1997 RM125 - Rebuild (lots of pictures)

First off, this is my first 2-stroke and therefor my first time working on a two stroke. But wow how easy it was to disassemble as far as I have. This is a continuation of the other thread of me contemplating buying it. I took a lot of pictures cause I'm not sure how bad things are. It was outside, undercover, for the last 6 months getting hit with moisture. So a given is replacing the rotors, sprokets, and chain

My biggest concern right now is the noise coming from the bottom end when I push the kickstarter. Its not loud really, it sounds like metal rubbing other metal with a little but of intermettent mild clicking or chugging. Maybe this is normal I don't know. I'm going to listed to my buddies yz125 and see if it makes similar noises while turning over.

Other concerns:

Denting on the top of the piston

Broken clutch line holder right near the clutch lever on the case

Here is a list thus far of what need to be fixed/replaced:

Silencer

Rear brake lever bolt

kickstarter bolt

brake resevior

clutch and brake levers and perches

girps

throttle tube

chain

kill switch

piston and ring

air filter assembly

spark plug

fuel line clamps

all plastics and mounting hardware

Goodies:

Works connection skid plate and frame guards

Rental fat bar handlebar and risers

FMF fatty pipe

please let me know what you all think of these pics, also any suggestions on other parts that should be replaced are welcomed. ** in one of the pictures the spark plug holder / cylinder cover looks cracked, its not.

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Wow. It looks as if something got in between the Piston and the cylinder walls and made its way up to the top and the piston was hitting it against the cylinder head. These do not look as normal wear skuffs. You definately looking at a new top end, cylinder and head. You can send it to Eric Gore or other professionals to get it bored out to a 134 or 144cc or just have it replated. I would also do the bottom end if I was you to be on the safe side. That sound is not normal. Take everything apart and inspect. You will regret when you put it together and the bottom end fries on the first or second ride if you don't replace it. Based on the condition it is right now, I doubt that the crank bearings and the rest are in good shape. Wait till you get to do the suspension bearings on the linkage, seering stem, swingarm and the shock. I guarantee those are toast just from being in the moist for a long time. I would suggest to inspect it as well. I did not see a new plug on your list.

This will be a fun bike when it's back together!

It looks like the previous owner used YamaBond to seal the cylinder head ~ which is not needed. Be sure to clean all of that junk out and just use the o-rings when you put it back together.

Bad news on the cylinder, you need to have it replated. The scars do not appear to be deep enough to need fixing, even so, plan on spending about $200 to replate it.

It looks like the previous owner used straight well water in the coolant system instead of radiator fluid. That (to me) explains all of the rust deposits, be sure to use a real coolant when you re-assemble.

Bottom end needs a total rebuild along with the cylinder needing to be replated. The head looks fine and just needs to be cleaned up. You can have a brand new rebuilt motor for about $500or less if you do it yourself. How much did you pay for it?

Good luck

I paid 300. Too much? Probably. But I need something to get me through winter and it will be super fun when its done.

I will be doing all the work myself, as much as possible at least. That said i have never attempted such a large undertaking. I've done cars and trucks, water pumps, timing belts, clutches. But for some reason splitting the bottom of this little engine makes me really nervous. Is there a thread or link to someone who has done it? Can i get by with just a manual? Anyone know where I can get a manual (ha)? I live in in the seattle area, does anyone know of a place that will recoat the cylinder, because i'm assuming it's not a diy kind of thing. I may just leave the cylinder alone for now because 1) it's not that bad and 2) it takes about 30 minutes to get it off again.

The bottom end makes me real nervous. I think its mostly cause the tranny is attached. I flipped through the gears and everything on that side of things seems to work well.

I was just ordering some parts for it and realized that oem handlebar stuff and not fit the renthal fat bar? I don't even have anything to compare it to.

Get ready to dig in! Pull it all split the cases and replace all seals ect.

New bearings throughout and check the tranny parts for damage or wear.

I rebuilt my 250 last year and it cost around $450 for everything in the botom end.

