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Suzuki FL125S Service Manual

Summary of FL125S

  • Page 1

    Printed in japan k7 dic120 top bottom (back: 13mm) 9 9 5 0 0 - 3 1 3 7 1 - 0 1 e.

  • Page 2: Notice

    Prepared by march, 2007 part no. 99500-31371-01e printed in japan 396 notice please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the messages highlighted by...

  • Page 3: Group Index

    Group index general information 1 periodic maintenance 2 engine 3 fuel and lubrication system 4 chassis 5 electrical system 6 servicing information 7 fl125sdw 8 foreword this manual contains an introductory description on the suzuki fl125s/sd/sdw and procedures for its inspection/service and overhau...

  • Page 4: How To Use This Manual

    How to use this manual to locate what you are looking for: 1. The text of this manual is divided into sections. 2. The section titles are listed in the group index. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily. 4. The contents are listed on ...

  • Page 5: Symbol

    Symbol listed in the table below are the symbols indicating instructions and other information necessary for servic- ing. The meaning of each symbol is also included in the table. Symbol definition symbol definition torque control required. Data beside it indicates specified torque. Apply or use bra...

  • Page 6: General Information

    1-1 general information general information contents general precautions ......................................................................... 1- 2 suzuki fl125sk7/sdk7 (’07-model)..................................................... 1- 3 serial number location .....................................

  • Page 7: General Precautions

    General information 1-2 1 6 general precautions ! # * proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle. * when 2 or more persons work together, pay attention to the safety of each other. * when it is necessary ...

  • Page 8: Serial Number Location

    1-3 general information suzuki fl125sk7/sdk7 (’07-model) serial number location the frame serial number or v.I.N. (vehicle identification number) 1 is stamped on the left side of the steer- ing head pipe. The engine serial number 2 is located on the left side of the crankcase. These numbers are requ...

  • Page 9: Fuel And Oil Recommendation

    General information 1-4 fuel and oil recommendation fuel gasoline used should be graded 91 octane (research method) or higher. Unleaded gasoline is recom- mended. Engine oil oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Use oil with ...

  • Page 10: Specifications

    1-5 general information specifications dimensions and dry mass overall length.......................................................................... 1 900 mm overall width ........................................................................... 715 mm overall height...............................

  • Page 11: Chassis

    General information 1-6 chassis front suspension..................................................................... Telescopic, coil spring, oil damped rear suspension ..................................................................... Swingarm type, coil spring, oil damped front fork stroke ......

  • Page 12: Contents

    2-1 periodic maintenance 6 contents periodic maintenance periodic maintenance schedule ...................................................... 2- 2 periodic maintenance chart .................................................... 2- 2 lubrication points ....................................................

  • Page 13: Periodic Maintenance Chart

    Periodic maintenance 2-2 2 6 periodic maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometer and time for your convenience...

  • Page 14: Lubrication Points

    2-3 periodic maintenance lubrication points proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Note: * before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or g...

  • Page 15: Air Cleaner

    Periodic maintenance 2-4 maintenance and tune-up procedures this section describes the servicing procedures for each item of the periodic maintenance requirements. Air cleaner if the air cleaner element is clogged with dust, intake resistance will be increased, with a resultant decrease in power out...

  • Page 16: Mounting Bolt

    2-5 periodic maintenance • remove the drain plug 2 from the air cleaner box to allow any water to drain out. Exhaust pipe nut and muffler mounting bolt • tighten the exhaust pipe nuts 1, muffler mounting bolts 2 and muffler connecting bolt 3. " exhaust pipe nut: 23 n·m (2.3 kgf-m) muffler mounting b...

  • Page 17: Valve Clearance

    Periodic maintenance 2-6 valve clearance removal • remove the leg shields, left and right. ( $5-6) • disconnect the spark plug cap 1 and remove the spark plug 2. • remove the valve inspection caps 3. • remove the valve timing inspection plug 4 and generator cover plug 5. • remove the camshaft sprock...

  • Page 18: Inspection and Adjustment

    2-7 periodic maintenance inspection and adjustment the valve clearance specification is same for both valves. The valve clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshaft is removed for servicing...

  • Page 19: Ex.: 0.08 – 0.13 Mm

    Periodic maintenance 2-8 • insert a thickness gauge between the valve stem end and the adjusting screw on the rocker arm. If the clearance is out of specification, bring it into the speci- fied value. % valve clearance (when cold): standard: in.: 0.03 – 0.08 mm ex.: 0.08 – 0.13 mm & 09900-20803: thi...

  • Page 20: Spark Plug

    2-9 periodic maintenance spark plug removal • disconnect the spark plug cap 1 and remove the spark plug 2. & 09930-10121: spark plug socket wrench set carbon deposit check the carbon deposit on the spark plug. If carbon is deposited, remove it with a spark plug cleaner machine or carefully using a t...

  • Page 21: Installation

    Periodic maintenance 2-10 installation # • install the spark plug to the cylinder head by finger tight, and then tighten it to the specified torque. " spark plug: 11 n·m (1.1 kgf-m) & 09930-10121: spark plug wrench set fuel line • remove the rear center leg shield. ( $5-6) • remove the frame cover. ...

  • Page 22: Engine Oil and Oil Filter

    2-11 periodic maintenance engine oil and oil filter engine oil replacement • place the motorcycle on the center stand. • place an oil pan below the engine. Drain oil by removing the engine oil drain plug 1. • remove the oil filler cap 2. • tighten the engine oil drain plug 1 to the specified torque....

  • Page 23: Oil Filter Replacement

    Periodic maintenance 2-12 oil filter replacement • drain engine oil as described in the engine oil replacement procedure. • remove the oil filter cap 1 and oil filter 2. • replace the oil filter with a new one. • install the spring 3 correctly. • apply engine oil lightly to the o-ring 4. • install t...

  • Page 24: Throttle Cable Play

    2-13 periodic maintenance throttle cable play adjust the throttle cable play a with the following procedures. • loosen the lock-nut 1 of the throttle cable. • turn the adjuster 2 in or out until the throttle cable play a at the throttle grip is between 2.0 – 4.0 mm. • tighten the lock-nut 1 while ho...

  • Page 25: Drive Chain

    Periodic maintenance 2-14 drive chain visually inspect the drive chain for the possible defects listed below. * loose pins * excessive wear * damaged rollers * improper chain adjustment * rusted links * kinked or binding links if any defects are found, the drive chain must be replaced. Note: when re...

  • Page 26: Service Limit: 259.0 Mm

    2-15 periodic maintenance • count out 21 pins (20-pitch) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the drive chain must be replaced. % drive chain 20-pitch length: service limit: 259.0 mm note: when replacing the drive chain, replace the...

  • Page 27: Brakes

    Periodic maintenance 2-16 # brakes brake fluid level • keep the motorcycle upright and place the handlebars straight. • check the brake fluid level by observing the lower limit line on the front brake fluid reservoir. • when the brake fluid level is below the lower limit line, replen- ish with brake...

  • Page 28: Front Brake Pads

    2-17 periodic maintenance front brake pads the extent of brake pad wear can be checked by observing the grooved limit line a on the brake pad. When the wear exceeds the grooved limit line, replace the pads with new ones. ( $5-16) # rear brake adjusting • by repositioning the rear brake adjusting nut...

  • Page 29: Rear Brake Light Switch

    Periodic maintenance 2-18 rear brake light switch adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. Air bleeding the brake fluid circuit air trapped in the brake fluid circuit acts like a cushion to absorb a large ...

  • Page 30: Tires

    2-19 periodic maintenance tires tire tread condition operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specific...

  • Page 31: Wheel

    Periodic maintenance 2-20 wheel make sure that the wheel runout (axial and radial) does not exceed the service limit when checked as shown. An excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings. If bearing replacement fails to red...

  • Page 32: Steering

    2-21 periodic maintenance steering the steering should be adjusted properly for smooth turning of handlebars and safe operation. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability. Check that there is no play in the front fork. Support the m...

  • Page 33: Chassis Bolts And Nuts

    Periodic maintenance 2-22 chassis bolts and nuts check that all chassis bolts and nuts are tightened to their specified torque. (refer to page 2-23 for the loca- tions of the following bolts and nuts on the motorcycle.) tighten initially at 1 000 km (5 months) and every 4 000 km (20 months) thereaft...

  • Page 34

    2-23 periodic maintenance.

  • Page 35: Compression Pressure Check

    Periodic maintenance 2-24 compression pressure check the compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should ...

  • Page 36: Oil Pressure Check

    2-25 periodic maintenance oil pressure check check the oil pressure periodically. This will give a good indication of the condition of the moving parts. Oil pressure specification if the oil pressure is lower or higher than specification, the following causes may be considered. Low oil pressure * cl...

  • Page 37: Automatic Clutch Inspection

    Periodic maintenance 2-26 automatic clutch inspection this motorcycle is equipped with an automatic clutch. The engagement of the clutch is governed by engine rpms and cen- trifugal mechanism located in the clutch. To insure proper performance and longer lifetime of the clutch assembly it is essenti...

  • Page 38: 3-1     Engine

    3-1 engine engine contents engine components removable with the engine in place.......................................................................................................... 3- 2 engine removal and installation ................................................. 3- 3 engine removal...........

  • Page 39: Engine     3-2

    Engine 3-2 3 6 engine components removable with the engine in place the parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. Engine center parts removal installation cylinder he...

  • Page 40: 3-3     Engine

    3-3 engine engine removal and installation engine removal before taking the engine out of the frame, wash the engine using a steam cleaner. The procedure of engine removal is sequentially explained in the following steps. • open the seat and disconnect the battery - lead wire. ( $6-9) • remove the f...

  • Page 41: Engine     3-4

    Engine 3-4 • disconnect the crankcase breather hose 6 and ground lead wire 7. • disconnect the gear position switch coupler 8. • disconnect the generator lead wire coupler 9 and pick-up coil lead wire coupler 0. • remove the engine guard. • remove the footrest..

  • Page 42: 3-5     Engine

    3-5 engine • remove the gearshift pedal. • remove the muffler mounting bolts a and muffler connecting bolt b. • remove the muffler c. • remove the exhaust pipe d. • remove the engine sprocket cover e. • remove the drive chain covers f..

  • Page 43: Engine     3-6

    Engine 3-6 • remove the engine sprocket g with the drive chain h. • remove the pillion footrest lower bolt i and spacers j, left and right. • remove the engine from the frame..

  • Page 44: 3-7     Engine

    3-7 engine engine installation reinstall the engine in the reverse order of engine removal. • install the engine mounting bolts and nuts as shown in the following illustration. • tighten the engine mounting nuts to the specified torque. Note: the engine mounting nuts are self-locking. Once the nuts ...

  • Page 45: Engine     3-8

    Engine 3-8 • tighten the engine sprocket bolts 1 to the specified torque. " drive chain sprocket bolt: 10 n·m (1.0 kgf-m) • install the exhaust pipe gasket 2. # • tighten the exhaust pipe nuts to the specified torque. " exhaust pipe nut: 23 n·m (2.3 kgf-m) • install a new exhaust gas sealer 3 into t...

  • Page 46: 3-9     Engine

    3-9 engine • tighten the muffler mounting bolts to the specified torque. " muffler mounting bolt: 23 n·m (2.3 kgf-m) • tighten the muffler connecting bolt to the specified torque. " muffler connecting bolt: 23 n·m (2.3 kgf-m) • tighten the footrest mounting bolts to the specified torque. " footrest ...

  • Page 47: Engine     3-10

    Engine 3-10 engine disassembly # kick starter lever • remove the kick starter lever. Pair valve • remove the pair valve assembly 1. Crankcase breather hose • remove the crankcase breather hose 2. Spark plug • remove the spark plug. Identify the position of each removed part. Organize the parts in th...

  • Page 48: 3-11     Engine

    3-11 engine starter motor • remove the starter motor. Camshaft sprocket/automatic decomp. • remove the valve timing inspection plug 1 and generator cover plug 2. • remove the camshaft sprocket cover 3 and gasket. • turn the generator rotor with a box wrench to set the piston at tdc on the compressio...

  • Page 49: Engine     3-12

    Engine 3-12 cam chain tension adjuster • remove the cam chain tension adjuster 1. • remove the gasket 2. • remove the decomp. Cam assembly 3 and camshaft sprocket 4. • remove the locating pin 5 and angle pin 6. Cylinder head • remove the cylinder head base bolts 1..

  • Page 50: 3-13     Engine

    3-13 engine • remove the cylinder head nuts 2 in diagonally. • remove the cylinder head nut gaskets 3. • remove the cylinder head assembly 4. Note: if the cylinder head does not come off easily, lightly tap it with a plastic mallet. Cylinder • remove the dowel pins 1, cylinder head gasket 2 and cam ...

  • Page 51: Engine     3-14

    Engine 3-14 oil filter • remove the oil filter cap 1. • remove the oil filter 2. • remove the o-ring 3 and spring 4. Oil sump filter • remove the oil sump filter cap 1 and oil sump filter 2. • remove the gasket 3. Generator cover • remove the generator cover 1. • remove the dowel pins 2 and gasket 3...

  • Page 52: 3-15     Engine

    3-15 engine starter idle gear • remove the starter idle gear spacer 1, starter idle gear 2 and shaft 3. Generator rotor • hold the conrod with the special tool. & 09930-44530: rotor holder • remove the generator rotor nut 1. • remove the generator rotor 2 with the special tool. & 09930-34951: rotor ...

  • Page 53: Engine     3-16

    Engine 3-16 gear position switch • remove the gear position switch 1. • remove the gear position switch pin 2 and spring 3. Clutch cover • remove the clutch cover 1. • remove the dowel pins 2 and gasket 3. Gearshift link • remove the washer 1, spring 2 and release ball outer guide 3..

  • Page 54: 3-17     Engine

    3-17 engine • remove the release ball 4, washer 5 and gearshift link arm no. 2 6. • remove the gearshift shaft assembly 7 and roller 8. First clutch • remove the clutch bearing 1 and clutch push piece 2. • hold the conrod with the special tool. & 09910-20116: conrod holder • remove the first clutch ...

  • Page 55: Engine     3-18

    Engine 3-18 • remove the first clutch housing 7 by removing the primary drive gear ring 8. • remove the primary drive gear spacer 9 and primary drive gear 0. Gearshift clutch • hold the clutch sleeve hub with the special tool. & 09930-40113: rotor holder • remove the release plate 1. • remove the cl...

  • Page 56: 3-19     Engine

    3-19 engine • remove the wave washer 4, washer 5, gearshift clutch assembly 6 and primary driven gear 7. • remove the spacer 8. Gearshift shaft • remove the gearshift cam drive plate 1. • remove the gearshift arm 2. • remove the gearshift shaft 3 and washer 4..

