1996 Suzuki RM125 2-Stroke Motorcycle Repair Manual

The owner's manual contains i mportant safety information and instructions which should be read carefully before operating the vehicle. If the vehicle has been res old. obtain the owner 's manual from the previous owner or contact your local SUZUKI dealer for assistance. •

FOREWORD This manual is presented as a means whereby you can maintain your RM125 in top working condition at all times . Your riding skill and the maintenance steps outlined in this manual will assure you of top performance from your machine under any type of competition . We sincerely wish you and your Suzuki motorcycle a successful partnership for many years of happy riding. All information . illustration, photographs and specifications contained in the manual are based on the latest product information available at the time of publication . Due to improvements or other changes , there may be some discrepan- cies in this manua1. Suzuki reserves the right to make production changes at any time , without notice and without incurring any obligation to make the same or similar changes to vehicles previous built or sold . Suzuki Motor Corporation believes in conserva- tion and pr otection of Earth's natural resources. To that end , we encourage every vehicle own - er to recycle, trade in, or properly dispose of. as appropriate, used motor oil, engine coolant, and other fruid, and tires. WARNING / CAUTION /NOTE Please read this manual and follow its instructions carefully. To emphas i ze special informa - tion , the symbol A and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlight- ed by these signal wo r ds : A WARNING Indicates a potential hazard that cou ld result in death or injury. A CAUTION Indicates a potential hazard th at could result in motorcycle damage. NOTE: Indicates special information to make maintenance easier or instructions clearer.

General considerations: • Wear a helmet and goggles A he l met is the most important piece of gear to wear. Helmets do not reduce essential vision or hearing. Generally, helmets do not cause or intensify injury if you crash. Helmets simply help your skull protect your intelli- gence, your memory , your personality , and your life. Vour eyesight is equally valuable. Wearing suitable eye protection can help keep your vision unblurred by the w ind and help shield your eyes from branches and airborne mat - ter like bugs, dirt, or pebbles kicked up by tires. Wear a hel met and eye protection every time you ride . • Wear protective gear Wear proper clothing when you ride. Avoid loose clothes or scarves, which could get caug ht in moving parts. Abrasion injuries can be minimized by wearing protective clothing including gloves, strong boots that fit ove r the ankle, long pants, and a long sleeve shirt or jackets. Experienced riders often wear a kidney belt and chest or back protector for additional comfort and protection. • Inspect your ma chine before riding Before each use, perform an inspection per "Periodic Inspection" section starting on page 2-1. • No Passengers Suzuki RMs are designed for the rider only. • Ride with teammates Share the fun of motoc ross riding. A riding partner can also be great help if one of you gets stranded or injured. Of course, your friends will need th eir own motorcyc l es be- cause motocross models are not designed for passengers. If none of your friends rides motocross , ask your Suzuki d ea ler how to go about joining a club. If your friends do ride, you can all join a club-o r sta rt one of your own! • Practice on level ground Before you begin riding, you should find a good place to practice the skills you need ri de safely. Find a flat, open area with enough space to maneuver. Check with your Suzuki dealer or call police department if you do not know w here you can ride. Review the contro ls on your motorcycle before riding. • Know your limits Always ride w i thin the boundaries of your ow n skills. Knowing these limits and stay ing within them will help you avoid accidents. Ri de only in events appropriate for your experience. Safely competing on a motorcycle requires that your mental and physical skills are fully part of the experience. You should not at- temp t to operate a motor vehicle, especially one wi th two wheels, if you are tired or under the influence of alcohol or other drugs. Alcohol , illegal drugs, and even some prescription and over-the-counter drugs and cause drowsiness , loss of coordination, loss of balance, and loss of good judgement. If you are tired or under the infl uence of alcohol or other drugs , PLEASE DO NOT RIDE your motorcycle .

• Conclusion. The actions of other riders are unpredictable. Your motorcycle's condition can change. These factors can best be dealt with by giv- ing every ride your full attention . Circumstances beyond your control could lead to an accident. You need to prepare for the unexpected by wearing a hel met and other protective gear, and practicing safe riding techniques to minimize the damage to you and your machine. Mayall of your rides on your new Suzuki be win - ning rides I J

WARNINGS FOR SERVICING A WARNING Never run the engine indoors or in a garage. Exhaust gas contains carbon monoxide, a gas that is colorless and odorless and can cause death or severe injury. Only run the engine outdoors where there is fresh air. A WARNING Hot engine and muffler can burn you. Wait until the engine and muffler cools before servicing . A WARNING Fuel can catch on fire if you do not handle it properly. Gasoline vapors can catch fire easily . Do not smoke when servicing the machine . Do not service the machine in an area where there are open flames or sparks. A WARNING <:; o o Brake fluids and engine coolant can be hazardous to humans and pets . Brake fluid and engine coolant are harmful or fatal if swallowed , and harmful if it comes in contact with your skin or eyes. Keep brake fluid and engine coolant away from children. Call your doctor immediately if swallowed . and induce vomiting. Flush eyes or skin with water if either brake fluid or engine coolant gets in eyes or comes in con - tact with skin .

AWARNING Servicing the machine with engine running can be hazardous. You can be caught in the moving parts such as the drive chain. sprock- ets etc. Be sure to stop the engine when servicing the machine. J PRECAUTIONS FOR SERVICING • Replace gaskets, circlips, O-rings and cotter pins with new ones. • Take care not to expand the end gap larger than required to s lip the circlip over the sha ft when installing a circli p. • Use special tools where specified. • Use genuine SUZUKI parts and re com mend - ed oil. • When two or more persons work together , pay attention to the safety of each o th er. • After reassembly, inspect parts for tightness and operation. AWARNING Servicing the machine without proper clothes and protective gear can be hazardous. You can be injured if you do not wear proper clothes and protective gear. Be sure to wear proper clothes and shoes for servicing and wear protective glasses, mask or gloves as necessary. t I 'I II REPLACEMENT PARTS Use only genuine SUZUKI replacement parts or their equivalent. Genuine SUZUKI parts are high quality parts which are designed and built spe~ cially for SUZUKI vehic les. NOTE: Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems and damage.

SYMBOL MARKS AND MATERIALS SYMBOL MARK MATERIALS ~ li] SUZUKI SUPER GREASE " A " 99000 - 25030 SUZUKI SILICONE GREASE 99000 - 25 100 THREAD LOCK SUPER " 1333B" 99000- 32020 THREAD LOCK " 1342 " 99000- 32050 T HREAD LOCK SUPER " 1303 " 99000 -32030 SUZUKI BOND 1207B 99 104-31 140

SYMBOL MARK MATERIALS Use or apply DOT4 Brake fluid. SUZUKI FORK OI L SS-05 99000-99001-SS5 SUZUKI RE AR SUSPENSION OIL SS-25 99000-99001-S25 Use engine coolant. Apply eng ine oil transmission oil. Tighten a nut or bolt to the specified torque.

SYMBOL MARK MATERIALS Replace a part with a new one when reassembling.

1996 Suzuki RM125 2-Stroke Motorcycle Repair Manual

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