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OldHalfway Liked a reply to forum topic 1987 RM125....I”m a sucker for old Suzuki”s..

4/29/2020 7:53am
Better late than never?
This forum topic has 223 replies.

JohnPainter Started a new thread Stupid silly ‘87 RM 125H rebuild

2/16/2020 6:50am
Why oh why do I buy cheap old (but not that old) bikes and get them running? To support the second hand parts market? See if my wife’s ability to swear is more fluent (she’s Hungarian)? Or maybe because garage therapy is pennies on the dollar compared to traditional psychotherapy. Well, I don’t know. But here is my latest lost...
This forum thread has 27 replies.

JohnPainter Added a reply to Stupid silly ‘87 RM 125H rebuild

2/16/2020 6:50am
The sound voice of reason. That’s exactly what I’m doing now, while I doubt I’ll ever love these late 80’s RM 125’s they are fun to wrench on and pretty inexpensive on top of it all - though I hate spending money on a bike I’m just going to to play around on, being able to do that for less...

sandman768 Liked a reply to forum topic Stupid silly ‘87 RM 125H rebuild

2/16/2020 6:31am
The seals are cheap, replace them, I would replace the water pump seal also, inspect water pump impeller, they are driven off the end of the crank, not gear driven. Plastic impeller is weak, they are still available from Suzuki for cheap. My 87 had massive air leaks on the stator side from case porosity. There are 3 indents in the case behind the stator, I performed a leak down test & was amazed to see air/gas/oil leaking right through the case! Only on a Suzuki! Apparently this was common on Suzuki cases, I epoxied the 3 spots on the...
This forum topic has 27 replies.

JohnPainter Added a reply to Stupid silly ‘87 RM 125H rebuild

2/15/2020 7:27am
Well I’ve had to let the RM sit for awhile, just to clear my head and work with other projects. So it runs, sort of. I took a chance and didn’t replace the right crank case oil seal - anything to save a buck, stupid, right?! It runs but smokes.... a lot. Also throws crank oil out the exhaust, so...

JohnPainter Added a reply to Stupid silly ‘87 RM 125H rebuild

11/24/2019 6:24am
Thank you, I appreciate the help. Sure would be easier to do left side first... but I’m an idiot I got everything together and functioning correctly doing it totally backwards. Well until I realized the jug is out of round. 😩 So it’s off to the shop to get bored. So the end is in sight,

sandman768 Liked a reply to forum topic Stupid silly ‘87 RM 125H rebuild

11/24/2019 6:06am
Here is the manual pages regarding the trans & shift assy installation...note: the left case is loaded first, then right case goes on, with the orientation of the shift drum spring, you have to load left case first.
This forum topic has 27 replies.

sandman768 Liked a reply to forum topic Stupid silly ‘87 RM 125H rebuild

11/24/2019 6:06am
Not sure if these will help you,
This forum topic has 27 replies.

sandman768 Liked a reply to forum topic Stupid silly ‘87 RM 125H rebuild

11/19/2019 6:01am
I did it a bunch of times w/out the crank installed to make sure everything was installed correctly, bench test the trans gears etc. . I can take some photos of my service manual later in the week, if you need. , I am out of town at the moment.
This forum topic has 27 replies.

JohnPainter Added a reply to Stupid silly ‘87 RM 125H rebuild

11/18/2019 7:08pm
I know the spring goes on the little post, but who was the evil contortionist who thought of this? I’m not even certain I have the orientation of the stopper cam correct, guess I’ll find out This is nuts, 🤯 Thanks for the assistance, I never figured this little bit would stump me.

sandman768 Liked a reply to forum topic Stupid silly ‘87 RM 125H rebuild

11/18/2019 6:57pm
It hooks on the left case, it makes assembly a little tricky , see the post just under the crank pocket at 7pm...I remember this because I was confused at first also. You have to load the left case half first...
This forum topic has 27 replies.

JohnPainter Added a reply to Stupid silly ‘87 RM 125H rebuild

11/5/2019 3:20pm
Other than some oily fingers on it when I was removing it, the piston and ring sure looks new. I think the PO attempted to rebuild but gave up when he couldn’t get the crank bearing off and then just buttoned it back up. I don’t know. It’s a fascinating little engine.

mb60 Liked a reply to forum topic Stupid silly ‘87 RM 125H rebuild

11/5/2019 3:11pm
I bought a 86 rm 125 a couple of years ago for $ 300.00. Took it home and pulled the head off it and was surprised with new piston on standard bore. Only problem was they put the piston in backwards and it seized. LOL
This forum topic has 27 replies.

JohnPainter Added a reply to Stupid silly ‘87 RM 125H rebuild

11/5/2019 11:01am
I appreciate that info on the porosity of the case behind the stator. I might just do a preemptive epoxy, though that part of the case looks excellent inside and out - the cover on the other hand... pitted, but usable, so I’m touching it up with JB Weld - it’s holding on to the areas that were pitted and...

project racer Liked a reply to forum topic Stupid silly ‘87 RM 125H rebuild

11/5/2019 10:53am
86- 87 RM125 would scorch a top end to the condition of the one in your pictures on the regular. That is detonation damage on the head. They would show good plug readings, jetted right, and the head would be ruined from detonation. About 6-8 races is a good life for one. Use the best gas you can buy.
This forum topic has 27 replies.

sandman768 Liked a reply to forum topic Stupid silly ‘87 RM 125H rebuild

11/5/2019 10:23am
This is a photo from a 1988 Suzuki RM125 service manual. Many changes from 87 to 88 RM125, I doubt the ignition was one of them, hope this helps. If you need any other info from the manual let me know. After you have assembled the engine, perform a leak down test, as I found out, the cases behind the stator are very porous, causing severe air leaks, easy fix, just clean really good & epoxy the case where it is leaking. Also pay close attention to the poorly designed water pump impeller, it is plastic & bolts to the...
This forum topic has 27 replies.

JohnPainter Added a reply to Stupid silly ‘87 RM 125H rebuild

11/5/2019 8:30am
I may have spoke too soon, I’d be interested in a stopper cam (25350-14501) part #18 in diagram and spring for it (09443-08036) part #19 if you have them, let me know pymt method if so.