Tear Down Updates
 

Well things are moving along. the bottom motor bolt was tough to take off. I had to put the torch on it twice and pound it out with a mini sledge. It was very rusted and bent.
https://i.imgur.com/qciVYPdm.jpg

Here is the bottom end on the workbench.
https://i.imgur.com/AJIcct9m.jpg

https://i.imgur.com/aX5dQyJm.jpg

The water pump cover came off without a problem. It looks like new inside.
https://i.imgur.com/IA7ds5cm.jpg

The impeller looks perfect as well.
https://i.imgur.com/Fv6hibym.jpg

I don't think the clutch cover has ever been off the bike. small dent in lower cover, looks like from the rear brake pedal when someone tipped over.
https://i.imgur.com/oeIs6hbm.jpg

Some sludge in the bottom of the clutch cover, I rinsed this all out with some brake cleaner.
https://i.imgur.com/nw9EVVvm.jpg

The clutch basket and plates look original and the clutch basket has never been off the bike.
https://i.imgur.com/7Sp7az9m.jpg

just a very small amount of grooving on the clutch basket.
https://i.imgur.com/CRNCEhRm.jpg

But the steel plates have rusted into the fiber plates.
https://i.imgur.com/dCr3Ewsm.jpg

One Problem
 

I need help on one problem. I can't get the primary gear nut on the crank loose. I read some threads that said Suzuki put a high strength locker on this nut and it was only removable with heat. Some thought the bolt was a left hand thread because it was so hard to remove, but other said it was right hand thread but it took a lot of heat. I put PB blaster and the torch on the nut, then put my 1200 pound Milwaukee Impact Wrench on it, it didn't move the nut at all and it rounded the edge of the nut but I stopped immediately and I straightened the damage with a file.

I could use my 3/4 breaker bar with a 3/4 inch 19mm socket.

Any suggestions?

https://i.imgur.com/7Sp7az9m.jpg

And the nut came right off the stator. I have 6 flywheel pullers and none of them fit this design which has the two locations to thread into the bolt holes. Any body have specific puller model to recommend?
https://i.imgur.com/P868ivOm.jpg
Any suggestions?

The clutch basket looks fabulous with no indication that it has ever been removed from the bike.
https://i.imgur.com/RCJJTMim.jpg

Have you researched the Factory Service Manual? Maybe there's an online version with specifics? I'm interested (and I'll poke around a bit) as I have a 1992 RM125 that will likely need a bit of help in the bottom end at some point.

Maybe try Thumpertalk in the Suzuki 2 stroke section as well?

Uh.Well
Its a Suzuki and their is a high probability that nut is reverse threads.Left hand.

Get out now while you still can.
Pretend you never saw it.
Quietly make it go away.

I ordered an oem manual, it should arrive tomorrow. Thanks, I will check thumpertalk.

LOL, you are cracking me up, you may be right......:eek:

Does anyone know the original blue paint code or the blue powdercoat code for the frame on this bike?