Suzuki TC125 motorcycle transmission and case assembly

Reassembly of the TC125 Suzuki transmission into the case assembly. Repair of the shift rod assembly, using a lathe, dial indicator and a crow bar. Preparing for clutch and side cover installation.

[@frankdillon6127]

Love your attention to important details, like that 1mmx24mm O ring on the counter shaft behind the spacer. easy to over look but very important to keep oil inside.

[@montana2strokeracer]

Thanks Frank, yes I learned the hard way. Also remember the spacer goes in with the inside taper toward the gears

[@frankdillon6127]

@@montana2strokeracer good to know, did notice as i removed the spacer. very, very, important to pay attention to these details as engine is dissembled.

[@jamesws3]

Noticed you are using JIS bits and screwdrivers. Way to few understand the importance of this! I would not have thought to tighten with an impact driver. Great idea. I tightened mine with a big JIS screwdriver and a bit of loctite. Hoping it all holds

[@montana2strokeracer]

Thanks for watching, the only way to save all those screws is with the proper drivers. You sir have a sharp eye.

[@caingrant5959]

You know that is a lot to keep up with. I need to do that to my CL 100

[@montana2strokeracer]

I havent been in a Honda engine in a very long time. Think I would be a duck out of water.

[@stevemarquez9628]

How do you like that engine stand? Did it work pretty well out of the box or did it take any mods to work as you wanted it to?

[@montana2strokeracer]

Hi Steve, yes it seems to work very well, I messed around with some different bolts and such to mount different engines, but other than that I just drilled some holes to bolt it together rather than using it without bolts. It tended to come apart. Thanks for your comment, and for watchin.

[@tallscreen59]

Hi there, can I ask why you didn't pre - lubricate the left hand crank bearing with two stroke oil, seeing as that is the only bearing that is fed by the 2t pump and is purely reliant on that type of oil?

[@montana2strokeracer]

Hi, thanks for your comment. All bearings were pre lubricated during assembly. Thanks for watchin

[@christophthoben6689]

Hy Dale, thank you so much for your tutorial videos. I like every Single one them. Alongside your clips, I rebuilt a suzuki TC 120 motor. That one has 3 gears, all down, plus the gear reduction. Unfortunately I lost the first gear at the end, which I realized, once the engine was put together again. I assume i installed my geardrum with a 180 degree offset. Do you think, I could somehow just open the clutch side, get the clutch off, get the levers off that turn the drum and than turn the drum 180 degrees in the right position? Or would I have to split the entire case again? I am asking, because it was not easy to get all gaskets for the first split, so I try to keep it together as much as possible. I kindly would appreciate your advice. Thanks, chris von Deutschland!😉

[@montana2strokeracer]

Sorry to here you had a problem like that Chris. What I would do is pull the detent plug out, be careful there is a spring and ball in there too. Use a magnet and remove the ball. Check in the hole with a flashlight and see if when the bike is in neutral you can see the depression in the shift drum. Then move to first gear you should no longer see the depression. If the depression is not visible in neutral then I feel your shift drum is not installed correctly. If that's the case I think you will have to unfortunately split the cases again. Good luck and let me know what you find. Thanks for watchin.