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2002_RM_125

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About 2002_RM_125

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    TT Newbie
  1. 2002_RM_125

    2002 RM125 Another Fresh Engine Being Built

    Now that I've got the drive shaft and counter shaft all together. I also resurfaced the cylinder head in a figure 8 motion. It looks awesomely smooth. There is a feeler gage technique to use to insure it is flat tolerance shown in the manual. Now i can start following the OEM manual and put this engine together. If anyone desires to know torque specs on any of the fasteners just comment and I will post it here. i hope to have it all together by Friday evening. I have a race this Saturday in Billingsley Alabama at X-bones. Then the holiday weekend at monster mountain. i will have my 2017 RMZ250 up for sale at that race the 31st and 1st. Just want one dirt to play on after that weekend.
  2. 2002_RM_125

    2002 RM125 Another Fresh Engine Being Built

    After the transmission inspect I determined to buy a complete transmission set of gears, bushings, washers, circlips, shift forks, shifting gears. There were big chunks out of #3, #19 and #20. The shift forks were thin. The Shift Cam Drum was SAT. I bought a circlip pliers kit and had to modify the tips to help ease the installation of the circlips. On page 10-9 of the OEM Manual there is a small instruction diagram that informs you of the direction of the flat side of the circlip. I had to confirm my interpretation of what that meant with a High School classmate who works at my local dealership. I also based the knowledge of getting it right with viewing some other blogs where a Honda Tech posted an awesome picture that left no doubt what direction these circlips are supposed to be facing. Basically the flat side faces away from washers. So throwing a wrench in there I eliminated the confusion of what thrust was meant by in the diagram. I will try to simplify it to this translation. Face the flat side of the circlip away from the Stationary Gear(s) towards the Sliding Gears the Shift Forks fit into. My classmate said "most people don't pay attention to that". When I was in the Navy, we had huge reduction gears and there was a term called back-lash. In our modern Chevy, Ford and Dodge trucks you can occasionally hear LOCK-Train in the rear-end gear of the truck. Take that noise and put it to the Power of 10. First time I heard it, I shit my pants. There are some photos to view below:
  3. 2002_RM_125

    2002 RM125 Another Fresh Engine Being Built

    After splitting the casings. It is Transmission Inspection time. OEM Manual Chapter 10. Insure your shift fork(s) aren't bent. There is a Gearshift fork thickness: Standard: 4.80-4.90mm. There is a Gearshift fork groove width: 4.95-5.05mm The picture below were reading I recorded from using digital calipers.
  4. 2002_RM_125

    2002 RM125 Another Fresh Engine Being Built

    Those pictures look like the transmission was ran for a short amount of time with all the engine assembly lube "redline assembly lube" maybe. Still looks thick. Where you hand spinning the shafts only testing it for gear jamming. The engine I took apart was missing shifts, dropping down on its own etc. When I measured the forks and gear grooves on #3, #19 & #20 they were all out of spec. I'll have pictures posted later in my thread showing what is SAT and then post a couple of the measurements that had me decide to buy all new OEM transmission and shifting components.
  5. 2002_RM_125

    Reeds

    I've had bad experiences with Motosport and their prices suck. Check out every other on-line store you can before you use Motosport is my suggestion. Just an opinion, I rather sit on the edge of the sea and let sand into my underwear that buy another item from Motosport.com
  6. 2002_RM_125

    2002 RM125 Another Fresh Engine Being Built

    do they make a slow motion camera, i used to live in CALI not too far from Hollywood. but even with me riding like a goon it still doesn't match ronnie's stuff. dude i am 61 years old and i can act a fool on the track but i am better in the grassy flats... I have freinds who say they took a nap while I made my 1st lap...
  7. 2002_RM_125

    2002 RM125 Another Fresh Engine Being Built

    BTW! 2 out of the 3 Shift drums I have that are used. They are shit drums... or should I say they look like shit. I'm sure from what I viewed on TT that there are people who would say they are fine, slap that bad boy in there and ride it like ya stole it. I ain't one of those people. But I am going to build an engine out of all the shit parts I've got and make it a test platform to see if I can mix-match casings that I've been informed by one of our more experienced TT Techs like yourself. I am doing that build with all the expertise I can muster but it is my Ronnie MAC engine. To intentionally build an engine to test how long it will last under extreme on the pipe, extreme pressure quick shifting, gate drop blasting over revving the crap out of it, blowing smoke and filling up the gate with it. I have a buddy who is the gate master and we will team up to put on a show. I will be wearing cover-alls and cutting a helmet plus the scarf. All in fun because I am all about having fun. That piston kit will be Namura just to keep the cost down or maybe the original OEM used piston with a new ring at best.
  8. 2002_RM_125

