1995/2016 RS125R RAM AIRBOX KIT - FITTING INSTRUCTIONS
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1: RE-POSITIONING THE IGNITION COIL
It is necessary to reposition the ignition coil as it is not possible to fit the airbox with the coil in theoriginal position. Remove the coil and grind away the cast mounting lugs on the frame to make room for the Airbox. Mount the coil to the right side front engine spar, using 2 aluminium spacers.You can either drill the spar and bolt the spacers from the engine side, or weld the spacers to thespar. The span of the coil spacers necessary is 60mm.
It is necessary to reposition the ignition coil as it is not possible to fit the airbox with the coil in theoriginal position. Remove the coil and grind away the cast mounting lugs on the frame to make room for the Airbox. Mount the coil to the right side front engine spar, using 2 aluminium spacers.You can either drill the spar and bolt the spacers from the engine side, or weld the spacers to thespar. The span of the coil spacers necessary is 60mm.
2: RAM AIRBOX
For easier fitting and removal of the airbox, cut back the seat sub frame at the front by approx5 ~ 10mm. Fit the rubber foam strips around the top of the airbox to seal it with the fuel tank.The fuel tank will then hold the airbox in position.
3: RADIATOR
To enable the airbox scoop to fit underneath the frame headstock, the radiator must be lowered.Make longer radiator brackets (Approximately 25mm) to mount the radiator lower and remove therib on the top of the radiator. It may be necessary to then cut out part of the bottom fairing.
Note: If fitting the letterbox type airbox, it will be necessary to cut out part of the left side headertank of the radiator to allow the airbox side pipe to pass the radiator
For easier fitting and removal of the airbox, cut back the seat sub frame at the front by approx5 ~ 10mm. Fit the rubber foam strips around the top of the airbox to seal it with the fuel tank.The fuel tank will then hold the airbox in position.
3: RADIATOR
To enable the airbox scoop to fit underneath the frame headstock, the radiator must be lowered.Make longer radiator brackets (Approximately 25mm) to mount the radiator lower and remove therib on the top of the radiator. It may be necessary to then cut out part of the bottom fairing.
Note: If fitting the letterbox type airbox, it will be necessary to cut out part of the left side headertank of the radiator to allow the airbox side pipe to pass the radiator
4: CARBURETTOR VALVE SLIDE
Drill a small hole (Ø 1.0mm ~ 1.5mm) in the outside face of the carburettor slide, centrally, at adistance of 16.5mm from the top of the slide.
5: FUEL TANK CAP - 1995~1999
Drill a larger hole in the fuel tank cap (If using 1995~1999 plastic fuel cap) and the rubber seal to Ø 3.00mm and remove the foam piece from between the cap and the rubber seal.
6: GEARBOX OIL BREATHER PIPE
Remove the black rubber pipe from the gearbox breather, under the carburettor.This part is not necessary.
7: THROTTLE & CLUTCH CABLE
Feed the throttle cable through the airbox at the front left side. When you remove the airboxalways remove the throttle cable completely from the carburettor top etc.The clutch cable will feed as normal, underneath the airbox.
8: INITIAL CARBURATION SETTINGS
When using ram airbox system you must use richer Main Jet and Needle Jet.If weather conditions similar to last time using without airbox, then start initially with Main Jet 2sizes richer and Needle Jet 1 size richer and on 1 clip position richer.
9: BREATHER PIPE AND BOTTLE FITTINGS
Take off original fuel overflow bottle and replace with ram airbox kit bottle supplied.Be sure to fit both pipes as shown below and make sure the pipes are not trapped or bent so thatair cannot pass. Fix the breather bottle to the side of the left side front engine spar.
*Note 1: It is essential that the fuel tank remains the same pressure as inside the ram airbox, otherwise the engine will give misfire due to fuel starvation. This is because the fuel is gravity fedto the carburettor and if the pressure is greater in the airbox than the fuel tank, then the fuel will notfeed to the carburettor and the engine will misfire or stop at high speed / rpm.