  • Page 57: Engine     3-20

    Engine 3-20 • remove the washer 5 and oil pump drive gear 6. Oil pump • remove the oil pump 1. • remove the dowel pins 2. Crank balancer drive/driven gear • hold the crank balancer driven gear with the special tool. & 09930-44570: crank balancer holder • remove the crank balancer driven gear nut 1. ...

  • Page 58: 3-21     Engine

    3-21 engine • remove the wave washer 3 and plate 4. • remove the spacer 5 and key 6. • remove the crank balancer drive gear 7. • remove the pin 8. Gearshift cam • remove the gearshift cam plate 1. • remove the gearshift cam stopper bolt 2, gearshift cam stopper 3, washer 4, return spring 5 and gears...

  • Page 59: Engine     3-22

    Engine 3-22 crankcase • remove the left crankcase bolts. • remove the right crankcase bolt. • separate the crankcase with the special tool. & 09920-13120: crankcase and shaft remover note: * fit the crankcase separating tool, so that the tool arms are in parallel with the side of crankcase. * the cr...

  • Page 60: 3-23     Engine

    3-23 engine • remove the kick starter shaft 3 by turning the shaft. Transmission • remove the gearshift fork shafts 1 and 2. • remove the gearshift cam 3. • remove the gearshift fork no. 1 4 and no. 2 5. • remove the washer 6. • remove the driveshaft drive gear assembly 7. • remove the countershaft ...

  • Page 61: Engine     3-24

    Engine 3-24 crankshaft • remove the crankshaft with the special tool. & 09920-13120: crankcase and shaft remover crank balancer • remove the crank balancer. Gearshift stopper pin bolt • remove the gearshift stopper pin bolt..

  • Page 62: 3-25     Engine

    3-25 engine engine components inspection and service # cylinder head disassembly • remove the cam chain tensioner 1. • remove the valve clearance inspection caps 2. • remove the camshaft retainer 3. • pull out the intake and exhaust rocker arm shafts 4 by using an 8-mm thread bolt. Identify the posi...

  • Page 63: Engine     3-26

    Engine 3-26 • remove the intake and exhaust rocker arms 5 and wave washers 6. • remove the camshaft 7. • compress the valve spring with the special tools. • remove the two cotter halves 8 from the valve stem. & 09916-14510: valve spring compressor 09916-14521: attachment 09916-84511: tweezers • remo...

  • Page 64: 3-27     Engine

    3-27 engine • remove the valve stem seal b and valve spring seat c. Rocker arm shaft o.D. Measure the diameter of rocker arm shaft. % rocker arm shaft o.D. (in. & ex.): standard: 9.981 – 9.990 mm & 09900-20205: micrometer (0 – 25 mm) rocker arm i.D. When inspecting the valve rocker arm, the inside d...

  • Page 65: Engine     3-28

    Engine 3-28 valve face wear the thickness of the valve face decreases as the face wears. Visually inspect each valve face for wear and replace any valve with an abnormally worn face. Measure the valve face thickness t. If it is out of specification, replace the valve with a new one. % valve head thi...

  • Page 66: 3-29     Engine

    3-29 engine valve stem wear if the valve stem is worn down to the limit, as measured with a micrometer, replace the valve. If the stem is within the limit, then replace the guide. After replacing valve or guide, be sure to recheck the deflection. % valve stem o.D.: standard (in.) : 4.975 – 4.990 mm ...

  • Page 67: Engine     3-30

    Engine 3-30 • cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °c with a hot plate. • apply engine oil to the valve guide hole. • drive the valve guide into the hole with the special tool. & 09916-44310: valve guide remover/installer note: instal...

  • Page 68: 3-31     Engine

    3-31 engine • if the seat width w measured exceeds the standard value or seat width is not uniform, reface the seat using the seat cutter. % valve seat width w: standard: 0.9 – 1.1 mm if the valve seat is out of specification, correct the seat by servic- ing it as follows: valve seat servicing • the...

  • Page 69: Engine     3-32

    Engine 3-32 valve stem end condition inspect the valve stem end face for pitting and wear. If pitting or wear is present, resurface the valve stem end. Make sure that the length a is not less than 2.2 mm. If this length becomes less than 2.2 mm, replace the valve. % valve stem end length: service li...

  • Page 70: 3-33     Engine

    3-33 engine camshaft bearing inspection rotate the camshaft bearing outer race by finger to check for abnormal play, noise and smooth rotation. Replace the bearings in the following procedure if there is any- thing unusual. Camshaft bearing replacement • remove the camshaft bearing with the special ...

  • Page 71: Engine     3-34

    Engine 3-34 • install the camshaft bearing to the cylinder head with the spe- cial tool. & 09913-70210: bearing installer set # cam sprocket inspection check the cam sprocket teeth for wear or damage. If any defects are found, replace the cam sprocket and cam chain as a set. Cam chain tensioner insp...

  • Page 72: 3-35     Engine

    3-35 engine • install the valve spring with the small-pitch portion a facing cylinder head. B large-pitch portion c upward d paint e cylinder head • put on the valve spring retainer 3, and using the valve lifter, press down the spring, fit the cotter halves to the stem end, and release the valve lif...

  • Page 73: Engine     3-36

    Engine 3-36 • apply engine oil to the rocker arm shafts and rocker arms. Note: face the thread part of the rocker arm shafts to the outside. • install the camshaft retainer 7. Valve clearance inspection cap • install the valve clearance inspection cap gasket 1. # • apply suzuki super grease “a” to t...

  • Page 74: 3-37     Engine

    3-37 engine cam chain tensioner • install the cam chain tensioner 1 and washer 2. • tighten the cam chain tensioner bolt 3 to the specified torque. " cam chain tensioner bolt: 10 n·m (1.0 kgf-m) cylinder distortion check the gasketed surface of the cylinder for distortion with a straightedge and thi...

  • Page 75: Engine     3-38

    Engine 3-38 piston piston diameter using a micrometer, measure the piston outside diameter at the place 10 mm from the piston skirt end as shown. If the measure- ment is less than the limit, replace the piston. % piston diameter: service limit: 53.335 mm & 09900-20203: micrometer (50 – 75 mm) piston...

  • Page 76: 3-39     Engine

    3-39 engine piston ring-to-groove clearance • measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • if any of the clearances exceeds the limit, replace both the piston and piston rings. % piston ring-to-groove clearance: service limit (1st) : 0.180 mm (2nd): 0.150 ...

  • Page 77: Engine     3-40

    Engine 3-40 piston pin and pin bore • measure the piston pin bore diameter using the small bore gauge. • if the measurement is out of specification, replace the piston. % piston pin bore i.D.: service limit: 14.030 mm & 09900-20602: dial gauge (1/1000 mm) 09900-22401: small bore gauge (10 – 18 mm) •...

  • Page 78: 3-41     Engine

    3-41 engine conrod and crankshaft conrod small end i.D. Using a caliper gauge, measure the conrod small end inside diameter. % conrod small end i.D.: service limit: 14.040 mm & 09900-20605: dial calipers if the conrod small end bore inside diameter exceeds the limit, replace the conrod. 1 primary dr...

  • Page 79: Engine     3-42

    Engine 3-42 conrod deflection and conrod big end side clearance wear on the big end of the conrod can be estimated by checking the movement of the small end of the conrod. This method can also check the extent of wear on the parts of the conrod’s big end. % conrod deflection: service limit: 3.0 mm &...

  • Page 80: 3-43     Engine

    3-43 engine crank balancer crank balancer inspection inspect the crank balancer for wear or damage. If any defects are found, replace the crank balancer with a new one. Balancer drive/driven gear inspection inspect the balancer driven gear 1 and drive gear 2 for wear or damage. If any defects are fo...

  • Page 81: Engine     3-44

    Engine 3-44 transmission disassembly • disassemble the transmission gears as shown in the illustration. Note: when removing the 2nd drive gear, use a gear puller and a proper attachment. Reassembly assemble the countershaft and driveshaft in the reverse order of disassembly. Pay attention to the fol...

  • Page 82: 3-45     Engine

    3-45 engine • when installing a new snap ring, pay attention to the direction of the snap ring. Fit the snap ring to the side where the thrust is as shown in the illustration. The rounded side should be against the gear surface. Thrust sharp edge.

  • Page 83: Engine     3-46

    Engine 3-46 gearshift cam inspect the gearshift cam wear or damage. If any defects are found, replace the gearshift cam with a new one. Gearshift forks gearshift fork-to-groove clearance measure the gearshift fork clearance in the groove of its respec- tive gear using the thickness gauge. The cleara...

  • Page 84: 3-47     Engine

    3-47 engine primary driven gear if the internal damper wears, play is generated between gear and housing, causing abnormal noise. If the play is extreme, replace the primary driven gear assembly with a new one. 1 primary driven gear 2 damper 3 clutch housing gearshift clutch clutch drive plates meas...

  • Page 85: Engine     3-48

    Engine 3-48 first clutch clutch shoes inspection inspect the clutch shoes for chips, cracks, uneven wear and burning. Check the thickness of the shoes using vernier calipers. If any damages are found or if the thickness is less than the ser- vice limit, replace the clutch shoe assembly. & 09900-2010...

  • Page 86: 3-49     Engine

    3-49 engine starter clutch inspection of starter clutch operation turn the starter driven gear by hand in the direction of arrow as shown and check that rotation is smooth. Also check that the gear is locked when attempted to turn in the other direction. If a large resistance is felt or noise occurs...

  • Page 87: Engine     3-50

    Engine 3-50 reassembly • reassemble the starter clutch in the reverse order of disas- sembly. Pay attention to the following points: • apply a small quantity of thread lock super to the starter clutch bolts. • holding the generator rotor with the special tool and tighten the starter clutch inside he...

  • Page 88: 3-51     Engine

    3-51 engine • when installing the generator coil set screws 2 and pick-up coil set screws 3, tighten them to the specified torque. " generator coil set screw: 4.7 n·m (0.47 kgf-m) pick-up coil set screw: 8.3 n·m (0.83 kgf-m) note: be sure to install the gromment 4 to the generator cover. Clutch cove...

  • Page 89: Engine     3-52

    Engine 3-52 • install the snap ring 2. # • install the oil seal 3 with the special tool. & 09913-70210: bearing installer set # • apply suzuki super grease “a” to the lip of the oil seal. * 99000-25010: suzuki super grease “a” • install the o-ring 4 to the release arm 5. # • install the release arm ...

  • Page 90: 3-53     Engine

    3-53 engine • remove the kick starter shaft 3 by turning the shaft. Crankcase bearing inspection • inspect the play of the crankcase bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. • replace the bearing in the followi...

  • Page 91: Engine     3-54

    Engine 3-54 left crankcase bearing removal • remove the left crankcase bearings with the special tools. & 09913-70210: bearing installer set 09921-20240: bearing remover set bearing 1: (52 attachment bearing 2: (10 attachment bearing 3: (20 attachment bearing 4: (10 attachment left crankcase oil sea...

  • Page 92: 3-55     Engine

    3-55 engine right crankcase bearing installation • install the right crankcase bearings with the special tool. & 09913-70210: bearing installer set bearing 1: (47 attachment bearing 2: (62 attachment bearing 3: (30 attachment bearing 4: (40 attachment bearing 5: (15 attachment bearing 6: (30 attachm...

  • Page 93: Engine     3-56

    Engine 3-56 left crankcase oil seal installation • install the left crankcase oil seal 1 to the left crankcase with the special tool. • apply suzuki super grease “a” to the oil seal lip. * 99000-25010: suzuki super grease “a” & 09913-70210: bearing installer set # • install the oil seal retainer 2 a...

  • Page 94: 3-57     Engine

    3-57 engine crankshaft shim selection • degrease the right crankshaft web, shim and inner race of the right crankshaft bearing. • place the removed shim 1 on the right crankshaft. • put the plasti-gauge (special tool) 2 cut out about 10 mm on the shim as shown. & 09900-22302: plasti-gauge • install ...

  • Page 95: Engine     3-58

    Engine 3-58 engine reassembly reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. Note: apply engine oil to each running and sliding part before reas- sembling. Gearshift stopper pin bolt • install the ge...

  • Page 96: 3-59     Engine

    3-59 engine kick • align the punched mark a of the kick starter drive gear with the groove b of the kick starter shaft. 1 kick starter lever 3 kick starter shaft 5 kick starter return spring 2 kick starter drive gear 4 kick starter.

  • Page 97: Engine     3-60

    Engine 3-60 • install the kick starter return spring 1, kick starter shaft 2 and kick starter spring hook end 3 onto the clutch cover boss 3. Transmission • install the countershaft assembly 1 and driveshaft assembly 2. • install the gearshift forks. 3: gearshift fork no. 1 4: gearshift fork no. 2 •...

  • Page 98: 3-61     Engine

    3-61 engine crankcase • thoroughly remove the sealant material and oil stains on the mating surface of the right and left crankcases. • install the dowel pins 1 into the left half of the crankcase. • apply engine oil to the conrod big end and transmission gears. • apply suzuki bond “1207b” to the ma...

  • Page 99: Engine     3-62

    Engine 3-62 note: * after the crankcase bolts have been tightened, make sure that the crankshaft, countershaft and driveshaft rotate smoothly. * if these shafts do not rotate smoothly, try to free it by tapping with a plastic mallet. Gearshift cam • install the return spring 1, washer 2, gearshift c...

  • Page 100: 3-63     Engine

    3-63 engine • install the crank balancer driven gear 6. Note: align the matching marks a as shown. • holding the crank balancer driven gear with the special tool, tighten the crank balancer driven gear nut 7 to the specified torque. & 09930-44570: crank balancer holder " crank balancer driven gear n...

  • Page 101: Engine     3-64

    Engine 3-64 gearshift shaft • install the gearshift shaft 1 and washer 2. • install the gearshift arm 3. • install the gearshift cam drive plate 4..

  • Page 102: 3-65     Engine

    3-65 engine clutch 1 push piece 0 first clutch shoe 2 release plate a primary drive gear spacer 3 clutch sleeve hub b first clutch housing 4 clutch drive plate c primary drive gear " 5 clutch driven plate a release plate bolt item n·m kgf-m 6 clutch pressure disc b clutch sleeve hub nut a 10 1.0 7 s...

  • Page 103: Engine     3-66

    Engine 3-66 gearshift clutch • install the spacer 1. Note: apply engine oil to the both surfaces of the spacer. • install the primary driven gear 2. Note: when engaging the primary drive and driven gears, rotate the primary driven gear counterclockwise. • install the clutch pressure disc 3 to the cl...

  • Page 104: 3-67     Engine

    3-67 engine • install the clutch springs 9. • install the release plate 0 and release plate bolts a. • hold the clutch sleeve hub 5 with the special tool and tighten the release plate bolts a to the specified torque. & 09930-40113: rotor holder " release plate bolt: 10 n·m (1.0 kgf-m) • install the ...

