Suzuki RM-125 1992 'USA' restoration

Slingshot92
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9/23/2015 11:08am
Once again, had to spend the evening fixing the previous owner "repair" quality. This way the exhaust valve rod might move all the way up again.









jlv148
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9/23/2015 7:19pm
Looks like you're missing the screw and washer that keeps that shaft from sliding into the cover.

The Shop

Mike P.
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9/23/2015 8:10pm
Did you use a 93 frame? I noticed the square tubing and as I recall those frames were used on 93 and later models...
Slingshot92
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9/23/2015 10:11pm Edited Date/Time 9/23/2015 10:14pm
Thank you for your replies. Mike P., I immediately thought the same when I got the bike. The frame color matches 1993 model, instead of -92. Didn't notice any structural differences like the square tubing though. Good spotting. Luckily otherwise they seems to fit perfectly. If you look closely, you can see that the rear swing arm is from the -89 model also. Did some modifying to fit the chain guide and rear brake cylinder plastic shield in it. In the long run would still like to swap it to -92 model but for now it is what it is. :/

jlv148: The power valve default /rest position is now all the way up. Need to preload the power valve spring. It seems that it is not preloaded now and keeps the power valve all the way up for this reason.

Should I order original OEM bolt and washer for the "locking" or can I use a regular bolt for this missing part? At least I would need to know the exact lenght of the bolt.
Mike P.
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9/24/2015 9:35am
Slingshot92,

Below is a picture of your frame, the frame on my 1990 and another 92 RM frame and I circled where your frame differs from the other two frames. What is the serial number of your frame as that will tell you the year. Or, it could be that Suzuki offered a later 92 model with a revised frame (they did this years ago back in 78 I remember when they offered the RM250 in two models that year (C1 & C2)). Also, sometimes the European market gets the latest bikes a year ahead of us in the states. But if you look at the photos, you can see that your frame is square tubed while the other tow are round (two different frames). Mike







Mike P.
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9/24/2015 1:27pm
Slingshot92,

Thank you for clarifying that. I was not into bikes back in 1992, I had left the sport in 1990 so I am catching up on the different changes over the years. The other reason I am asking all these questions about the frames is because I have Works Suzuki RA swingarm for a 92 RM125 that I want to put on my 1990, so I am crossing my fingers hoping the 92 swingarm works on my 1990. Bu the way that looks like Stefen Everts 92 works RA125 in the last set of photos you sent (I have that same swingarm). Thanks again, Mike
Slingshot92
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9/24/2015 1:42pm
That swingarm will fit OK. Like said before, I have -89 swingarm on my -92 frame.
Mike P.
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9/24/2015 1:49pm
Thanks, and I'll have to stop by and see you next time I am in Finland (my wife's from Kalajoki). Mike
jlv148
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9/24/2015 7:59pm
The missing bolt and washer just keeps the shaft from sliding out. It doesn't affect the rotation. All you need is a short bolt and a washer big enough to overlap the other part.
Slingshot92
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9/24/2015 10:45pm Edited Date/Time 9/24/2015 10:47pm
Hi,

Yesterday I opened the other side of the power valve with tension 'knob'. The power valve adjustment /tension spring was broken /cut in half. It was also missing it's spring fitter /spacer. This explains very well why the power valve arm / rod was already in full up position.

I ordered all missing parts yesterday from Suzuki Europe. The parts were basically free and the delivery time is only 4 days.

One more question concerning the bolt that you are referring above. Since the engine is already attached to the frame there's no space to open the front power valve cover to see the valve movement, is there a certain point where the power valve should be aligned when the bolt is tightened? i.e. should I somehow preload the valves before I install the 'locking' bolt and spacer?

p.s. here's the troublemaker, part II:


p.s.2:
It keeps on wondering me how people treat their bikes. They just throw parts away and keep on riding although many vital parts are missing. Makes me mad! Smile

Mike P.
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9/25/2015 10:37am
Mastercross in Italy (just Google online). I also have an alloy works fuel tank and works exhaust for the same bike.
jlv148
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9/25/2015 7:13pm
You want one turn of preload on the exhaust valve spring. You should definitely clean the exhaust valve on that bike. When it gets sticky it loses a lot of responsiveness.
notme
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9/26/2015 10:19am
jlv148 wrote:
You want one turn of preload on the exhaust valve spring. You should definitely clean the exhaust valve on that bike. When it gets sticky it...
You want one turn of preload on the exhaust valve spring. You should definitely clean the exhaust valve on that bike. When it gets sticky it loses a lot of responsiveness.
Absolutely! Try to stay away from castor type premix, you want lean and clean to help lengthen service intervals.
Even more important on the RMX pv system.
Slingshot92
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9/26/2015 1:02pm
By the way, it still seems that I'll need few extra bolts (x3). If I recall right, these missing bolts keeps the power valve parts in their place.



Any idea what this marking in cylinter tells?


notme
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9/26/2015 7:54pm
Those 3 screws you need are only 6x12mm phillips head, nothing special.

I couldnt tell you on the stampings.
Mike P.
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10/2/2015 5:59pm
Slingshot92

That works swingarm I told you about arrived today (see below picture). And though it's for a 92-95, I think you are right and that it will fit my 90 RM. The carbon fiber sheet arrived the day before so I'll get started on making the carbon fiber chain guide. Mike



Slingshot92
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10/2/2015 9:03pm
Wow! That's just so cool mate. Smile

Since there's no any good, detailed pictures of that swing arm, maybe you could take more detailed, high resolution images with welding measurements. This way the rest of us could make cool replicas. Wink
Slingshot92
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10/9/2015 1:16pm Edited Date/Time 10/9/2015 1:17pm
Aftermarket cylinder liner / ports fixed /fine tuned. New Hy-tech carbon fiber reeds. Power valve cleaned and fixed. Lot's of missing parts once again.








Slingshot92
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10/26/2015 12:55pm Edited Date/Time 10/26/2015 1:31pm
Small progress again. I finally found the original -92 air/filterbox mudguard from Holland.
Also got Apico brake pedal tip from UK. Needed to modify and custom fit it but it was pretty straightforward.
















QA
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AU
11/15/2015 2:48pm
Your RM looks great. Well done!

Where did you end up sourcing all of the decals? I know you said Finland and EVO-MX but it looks like you have multiple different types - yellow and white!
Slingshot92
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11/15/2015 8:46pm
Both (yellow 'euro' /Slingshot -version and white 'USA' /Motocross -version) are from EVO MX.

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