I would send the cylender off to power seal and have it replated and put in a new piston.

Have fun with it i think $300 is reasonable i paid $800 for my 250 but the chasis and plastics were all in good condition.

I was just ordering some parts for it and realized that oem handlebar stuff and not fit the renthal fat bar? I don't even have anything to compare it to.

Yeah you have to get standard 7/8 bars unless you want to buy aftermarket triple clamps.

Are you ever going to ride that bike again?

The biggest problem is I have no way of transporting my bike. I used to borrow my mothers pickup truck but she recently moved to Florida. There are some not-so-legal spots around my house but I'm not sure where they are and haven't been able to find any locals to show me. So to answer your question: in the near future-probably not. I'm looking for a small pickup to be my toy hauler.

The biggest problem is I have no way of transporting my bike. I used to borrow my mothers pickup truck but she recently moved to Florida. There are some not-so-legal spots around my house but I'm not sure where they are and haven't been able to find any locals to show me. So to answer your question: in the near future-probably not. I'm looking for a small pickup to be my toy hauler.

Well hurry the "F" up! Summer is almost here!

Well hurry the "F" up! Summer is almost here!

Thanks for offering to give me a ride.

I saw that thread it gave me a little bit of good info, what I reallyneed though is input on redoing the bottom end.

Wiseco sells a bottom end rebuild kit for 01-04 or something like that, but not 96-00. Does anyone know where I can get a bottom end rebuild kit or do I have to buy all the parts individually from suzuki?

I saw that thread it gave me a little bit of good info, what I reallyneed though is input on redoing the bottom end.

Wiseco sells a bottom end rebuild kit for 01-04 or something like that, but not 96-00. Does anyone know where I can get a bottom end rebuild kit or do I have to buy all the parts individually from suzuki?

Get a connecting rod kit and have a local shop press it onto the crankshaft.

http://shop.thumpertalk.com/ProductDetails.asp?ProductCode=TR_164860

Thanks for offering to give me a ride.

OH yeah If you need a ride just text me! lol! Sorry about that.:cheers:

Oh You know what I can drive down in my truck and then you can take my truck to the track and I'll take your girl out to dinner! Does she like Tube steak?:moon:

First off, this is my first 2-stroke and therefor my first time working on a two stroke. But wow how easy it was to disassemble as far as I have. This is a continuation of the other thread of me contemplating buying it. I took a lot of pictures cause I'm not sure how bad things are. It was outside, undercover, for the last 6 months getting hit with moisture. So a given is replacing the rotors, sprokets, and chain

My biggest concern right now is the noise coming from the bottom end when I push the kickstarter. Its not loud really, it sounds like metal rubbing other metal with a little but of intermettent mild clicking or chugging. Maybe this is normal I don't know. I'm going to listed to my buddies yz125 and see if it makes similar noises while turning over.

Other concerns:

Denting on the top of the piston

Broken clutch line holder right near the clutch lever on the case

Here is a list thus far of what need to be fixed/replaced:

Silencer

Rear brake lever bolt

kickstarter bolt

brake resevior

clutch and brake levers and perches

girps

throttle tube

chain

kill switch

piston and ring

air filter assembly

spark plug

fuel line clamps

all plastics and mounting hardware

Goodies:

Works connection skid plate and frame guards

Rental fat bar handlebar and risers

FMF fatty pipe

please let me know what you all think of these pics, also any suggestions on other parts that should be replaced are welcomed. ** in one of the pictures the spark plug holder / cylinder cover looks cracked, its not.

