Suzuki rm gear dogs!

1/12/2016 1:56pm Edited Date/Time 1/18/2016 4:16pm
Hey, after stripping my 02 rm 125 which I bought with a blown crank I discovered most of the dogs on all of the driven (output shaft) side gears are worn, I had the same issue on my other 08 rm 125 after only around 25 hours! I have also found some damage to one shift fork and to the shift drum! Total for all the parts needed is around £750 ($1080) on an 02 bike this is nearly as much as the value of the bike! Has anyone had any luck with repairing or undercutting the dogs? On my 2008 bike I replaced all the worn gears and had the entire transmission isf super finished which has made a massive difference to the shifting of that bike but on an 02 bike that I only plan on running for a season in enduro I'm not sure it justifies the cost. Any ideas here guys?











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Jakes Dad
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1865
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6/22/2009
Location
Brooksville, FL US
1/12/2016 4:37pm
Spent near $1400 in a year and a half on tranny parts for an 06' and 07'

From my research the mating surfaces on the dogs aren't true meaning the engagement surface is not 100%. Having the mating surfaces re-machined and then back cut would really help.

Check this beauty out.
http://www.vitalmx.com/forums/Moto-Related,20/Gearbox-Porn,1296490
BAMX
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1/22/2012
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Fallbrook, CA US
1/12/2016 8:20pm
I bought my 02 in essentially the same condition as yours. I ended up buying a trans and cylinder on Ebay. When I initially rebuilt it, the thing mis shifted. I pulled it back apart and changed the trans bearings and used the best parts from the two trans. That fixed the mis shifting. I think that I paid $100 for a complete used bottom end.
pete24
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10/20/2011
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Marlborough, MA US
1/13/2016 7:38am
this isnt going to help you , but i tend to steer clear of used RMs because every one i see needs all the clutch parts and most of the trans is cooked, they definatly didnt build them for longevity
on a side note we did have some 88 kx500 gears welded and recut, by a regular machine shop, not a bike guy or a trans guy, and it lasted for about 25 hrs of hard vintage abuse, it didnt really think it was worth the trouble
Matt Fisher
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4/1/2008
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Visalia, CA US
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1084th
1/13/2016 11:02pm
Grenaded trans was why I parted out my 02 RM125, seems that it's a common issue. I still have a few parts that I either forgot to put on eBay or didn't sell...

The Shop

Micahdogg
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1267
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1/3/2011
Location
US
1/14/2016 8:30am
Could you not just use a carbide bit to smooth out the rough sections? I sure wouldn't be spending a lot of money on it.

Wonder if using ATF for gear lube would help engagement as well.
rivvs
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9/15/2011
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saguenay CA
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1262nd
1/18/2016 4:16pm
i had the same problem on 2003 i welded the drum and i machined the dog and i don't have any problem with the trans anymore!

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