    2002 RM125 Another Fresh Engine Being Built

    I am with you on that part of the inspection. The 1st engine I built for the bike I just bought all brand new OEM Part(s). Just about every used transmission I bought off ebay or pre-ebay posting relationships I had with sellers the transmission parts were iffy most of the time. You're right though, when I inspected the transmission and other components that make up the engine. It was so close to being just yard art. Meaning my wife wants gears to make some sort of guy stuff wall hanging nick-knack for my step-son's room of choice to hang it on I guess. This engine build is going to have all new shafts, gears, bushings, washers, circlips, forks, fork pins and some of the shifting pawl parts etc. I quit counting how much money I was spending because for me its called commitment. The drum I picked from all the extra transmission parts I bought used. It actually fairly new from how it looked. I went to Trade School for this and spent 20 years in the Navy as a Mechanical Engineer. I'm not saying I don't need your suggestions but you have beaten me to my next post on all the things that are related to an engine build or methods of rebuilding an engine. I am patient with how I do things especially with engine builds. I have a RM125 that is running great "no current issues". This is just a 2nd engine to install upon completion. Plus I have another bike to ride/race if this one blew up tomorrow while I am practicing or more like blowing off steam should I say because this has been one H3LL of a week. Thanks for the input but I will chalk that one up to being for other readers who might need help to insure they are spotting things most people miss during a build.
  9. 2002_RM_125

    Recommend a needle ‘03 RM125

    I agree with you on your set up. I am following your lead with running similar leaner jetting with the engine I am building with Wiseco Components but I also want to see what a V-Force3 Reed Cage is going to do to pep-up the 125cc ZUK. It is hot as H3LL here but I am only doing a 1/2 needle jet size purchase and play with the clip setting like you are. I am not a trail rider (tried it once on my RM450) in 2015. Personal Opinion with trail riding but not judgemental at all. Just a choice. I look forward to exchanging test platform results on your thread if you don't mind. My jetting is the 32 / 455, not sure what the air screw will be till I crank her up. I am too old to remember off the top of my head what OEM Needle I bought but I do know it is a half size to stock OEM. Good luck Spencerdiesel I wish you all the success. If you live in the tri-state area and you know where Monster Mountain MX Park is. Then come ride/race with us in the SEVMX Series (SAT) 30 AUG & (SUN) 1 SEPT 2019. Especially if you want to hang out with guys in the late 40's thru 60's. Shoot one guy is 70+ and rides like hell. It is a true family racing event and we race modern, vintage and everything in between Male, Female, age 3 and up. Check You-Tube to view some of the event vids people have posted if you please...
  10. 2002_RM_125

    Recommend a needle ‘03 RM125

    There are aftermarket CARB rebuild kits all over the on-line market places. I tend to price shop. I personally buy my part(s) from RockymountainATVMC. Their site is user friendly and have 9 pages of aftermarket parts and accessories for your bike. I like the All Balls CARB Kit they sell. I've bought both brands for my CARBs. I have one CARB for the break-in process using over size jetting during that by 1-2 sizes up on the pilot and main. I personally buy OEM Needle jets to insure I have half sizes to mess with the tuning for Winter and Summer months. But that's just me, most people only own a dirt bike for a season or up to 2 years. I don't plan to sale my bike. I built an engine for it last year, I might have 12 hours on it. I am currently building a 2nd engine with Wiseco Crank and Piston. I plan to build a 3rd engine with Wossner Rod Kit and a Wossner Piston. Not sure if I've scraped enough parts up while over buying last year to gear up for a life in my shop staying way from my wife and her honey-do list. Meaning I might BS her by telling her I'm building a 4th engine to Ronnie MAC the throttle on the start gate while wearing my own Cover Alls and nose piece cut out of the helmet. I do that for the little kids and the adults who follow Ronnie's You-Tube vids to give them a live show as Jimmy MAC.
  11. 2002_RM_125

    2002 RM125 Another Fresh Engine Being Built

    Next step is the splitting of the casings. I use the TUSK brand casing separator tool. There are other brands but I get paid by R/M to buy their products at 5% RM Cash. Splitting the cases is Chapter 10 of the OEM Manual. I boofed a little here, naturally I had to remove the kick-starter mechanism and gear shifting part prior to splitting the casings.
  12. 2002_RM_125