  • Page 105: Engine     3-68

    Engine 3-68 • install the first clutch shoe 3, washer 4 and wave washer 5. • hold the conrod with the special tool. & 09910-20116: conrod holder • install the first clutch nut 6 and tighten it to the specified torque. " first clutch nut: 50 n·m (5.0 kgf-m).

  • Page 106: 3-69     Engine

    3-69 engine gear shift 1 gearshift link arm no. 2 8 gear position switch 2 gearshift cam drive plate 9 gearshift stopper 3 gearshift arm 0 gearshift fork no. 1 " 4 gearshift link arm no. 1 a gearshift fork no. 2 item n·m kgf-m 5 gearshift shaft a gearshift stopper pin bolt a 23 2.3 6 gearshift cam p...

  • Page 107: Engine     3-70

    Engine 3-70 gearshift link • install the gearshift shaft assembly 1 and roller 2. • install the spring 3, gearshift link arm no. 2 4, washer 5 and release ball 6. Note: face the lug a of the release ball 6 to the outside. • install the release ball outer guide 7, spring 8 and washer 9. Clutch cover ...

  • Page 108: 3-71     Engine

    3-71 engine clutch adjustment • loosen the clutch adjustment lock-nut 1. • first, turn the adjusting bolt clockwise by one turn and turn it counterclockwise until resistance is felt, then turn it clockwise by 1/8 turn. • tighten the clutch adjustment lock-nut to the specified torque. " clutch adjust...

  • Page 109: Engine     3-72

    Engine 3-72 • install the starter driven gear 2 and key 3. • degrease the tapered portion of the generator rotor and also the crankshaft. Use nonflammable cleaning solvent to wipe off oily or greasy matter to make these surface completely dry. • install the generator rotor 4. • hold the generator ro...

  • Page 110: 3-73     Engine

    3-73 engine oil sump filter • clean the oil sump filter with compressed air. • apply engine oil lightly to the gasket 1. • install the gasket 1 to the oil sump filter cap 2. • install the oil sump filter 3. # # • install the oil sump filter cap 3. • tighten the oil sump filter cap bolts to the speci...

  • Page 111: Engine     3-74

    Engine 3-74 oil filter • install the oil filter 1. • apply engine oil lightly to the gasket 2 of oil filter before installation. # • apply engine oil lightly to the o-ring 2. • install the o-ring 2 and spring 3 to the oil filter cap 4. # tighten the oil filter cap bolts to the specified torque. " oi...

  • Page 112: 3-75     Engine

    3-75 engine • the 1st and 2nd piston rings should be installed with their marks facing up. • position the gaps of the three rings as shown. Note: before inserting piston into the cylinder, check that the gaps are so located. Piston • apply a small quantity of molybdenum oil solution onto the piston ...

  • Page 113: Engine     3-76

    Engine 3-76 cylinder • thoroughly wipe off oil from the fitting surface of the crank- case. • apply suzuki bond “1207b” to the crankcase as shown. , 99104-31140: suzuki bond “1207b” # • apply molybdenum oil solution to the sliding surface of the piston and piston rings. ) molybdenum oil solution • i...

  • Page 114: 3-77     Engine

    3-77 engine • install the cylinder head assembly 3. • install the cylinder head nut gaskets 4. # • tighten the cylinder head nut diagonally to the specified torque. " cylinder head nut: 25 n·m (2.5 kgf-m) • tighten the cylinder head base bolts to the specified torque. " cylinder head base bolt: 10 n...

  • Page 115: Engine     3-78

    Engine 3-78 • install the camshaft sprocket 3. • engage the cam chain onto the camshaft sprocket with the mark c at just top position. • align the mark c of the cam sprocket with the concave line d of the cylinder head. • install the spring 4, plastic washer 5 and decomp. Cam 6 as shown. • hook the ...

  • Page 116: 3-79     Engine

    3-79 engine • install the gasket 1 and cam chain tension adjuster 2. # • holding the push rod with the - screwdriver, install the cam chain tension adjuster 2 to the cylinder. • tighten the cam chain tension adjuster mounting bolts to the specified torque. " cam chain tension adjuster mounting bolt:...

  • Page 117: Engine     3-80

    Engine 3-80 • tighten the camshaft sprocket cover bolts to the specified torque. " camshaft sprocket cover bolt: 10 n·m (1.0 kgf-m) • install the spark plug. ( $2-9) valve timing inspection plug/generator cover cap • apply suzuki super grease “a” to the generator cover plug o-ring 1. • tighten the g...

  • Page 118: 3-81     Engine

    3-81 engine pair valve • install the pair valve assembly 1 and tighten its mounting bolts to the specified torque. " pair valve mounting bolt: 10 n·m (1.0 kgf-m) • install the pair pipe nuts and tighten them to the specified torque. " pair pipe nut: 10 n·m (1.0 kgf-m) kick starter lever • apply suzu...

  • Page 119: Engine     3-82

    Engine 3-82 pair (air supply) system pair hoses inspection • remove the leg shields, left and right. ( $5-6) • check the pair hoses for wear or damage. • check the pair hoses are securely connected. Disassembly • remove the pair valve. ( $3-10) • remove the pair valve cover 1. • remove the pair reed...

  • Page 120: 3-83     Engine

    3-83 engine pair valve inspection • remove the pair valve. ( $3-10) • check that air flows through the pair valve air inlet port to the air outlet port. If air does not flow out, replace the pair valve with a new one. • connect the vacuum pump gauge to the vacuum port of the valve as shown in the ph...

  • Page 121: Contents

    2 4 6 fuel and lubrication system 4-1 contents fuel and lubrication system fuel tank and fuel tap ........................................................................ 4- 2 removal ............................................................................................. 4- 2 inspection .........

  • Page 122: Fuel Tank and Fuel Tap

    4-2 fuel and lubrication system fuel tank and fuel tap removal • remove the front frame cover. ( $5-5) • remove the frame covers, left and right. ( $5-7) • drain the gasoline. • disconnect the fuel hose 1. ! • remove the rubber cover 2. • disconnect the fuel level gauge coupler 3. • remove the fuel ...

  • Page 123: Inspection

    Fuel and lubrication system 4-3 • remove the fuel hose 7 and fuel tap vacuum hose 8. • remove the fuel tap 9. Inspection fuel filter if the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel fil- ter with compressed air. Also c...

  • Page 124: Fuel Level Gauge

    4-4 fuel and lubrication system fuel level gauge removal • open the seat. ( $5-5) • disconnect the fuel level gauge coupler 1. • remove the fuel gauge retainer 2. ! • remove the fuel level gauge 3. • remove the rubber cushion 4. Gasoline is highly flammable and explosive. Keep heat, spark and flame ...

  • Page 125: Inspection

    Fuel and lubrication system 4-5 inspection measure the resistance between the terminals when the float is at the position listed below. & 09900-25008: multi-circuit tester if the resistance is incorrect, replace the fuel level gauge assem- bly with a new one. Float position resistance full 37.9 mm 4...

  • Page 126: Installation

    4-6 fuel and lubrication system installation • install the rubber cushion 1. • install the fuel level gauge 2. # • install the fuel gauge retainer 3. • install the fuel level gauge coupler 4. The removed rubber cushion must be replaced with a new one..

  • Page 127: Carburetor

    Fuel and lubrication system 4-7 carburetor construction 1 top cap 0 starter plunger i main jet 2 gasket a coasting valve cover j pilot jet 3 spring b coasting valve k needle valve 4 jet needle locker c spring l pin 5 jet needle d pilot air screw m float 6 throttle valve e throttle valve adjuster n g...

  • Page 128: Specifications

    4-8 fuel and lubrication system specifications removal • remove the leg shields, left and right. ( $5-6) • disconnect the fuel hose 1 and air vent hose 2. ! • remove the pair valve vacuum hose 3 and fuel tap vacuum hose 4. • remove the intake pipe mounting nuts 5. Note: first, remove the intake pipe...

  • Page 129: Disassembly

    Fuel and lubrication system 4-9 • loosen the clamp screw 6. • disconnect the starter cable 7. • remove the throttle cable assembly 8. • remove the carburetor 9 with intake pipe. Disassembly • remove the intake pipe 1 and insulator 2. • remove the o-rings 3 and 4. • disconnect the breather hose 5. • ...

  • Page 130

    4-10 fuel and lubrication system • remove the float assembly 8 by removing the pin 9. • remove the following parts. 0 main jet a needle jet holder b needle jet c pilot jet # • remove the following parts. D pilot air screw h throttle valve adjuster e spring i spring f washer j washer g o-ring k o-rin...

  • Page 131

    Fuel and lubrication system 4-11 • remove the following parts. L coasting valve cover m spring n coasting valve • remove the throttle cable a. • disconnect the throttle position switch lead wire coupler b. • remove the top cap l, gasket m, spring n and throttle valve o. • remove the following parts ...

  • Page 132

    4-12 fuel and lubrication system • remove the throttle position switch t from the top cap l..

  • Page 133: Carburetor Cleaning

    Fuel and lubrication system 4-13 carburetor cleaning ! • clean all jets with a spray-type carburetor cleaner and dry them using compressed air. • clean all circuits of the carburetor thoroughly – not just the perceived problem area. Clean the circuits in the carburetor body with a spray-type cleaner...

  • Page 134: Needle Valve Inspection

    4-14 fuel and lubrication system needle valve inspection if foreign matter is caught between the valve seat and the nee- dle valve, the gasoline will continue flowing and cause it to over- flow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur. Co...

  • Page 135: To Prevent Fuel Leakage.

    Fuel and lubrication system 4-15 • install the pilot air screw 1 and throttle valve adjuster 2. Note: turn in the pilot air screw 1 until it lightly seats, then back it out the counted number of turns. ( $ 4-8) # • install the gasket 3 to the top cap 4. # • install the gasket 5 to the float chamber ...

  • Page 136: To Prevent Fuel Leakage.

    4-16 fuel and lubrication system • install the o-rings 0 to the intake pipe. # • install the o-ring a to the carburetor body. # • when installing the carburetor, align the hole c of the jet nee- dle locker with the part d of the throttle position rod. • when installing the carburetor, align the hole...

  • Page 137: Lubrication System

    Fuel and lubrication system 4-17 lubrication system oil pressure $2-25 oil filter $2-11 oil sump filter $3-73 oil pump $3-43 engine lubrication system chart oil orifice oil filter oil jet cylinder head cylinder wall driveshaft gear counter shaft gear conrod big end bearing primary drive gear first c...

  • Page 138: Chassis

    Chassis contents 5-1 chassis exterior parts ...................................................................................... 5- 3 fastener removal and installation..................................... 5- 3 removal ...................................................................................

  • Page 139: Chassis     5-2

    Chassis 5-2 chassis contents 5 rear wheel.............................................................................................. 5-42 construction .................................................................................. 5-42 removal .....................................................

  • Page 140: 5-3      Chassis

    5-3 chassis exterior parts fastener removal and installation removal • turn the head of fastener center screw 1 counterclockwise. • pull out the fastener. Installation • pull out the fastener center screw toward the head so that the pawls 2 close. • insert the fastener into the installation hole. No...

  • Page 141: Chassis     5-4

    Chassis 5-4 removal handlebar covers • remove the rear view mirrors 1. • remove the front handlebar cover 2. • disconnect the headlight coupler 3. • disconnect the speedometer cable 4 and speedometer indi- cator lights couplers 5 and 6. • remove the rear handlebar cover 7. • disconnect the following...

  • Page 142: 5-5      Chassis

    5-5 chassis front center leg shield • remove the front center leg shield. Front frame cover • open the seat 1 using the ignition key, to push in and turn the ignition key clockwise. • remove the front frame cover 2. Luggage box • open the seat. ( $above) • remove the battery. ( $6-37) • remove the f...

  • Page 143: Chassis     5-6

    Chassis 5-6 rear center leg shield • remove the front center leg shield. ( $5-5) • remove the front frame cover. ( $5-5) • remove the rear center leg shield. Leg shield • remove the rear center leg shield. ( $above) • remove the leg shield. Frame head cover • remove the leg shields, left and right. ...

  • Page 144: 5-7      Chassis

    5-7 chassis pillion rider handle • remove the pillion rider handle 1. Frame cover • remove the rear center leg shield. ( $5-6) • remove the pillion rider handle. ( $above) • remove the frame cover. .: hooked part.

  • Page 145: Chassis     5-8

    Chassis 5-8 • disconnect the rear turn signal light coupler 1 and rear com- bination light coupler 2..

  • Page 146: 5-9      Chassis

    5-9 chassis front wheel construction " removal • remove the front brake caliper. ( $5-16) • disconnect the speedometer cable 1. • remove the front axle nut 2. • raise the front wheel off the ground with a jack or wooden block. • remove the front axle shaft and front wheel. # • remove the brake disc ...

  • Page 147: Chassis     5-10

    Chassis 5-10 inspection and disassembly wheel bearing inspect the wheel bearing play by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the following procedure if there is any- thing unusual. Remove the whe...

  • Page 148: 5-11      Chassis

    5-11 chassis speedometer gearbox turn the speedometer gear and check to see that the gear turns smoothly together with the speedometer pinion. If any defects are found, replace the speedometer gearbox with a new one. Wheel rim ................................................................ $2-19 sp...

  • Page 149: Chassis     5-12

    Chassis 5-12 reassembly and installation reassemble and install the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: wheel bearing • apply suzuki super grease “a” to the wheel bearings. * 99000-25010: suzuki super grease “a” • install the front whee...

  • Page 150: 5-13      Chassis

    5-13 chassis speedometer gearbox • apply suzuki super grease “a” to the speedometer gearbox. * 99000-25010: suzuki super grease “a” • align the lugs a on the speedometer gearbox with the recesses b on the front wheel. • align the speedometer gearbox case 1 with the concave por- tion of the front for...

  • Page 151: Chassis     5-14

    Chassis 5-14 • tighten the front axle nut 4 to the specified torque. " front axle nut: 42 n·m (4.2 kgf-m) • connect the speedometer cable 5. • install the brake caliper 6. ( $5-17) # # when installing the front wheel, position the brake disc between the brake pads. Be careful not to dam- age the bra...

  • Page 152: 5-15      Chassis

    5-15 chassis front brake construction 1 reservoir cap a dust seal 2 diaphragm b piston seal 3 master cylinder c piston 4 piston set d brake caliper " 5 dust boot e pad spring item n·m kgf-m 6 brake hose a master cylinder mounting bolt a 10 1.0 7 caliper holder b brake hose union bolt b 22.5 2.25 8 c...

  • Page 153: Chassis     5-16

    Chassis 5-16 ! # brake fluid replacement • remove the front handlebar cover. ( $5-4) • place the motorcycle on a level surface and keep the handle- bars straight. • remove the master cylinder reservoir cap and diaphragm. • suck up the old brake fluid as much as possible. • fill the reservoir with ne...

