Segment:
Lightweight off-road/trail motorcycle, dual-sport capability.
Target Audience:
Enthusiasts and mechanics working on the Suzuki RV125 for trail riding, casual off-road use, or vintage restoration.
Competitors 1978:
Yamaha CT125, Honda SL125, Kawasaki KE125.
Vehicle Attributes:
Torquey 2-stroke engine, good low-end power for off-road, relatively simple construction, robust suspension for its class, dual-sport styling.
Benefit To Owner:
Enables owners to perform all necessary maintenance and repairs, diagnose issues accurately, and maintain the longevity and performance of their vintage Suzuki RV125.
Systems Covered:
Engine, Fuel System, Ignition System, Lubrication System, Transmission, Drive Shaft, Suspension (Front & Rear), Wheels & Tires, Brakes (Front & Rear), Electrical System (Lighting, Ignition, Charging, Starting), Frame, Bodywork, Controls, Tools, Troubleshooting, Maintenance
Total Pages:
Estimated 200-300 pages (typical for factory service manuals of this era, exact count not specified in product data)
Type:
Factory Service Repair Manual
Format:
Likely Printed or PDF (common formats for historical manuals)
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of the 123cc 2-stroke engine. Includes cylinder head, piston, rings, connecting rod, crankshaft, bearings, seals, gaskets, and timing.
Fuel System:
Carburetor (Mikuni VM series likely) disassembly, cleaning, adjustment, and troubleshooting. Fuel tank, fuel lines, and fuel filter maintenance.
Ignition System:
CDI ignition system, spark plug specifications, ignition timing adjustment, coil and capacitor testing.
Lubrication System:
2-stroke oil injection system (if equipped), oil pump, and lubrication points. Oil type and mixing ratios.
Transmission Drivetrain:
Clutch operation, gear shifting mechanism, gearbox disassembly and reassembly, final drive (likely chain drive) maintenance and adjustment.
Suspension Steering:
Front fork disassembly, seal replacement, oil level and type. Rear shock absorber inspection and replacement. Steering system components and adjustment.
Brakes:
Front and rear brake system inspection, adjustment, and component replacement (likely drum brakes for this model). Brake fluid specifications and bleeding procedures.
Electrical System:
Wiring diagrams, battery specifications, charging system (stator, rectifier/regulator), starting system (kick start primarily), lighting circuits (headlight, tail light, turn signals), horn.
Frame Bodywork:
Frame inspection for damage, mounting points, body panel removal and installation, seat, fenders, handlebars.
Scheduled Maintenance:
Regular service checks, lubrication, filter replacements, spark plug changes, chain adjustment.
Repair Overhaul:
Detailed step-by-step instructions for major and minor repairs, including engine rebuilds, carburetor overhauls, suspension component replacement, and electrical troubleshooting.
Troubleshooting:
Diagnostic guides and charts for common problems, symptom-cause-remedy analysis.
Adjustment Calibration:
Precise procedures for adjusting carburetor, ignition timing, clutch, brakes, and other critical components.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Tire Wheel Service:
Information on tire replacement, wheel truing, spoke tensioning, and wheel bearing maintenance.
Depth:
Comprehensive. Covers from basic maintenance checks to full engine and transmission rebuilds, including detailed specifications and diagrams for advanced diagnostics.
Diagnostic Capability:
Includes troubleshooting sections for electrical and mechanical issues, allowing for component-level diagnosis.
Format Type:
PDF (if digital), Printed Booklet (if physical)
Quality:
High-resolution scans of original factory documentation, ensuring clarity of text and diagrams. Expect black and white print with line drawings.
Binding:
Perfect bound or spiral bound (if printed) for ease of use during repairs.
Paper Quality:
Durable, non-reflective paper suitable for workshop environments (if printed).
Text Searchability:
If provided as a PDF, it is likely to be text-searchable, allowing quick access to specific topics.
Engine Type:
2-stroke, forced air-cooled, single cylinder
Displacement:
123 cc (7.5 cubic inches)
Bore X Stroke:
56.0 mm x 50.0 mm (2.20 in x 1.97 in)
Compression Ratio:
Approximately 7.2:1 (typical for this era)
Horsepower:
Approximately 11-13 HP @ 7000-7500 RPM (exact figure may vary based on tuning and measurement)
Torque:
Estimated 10-12 Nm @ 5500-6000 RPM
Carburetor Type:
Mikuni VM series, likely 22mm or 24mm throat diameter
Fuel Type:
Unleaded gasoline, minimum 87 octane (RON/MON combined), mixed with 2-stroke oil
Fuel Mixture Ratio:
50:1 (Gasoline: 2-stroke Oil) - Always consult manual for exact ratio
Oil Change Interval:
2-stroke oil replenishment is ongoing with fuel. Gearbox oil change interval is typically every 6,000-10,000 km or annually.
Spark Plug Replacement:
Every 3,000-5,000 km or as needed based on inspection. Manual will specify plug type (e.g., NGK B8ES).
Air Filter Cleaning:
Regularly, especially if ridden in dusty conditions. Cleaning frequency detailed in manual.
Chain Lubrication Adjustment:
Every 500-1000 km or after riding in wet conditions. Adjustment as per slack specified in manual.
Gearbox Oil Type:
API GL-4, SAE 80W or 90W hypoid gear oil. Manual will specify exact viscosity and quantity.
Fork Oil Type:
Typically SAE 10W fork oil. Manual will specify type and quantity per fork leg.
Common Wear Items:
Piston rings, crank seals, carburetor jets/needles, fork seals, rear shock absorber seals, electrical connections due to age.
2 Stroke Specific:
Carbon buildup in exhaust and cylinder head, potential for seized piston if lubrication is inadequate or engine overheats.
