1985 RM125

[BAHNZY]

At what point do you say 'its farked'? Good luck with it, good old RMs are cool but that one looks like 12 months worth.

I'm going to try real hard to see if i can have it ready for the Honda Bonanza.
One thing i have worked out over the last few years is that the smaller the capacity the more work and cost involved to get it rideable. I put it down to the fact that 125's and to a lesser extent the 250's are used by father/son combinations at the local track and their mates farm and they ride them (cause they can) into the ground then dump them for the next bike. 250's and 500's are simply to much for little Johnny hence they are usually not as flogged as the smaller capacity bikes. Thats my take anyway.

At what point do you say 'its farked'?
For me its about the challenge, although i have given up on one 84 125 before this one and turned it int o a parts bike as it was simply to much work and cost.

[Lozza]

Just a few small points the 'tang' on the bottom of the cylinder is to support the skirt the rings go nowhere near them. I managed to pry apart a set of cases that were seized in the pivot. The trick is when you fell like whacking it really really hard don't walk away and do something else and come back to it after you have calmed dow. Took me the best part of 2 hours with heat, diesel, dolly's an some Bunnings or Super crap 'pry bar set' which made it easy.

[DR]

The trick is when you fell like whacking it really really hard don't walk away and do something else and come back to it after you have calmed dow.

So what you are saying Lozza is when I am totally at the end of my tether and about to suffer a serious  brainsnap don't walk away and come back to survey the damage after I have calmed down but beat the living shit out of it then and there? hmmm..sounds like my regular method so nothing changes

[Lozza]

  You got me there Doc my shocking punctuation should have had comma's before and after DON'T

[vmx42]

Just a few small points the 'tang' on the bottom of the cylinder is to support the skirt the rings go nowhere near them.

Lozza,
I have got the same cylinder, with the same problem and as Bahnzy says its a $450 fix. Are there any other options…?
VMX42

[NR555]

Bahnzy, my brother restored an 85 a couple of years ago, although I don't think his was as close to death as yours.  He might have some bits & pieces lying around from when he did his restoration.  Give Marty at Krooz Tune a buzz to see if he has anything lying around or some useful contacts. 

It turned out to be a very nice little bike.  I think the only bit he couldn't find for it was the original graphics kit.  Some wanker had a shitfit because he rode it in Pre85 in Viper a couple of years ago and it's never been ridden since (maybe he should have invested in that drum brake)! 

[Lozza]

Lozza,
I have got the same cylinder, with the same problem and as Bahnzy says its a $450 fix. Are there any other options…?
VMX42

There would be a few good options. From the obvious machine it off and run it (plenty of cylinders are unsupported there), the bargain basement dowl then JB Weld and hope for the best(though the liners are thin from memory) to taking out the sleeve and finding a 56mm or so piston and nicasil the bore. All of which would be far less than the OTT $450 for a resleeve

[Hoony]

............
One thing i have worked out over the last few years is that the smaller the capacity the more work and cost involved to get it rideable. I put it down to the fact that 125's and to a lesser extent the 250's are used by father/son combinations at the local track and their mates farm and they ride them (cause they can) into the ground then dump them for the next bike. 250's and 500's are simply to much for little Johnny hence they are usually not as flogged as the smaller capacity bikes. Thats my take anyway.

Exact-a-mondo Barnster, when i bought my 500 (it was very rough, but all there and rideable) i went over everything except engine and went to that ride day in early 2006 at Ravo, the motor was strong so i did 2 seasons on it before i rebuilt it. 

 it even had barkbusters fitted and the guy i got it off was using it as a trail bike  , could not think of a worse bike to use as a trail bike 

[whitey 43]

Project update?

[asasin]

may be a bit late but i have a spare barrel , it is at 55.5 but may clean up ok, it does not have any thing broken on it. Pm me if you are interested

[BAHNZY]