  • Page 154: 5-17      Chassis

    5-17 chassis brake pad replacement • loosen the brake pad mounting pin bolts 1. • remove the brake caliper 2 by removing the brake caliper mounting bolts. • remove the brake pad mounting pin bolts 1 and brake pads 3 . # • install the new brake pads. • temporarily tighten the brake pad mounting pin b...

  • Page 155: Chassis     5-18

    Chassis 5-18 caliper disassembly • remove the brake pads. ( $5-17) • remove the caliper holder 1. • remove the pad spring 2. • remove the rubber parts 3. • place a rag over the pistons to prevent them from popping out and then force out the pistons using compressed air. # • remove the dust seals 4 a...

  • Page 156: 5-19      Chassis

    5-19 chassis caliper inspection caliper and piston inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages. If any abnormal condition are found, replace the caliper or cali- per piston with a new one. Pad spring inspect the brake pad spring for damage or excessiv...

  • Page 157: Chassis     5-20

    Chassis 5-20 caliper reassembly reassemble the brake caliper in the reverse order of disassem- bly. Pay attention to the following points: clean the caliper bores and pistons with the specified brake fluid. Thoroughly wash the dust seal grooves and piston seal grooves. # ' specification and classifi...

  • Page 158: 5-21      Chassis

    5-21 chassis • install the pad spring 1. • install the brake pads 2. • temporarily tighten the brake pad mounting pin bolts 3. Caliper installation install the caliper in the reverse order of removal. Pay attention to the following points: • tighten the brake caliper mounting bolts 1 to the specifie...

  • Page 159: Chassis     5-22

    Chassis 5-22 brake disc inspection check the brake disc for cracks or damage. Measure the thickness with the micrometer. Replace the disc if the thickness is less than the service limit, or if damage is found. % brake disc thickness: service limit: 3.5 mm & 09900-20205: micrometer (0 – 25 mm) • meas...

  • Page 160: 5-23      Chassis

    5-23 chassis • remove the brake lever 5 and front brake switch 6. • remove the reservoir cap 7, diaphragm plate 8 and dia- phragm 9. • pull out the dust seal boot 0 and remove the snap ring a. • remove the piston b and spring c..

  • Page 161: Chassis     5-24

    Chassis 5-24 master cylinder inspection master cylinder inspect the master cylinder bore for any scratches or damage. If any defects are found, replace the master cylinder with a new one. Piston and cup set inspect the piston 1 surface for any scratches or other damage. Inspect the primary cup 2, se...

  • Page 162: 5-25      Chassis

    5-25 chassis master cylinder reassembly and installation reassemble and install the master cylinder in the reverse order of removal and disassembly. Pay attention to the following points: # ' specification and classification: dot 4 • install the piston/cup set as shown. • when installing the front b...

  • Page 163: Chassis     5-26

    Chassis 5-26 • tighten the brake lever nut 4 and front brake switch screw 5. " brake lever nut: 6 n·m (0.6 kgf-m) front brake switch screw: 1 n·m (0.1 kgf-m) • when installing the master cylinder onto the handlebars, align the master cylinder holder’s mating surface c with the punched mark d on the ...

  • Page 164: 5-27      Chassis

    5-27 chassis front fork construction " removal and disassembly • remove the front wheel. ( $5-9) • remove the front brake hose guide 1 and front brake caliper. • remove the front fender no. 1 2. • remove the front fender no. 2 3. .: hooked parts 1 stopper ring 2 front fork cap 3 o-ring 4 front fork ...

  • Page 165: Chassis     5-28

    Chassis 5-28 • remove the front fork clamp bolts 4. Note: hold the front fork by hand to prevent sliding out of the steering stem. • remove the front fork 5. • remove the front fork cap 6, stopper ring 7 and front fork spring 8. • invert the front fork and stroke it several times to drain out the fo...

  • Page 166: 5-29      Chassis

    5-29 chassis • pull out the inner tube b from the outer tube. • remove the oil seal stopper ring c. • remove the oil seal d with the special tool. & 09913-50121: oil seal remover inspection inner and outer tube inspect the inner tube sliding surface and outer tube sliding sur- face for any scuffing ...

  • Page 167: Chassis     5-30

    Chassis 5-30 front fork spring measure the front fork spring free length. If the front fork spring free length is shorter than the service limit, replace the front fork spring with a new one. % front fork spring free length: service limit: 290 mm damper rod ring inspect the damper rod ring for wear ...

  • Page 168: 5-31      Chassis

    5-31 chassis oil seal • install the inner tube 1 into the outer tube 2. • apply fork oil to the lip of oil seal 3 lightly. 0 99000-99001-ss8: suzuki fork oil ss-08 or equivalent fork oil • insert the oil seal 3 to the inner tube. # • fit the oil seal 3 into the outer tube with the special tool. & 09...

  • Page 169: Chassis     5-32

    Chassis 5-32 damper rod • install the gasket 1 and damper rod bolt 2. • tighten the damper rod bolt 2 to the specified torque. " damper rod bolt: 20 n·m (2.0 kgf-m) # fork oil • pour specified fork oil into the outer tube. % front fork oil capacity (each leg): 51 ml 0 99000-99001-ss8: suzuki fork oi...

  • Page 170: 5-33      Chassis

    5-33 chassis installation • install the front fork to the steering stem. • tighten the front fork clamp bolts 1 to the specified torque. " front fork clamp bolt: 32.5 n·m (3.25 kgf-m) • install the front fender no. 2 2 and front fender no. 1 3. • install the front brake holder guide 4. • install the...

  • Page 171: Chassis     5-34

    Chassis 5-34 handlebars construction " removal • remove the handlebar covers. ( $5-4) • remove the front center leg shield. ( $5-5) • remove the frame head cover. ( $5-6) handlebar left side parts • remove the handlebar balancer 1. • remove the left handlebar grip 2. • remove the starter lever 3. Ha...

  • Page 172: 5-35      Chassis

    5-35 chassis • disconnect the front brake lever switch lead wires 4. • remove the brake master cylinder 5. ( $5-22) • remove the handlebars by removing the handlebar clamp nut 6. Inspection inspect the handlebars for distortion or damage. If any defects are found, replace the handlebars with a new o...

  • Page 173: Chassis     5-36

    Chassis 5-36 handlebar left side parts • apply handle grip bond onto the handlebars before installing the handlebar grip. • install the starter lever 1. After installing the steering, the following adjustments are required before driving. • cable routing. ( $7-16) • check the throttle operation and ...

  • Page 174: 5-37      Chassis

    5-37 chassis steering construction " removal • remove the handlebars. ( $5-34) • support the motorcycle with a jack or wood block. # • remove the front wheel. ( $5-9) • remove the front fender and front forks. ( $5-27) • remove the steering stem lock-nut 1 with the special tool. & 09910-60611: unive...

  • Page 175: Chassis     5-38

    Chassis 5-38 • remove the washer 2. • remove the steering stem nut 3 with the special tool. Note: hold the steering stem by hand to prevent it from falling. & 99000-60611: universal clamp wrench • remove the dust cover 4. • remove the upper bearing inner race 5. • remove the upper and lower steel ba...

  • Page 176: 5-39      Chassis

    5-39 chassis • remove the lower bearing inner race with a chisel. # • drive out the upper and lower bearing outer races. # the removed lower bearing inner race must be replaced with a new one. The removed bearing outer races must be replaced with new ones..

  • Page 177: Chassis     5-40

    Chassis 5-40 reassembly reassemble and install the steering in the reverse order of removal and disassembly. Pay attention to the following points: • press fit the upper and lower bearing outer races with the special tool. & 09941-34513: steering race installer • press fit the lower bearing inner ra...

  • Page 178: 5-41      Chassis

    5-41 chassis • turn the steering stem about five or six times to the left and right so that the steel balls will be seated properly. • loosen the stem nut by 1/4 – 1/2 turn. Note: this adjustment will vary from motorcycle to motorcycle. Note: when installing the washer, align the stopper lug of wash...

  • Page 179: Chassis     5-42

    Chassis 5-42 rear wheel construction " 1 rear axle shaft 2 lock washer 3 rear sprocket 4 sprocket drum spacer 5 oil seal 6 sprocket drum bearing 7 sprocket drum 8 sprocket drum retainer 9 rear sprocket damper 0 rear wheel outer bearing (left) a rear wheel inner bearing (left) b spoke nipple c rear w...

  • Page 180: 5-43      Chassis

    5-43 chassis removal • support the motorcycle with the center stand. • remove the drive chain covers 1 by removing the bolts and screw. • remove the rear brake adjuster nut 2. • remove the cotter pin and torque link nut 3. • loosen the rear axle nut 4. • loosen the drive chain adjusters 5, left and ...

  • Page 181: Chassis     5-44

    Chassis 5-44 disassembly and inspection rear axle shaft ................................................... $5-10 rear wheel ............................................................ $2-19 spoke nipples........................................................ $2-19 tire ..............................

  • Page 182: 5-45      Chassis

    5-45 chassis • remove the rear wheel bearings left 4 and right 5 with the special tool. & 09941-50111: wheel bearing remover # rear sprocket drum • remove the sprocket drum spacer 1 and sprocket drum retainer 2. • remove the rear sprocket 3. • when removing the rear sprocket nuts a, flatten the lock...

  • Page 183: Chassis     5-46

    Chassis 5-46 rear sprocket drum • inspect the play of the rear sprocket drum bearing by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. • replace the bearing in the following procedure if there is any- thing unusual. • remove the...

  • Page 184: 5-47      Chassis

    5-47 chassis reassembly and installation reassemble and install the rear wheel and sprocket drum in the reverse order of removal and disassembly. Pay attention to the following points: rear wheel bearings • apply suzuki super grease “a” to the rear wheel bear- ings before installing. * 99000-25010: ...

  • Page 185: Chassis     5-48

    Chassis 5-48 sprocket drum • apply suzuki super grease “a” to the sprocket drum bearing before installing. * 99000-25010: suzuki super grease “a” • install the sprocket drum bearing 1 with the special tool. & 09913-70210: bearing installer set note: the stamped mark side of the gearshift cam bearing...

  • Page 186: 5-49      Chassis

    5-49 chassis • adjust the drive chain slack after installing the rear wheel. ( $2-12) • tighten the rear axle nut 3 and torque link nut 4 to the spec- ified torque. " rear axle nut: 42 n·m (4.2 kgf-m) torque link nut: 13 n·m (1.3 kgf-m) • install the cotter pin 5. # • tighten both chain adjusters se...

  • Page 187: Chassis     5-50

    Chassis 5-50 rear brake " removal and disassembly • remove the rear wheel. ( $5-43) • remove the rear brake panel 1. • remove the brake shoes 2 from the rear brake panel 1. 1 brake shoe 2 rear brake panel 3 brake camshaft 4 dust seal 5 brake lining wear indi- cator plate 6 rear axle spacer 7 brake c...

  • Page 188: 5-51      Chassis

    5-51 chassis • remove the brake cam lever nut 3 and bolt. • remove the brake cam lever 4. • remove the brake lining wear indicator plate 5. • remove the brake camshaft 6 and dust seal 7. Inspection brake drum inspect the brake drum and measure the brake drum i.D. To determine the extent of wear. If ...

  • Page 189: Chassis     5-52

    Chassis 5-52 brake shoe inspect the brake shoes for wear or damage. If any defects are found, replace the brake shoes as a set. # brake camshaft inspect the brake camshaft for wear or damage. If any defects are found, replace the brake camshaft with a new one. Rear brake panel inspect the rear brake...

  • Page 190: 5-53      Chassis

    5-53 chassis • install the dust seal 1. # • install the camshaft 2. • when installing the brake lining wear indicator plate 3, align the tongue 4 on the brake lining wear indicator plate 3 with the cutaway 5 on the brake camshaft. • when installing the brake cam lever 6, align the punched mark 7 on ...

  • Page 191: Chassis     5-54

    Chassis 5-54 • install the brake shoes 0. • install the rear wheel. ( $5-47) rear brake pedal • remove the muffler. ( $3-5) • remove the rear brake adjuster nut 1. • remove the rear brake switch spring 2. • remove the rear brake pedal return spring 3..

  • Page 192: 5-55      Chassis

    5-55 chassis • remove the pillion footrest bracket lower bolt 4, spacer 5, swingarm pivot nut 6 and washer 7. • remove the right pillion footrest bracket 8. • remove the rear brake pedal 9. Installation install the rear brake pedal in the reverse order of removal. Pay attention to the following poin...

  • Page 193: Chassis     5-56

    Chassis 5-56 rear suspension construction " removal and disassembly • remove the frame covers, left and right. ( $5-7) • remove the muffler. ( $3-5) • remove the rear shock absorber upper mounting bolts 1. • remove the rear shock absorber lower mounting bolts 2. • remove the rear shock absorbers 3. ...

  • Page 194: 5-57      Chassis

    5-57 chassis inspection shock absorber inspect the rear shock absorber for damage and oil leakage. If any defects are found, replace the rear shock absorber with a new one. # spacer and bush inspect the spacers and bushes for wear and damage. If any defects are found, replace the spacer or bush with...

  • Page 195: Chassis     5-58

    Chassis 5-58 swingarm construction " removal and disassembly • remove the muffler. ( $3-5) • remove the rear wheel. ( $5-43) • remove the rear shock absorber lower mounting bolts 1. • remove the drive chain adjusters 2. • remove the pillion footrest bracket lower bolt 3 and spacer 4. 1 swingarm 2 ch...

  • Page 196: 5-59      Chassis

    5-59 chassis • remove the swingarm pivot nut 5, washer 6 and shaft 7. • remove the pillion footrest brackets 8, left and right. • remove the swingarm 9. Swingarm • remove the chain buffer 1 and washer 2. • remove the cotter pin 3, torque link nut 4, washer 5 and torque link 6. Pillion footrest brack...

  • Page 197: Chassis     5-60

    Chassis 5-60 • remove the pin 4, washer 5 and pillion footrest 6. Inspection swingarm inspect the swingarm for damage. If any defects are found, replace the swingarm with a new one..

  • Page 198: 5-61      Chassis

    5-61 chassis swingarm pivot shaft measure the swingarm pivot shaft runout using the dial gauge. If the runout exceeds the service limit, replace the swingarm pivot shaft with a new one. % swingarm pivot shaft runout service limit: 0.6 mm & 09900-20607: dial gauge 09900-20701: magnetic stand 09900-21...

  • Page 199: Chassis     5-62

    Chassis 5-62 torque link inspect the torque link for bend or damage. If any defects are found, replace the torque link with a new one. Reassembly and remounting reassemble and remount the swingarm and pillion footrest in the reverse order of removal and disassembly. Pay attention to the following po...