*Note 2: It is normal for some fuel to be in the breather bottle after each practice or race.This is caused by the fuel passing into the breather pipe during heavy braking. Be sure to empty breather bottle between practice or race to avoid air blockage if bottle gets full offuel as this will stop pressure in fuel tank and ram airbox from being equal.
Drill a small hole (Ø 1.0mm ~ 1.5mm) in the outside face of the carburettor slide, centrally, at adistance of 16.5mm from the top of the slide.
5: FUEL TANK CAP - 1995~1999
Drill a larger hole in the fuel tank cap (If using 1995~1999 plastic fuel cap) and the rubber seal to Ø 3.00mm and remove the foam piece from between the cap and the rubber seal.
6: GEARBOX OIL BREATHER PIPE
Remove the black rubber pipe from the gearbox breather, under the carburettor.This part is not necessary.
7: THROTTLE & CLUTCH CABLE
Feed the throttle cable through the airbox at the front left side. When you remove the airboxalways remove the throttle cable completely from the carburettor top etc.The clutch cable will feed as normal, underneath the airbox.
8: INITIAL CARBURATION SETTINGS
When using ram airbox system you must use richer Main Jet and Needle Jet.If weather conditions similar to last time using without airbox, then start initially with Main Jet 2sizes richer and Needle Jet 1 size richer and on 1 clip position richer.
9: BREATHER PIPE AND BOTTLE FITTINGS
Take off original fuel overflow bottle and replace with ram airbox kit bottle supplied.Be sure to fit both pipes as shown below and make sure the pipes are not trapped or bent so thatair cannot pass. Fix the breather bottle to the side of the left side front engine spar.
*Note 1: It is essential that the fuel tank remains the same pressure as inside the ram airbox, otherwise the engine will give misfire due to fuel starvation. This is because the fuel is gravity fedto the carburettor and if the pressure is greater in the airbox than the fuel tank, then the fuel will notfeed to the carburettor and the engine will misfire or stop at high speed / rpm.
*Note 2: It is normal for some fuel to be in the breather bottle after each practice or race.This is caused by the fuel passing into the breather pipe during heavy braking. Be sure to empty breather bottle between practice or race to avoid air blockage if bottle gets full offuel as this will stop pressure in fuel tank and ram airbox from being equal.
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Exports to EC Countries are exempt from VAT if a valid VAT registration number is supplied.
Exports to EC Countries are exempt from VAT if a valid VAT registration number is supplied.
SP125 Limited
22 Walker Wood, Baildon, Shipley, West Yorkshire, BD17 5BE, England
Telephone 01274 583231 steve@sp125racing.com Mobile 07738 626165
22 Walker Wood, Baildon, Shipley, West Yorkshire, BD17 5BE, England
Telephone 01274 583231 steve@sp125racing.com Mobile 07738 626165
SP125 Limited Disclaimer
Honda, HRC and all other parts supplied by the SP125 Limited are not guaranteed when used in competition events.
As such, it is a condition of our making all parts available that it is solely the decision of each individual, rider, team member or
team whether they choose to use any part supplied and in doing so, absolve the manufacturer and SP125 Limited of any or all
such claims, including damage to equipment and/or injury to personnel irrespective of how caused.
All parts remain property of SP125 Limited until paid for in full.
All 'special order' parts, that are ordered specially under the instruction of the customer, are non returnable and non refundable.
Honda, HRC and all other parts supplied by the SP125 Limited are not guaranteed when used in competition events.
As such, it is a condition of our making all parts available that it is solely the decision of each individual, rider, team member or
team whether they choose to use any part supplied and in doing so, absolve the manufacturer and SP125 Limited of any or all
such claims, including damage to equipment and/or injury to personnel irrespective of how caused.
All parts remain property of SP125 Limited until paid for in full.
All 'special order' parts, that are ordered specially under the instruction of the customer, are non returnable and non refundable.