Official Suzuki RM125 Owner's Service Manual - Factory Maintenance & Tuning Procedures for RM 125 Motocross Motorcycle (1990s-2000s)

Official Suzuki RM125 Owner's Service Manual - Factory Maintenance & Competition Tuning Guide

Unlock the full potential of your motocross machine with the definitive Suzuki RM125 Owner's Service Manual. Designed specifically for the high-performance RM125 series, this factory-grade manual is the identical resource used by professional race teams and Suzuki technicians to achieve podium-topping results. Whether you are performing a quick trackside adjustment or a full winter engine overhaul, this comprehensive guide provides the technical precision needed to maintain the aggressive power delivery and razor-sharp handling of Suzuki's legendary 125cc two-stroke.

Targeted Model Coverage

This manual is the primary technical authority for the Suzuki RM125 competition series, specifically covering the evolution of the 36E0 series:

• Suzuki RM125 (Standard Moto-Cross Models)
• Technical Series ID: 36E0

Vehicle Identification & Serial Numbers

For precise parts procurement and chassis verification, this manual provides clear guidance on identifying your specific machine through official serial number locations:

• Frame Serial Number: Located on the right side of the steering head pipe for easy verification.
• Engine Serial Number: Stamped clearly on the lower part of the right-side crankcase.
• Carburetor Identification: Standard ID "36E0" is stamped on the carburetor body to ensure correct jetting and slide configurations.

Professional Technical Insights & Performance Data

• High-Performance Two-Stroke Engine: Detailed specifications for the 124.8cc liquid-cooled, crankcase reed valve engine, featuring a corrected compression ratio of 8.9:1 (valve open) to 10.9:1 (valve close).
• Competition Carburetion: Complete tuning specs for the KEIHIN PWK36 carburetor, including factory-standard jetting (Main Jet: #170, Slow Jet: #50, Jet Needle: R1469MS) and float height adjustments (16.0 mm).
• Precision Chassis Setup: Comprehensive torque values, such as the 100 N-m (72.5 lb-ft) rear axle nut and the 90 N-m (65.5 lb-ft) steering stem head nut.
• Pro-Level Maintenance: Specific wear limits for the chrome-plated cylinder bore (54.000-54.015 mm) and critical spark plug gap settings (0.55-0.65 mm using NGK R6918B-8).

What’s Inside?

Table of Contents

1. General Instructions: Location of parts, break-in procedures, and competition fuel/oil mixing (32:1 ratio).
2. Periodic Maintenance: Rigorous inspection schedules for pre-practice and pre-race readiness.
3. Troubleshooting: Expert diagnostic charts for engine performance, cooling issues, and chassis handling.
4. Machine Tuning: Extensive guides for carburetor jetting (based on altitude/temperature), front fork damping, and rear suspension balance.
5. Engine Management: Step-by-step procedures for engine dismounting, cylinder/piston inspection, and exhaust valve (AETC) servicing.
6. Transmission & Clutch: Detailed overhaul of the 6-speed constant mesh transmission and wet multi-plate clutch system.
7. Cooling & Electrical: Radiator maintenance, water pump service, and CDI ignition system testing (Stator/Coil resistance).
8. Suspension & Brakes: Full service for the telescopic front forks, linkage-driven rear shock, and hydraulic DOT4 brake systems.
9. Service Data: Complete tables for tightening torques, wear limits, and special tool requirements.

Equip yourself with the factory-level data required to keep your Suzuki RM125 in peak racing condition. From adjusting the high-speed rebound on your rear shock to optimizing your power valve timing, this manual ensures you stay ahead of the competition. Order your factory service guide today and master your machine's maintenance.