  • Page 200: 5-63      Chassis

    5-63 chassis • install the rear shock absorber. ( $5-57) • install the rear wheel. ( $5-47) final inspection and adjustment after installing the rear brake, rear sprocket drum and wheel, the following adjustments are required before driving. * drive chain ( $2-14) * rear brake ( $2-19).

  • Page 201: Electrical System

    Electrical system 6-1 electrical system contents 2 6 cautions in servicing ......................................................................... 6- 2 connector ........................................................................................ 6- 2 coupler......................................

  • Page 202: Cautions In Servicing

    6-2 electrical system cautions in servicing connector • when connecting a connector, be sure to push it in until a click is felt. • inspect the connector for corrosion, contamination and break- age in its cover. Coupler • with a lock type coupler, be sure to release the lock when dis- connecting, an...

  • Page 203: Semi-Conductor Equipped Part

    Electrical system 6-3 semi-conductor equipped part • be careful not to drop the part which has a semi-conductor built in such as a cdi unit and regulator/rectifier. • when inspecting these parts, follow the instructions carefully. Failure to follow the proper procedure can cause damage to these part...

  • Page 204: Tion Manual.

    6-4 electrical system using the multi-circuit tester • properly use the multi-circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. • if the voltage and current values are not known, begin mea- suring in the highest range. • when measuring the resistance, make su...

  • Page 205

    Electrical system 6-5 location of electrical components 1 regulator/rectifier 2 turn signal relay 3 horn 4 battery 5 fuse 6 ignition coil 7 generator.

  • Page 206

    6-6 electrical system 1 cdi unit 2 starter relay (for fl125sd) 3 starter motor (for fl125sd).

  • Page 207: Charging and Lighting System

    Electrical system 6-7 charging and lighting system troubleshooting note: * make sure that the fuse is not blown and the battery is fully-charged before diagnosing. Battery runs down quickly. Step 1 1) check accessories which use excessive amounts of electricity. Are accessories installed? Yes remove...

  • Page 208: Step 2

    6-8 electrical system step 2 1) check the battery for current leaks. ( $6-9) is the battery ok? Step 3 1) measure the charging output between the battery terminals. ( $6-9) is the charging output ok? Step 4 1) measure the resistance of the generator coil. ( $6-10) is the generator coil resistance ok...

  • Page 209: Inspection

    Electrical system 6-9 inspection battery current leakage • turn the ignition switch to the off position. • open the seat. ( $5-5) • remove the battery box lid 1. • disconnect the battery - lead wire. • measure current between the - battery terminal and - bat- tery lead wire using the multi-circuit t...

  • Page 210: Generator Coil Resistance

    6-10 electrical system generator coil resistance • remove the front frame cover. ( $5-5) • remove the rear center leg shield. ( $5-6) • disconnect the generator coupler. Measure the resistance between generator lead wires using the multi-circuit tester. If the resistance is not within the specified ...

  • Page 211: Regulator/rectifier

    Electrical system 6-11 regulator/rectifier • remove the frame head cover. ( $5-6) • disconnect the regulator/rectifier coupler 1. • remove the regulator/rectifier 2. Measure the voltage between the terminals using the multi-cir- cuit tester, as indicated in the table below. If the voltage is not wit...

  • Page 212: Starter Motor Will Not Run.

    6-12 electrical system starter system (for fl125sd) troubleshooting (for fl125sd) note: * make sure that the fuse is not blown and the battery is fully-charged before diagnosing. Starter motor will not run. Step 1 1) disconnect the starter motor lead wire. 2) turn the ignition switch to the “on” pos...

  • Page 213: Step 3

    Electrical system 6-13 step 3 1) measure the starter relay voltage at the starter relay couplers (between y/g + and b/w -) when the starter button is pushed. Is the voltage ok? Step 4 1) check the starter relay. ( $6-19) is the starter relay ok? Starter motor runs but does not crank the engine. Step...

  • Page 214: Item

    6-14 electrical system starter motor disassembly (for fl125sd) • disassemble the starter motor as shown in the illustration. • remove the housing end (inside) 1. • remove the slip washer 2, thrust washer 3 (t: 0.2), thrust washer 4 (t: 0.5) and starter motor case 5. 1 housing end (outside) 5 o-ring ...

  • Page 215

    Electrical system 6-15 • remove the armature 6. • remove the thrust washer 7 (t: 0.8), thrust washer 8 (t: 0.2) and brush holder 9. • remove the insulators 0. • remove the nut a, washer b, slip washer no. 1 c, slip washers no. 2 d, o-ring e and brush f. • remove the supporter g..

  • Page 216: Starter Motor Inspection

    6-16 electrical system starter motor inspection (for fl125sd) carbon brush inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any defects are found, replace the brush assembly with a new one. Make sure that the length a is not less than 3.5 mm, if this length become...

  • Page 217: Bush

    Electrical system 6-17 bush check the bush for wear or damage. If any defects are found, replace the housing end (outside). Starter motor reassembly and installation (for fl125sd) reassemble and install the starter motor in the reverse order of disassembly. Pay attention to the following points: • a...

  • Page 218: Starter Motor Installation

    6-18 electrical system • install the o-ring. # • apply suzuki super grease “a” to the o-ring. * 99000-25010: suzuki super grease “a” starter motor installation • tighten the starter motor mounting bolts 1 to the specified torque. " starter motor mounting bolt: 10 n·m (1.0 kgf-m) • tighten the starte...

  • Page 219: Starter Relay Inspection

    Electrical system 6-19 starter relay inspection (for fl125sd) • remove the front frame cover. ( $5-5) • disconnect the battery - lead wire from the battery. • disconnect the starter relay coupler 1. • remove the starter relay 2. • apply 12 v to a and b terminals and check for continuity between the ...

  • Page 220: Ignition System

    6-20 electrical system ignition system troubleshooting note: * make sure that the fuse is not blown and the battery is fully-charged before diagnosing. No spark or poor spark step 1 1) check the ignition system couplers for poor connections. Are there connection in the ignition switch couplers? Step...

  • Page 221: Step 3

    Electrical system 6-21 step 3 1) measure the ignition coil primary peak voltage and ignition coil resistance. ( $6-23) note: this inspection method is applicable only with the multi-circuit tester and the peak volt adaptor. Are the primary peak voltage and resistance ok? Step 4 1) inspect the spark ...

  • Page 222: Inspection

    6-22 electrical system inspection ignition coil primary peak voltage • remove the leg shield. ( $5-6) • disconnect the spark plug cap 1. • connect a new spark plug 2 to the spark plug cap and ground it to the cylinder head cover. Note: make sure that the spark plug cap and spark plug are connected p...

  • Page 223: Ignition Coil Resistance

    Electrical system 6-23 ignition coil resistance • remove the rear center leg shield. ( $5-6) • disconnect the ignition coil lead wire 1 and remove the igni- tion coil 2. • remove the spark plug cap. ( $6-22) measure the ignition coil resistance in both the primary and sec- ondary windings using the ...

  • Page 224: - Probe: Ground

    6-24 electrical system if the peak voltage measured on the cdi unit coupler is lower than the specified value, measure the peak voltage on the pick-up coil coupler as follows. • remove the rear center leg shield. ( $5-6) • disconnect the pick-up coil coupler 1. • connect the multi-circuit tester wit...

  • Page 225: Speedometer

    Electrical system 6-25 speedometer removal and disassembly • remove the rear view mirrors. ( $5-4) • remove the rear handlebar covers. ( $5-4) • remove the speedometer 1. • disassemble the speedometer as shown..

  • Page 226: Inspection

    6-26 electrical system inspection check the continuity between the lead wires using the multi-circuit tester. If there is no continuity replace the respective parts. & 09900-25008: multi-circuit tester set 7 tester knob indication: continuity test (8) y: high beam o: fuel gauge y/b: fuel gauge fuel ...

  • Page 227: Fuel Meter Inspection

    Electrical system 6-27 fuel meter and fuel level gauge fuel meter inspection to test the fuel meter, perform the following tests. Test 1 this test will determine if the fuel meter is operating. • open the seat. ( $5-5) • disconnect the fuel level gauge coupler. ( $4-2) • connect a jumper wire betwee...

  • Page 228: Relays

    6-28 electrical system relays turn signal relay inspection • remove the frame head cover. ( $5-4) 1: turn signal relay before removing the turn signal relay, check the operation of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit c...

  • Page 229: Lamps

    Electrical system 6-29 lamps headlight 1: headlight bulb: 12 v 25/25 w headlight bulb replacement • remove the handlebar cover. ( $5-4) • remove the headlight bulbs 1. # headlight beam adjustment • loosen the screw a. • moving the headlight assembly, adjust the headlight vertical beam. A: vertical a...

  • Page 230: Front Turn Signal Light

    6-30 electrical system front turn signal light 1: front turn signal light bulb: 12 v 10 w front turn signal light bulb replacement • remove the frame head cover. ( $5-6) • remove the front turn signal light bulbs 1, left and right. # if you touch the bulb with your bare hands, clean the bulb with a ...

  • Page 231

    Electrical system 6-31 brake light/taillight and rear turn signal light 1: brake light/taillight: led 2: rear turn signal light bulb: 12v 10 w rear turn signal light bulb replacement • remove the frame covers, left and right. ( $5-7) • remove the rear turn signal light bulbs, left and right. # brake...

  • Page 232

    6-32 electrical system • remove the rear combination light bracket 2. • remove the rear combination light lens 3. • remove the brake light/taillight assembly 4..

  • Page 233: License Plate Light

    Electrical system 6-33 license plate light 1: license plate light bulb: 12 v 5 w # license plate light bulb replacement • remove the license plate light case 1. • remove the license plate light bulb. Do not overtighten the lens fitting screws..

  • Page 234: Switches

    6-34 electrical system switches measure each switch for continuity using the multi-circuit tester. If there is no continuity, replace the respec- tive switch with a new one. Dimmer switch y/w y w hi lo color position wire color b : black w : white bl : blue o : orange y : yellow r : red b/g : black ...

  • Page 235: Battery

    Electrical system 6-35 battery specifications 1 upper cover breather 5 terminal 2 cathode plates 6 safety valve 3 stopper 7 anode plates 4 filter 8 separator (fiberglass plate) initial charging filling electrolyte • remove the aluminum tape 1 sealing the battery electrolyte filler holes a. Note: whe...

  • Page 236: Not Remove The Caps.

    6-36 electrical system • make sure air bubbles 5 are coming up in each electrolyte container, and leave in this position for about more than 20 minutes. Note: if no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the containe...

  • Page 237: Servicing

    Electrical system 6-37 servicing visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powder...

  • Page 238: Servicing Information

    7-1 servicing information servicing information contents troubleshooting .................................................................................. 7- 2 engine .................................................................................................. 7- 2 clutch ........................

  • Page 239: Troubleshooting

    Servicing information 7-2 7 troubleshooting engine complaint symptom and possible causes remedy engine will not start, or is hard to start. Compression too low 1. Valve clearance out of adjustment. 2. Worn valve guides or poor seating of valves. 3. Mistimed valves. 4. Excessively worn piston rings. ...

  • Page 240: Complaint

    7-3 servicing information complaint symptom and possible causes remedy noisy engine. Noise seems to come from timing chain 1. Stretched chain. 2. Worn sprocket. 3. Not working tension adjuster. Noise seems to come from clutch 1. Worn splines of countershaft or hub. 2. Worn teeth of clutch plates. 3....

  • Page 241: Complaint

    Servicing information 7-4 complaint symptom and possible causes remedy transmission will not shift. 1. Broken gearshift cam. 2. Distorted gearshift forks. 3. Worn gearshift pawl. Replace. Replace. Replace. Transmission jumps out of gear. 1. Worn shifting gears on driveshaft or countershaft. 2. Disto...

  • Page 242: Clutch

    7-5 servicing information clutch complaint symptom and possible causes remedy engine lacks power. 1. Loss of valve clearance. 2. Weakened valve spring. 3. Valve timing out of adjustment. 4. Worn piston rings or cylinder. 5. Poor seating of valves. 6. Fouled spark plug. 7. Incorrect spark plug. 8. Cl...

  • Page 243: Carburetor

    Servicing information 7-6 carburetor complaint symptom and possible causes remedy starting difficulty. 1. Clogged starter plunger. 2. Clogged starter plunger passage. 3. Air leaking from joint between starter lever and carburetor. 4. Air leaking from carburetor joint or vacuum hose joint. 5. Imprope...

  • Page 244: Chassis

    7-7 servicing information chassis complaint symptom and possible causes remedy heavy steering. 1. Overtightened steering stem nut. 2. Broken bearing in steering stem. 3. Distorted steering stem. 4. Not enough pressure in tires. Adjust. Replace. Replace. Adjust. Wobbly handlebars. 1. Loss of balance ...

  • Page 245: Brakes

    Servicing information 7-8 brakes complaint symptom and possible causes remedy insufficient front brake power. 1. Leakage of brake fluid from hydraulic system. 2. Worn pads or disc. 3. Oil adhesion on friction surface of pads. 4. Air in hydraulic system. 5. Excessive brake lever play. 6. Friction sur...

  • Page 246: Electrical

    7-9 servicing information electrical complaint symptom and possible causes remedy no sparking or poor sparking. 1. Defective ignition coil or cdi unit. 2. Defective spark plug. 3. Defective pick-up coil or generator coil. 4. Open-circuited wiring connections. Replace. Replace. Replace. Check and rep...

  • Page 247: Battery

    Servicing information 7-10 battery complaint symptom and possible causes remedy “sulfation”, acidic white powdery sub- stance or spots on surface of cell plates. 1. Cracked battery case. 2. Battery has been left in a run-down condition for a long time. Replace the battery. Replace the battery. Batte...

  • Page 248: Wiring Diagram

    7-11 servicing information wiring diagram fl125s fuel level ga uge turn signal switch b a tter y main fuse regula t or/ rectifier genera t o r pick-up coil horn n 1 2 3 4 on off gear position switch push horn b utt on gear position n 1 234 dimmer switch lo hi ignition coil on off close full y open r...

  • Page 249: Fl125Sd

    Servicing information 7-12 fl125sd fuel level ga uge turn signal switch b a tter y st ar ter rela y st ar ter m oto r main fuse regula t or/ rectifier genera t o r pick-up coil horn n 1 2 3 4 on off gear position switch push push horn b utt on st ar ter b utt on gear position dimmer switch lo hi ign...

  • Page 250: Wiring Harness Routing

    7-13 servicing information wiring harness, cable and hose routing wiring harness routing battery rear combination coupler clamp cdi unit license plate light coupler license plate light lead wire clamp clamp clamp clamp clamp frame stop light switch luggage box seat lock cable rear brake switch rear ...

