Suzuki 2 Strokes

I have a T125 I am working on and I have ran into an issue trying to remove the ignition rotor assembly so I can access the plate behind it so I can split the cases.

This flywheel/rotor has no external or internal threading or set of small threaded holes like I have seen on every other type. The large steel flywheel part is so close to the cases I cant fit the 3 jaw type pullers arms behind it. The only thing on there is three small holes for a holder tool I am assuming.

Any tips for getting this bad boy off? Thanks

I couldn't tell you for sure, but on the gt triples you insert a spacer rod and screw one of the 10mm engine mounting bolts (designed so that it has an extended tip to avoid thread damage. Only one of the engine bolts is designed this way) into the centre hole.
It acts as its own puller that way. But you may wish to verify that with someone that has T125 experience to check it is the same.
In the manual it suggests you can make your own 7mm diameter spacer rod (I can't remember the length. Be careful not to make it too short or you will accidentally damage the 8mm thread for the securing bolt in the crank). But don't do what I did and make it out of an old bolt with the head ground off. The metal was too soft and it got stuck in there. Use an old allen key (or drill bit?) instead and cut the head off that. It needs to be hardened steel.
Insert spacer rod, then screw in 10mm engine bolt until tight. Then give the end of the bolt a sharp tap with a hammer.
I repeat; verify this is the same on the T125 before you attempt this. I don't have experience with that model and it might be different.

Hi!

If there are threads in the three holes, you possibly can use a tool like the one for GT500:
09930-30190
Rotor remover + several attachments to fit to different generators
http://www.alpha-sports.com/tools/Suzuki-Tools.htm

What about the ignition cam? It should be removable. Isn't a larger thread behind it?

bye
Markus

yip, that's the way. tighten up and then TAP with a hammer [small one will do]. tighten a bit more, another tap. it should fall off.
failing that you could always use a bearing puller/splitter, like one of these:
https://www.ebay.co.uk/itm/14pc-Bearing ... Swa3BZ~Q74" onclick="window.open(this.href);return false;
cheers, dd.

Well I got it off. That ignition cam portion does come off. I found that out after trying the spacer rod method which did not work.

Once the ignition cam portion came out it revealed a threaded hole. I actually used the inner portion of my Tusk puller and it came right off. Hope this helps a future T125 owner.





I am ordering a parts catalog and service manual tonight since I cant find a free PDF one online.

Ah, so the same principle as i suggested but without a spacer rod needed and using a much fatter bolt.
Glad you got to the bottom of it. Well done.

So it's like at the T/GT250/350... generator rotor.
There you can use the rear wheel axle bolt as puller.
May be, you could have done this in the same way.

Its very clever of the Japs to think of that. Cunning fellows, wot?