    2002 RM125 Another Fresh Engine Being Built

    Jeez! It's the 15th of August around 7pm and it's 90 degrees outside but feels like a 101 in the shop. I ordered some parts on Tuesday from RockyMountainATVMC = R/M and they arrived today. I planned to assemble my transmission parts (all new) might I add. But sitting here in the A/C is the better option. As you can see at the beginning of this thread I've already pulled the engine from the bike and now its time to disassemble it. I open my OEM Manual to Chapter 7 and followed the pubs instructions. I personally keep my parts in containers to insure no dirt and dust with the occasional bird who nests in the shop might poop on my parts. Who wants bird dong to clean up. Anyway I have a brand new Aftermarket Pro-X Clutch System to install upon re-assembly. I posted some pictures from the manual.
  13. 2002_RM_125

    Recommend a needle ‘03 RM125

    Take the CARB off clean it. Issues you start out with stock size jets within the parameters of you sea level and temps. Insure your float level is dead on. Put the clip on the middle of the needle jet. And tune you air screw to OEM specs. Let us know more. Also clean your air filter or replace it with a new one. Clean your powder valve assembly. Check your compression. New spark plug helps. Doing a plug reading as you go is essential too. What some you-tube vids they help a lot.
  14. 2002_RM_125

    RM125 Project Rebuild (HELP!!)

    I agree with mountainrider. I suggest buying an OEM Service manual used at the least to help get it done right. I own a 2002 and have a thread posted to help lead you in the right direction. But I am taking a lot of time with the engine build so be patient with my posts. Just got start, its hot is hell here and thunderstorms every evening with lightning is slowing my progress. You've got a couple RM125 fans on here to help you get through this. I suggest you set up a Rockymountainatvmc account and use Partzilla.com too for researching parts. EBay has NOS = new old stock which only means they are brand new parts collecting dust and they can be bought at great price. I built a complete brand new parts engine using eBay and the other two for around 3K but I also need to do that for the $500 bike I bought. If you need me to keep helping just ask. I will try to make speedy responses. I am certainly good at parts supply suggestion once you get started. But I do work Monday through Friday so my help will come after working hours. Check out 2002 RM125 Another Fresh Engine Build for my post. And there is another member making suggestion for me. You can PM me and others if you need our help directly if a bunch of rifraf people are slithering in on you topic. Basically I am here to help all 2000 and newer year model RM125 owners as best as I can.
  15. 2002_RM_125

    2002 RM125 Another Fresh Engine Being Built

    Please! Excuse any spelling and grammar mistakes. Well as long as have my current income level I won't have to worry about owning a KTM. Those are some awesome dirt bikes but are too expensive even pre-owned for the year/model I desire to own. Maybe one day but I can't see it in the near future. Plus! I have a true love affair for Suzuki. That started when I was 17. I had a 1973 Suzuki 400 like Roger raced for most of his Championship. Heck I might have weighed 129 lbs in the 12 grade. Skipped school to ride that bike for 3 days. Blew it up on a Saturday. Didn't ride another dirt bike till I was 55 years old. But in 3 years from the time I started back on a 2013 Suzuki RMZ450 I won a Championship. But now I just ride two Suzuki dirt bikes. My favorite dirt bike I've owned is the 2002 RM125. I'll sale the 2017 250 but this 125 I'll have till I die even if it is collecting dust. I've got a grand niece and a grand daughter who might be willing to ride/race it for me. Who knows but I am a big fan of your input/comments on all the TT Topics you make suggestions and give advice on. I get an education from a few of these threads especially when the experienced technicians give input. I try to plug in with a few now and then but under a different TT name. This post is a stand alone to help other RM Small Bore Engine Builders. I have hours of meticulous work to accomplish and I'm trying to post photos as I go. I'm not sure how well it will provide info to those in need but I hope it will draw attention from the better TT Member to deploy their knowledge into the Topic. I also hope it will be within the pattern of how an Engine Build is done as per the OEM Service Manual for the RM125. I'm a huge believer in following a publication that was written specifically for the bike(s) I own. I buy two manuals for every bike I own. One for the shop and the other stays in my truck or in the house during builds so I can place orders for parts as needed. Just a way of life for me and no one else has to live up to my standard. But that's why every where I've worked the boss sees how I operate as a prime example for my piers to follow. I get a feeling that's why they lay back and tell the others to follow my lead. Pisses me off the rest of them don't give a shit but its this newest generations down fall and I believe as long as there will be this down trend of no one wants to be responsible and wants everything to be given to them. As I get older I see a shit pot full of numb &%$#@!s on the rise. But maybe that's just my point of view. I damn sure know its my opinion. Again, thanks for punching in and giving advise. It is always welcome.
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