The next instalment.
Frame
Gave up on the 85 frame and swapped it out for the 84 frame. The broken, twisted and trashed brackets combined with the rusted lower frame rails was too much to contend with. She's on the way to the powder coaters this weekend.
Suspension
Stripped three shocks and was lucky enough to build (only just) one shock out of them all. New seal head, new bump stop and lots of linishing on the shaft and we are on the way. Swapped the spring out for one that will take something better than a 50kg rider. The front forks have been stripped and cleaned and await re-assembly with fresh oil and seals. I've machined down the steerer tube and fitted taper roller bearings in place of the ball bearing system so where go to go in that area.
Engine
Picked up a genuine Suzuki con rod & main bearing kit via e-bay USA and have them on their way. I have 3 gearboxes to go through and make one good one out of the lot. I just hope that they are all 85 internals as they differ from the 84.
Wheels
Haven't decided where to head with these yet. I am thinking that a strip, clean and polish of the spokes maybe as far as I need to go. The difference between shiny spokes and dull ones is close to a top end in costs so I may just pass on that one.
Plastics
Have de-stickered and cleaned them up now I need to get the wet & dry out and some polish to them.  Ordered a new version of radiator shroud stickers that I did for the 84 so that should make them o/k.
Seat
The seat is the “standard” seat from my 84 model as I had a “high” seat made up for it. That seat has a new foam and cover so nothing to do there.

[BAHNZY]

An update on the 85 125.
I've mocked up the bike with old cases etc and just need to finish off the exhaust hangers and mounts then i can strip and send out for powdercoat. Had planned on doing this a month or so back but run out of time.





Ive heard from Suzuki central in En-Zed that the crank & water pump bits are not far away so time to get cracking on the engine.
If got the cylinder back that Mario gave me and she is now 1.0mm OS with a shiney new Woosner piston. I found that the bike had been messed with in the engine department and had an 84 head on it. This has now been swapped our for the correct 85 head. Ordered and recived a new set of clutch plates and springs. Have got the correct flat slide carb but given the amount of work i've got to decide if i put a new carb on it ir perservere with the old one. This is the engine at the moment.


As far as the parts list, things are looking good. What parts Suzuki had i have now got as well.

Chain Guide - 61348-14510 (o/k)
Lock Washer - 09167-17002 (o/k)
RH Crank Seal - 09289-28007 (o/k)
LH Crank Seal - 09283-18004 (o/k)
Crank O Ring - 09280-20004 (o/k)
Crank Lock Washer - 09166-12007 (o/k)
Intake Manifold    - 13111-14510 (o/k)
Disc Brake Cover - 59231-14500 (n/g)
CDI Protector - 32941-14300 (o/k)
CDI Holder - 32942-14111 (o/k)
Front Number Plate - 94911-00B10-25Y (o/k)
Tank Holder - 44560-14500 (o/k)
Shock Flap (Protector) -    63112-14500 (n/g)
Rear Guard Protector - 63331-14500 (n/g)
Chain Guide - 61273-14500 (n/g)
Oil Seal - 64845-14100 (o/k)
Shock Canister Buffer - 62423-14500  (o/k)
Canister Grommet - 62423-14510 (o/k)
Canister Cushion - 62331-14502 (o/k)
Canister Holder - 09462-00082-XC0 (o/k)
Cable Holder (Guide) - 58621-14520 (o/k)
Water Pump Seal - 09168-06025 (ex ebay USA)
Water Pump Seal - 17470-02F00 (ex ebay USA)
Throttle Cable & Clutch Cable (o/k)

Complete Gasket kit (o/k)
Piston & Ring Kit (Woosner)
Con-Rod Kit (ex ebay USA)
Full engine bearing kit (ex ebay USA)
Full engine seal kit  (o/k)
Clutch Fibre set (o/k)
Spark Plug and Cap (o/k)
Grips & Lever Sets (o/k)
Kill Switch (o/k)
Button bend bars (o/k)
All Bars Swing arm rebuild kit  (o/k, but jeez there exxy)
All Balls Tapered Head Stem Conversion (o/k, but jeez there exxy)
Front & Rear Sprocket & Chain (TBA - Undecided on whether to run a 50 or 52 rear)
Front & Rear Wheel Bearings (o/k)
Front Brake Pads, Rear Brake Linings
Front & Rear Tyres, Tubes & Rim Locks  (o/k)
Fork Seals & Oil (o/k)
Rear Shock Seal Head  (o/k)
Twin-Air Air Filter (still on back order from Twin-Air)

[holeshot buddy]

better drill some more holes in the airbox bahnsy

[BAHNZY]

What is it that makes someone think that adding random holes into an airbox will make a difference to the performance of the bike. I'd bet my left one that every one that has ben on evil pay in the last 12 months has been butchered in the same way, albeit with proably less holes.

[monaro308]

Good stuff Rod 
You've picked up a few bits by the look of it!
I found the w/pump housing from that engine going through my stuff if you need it.
Are you on holidays? I am at the moment.
cheers...mario