  • Page 251

    Servicing information 7-14 front fork upper bracket speedometer front brake switch relay bracket starter motor relay clamp clamp clamp clamp clamp fuel level gauge lead wire seat lock cable generator coupler gear position switch starter motor engine ground lead wire speedometer cable speedometer cab...

  • Page 252

    7-15 servicing information gear position lead wire generator rotor clamp clamp crank case (l) gear position switch engine sprocket cover.

  • Page 253: Cable Routing

    Servicing information 7-16 cable routing starter cable starter lever harness speedometer cable front brake hose starter cable throttle cable starter cable front brake hose speedometer cable pass through the throttle cable and speedometer inside of the starter cable. Starter cable starter cable frame...

  • Page 254: Seat Lock Cable Routing

    7-17 servicing information seat lock cable routing pass through the seat lock cable inside of the air cleaner box mount. Pass through the seat lock cable inside cable guide. Pass through the seat lock cable inside the left frame cover plate. Clamp clamp seat lock cable clamp clamp clamp clamp clamp ...

  • Page 255: Front Brake Hose Routing

    Servicing information 7-18 front brake hose routing set the brake hose into clamp firmly. Pass through the brake hose inside the guide. Pass through the brake hose inside the guide. 90˚ 28˚.

  • Page 256: Fuel Hose Routing

    7-19 servicing information fuel hose routing fuel filter fuel tank hose vacuum hose fuel hose guide fuel hose guide fuel hose clamp fuel tank pass through the vacuum of the wiring harness fuel tap vacuum hose clamp.

  • Page 257: Hose Routing

    Servicing information 7-20 hose routing crank case breather hose fuel hose fuel tap vacuum hose pass the breather hose through the guide. Pair valve vacuum hose air vent carburetor hose breather hose clamp.

  • Page 258

    7-21 servicing information pair (air supply) system hose routing intake pipe pass the second air cleaner hose the through the downward of the high tension cord. Pair valve pair valve pipe pair valve vacuum hose air cleaner box direct the grip section of the clamp downward matching mark (white).

  • Page 259: Exterior Parts Construction

    Servicing information 7-22 exterior parts construction frame head cover front right leg shield front left leg shield front center leg shield rear center leg shield rear left leg shield frame rear right leg shield.

  • Page 260

    7-23 servicing information front frame cover right lower frame cover battery box lid right frame cover rear fender luggage box luggage box mud guard helmet holder frame left lower frame cover left frame cover rear combination lamp frame center cover.

  • Page 261: Prop Stand Installation

    Servicing information 7-24 prop stand installation center stand installation assembling direction of return spring. Outside 40 n.M (4.0 kgf-m) long assembling direction of return spring. Short.

  • Page 262: Brake Pedal

    7-25 servicing information brake pedal long 11 mm s h o rt.

  • Page 263: Pillion Footrest

    Servicing information 7-26 pillion footrest cotter pin (bend the cotter pin and its ends should f a ce upw ard.).

  • Page 264: Special Tools

    7-27 servicing information special tools 09900-20101 09900-20102 vernier calipers 09900-20202 micrometer (25 – 50 mm) 09900-20203 micrometer (1/100 mm, 50 – 75 mm) 09900-20205 micrometer (1/1 000 mm, 0 – 25 mm) 09900-20530 cylinder gauge set (1/100 mm, 40 – 80 mm) 09900-20602 dial gauge (1/1 000 mm,...

  • Page 265: 09915-63311

    Servicing information 7-28 09915-63311 compression gauge adaptor 09915-64512 compression gauge set 09915-72410 adaptor 09915-74511 oil pressure gauge 09915-74533 oil pressure gauge adaptor 09916-10911 valve lapper set 09916-14510 valve lifter 09916-14522 valve lifter attachment 09916-34542 valve gui...

  • Page 266: 09930-44570

    7-29 servicing information note: before placing order for the special tool, please check for availability. 09930-44570 crank barancer holder 09940-51710 bearing installer 09940-52861 front fork oil seal installer set 09940-60113 spoke nipple wrench 09941-34513 steering outer race installer 09941-501...

  • Page 267: Tightening Torque

    Servicing information 7-30 tightening torque engine item n·m kgf-m exhaust pipe nut 23 2.3 muffler mounting bolt 23 2.3 muffler connecting bolt 23 2.3 valve clearance adjuster lock-nut 10 1.0 spark plug 11 1.1 engine oil drain plug 17.5 1.75 oil filter cap bolt 10 1.0 main oil gallery plug 10 1.0 en...

  • Page 268: Chassis

    7-31 servicing information chassis item n·m kgf-m rear axle nut 42 4.2 air bleeder valve 5.5 0.55 spoke nipple 2.75 0.275 pillion footrest bracket lower bolt 55 5.5 footrest mounting bolt 14.5 1.45 front fork clamp bolt 32.5 3.25 handlebar clamp nut 60 6.0 steering stem nut 80 8.0 front axle nut 42 ...

  • Page 269: Tightening Torque Chart

    Servicing information 7-32 tightening torque chart for other nuts and bolts not listed in the preceding page, refer to this chart: bolt diameter a (mm) conventional or “4” marked bolt “7” marked bolt n·m kgf-m n·m kgf-m 4 1.5 0.15 2.3 0.23 5 3 0.3 4.5 0.45 6 5.5 0.55 10 1.0 8 13 1.3 23 2.3 10 29 2.9...

  • Page 270: Service Data

    7-33 servicing information service data valve + guide unit: mm camshaft + cylinder head unit: mm item standard limit valve diam. In. 25 — ex. 22 — valve clearance (when cold) in. 0.03 – 0.08 — ex. 0.08 – 0.13 — valve guide-to-valve stem clearance in. 0.010 – 0.037 — ex. 0.030 – 0.057 — valve guide i...

  • Page 271: Conrod + Crankshaft

    Servicing information 7-34 cylinder + piston + piston ring unit: mm conrod + crankshaft unit: mm oil pump first clutch unit: mm item standard limit compression pressure 1 200 – 1 700 kpa (12 – 17 kgf/cm²) 750 kpa (7.5 kgf/cm²) piston-to-cylinder clearance 0.04 – 0.05 0.120 cylinder bore 53.500 – 53....

  • Page 272: Gear Shift Clutch

    7-35 servicing information gear shift clutch unit: mm transmission + drive chain unit: mm (in) (except ratio) carburetor item standard limit clutch release screw 1/8 turn back — drive plate thickness 2.9 – 3.1 2.6 drive plate claw width 11.80 – 12.00 11.0 driven plate distortion — 0.10 clutch spring...

  • Page 273: Electrical

    Servicing information 7-36 electrical unit: mm item specification note spark plug type ngk: c6hsa denso: u20fs-u gap 0.6 – 0.7 spark performance 8.0 mm or more at 1 atm. Pick-up coil resistance 180 – 280 Ω bl/y – ground pick-up coil peak voltage 2.0 v or more +: bl/y – -: ground ignition coil resist...

  • Page 274: Wattage

    7-37 servicing information wattage unit: w brake + wheel unit: mm suspension unit: mm item specification headlight hi 25 lo 25 brake light/taillight led license plate light 5 turn signal light 10 speedometer light 1.7 high beam indicator light 1.7 turn signal indicator light 1.7 × 2 gear position in...

  • Page 275: Tire

    Servicing information 7-38 tire fuel + oil item standard limit cold inflation tire pressure (solo riding) front 175 kpa (1.75 kgf/cm²) — rear 225 kpa (2.25 kgf/cm²) — cold inflation tire pressure (dual riding) front 175 kpa (1.75 kgf/cm²) rear 280 kpa (2.80 kgf/cm²) tire size front 60/100-17 m/c 33p...

  • Page 276: 8-1     Fl125Sdw

    8-1 fl125sdw fl125sdw contents this chapter describes service data, service specifications, troubleshooting for fi system and servicing procedures which differ from those of the fl125s/sd. Note: • any differences between the fl125s/sd and fl125sdw in specifications and service data are indicated wit...

  • Page 277: Fl125Sdw     8-2

    Fl125sdw 8-2 fl125sdw contents 8 fuel system ............................................................................................... 8-81 fuel filter ........................................................................................ 8-81 throttle body......................................

  • Page 278: 8-3     Fl125Sdw

    8-3 fl125sdw abbreviations used in this manual a abdc : after bottom dead center ac : alternating current acl : air cleaner, air cleaner box api : american petroleum institute atdc : after top dead center a/f : air fuel mixture b bbdc : before bottom dead center btdc : before top dead center b+ : ba...

  • Page 279: Fl125Sdw     8-4

    Fl125sdw 8-4 wire color b : black o : orange bl : blue p : pink dg : dark green r : red g : green w : white gr : gray y : yellow lg : light green b/g : black with green tracer b/lg : black with light green tracer b/lbl : black with light blue tracer b/w : black with white tracer bl/w : blue with whi...

  • Page 280: 8-5     Fl125Sdw

    8-5 fl125sdw specifications (fl125sdw) dimensions and dry mass overall length.......................................................................... 1 885 mm overall width ........................................................................... 715 mm overall height...............................

  • Page 281: Fl125Sdw     8-6

    Fl125sdw 8-6 chassis front suspension..................................................................... Telescopic, coil spring, oil damped rear suspension ..................................................................... Swingarm type, coil spring, oil damped front fork stroke .................

  • Page 282: 8-7     Fl125Sdw

    8-7 fl125sdw periodic maintenance schedule the chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometer and time for your convenience. Note: more fre...

  • Page 283: Fl125Sdw     8-8

    Fl125sdw 8-8 maintenance and tune-up procedures this section describes the servicing procedures for each peri- odic maintenance item which differ from those of the fl125s/ sd. For details other than the following items, refer to the fl125s/ sd service manual. Fuel line inspect the fuel hoses for dam...

  • Page 284: 8-9     Fl125Sdw

    8-9 fl125sdw sds check using sds, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehi...

  • Page 285: Fl125Sdw     8-10

    Fl125sdw 8-10 data at 3 000 r/min under no load data at the time of racing 3 000 r/min check the manifold absolute pressure. Approx. Xxx kpa (xxx mmhg) throttle: quick wide open throttle: slowly open.

  • Page 286: 8-11     Fl125Sdw

    8-11 fl125sdw data of intake negative pressure during idling (90 °c) example of trouble three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in compar- ison by showing them in the graph. Read the change of value by comparing the current data to the past ...

  • Page 287: Fl125Sdw     8-12

    Fl125sdw 8-12 fi system diagnosis precautions in servicing when handling the component parts or servicing the fi system, observe the following points for the safety of the system. Electrical parts connector/coupler • when connecting a connector, be sure to push it in until a click is felt. • with a ...

  • Page 288: 8-13     Fl125Sdw

    8-13 fl125sdw • when connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- mina...

  • Page 289: Fl125Sdw     8-14

    Fl125sdw 8-14 • when disconnecting and connecting the ecm, make sure to turn off the ignition switch 1, or electronic parts may get damaged. • battery connection in reverse polarity is strictly prohibited. Such a wrong connection will damage the components of the fi system instantly when reverse pow...

  • Page 290: 8-15     Fl125Sdw

    8-15 fl125sdw electrical circuit inspection procedure while there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. Open circuit check possible causes for the open circuits are as follows. ...

  • Page 291: Fl125Sdw     8-16

    Fl125sdw 8-16 continuity check • measure resistance across coupler b (between a and c in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals a and c. 1 ecm • disconnect the coupler b and measure resistance between couplers a and b. If no continu...

  • Page 292: 8-17     Fl125Sdw

    8-17 fl125sdw short circuit check (wire harness to ground) • disconnect the negative cable from the battery. • disconnect the connectors/couplers at both ends of the circuit to be checked. Note: if the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of thos...

  • Page 293: Fl125Sdw     8-18

    Fl125sdw 8-18 using the multi-circuit tester • use the suzuki multi-circuit tester set (09900-25008). • use well-charged batteries in the tester. • be sure to set the tester to the correct testing range. Using the tester • incorrectly connecting the + and - probes may cause the inside of the tester ...

  • Page 294: 8-19     Fl125Sdw

    8-19 fl125sdw fi system technical features injection time (injection volume) the factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensat...

  • Page 295: Fl125Sdw     8-20

    Fl125sdw 8-20 compensation of injection time (volume) the following different signals are output from the respective sensors for compensation of the fuel injection time (volume). Injection stop control signal description engine temperature sensor signal when engine temperature is low, injection time...

  • Page 296: 8-21     Fl125Sdw

    8-21 fl125sdw fi system parts location a ecm e intake air pressure sensor/throttle position sensor/intake air tem- perature sensor (iaps/tps/iats) b tip-over sensor (tos) c fuel injector f engine temperature sensor (ets) d isc valve g heated oxygen sensor (ho2s).

  • Page 297: Fl125Sdw     8-22

    Fl125sdw 8-22 a ecm i ignition coil (ig coil) h speedometer j crankshaft position sensor (ckps).

  • Page 298: 8-23     Fl125Sdw

    8-23 fl125sdw fi system wiring diagram crankshaft position sensor (ckps) throttle position sensor (tps) intake air pressure sensor (iaps) intake air temperature sensor (iats) tip-over sensor (tos) ho2 sensor (ho2s) side-stand switch gear position switch (neutral) engine temperature sensor (ets) fuel...

  • Page 299: Fl125Sdw     8-24

    Fl125sdw 8-24 fuel injector the system employs fuel injector (discharge pump; dcp) that causes injection fuel to be pressurized within the pump. The fuel injector pressurizes gravity fed fuel with its plunger and injects the pressurized fuel into the intake pipe. With the pressure plunger controlled...

  • Page 300: 8-25     Fl125Sdw

    8-25 fl125sdw ecm ecm (engine control module) consists of cpu (central pro- cessing unit), memory (rom/ram) and in/out section. Sig- nals from various sensors are sent to the input section and then to cpu. On the basis of information received, cpu performs cal- culation of necessary amount of fuel i...

  • Page 301: Fl125Sdw     8-26

    Fl125sdw 8-26 iap/tp/iat sensor the iap sensor/tp sensor/iat sensor are combined into one. Iap sensor the value of intake air pressure is converted into an electrical signal and sent to ecm. The base fuel injection time (volume) in light load is determined in accordance with this electrical signal (...

  • Page 302: 8-27     Fl125Sdw

    8-27 fl125sdw ho2 sensor ho2 (heated oxygen) sensor is made of zirconia element (plat- inum plated) which changes output voltage depending on the oxygen concentration difference between its internal and exter- nal surfaces. The terminal voltage change is dependent on the oxygen con- centration in th...

