2001 rm125 powervalve rod failure

AMinkman · Jan 29, 2002

What is everybody doing about the powervalve rod failure. This is the 2nd time mine has been sheared by the waterpump gear. This time it took 3 bearings and a gear in the tranny. Suzuki says that it's only the 2nd time they have heard of it even though they redesigned it for 2002. I guess we'll be getting a couple of yz85s instead of the rm85s.

MN KDXer · Jan 29, 2002

Suzuki is lying if they say they've never heard of it before. I talked to the guy out in Suzuki US in California, and he said there is something wrong with the bend of the cheezey rod and it gets eaten in half by the gear. He also said that for 02, the problem is corrected. (diff bend, I think) He thought the problem might already be solved with an updated/corrected part.

Besides my son's bike, I know another guy whose kid's bike did the same, and I heard about another guy going thru a couple.

I would suggest to buy a new rod for an 02. As to the RM/YZ85, I would judge those two bikes on their individual merits and not relate them to the 125's powervalve rod.

AMinkman · Jan 29, 2002

I was hoping you would see this post, MnKDXer. I was told of the problem before I got the bike by a Factory supported rider and did the "fix" when I did the first topend. Sure enough, the rod was hanging by the plastic clip.
The second topend, same thing. On break-in we had tranny noise and discovered the one disinegrated bearing, 3 bad bearings, and 1 bad gear.
The dealer called Suzuki and they said they had only heard of one other problem which I knew was garbage because of the support riders warning. My pick for the 85s is not so much for the merits as it is for Suzuki not claiming responsibilty. My son has ridden the rm85 and that is his pick, but I have to pay for it. Suzuki knows there is a problem but will not take care of it. I don't mind paying for a rod and a couple of clips, splitting cases, gears and bearings
is another matter. If you have a contact, send me an e-mail. I want to stay yellow, but my brain says BLUE .

AMinkman · Jan 30, 2002

I just talked to the customer rep at American Suzuki and asked him " even though it's a defect you guys won't cover it" and he replied " no, it's your responsibilty. It's hard for me to stay with a bike when they design something
wrong and it causes serious damage and they take no responsibility. Oh well, lesson learned.

MN KDXer · Jan 30, 2002

Aminkman,

Geez, that bites about your tranny getting trashed from the steel chunks. Suzuki really could try to do something to help out, even if it is only to give you a free gasket and $2.95 linkage.

Luckily, my son is pretty aware of his bike's performance and stopped as soon as the top end power dropped off (when the rod broke). At first, I called the bigger MN dealer, and he didn't stock the link. But, then a smaller dealer had TWO in stock, and I KNEW mine was not the first.

Did the Suzuki rep have anything to say about whether the trouble was fixed for '02, or is it going to be the same thing again? It can't be too tough to design a rod which doesn't grind on the gear.

I'll try to do some research on part numbers, or maybe do surgery on my son's 02 and give you a report.

AMinkman · Jan 30, 2002

The advice that my dealer got from the Tech Rep was that I should "try the one for the '02 because it was redesigned". Apparently the numbers aren't there for a recall. Both times ours failed it was caught during top-end rebuild. It was ony hanging on by the plastic clip. I saw the '02 rod and it is attached to the governor end permanently and the clip on top. The rod has a straighter bend also. Looks like your '02 is probably safe. As for mine, when it's back together it's for sale.
My son rode a yz85 today and said the power was good but it's owner was small so he couldn't actually "ride it".

MN KDXer · Jan 31, 2002

AMinkman,

I took a look at the repair manuals of the 01 and the 02's tonight. The two yr models are quite a bit different. As you pointed out, the 01 has the plastic rod clips in both the top and bottom, whereas the 02 is only the top. Also, the 02 has the rod on the inside (away from the gear) whereas the 01 has the rod facing the gear. I don't know if a different rod would make any difference, but maybe a sturdier plastic clip would help. (maybe, the plastic gets soft and allows the rod to twist?)

As to the fix, I couldn't tell 100% from the assembly views, whether the 02's linkage would fit, but IMO, it sure looks like it. If you'd be interested, I can scan and send the 02 pictures from the manual. The 02's assy price is somewheres around $38. If this would cure the trouble, it would certainly be worth doing.

AMinkman · Jan 31, 2002

MnKDXer, I appreciate your efforts to help, but you probably have already noticed that I'm a little bent at this point at Suzuki. My last ditch effort is in motion. My wife works with a lady whose husband works for Suzuki and he will advise tomorrow whether it is worth pursuing. I am also in motion for the YZ aquisition.
My RM parts were supposed to be here today, they all came except for one bearing. My frustration builds by the day. If I don't buy a YZ tomorrow, it's another lost weekend. A broken thumb, Christmas break, and a broken bike
have all conspired to #*$$ me off. There are 3 series going on now paying contingency. To top it off, he's training now on my WR 400.? :ugg:

_j0kA_ · Feb 1, 2002

I have a 2001 RM 125 and I would like some tips to prevent this from happening to my bike..

Also do any of you have pipes on your bike? I want to buy a pipe in the next few weeks, but im not sure what works well on Suzukis.. I was thinking about the FMF Fatty ( or SST ) and a Powercore II silencer.. Does it sound like it would work good for mx?

And finally... When my bike is in gear, I pull the clutch in, and if I try to push it forward, my rear wheel locks up as if the clutch didn't engage.. I have heard that it is common with Suzuki's, and tommoro I am going to buy some SYNTHETIC tranny oil to see if it reduces the problem.. Some of you are probably wondering why this is bugging me so much, and the reason is that when I race and stall ( crash in a corner, etc.. ) the bike, then I have to find neutral to start it again.. If I try to start it in gear with the clutch pulled in, then the bike just jumps forward.. It becomes a P.I.T.A when your fighting for your position, stall the bike, and cant get it started again because you cant find neutral..

Any input is appreciated!

AMinkman · Feb 1, 2002

You should probably get the powervalve governor/rod assy. from the 2002 ASAP.
As far as pipes, we use Pro Circuit so I can't give you a comparison.

MN KDXer · Feb 1, 2002

I checked the powervalve linkage in 250s' manuals; Guess what- the 02 250's have a similar upgrade to the actuator rod.

If it wasn't such a pain to swap and check, I'd tear the two bikes apart to verify. Someone at Suzuki should be able to tell us whether the 02 powervalve parts would fit.

Keep me posted. I've got a buyer for the 125, and I do want to advise him about any updates.

MXP1MP · Feb 5, 2002

Has anyone done the '01 to '02 parts upgrade? does it look like it would fit up easy or does it mount in different area's? my friend with an '01 is really interested in knowing more about this (why i'm asking for them). Like to keep it from becoming a yellow hand gernade.

_j0kA_ · Dec 31, 2003

hey guys, stupid me didnt change the parts when you suggested and 2 years later mine finally goes lol.. if you have a solution to the problem please reply in the my new thread
http://dirtrider.net/forums3/showthread.php?s=&postid=709601#post709601

2001 rm125 powervalve rod failure

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