIT

—

2.5

(0.10)

3.5

(0.14)

0.30

(0.01)

—

2.0

(0.08)

2.0

(0.08)

Axial

Radial

Model: RM125K4

3/5

000, E-03, 28

ITEM

Wheel rim size

Wheel axle runout

Front

Rear

Front

Rear

Tire size

Front

Rear

STANDARD

1.60

1.85

—

80/100-21 51M

100/90-19 57M

LIMIT

0.25

(0.010)

0.25

(0.010)

—

SUSPENSION

ITEM

Front fork stroke

Front fork spring free

length

Front fork damping

force adjuster

STANDARD

310

(12.2)

494 ± 2.4

(19.45 ± 0.09)

MAX-11 clicks

turns back

MAX-9 clicks

turns 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)

6.7 (0.26)

50 N/mm

(5 kgf/mm)

MAX-11 clicks

turns back

MAX-2 and 1/8

turns back

MAX-8 clicks

turns back

310

(12.6)

—

LIMIT

—

487 (19.17)

—

0.3

(0.01)

6.7 mm compressed

from spring free length

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

TIRE PRESSURE

Front &

Rear

70 – 110 kPa

(0.7 – 1.1 kgf/cm

, 10 – 16 psi)

Model: RM125K4

4/5

000, E-03, 28

FUEL + OIL + COOLANT

ITEM

Fuel type

SPECIFICATION

Use only unleaded gasoline of at least 90 pump

octane (R/2 + M/2 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 LUBURICANT

or equivalent Two Cycle Racing Lubricant

MOTUL 800 2T

FACTORY LINE OFF ROAD

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

373 ml

(12.6/13.1 US/Imp oz)

180 ml

(6.08/6.33 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)

NOTE

E-03, 28

The others

Fuel tank capacity

Engine oil type

E-03

The others

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 capacity

Rear shock absorber oil type

Rear shock absorber oil capacity

Model: RM125K4

5/5

000, E-03, 28

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