  • Page 303: Fl125Sdw     8-28

    Fl125sdw 8-28 ecm terminal terminal no. Circuit terminal no. Circuit 1 power ground (e0) d ignition coil 2 isc valve (isc) e fi indicator light 3 control ground (e1) f fuel injector - 4 sensor ground (e2) g mode select switch 5 power source (+b) h fuel injector + 6 ho2 sensor heater (ho2h) i — 7 loa...

  • Page 304: 8-29     Fl125Sdw

    8-29 fl125sdw self-diagnosis function the self-diagnosis function is incorporated in the ecm. The function has two modes, “user mode” and “dealer mode”. The user can only be notified by the fi indicator light. To check the function of the individual fi system devices, the dealer mode is provided. In...

  • Page 305: Fl125Sdw     8-30

    Fl125sdw 8-30 dealer mode the defective function is memorized in the ecm. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is indicated by the flashing pattern of fi indicator light. Mal- function means that the ecm does not receive normal signal f...

  • Page 306: 8-31     Fl125Sdw

    8-31 fl125sdw fail-safe function fi system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. The engine can start and can run even if the above signal is not received from each sensor. But...

  • Page 307: Fl125Sdw     8-32

    Fl125sdw 8-32 fi system troubleshooting customer complaint analysis record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis ...

  • Page 308: 8-33     Fl125Sdw

    8-33 fl125sdw note: the above form is a standard sample. The form should be modified according to conditions and characteris- tics of each market. Visual inspection • prior to diagnosis using the mode select switch or sds, perform the following visual inspections. The rea- son for visual inspection ...

  • Page 309: Fl125Sdw     8-34

    Fl125sdw 8-34 self-diagnostic procedures note: * do not disconnect the coupler from ecm, battery cable from battery, ecm ground wire from engine or main fuse before confirming the dtc (diagnostic trouble code) stored in mem- ory. Such disconnection will erase the memorized information in ecm memory....

  • Page 310: 8-35     Fl125Sdw

    8-35 fl125sdw understanding the dtc (diagnostic trouble code) a two-digit dtc is shown through the flashing pattern of the fi indicator light. The dtcs are indicated from a smaller number to a larger number in that order. When all the applicable dtcs have been indicated, the displaying of the dtcs r...

  • Page 311: Fl125Sdw     8-36

    Fl125sdw 8-36 dtc indication chart flashing pattern dtc no. Malfunction part remarks 00 none 12 ckp sensor ( #8-43) pick up coil signal 13 iap sensor ( #8-46) 14 tp sensor ( #8-51) 15 et sensor ( #8-56) 21 iat sensor ( #8-60) 23 to sensor ( #8-64) 24 ignition coil ( #8-68) 32 fuel injector ( #8-68) ...

  • Page 312: 8-37     Fl125Sdw

    8-37 fl125sdw *40: 40 code has no first digit display. For this reason, the interval a between the displays as shown below is longer than the others. Self-diagnosis reset procedure • after repairing the trouble, turn off the ignition switch and turn on again. • if the fi indicator light turns off, t...

  • Page 313: Fl125Sdw     8-38

    Fl125sdw 8-38 use of sds diagnostic procedures note: * do not disconnect the coupler from ecm, battery cable from battery, ecm ground wire from engine or main fuse before confirming the dtc (diagnostic trouble code) stored in mem- ory. Such disconnection will erase the memorized information in ecm m...

  • Page 314: 8-39     Fl125Sdw

    8-39 fl125sdw use of sds diagnosis reset procedure • after repairing the trouble, turn off the ignition switch and turn on again. • click the dtc inspection button 1. • check the dtc. • the previous malfunction history code (past dtc) still remains stored in the ecm. Therefore, erase the history cod...

  • Page 315: Fl125Sdw     8-40

    Fl125sdw 8-40 show data when trouble (displaying data at the time of dtc) ecm stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “show data when trouble”. Therefore, it is possible t...

  • Page 316: 8-41     Fl125Sdw

    8-41 fl125sdw dtc table and defective condition dtc no. Detected item detected failure condition check for 00 no fault ––––––––––– ––––––––––– 12 ckp sensor the ckp sensor signal does not reach ecm for 4 sec. Or more, after receiving the iap sensor signal. Ckp sensor wiring and mechan- ical parts. C...

  • Page 317: Fl125Sdw     8-42

    Fl125sdw 8-42 dtc no. Detected item detected failure condition check for 23 to sensor the sensor voltage should be the fol- lowing for 2 sec. Or more, after ignition switch is turned on. 0.2 v sensor voltage in other than the above value, 23 (p1651) is indicated. To sensor, lead wire/coupler connect...

  • Page 318: 8-43     Fl125Sdw

    8-43 fl125sdw “12” (p0335) ckp sensor circuit malfunction inspection step 1 1) turn the ignition switch off. 2) remove the right leg shield. ( #5-6) 3) check the ckp sensor coupler 1 for loose or poor contacts. If ok, then measure the ckp sensor resistance. 4) disconnect the ckp sensor coupler and m...

  • Page 319: Fl125Sdw     8-44

    Fl125sdw 8-44 5) if ok, then check the continuity between each terminal and ground. ! Ckp sensor continuity: ∞Ω (infinity) (bl/y – ground) (g/w – ground) $ 09900-25008: multi-circuit tester set & tester knob indication: resistance (Ω) are the resistance and continuity ok? 6) after repairing the trou...

  • Page 320: 8-45     Fl125Sdw

    8-45 fl125sdw step 2 1) crank the engine a few seconds with the starter motor, and measure the ckp sensor peak voltage at the coupler. 2) repeat the above test procedure a few times and measure the highest peak voltage. ! Ckp sensor peak voltage: 2.0 v or more ( + bl/y – - g/w) 1 peak volt adaptor $...

  • Page 321: Fl125Sdw     8-46

    Fl125sdw 8-46 “13” (p0105-h/l) iap sensor circuit malfunction note: iap sensor is incorporated in the tp sensor/iat sensor. Inspection step 1 (when indicating 13:) 1) turn the ignition switch off. 2) remove the right leg shield. ( #5-6) 3) check the iap sensor coupler 1 for loose or poor contacts. I...

  • Page 322: 8-47     Fl125Sdw

    8-47 fl125sdw 4) disconnect the iap sensor coupler. 5) turn the ignition switch on. 6) measure the voltage at the r wire a and ground. 7) if ok, then measure the voltage at the r wire a and br/b wire b. ! Iap sensor input voltage: 4.5 – 5.5 v ( + r – - ground) ( + r – - br/b) $ 09900-25008: multi-ci...

  • Page 323: Fl125Sdw     8-48

    Fl125sdw 8-48 6) disconnect the ecm coupler. 7) check the continuity between g/b wire c and terminal n. 8) if ok, then check the continuity between br/b wire b and ter- minal 4. ! Iap sensor lead wire continuity: continuity ()) $ 09900-25008: multi-circuit tester set 09900-25009: needle pointed prob...

  • Page 324: 8-49     Fl125Sdw

    8-49 fl125sdw 7) disconnect the ecm coupler. 8) check the continuity between r wire a and terminal 9. ! Iap sensor lead wire continuity: continuity ()) $ 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set * tester knob indication: continuity test ()) % is the continuity ok? ...

  • Page 325: Fl125Sdw     8-50

    Fl125sdw 8-50 step 2 1) connect the iap sensor coupler and ecm coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) start the engine at idle speed and measure the iap sensor output voltage (between br/b wire b and g/b wire c). ! Iap sensor output voltage: 2.0 – 3.5 v at idle spe...

  • Page 326: 8-51     Fl125Sdw

    8-51 fl125sdw “14” (p0120-h/l) tp sensor circuit malfunction note: tp sensor is incorporated in the iap sensor/iat sensor. Inspection step 1 (when indicating 14:) 1) turn the ignition switch off. 2) remove the right leg shield. ( #5-6) 3) check the tp sensor coupler 1 for loose or poor contacts. If ...

  • Page 327: Fl125Sdw     8-52

    Fl125sdw 8-52 4) disconnect the tp sensor coupler. 5) turn the ignition switch on. 6) measure the voltage at the r wire a and ground. 7) if ok, then measure the voltage at the r wire a and br/b wire b. ! Tp sensor input voltage: 4.5 – 5.5 v ( + r – - ground) ( + r – - br/b) $ 09900-25008: multi-circ...

  • Page 328: 8-53     Fl125Sdw

    8-53 fl125sdw 6) disconnect the ecm coupler. 7) check the continuity between br/b wire b and terminal 4. ! Tp sensor lead wire continuity: continuity ()) $ 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set * tester knob indication: continuity test ()) % is the continuity ok...

  • Page 329: Fl125Sdw     8-54

    Fl125sdw 8-54 7) disconnect the ecm coupler. 8) check the continuity between r wire a and terminal 9. 9) also, check the continuity between p wire c and terminal m. ! Tp sensor lead wire continuity: continuity ()) $ 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set * tester...

  • Page 330: 8-55     Fl125Sdw

    8-55 fl125sdw step 2 1) connect the tp sensor coupler and ecm coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. 4) measure the tp sensor output voltage (between + p wire c and - br/b wire b) by turning the throttle grip. ! Tp sensor output voltage...

  • Page 331: Fl125Sdw     8-56

    Fl125sdw 8-56 “15” (p0115-h/l) et sensor circuit malfunction inspection step 1 (when indicating 15:) 1) turn the ignition switch off. 2) remove the rear center leg shield. ( #5-6) 3) check the et sensor coupler 1 for loose or poor contacts. If ok, then measure the et sensor voltage at the coupler. D...

  • Page 332: 8-57     Fl125Sdw

    8-57 fl125sdw 4) disconnect the et sensor coupler and turn the ignition switch on. 5) measure the voltage between o/b wire a and ground. 6) if ok, then measure the voltage between o/b wire a and br/ b wire b. ! Et sensor voltage: 4.5 – 5.5 v ( + o/b – - ground) ( + o/b – - br/b) $ 09900-25008: multi...

  • Page 333: Fl125Sdw     8-58

    Fl125sdw 8-58 step 1 (when indicating p0115-l:) 1) turn the ignition switch off. 2) remove the rear center leg shield. ( #5-6) 3) check the et sensor coupler 1 for loose or poor contacts. If ok, then check the et sensor lead wire continuity. 4) disconnect the et sensor coupler. 5) check the continui...

  • Page 334: 8-59     Fl125Sdw

    8-59 fl125sdw step 2 1) turn the ignition switch off. 2) disconnect the et sensor coupler. 3) measure the et sensor resistance between b wires. ! Et sensor resistance: approx. 13.0 kΩ at 20 °c approx. 6.2 k Ω at 40 °c (b – b) $ 09900-25008: multi-circuit tester set & tester knob indication: resistan...

  • Page 335: Fl125Sdw     8-60

    Fl125sdw 8-60 “21” (p0110-h/l) iat sensor circuit malfunction note: iat sensor is incorporated in the iap sensor/tp sensor. Inspection step 1 (when indicating 21:) 1) turn the ignition switch off. 2) remove the right leg shield. ( #5-6) 3) check the iat sensor coupler 1 for loose or poor contacts. I...

  • Page 336: 8-61     Fl125Sdw

    8-61 fl125sdw step 1 (when indicating p0110-h:) 1) turn the ignition switch off. 2) remove the right leg shield. ( #5-6) 3) check the iat sensor coupler 1 for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 4) disconnect the iat sensor coupler and ecm coupler. 5) check...

  • Page 337: Fl125Sdw     8-62

    Fl125sdw 8-62 step 1 (when indicating p0110-l:) 1) turn the ignition switch off. 2) remove the right leg shield. ( #5-6) 3) check the iat sensor coupler 1 for loose or poor contacts. If ok, then check the iat sensor lead wire continuity. 4) disconnect the iat sensor coupler. 5) check the continuity ...

  • Page 338: 8-63     Fl125Sdw

    8-63 fl125sdw step 2 1) turn the ignition switch off. 2) disconnect the iat sensor coupler. 3) measure the iat sensor resistance. ! Iat sensor resistance: approx. 2.56 kΩ at 20 °c approx. 1.20 k Ω at 40 °c (terminal a – terminal b) $ 09900-25008: multi-circuit tester set & tester knob indication: re...

  • Page 339: Fl125Sdw     8-64

    Fl125sdw 8-64 “23” (p1651-h/l) to sensor circuit malfunction inspection step 1 (when indicating 23:) 1) turn the ignition switch off. 2) remove the front frame cover. ( #5-5) 3) check the to sensor coupler 1 for loose or poor contacts. If ok, then measure the to sensor resistance. 4) remove the to s...

  • Page 340: 8-65     Fl125Sdw

    8-65 fl125sdw step 1 (when indicating p1651-h:) 1) turn the ignition switch off. 2) remove the front frame cover. ( #5-5) 3) check the to sensor coupler 1 for loose or poor contacts. If ok, then check the to sensor lead wire continuity. 4) disconnect the to sensor coupler. 5) check the continuity be...

  • Page 341: Fl125Sdw     8-66

    Fl125sdw 8-66 step 1 (when indicating p1651-l:) 1) turn the ignition switch off. 2) remove the front frame cover. ( #5-5) 3) check the to sensor coupler 1 for loose or poor contacts. If ok, then check the to sensor lead wire continuity. 4) disconnect the to sensor coupler. 5) check the continuity be...

  • Page 342: 8-67     Fl125Sdw

    8-67 fl125sdw step 2 1) connect the to sensor coupler and ecm coupler. 2) insert the needle pointed probes to the lead wire coupler. 3) turn the ignition switch on. 4) measure the voltage between bl/w wire b and br/b wire c. ! To sensor voltage (normal): 0.4 – 1.4 v ( + bl/w – - br/b) also, measure ...

  • Page 343: Fl125Sdw     8-68

    Fl125sdw 8-68 “32” (p0201) fuel injector circuit malfunction note: when the ignition switch is turned to on position, the fuel injector starts to operate approx. 2 sec. As purge operation (initial operation) inspection step 1 1) turn the ignition switch off. 2) remove the right leg shield. ( #5-6) 3...

  • Page 344: 8-69     Fl125Sdw

    8-69 fl125sdw 6) if ok, then check the continuity between each terminal and ground. ! Fuel injector continuity: ∞Ω (infinity) (terminal – ground) $ 09900-25008: multi-circuit tester set & tester knob indication: resistance (Ω) are the resistance and continuity ok? 7) after repairing the trouble, cle...

  • Page 345: Fl125Sdw     8-70

    Fl125sdw 8-70 “40” (p0505) isc valve circuit malfunction inspection step 1 1) turn the ignition switch off. 2) remove the right leg shield. ( #5-6) 3) check the isc valve coupler 1 for loose or poor contacts. If ok, then check the isc valve resistance. 4) disconnect the isc valve coupler. 5) measure...