CIMG2333.jpg

CIMG2334.jpg

CIMG2335.jpg

CIMG2336.jpg

CIMG2337.jpg

CIMG2339.jpg

CIMG2340.jpg

CIMG2341.jpg

CIMG2342.jpg

CIMG2343.jpg

CIMG2344.jpg

CIMG2345.jpg

CIMG2346.jpg

CIMG2347.jpg

CIMG2348.jpg

CIMG2349.jpg

CIMG2350.jpg

IMG_0845.jpg

spike and mike hy-jacking your thread, don't mind them:bonk: 300.00 for the bike's not too bad, count on at least 1,000 for parts, which would include all the running gear too, chain, sprockets, tires, wheel bearings, and such, hopefully your trans is good, i put 700.00 in trans parts just this past year, and another 400 - 500 to freshen up my cyl and some other stuff, this winter, a good start would be pull the bottom apart and inspect everything, get a service manual too, for reference. and start making a list:thumbsup:
OH yeah If you need a ride just text me! lol! Sorry about that.:cheers:

Oh You know what I can drive down in my truck and then you can take my truck to the track and I'll take your girl out to dinner! Does she like Tube steak?:moon:

:smirk::lol:

I'm making a long list now with all the links to the parts. I'll post it in a bit for any suggestions on things to add.

I havent decided about the FMF fatty pipe, its dented pretty bad but I've seen threads about using ice to get the dents out, but my memory tells me those were all smaller dents. Is it worth trying to salvage?

Anyone have any input on this list?

Silencer

27-0330 FMF Shorty

http://shop.thumpertalk.com/catalogs/Tucker_Rocky_Offroad_2009/default.asp?p=18

Brake Resevior

Chain

R1-520-114 Renthal

http://shop.thumpertalk.com/catalogs/Parts_Unlimited_Offroad_2009/default.asp?p=515

Sprockets

Front

R254-520-12 (12T) Renthal

http://shop.thumpertalk.com/catalogs/Parts_Unlimited_Offroad_2009/default.asp?p=461

Rear

R123-50 (50T) Renthal

http://shop.thumpertalk.com/catalogs/Parts_Unlimited_Offroad_2009/default.asp?p=461

Kill Switch

57-5014 WPS

http://shop.thumpertalk.com/catalogs/Western_Power_Sports_Offroad_2009/default.asp?p=557

Top end kit

16-66(19,20,21,22,23) Wiseco

http://shop.thumpertalk.com/catalogs/Tucker_Rocky_Offroad_2009/default.asp?p=430

Connecting rod kit

16-4860 Wiseco

http://shop.thumpertalk.com/catalogs/Tucker_Rocky_Offroad_2009/default.asp?p=460

Complete engine gasket set

99-0842 Athena

http://shop.thumpertalk.com/catalogs/Tucker_Rocky_Offroad_2009/default.asp?p=422&s=2

Crankshaft bearings and seals

22-41016 All Balls

http://shop.thumpertalk.com/catalogs/Western_Power_Sports_Offroad_2009/default.asp?p=605&s=2

Swing arm bearings

22-81047 All Balls

http://shop.thumpertalk.com/catalogs/Western_Power_Sports_Offroad_2009/default.asp?p=689&s=2

Linkage bearings

22-71064 All Balls

http://shop.thumpertalk.com/catalogs/Western_Power_Sports_Offroad_2009/default.asp?p=689&s=2

Wheel bearings

Front

41-3611 MSR

http://shop.thumpertalk.com/catalogs/Tucker_Rocky_Offroad_2009/default.asp?p=111&s=2

Rear

41-3655 MSR

http://shop.thumpertalk.com/catalogs/Tucker_Rocky_Offroad_2009/default.asp?p=113&s=2

Air filter assembly

23-3211 Twin Air

http://shop.thumpertalk.com/catalogs/Tucker_Rocky_Offroad_2009/default.asp?p=488

Spark plug

BR8ES NGK

http://shop.thumpertalk.com/catalogs/Parts_Unlimited_Offroad_2009/default.asp?p=652

Plastics

Tires

Front

31-8445 Dunlop MX51

http://shop.thumpertalk.com/catalogs/Tucker_Rocky_Offroad_2009/default.asp?p=67&s=2

Rear

31-8460 Dunlop MX51

http://shop.thumpertalk.com/catalogs/Tucker_Rocky_Offroad_2009/default.asp?p=67&s=2

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