  • Page 346: 8-71     Fl125Sdw

    8-71 fl125sdw 6) if ok, then check the continuity between each terminal and ground. ! Isc valve continuity: ∞Ω (infinity) (terminal – ground) $ 09900-25008: multi-circuit tester set & tester knob indication: resistance (Ω) are the resistance and continuity ok? 7) after repairing the trouble, clear t...

  • Page 347: Fl125Sdw     8-72

    Fl125sdw 8-72 active control inspection (isc rpm control) check 1 1) set up the sds tool. (refer to the sds operation manual for further details.) 2) check that the engine is running. 3) make sure that the engine temperature on data monitor is indicated 80 °c or more. 4) click the “active control”. ...

  • Page 348: 8-73     Fl125Sdw

    8-73 fl125sdw check 3 1) input 1 900 to the isc rpm “spec” field 1. 2) check that the “desired idle speed” 2 is equal or close to the “spec” 1. 3) check that the “engine speed” 3 is close to 1 900. Note: be careful not to increase the “spec” to more than 3 000 or the “engine speed” may reach the upp...

  • Page 349: Fl125Sdw     8-74

    Fl125sdw 8-74 “44” (p0130/p0135) ho2 sensor (ho2s) circuit malfunction inspection step 1 (when indicating 44/p0130:) 1) turn the ignition switch off. 2) remove the frame covers, left and right. ( #5-7) 3) check the ho2 sensor coupler 1 for loose or poor contacts. If ok, then check the ho2 sensor lea...

  • Page 350: 8-75     Fl125Sdw

    8-75 fl125sdw 7) disconnect the ecm coupler. 8) check the continuity between w/g wire a and terminal c. 9) also, check the continuity between br/b wire b and terminal 4. % ! Ho2 sensor lead wire continuity: continuity ()) $ 09900-25008: multi-circuit tester set 09900-25009: needle pointed probe set ...

  • Page 351: Fl125Sdw     8-76

    Fl125sdw 8-76 is the voltage ok? % 6) after repairing the trouble, clear the dtc using sds tool. ( #8-39) step 1 (when indicating 44/p0135:) 1) turn the ignition switch off. 2) remove the frame covers, left and right. ( #5-7) 3) check the ho2 sensor 1 for loose or poor contacts. If ok, then measure ...

  • Page 352: 8-77     Fl125Sdw

    8-77 fl125sdw step 2 (when indicating 44/p0135:) 1) connect the ho2 sensor coupler. 2) insert the needle pointed probes to the ho2 sensor coupler. 3) turn the ignition switch on and measure the heater voltage between w wire c (harness side) and ground. 4) if the tester voltage indicates the battery ...

  • Page 353: Fl125Sdw     8-78

    Fl125sdw 8-78 sensors ckp sensor inspection the crankshaft position sensor is installed in the generator cover. ( #8-43) ckp sensor removal and installation • remove the generator cover. ( #3-14) • install the generator cover in the reverse order of removal. Iap/tp/iat sensor inspection the intake a...

  • Page 354: 8-79     Fl125Sdw

    8-79 fl125sdw • if the et sensor ohmic value does not change in the propor- tion indicated, replace it with a new one. ! Engine temperature sensor specification $ 09900-25008: multi-circuit tester set & tester knob indication: resistance (Ω) % et sensor removal and installation • remove the rear cen...

  • Page 355: Fl125Sdw     8-80

    Fl125sdw 8-80 to sensor removal and installation • remove the front frame cover. ( #5-5) • remove the to sensor. • install the to sensor in the reverse order of removal. Note: when installing the to sensor, the arrow mark a must be pointed upward. Ho2 sensor inspection the heated oxygen sensor is in...

  • Page 356: 8-81     Fl125Sdw

    8-81 fl125sdw fuel system fuel filter removal % " • remove the luggage box. ( #5-5) • place a rag under the hose joint and disconnect the fuel hoses. • remove the fuel filter 1. Inspection • when gasoline is poured lightly to the fuel filter from the port 1, the gasoline should flow out through the ...

  • Page 357: Fl125Sdw     8-82

    Fl125sdw 8-82 throttle body construction 1 throttle body 8 return pipe 2 isc valve 9 upper cushion seal 3 o-ring 0 spacers + 4 intake pipe a holder item n·m kgf-m 5 insulator a isc valve screw a 2 0.2 6 lower cushion seal b throttle body bolt b 9 0.9 7 fuel injector c fuel injector bolt c 9 0.9.

  • Page 358: 8-83     Fl125Sdw

    8-83 fl125sdw removal and disassembly % • remove the leg shields, left and right. ( #5-6) • remove the air cleaner box 1. • disconnect the isc valve coupler 2 and iap/tp/iat sensor coupler 3. • disconnect the throttle cables 4 from their drum. • remove the throttle body 5. % the throttle body is ass...

  • Page 359: Fl125Sdw     8-84

    Fl125sdw 8-84 • remove the o-ring 6. • remove the isc valve 7. % % note: * avoid removing the adjuster 0 and throttle stop screw a . Never remove the iap/tp/iat sensor 8 from the throt- tle body. * never remove the throttle valve 9 from the throttle body. * never use carburetor cleaning chemicals to...

  • Page 360: 8-85     Fl125Sdw

    8-85 fl125sdw inspection throttle valve visually inspect the throttle valve for any damage or clogging, replace it with a new one if necessary. Isc valve • remove the o-ring 1. • visually inspect the isc valve for wear, damage or carbon deposit, replace it with a new one if necessary. Note: the isc ...

  • Page 361: Fl125Sdw     8-86

    Fl125sdw 8-86 • connect the throttle pulling cable 4 and throttle returning cable 5 to the throttle cable drum. • tighten each lock-nut. • adjust the throttle cable play. ( !8-8) • route the harness and fuel hoses properly. ( !8-107 and 111) fuel injector removal " # • remove the right leg shield. (...

  • Page 362: 8-87     Fl125Sdw

    8-87 fl125sdw • remove the insulator 8. • remove the return pipe 9, upper cushion seal 0, o-ring a and lower cushion seal b. Installation installation is in the reverse order of removal. Pay attention to the following points: • apply thin coat of engine oil to the o-ring 1, upper cushion seal 2 and ...

  • Page 363: Fl125Sdw     8-88

    Fl125sdw 8-88 electrical system battery cut off relay the battery cut off relay 1 cuts off the battery power from the charging circuit while kick-starting if the battery voltage is in lower condition or the battery terminal is disconnected. Load cut off relay the load cut off relay 2 cuts off the ba...

  • Page 364: 8-89     Fl125Sdw

    8-89 fl125sdw step 3 1) measure the regulated voltage between the battery terminals. ( #6-9) is the regulated voltage ok? Step 4 1) inspect the battery cut off relay. ( #8-101) is the battery cut off relay ok? Step 5 1) measure the resistance of the generator coil. ( #8-90) is the resistance of gene...

  • Page 365: Fl125Sdw     8-90

    Fl125sdw 8-90 step 2 1) inspect wirings. Are the wirings ok? Battery overcharges. • faulty regulator/rectifier. • faulty battery. • poor contact of generator lead wire coupler. Inspection generator coil resistance • remove rear center leg shield. ( #5-6) • disconnect the generator coupler. Measure t...

  • Page 366: 8-91     Fl125Sdw

    8-91 fl125sdw regulator/rectifier • remove the frame covers, left and right. ( #5-7) • disconnect the regulator/rectifier coupler. • remove the regulator/rectifier. Measure the voltage between the terminals using the multi cir- cuit tester as indicated in the table below. If the voltage is not withi...

  • Page 367: Fl125Sdw     8-92

    Fl125sdw 8-92 starter system and side-stand/ignition interlock system troubleshooting make sure that the fuse are not blown and the battery is fully-charged before diagnosing. Starter motor will not run. Step 1 1) shift the transmission to neutral position. 2) grasp the front brake lever, turn on th...

  • Page 368: 8-93     Fl125Sdw

    8-93 fl125sdw step 3 1) measure the starter relay voltage at the starter relay connectors (between y/g + and y/b -) when the starter button is pushed. Is a voltage ok? Step 4 1) check the starter relay. ( #6-19) is the starter relay ok? Starter motor runs but does not crank the engine. Step 1 1) the...

  • Page 369: Fl125Sdw     8-94

    Fl125sdw 8-94 side-stand/ignition interlock system parts inspection check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. Side-stand swit...

  • Page 370: 8-95     Fl125Sdw

    8-95 fl125sdw side-stand relay • remove the frame head cover. ( #5-6) • remove the side-stand relay. First, check the insulation between a and b terminals with tester. Then, apply 12 v to c and d terminals, + to c and - to d, and check the continuity between a and b terminals. If there is no continu...

  • Page 371: Fl125Sdw     8-96

    Fl125sdw 8-96 ignition system note: the fuel and ignition cut-off circuits are incorporated in this ecm in order to prevent over-running of engine. When engine speed reaches 9 700 r/min, this circuit cuts off fuel at the fuel injector and ignition primary cur- rent for spark plug. Troubleshooting no...

  • Page 372: 8-97     Fl125Sdw

    8-97 fl125sdw step 3 1) measure the ignition coil primary peak voltage. ( #6-22) note: this inspection method is applicable only with the multi-circuit tester and the peak volt adaptor. Is the peak voltage ok? Step 4 1) inspect the spark plug. ( #2-9) is the spark plug ok? Step 5 1) inspect the igni...

  • Page 373: Fl125Sdw     8-98

    Fl125sdw 8-98 inspection ignition coil resistance • remove the rear center leg shield. ( #5-6) • disconnect the ignition coil lead wires 1 and 2. • remove the ignition coil 3. • remove the spark plug cap. Measure the ignition coil resistance in both the primary and sec- ondary windings using the mul...

  • Page 374: 8-99     Fl125Sdw

    8-99 fl125sdw if the peak voltage measured on the ecm coupler is lower than the specified value, measure the peak voltage on the ckp sen- sor coupler as follows. • remove the rear center leg shield. ( #5-8) • disconnect the ckp sensor coupler 2. • connect the multi-circuit tester with the peak volt ...

  • Page 375: Fl125Sdw     8-100

    Fl125sdw 8-100 speedometer inspection check the continuity between the lead wires using the multi-circuit tester. If there is no continuity replace the respective parts. $ 09900-25008: multi-circuit tester set * tester knob indication: continuity test ()) y: high beam o: fuel gauge, gear position y/...

  • Page 376: 8-101     Fl125Sdw

    8-101 fl125sdw relays battery cut off relay and load cut off relay removal and installation • remove the front frame cover. ( #5-5) • remove the battery cut off relay 1 and load cut off relay 2. • install the battery cut off relay 1 and load cut off relay 2 in the reverse order of removal. Sds opera...

  • Page 377: Fl125Sdw     8-102

    Fl125sdw 8-102 diodes removal and installation battery diodes • remove the right frame cover. ( #5-7) • remove the battery diodes 1, 2, 3, 4 and 5. • install the battery diodes in the reverse order of removal. Note: the battery diodes 1 , 2 , 3 , 4 and 5 are the same parts. Neutral diode • remove th...

  • Page 378: 8-103     Fl125Sdw

    8-103 fl125sdw lamps headlight, position/parking light 1: headlight bulb: 12 v 35/35 w (hs1) 2: position/parking light bulb: 12 v 5 w % if you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure..

  • Page 379: Fl125Sdw     8-104

    Fl125sdw 8-104 turn signal light 1: turn signal light bulb: 12 v 21 w % * if you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. * do not overtighten the lens fitting screws..

  • Page 380: 8-105     Fl125Sdw

    8-105 fl125sdw brake light/taillight 1: brake light/taillight: 12 v 21/5 w % * if you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. * do not overtighten the lens fitting screws..

  • Page 381: Fl125Sdw     8-106

    Fl125sdw 8-106 wiring diagram w/b gr y/b b/w o/r r/w o b/g o b/w o gr g y/b bl y y y bl br/b y y y r/w b/w r r y/g y/b r r/w r/w r b/w b/w r p g/b dg br/b y/r o r/w w/bl o br/b w/g w br/b o/b o y/g r/w r y/b o y/w o r r/w r r/w r r/w r r/w r r/w bl w/y r/b g/bl y/bl o/r r o b/w o w gr b w b b bl w/y...

  • Page 382: 8-107     Fl125Sdw

    8-107 fl125sdw wiring harness, cable and hose routing wiring harness routing wiring harness speedometer cable clamp clamp clamp battery lead wire clamp fuel level gauge lead wire load cut off relay seat lock cable fuel level gauge lead wire starter motor lead wire starter motor side-stand switch lea...

  • Page 383: Fl125Sdw     8-108

    Fl125sdw 8-108 dealer mode coupler battery cap battery terminal rear turn signal light (l) coupler rear combination light coupler condenser license plate light lead wire regulator/rectifirer rear turn signal light lead wire rear brake switch coupler fuse lead wire fi cintrol unite lead wire battery ...

  • Page 384: 8-109     Fl125Sdw

    8-109 fl125sdw clamp gener ator co v e r gener ator star tor grommet gener ator rotor gener ator co v e r gear position s w itch lead wire engine sproc k e t co v e r gear position s w itch cr ank case (l) ckp sensor gener ator lead wire clamp ckp sensor gener ator lead wire.

  • Page 385: Fl125Sdw     8-110

    Fl125sdw 8-110 cable routing handlebar harness speedometer cable front brake hose throttle returning cable throttle pulling cable clamp throttle returning cable throttle returning cable throttle pulling cable throttle returning cable throttle pulling cable speedometer cable guide wiring harness fron...

  • Page 386: 8-111     Fl125Sdw

    8-111 fl125sdw fuel hose routing fuel filter fuel hose 3-way union fuel injector fuel injector marking (red) marking (red) upper upper lo w e r low er lo we r left right marking (white) marking (yellow) marking (red) 30˚.

  • Page 387: Fl125Sdw     8-112

    Fl125sdw 8-112 exterior parts construction frame head cover front right leg shield front left leg shield front center leg shield rear center leg shield rear left leg shield frame rear right leg shield.

  • Page 388: 8-113     Fl125Sdw

    8-113 fl125sdw front frame cover right frame lower cover battery box lid right frame cover rear fender luggage box frame left lower frame cover left frame cover rear combination light frame center cover.

  • Page 389: Fl125Sdw     8-114

    Fl125sdw 8-114 throttle body and fuel injector installation 1 throttle body 5 spacer 2 intake pipe 6 holder 3 fuel injector 7 return pipe 4 insulator *1 adjust the clearance between the fuel injector coupler and bolt to provide 1 to 2 mm. 9 n·m (0.9 kgf-m) 9 n·m (0.9 kgf-m) 9 n·m (0.9 kgf-m) *1 1 – ...

  • Page 390: 8-115     Fl125Sdw

    8-115 fl125sdw special tools note: when order the special tool, please confirm whether it is available or not. Tightening torque 09900-25008 multi-circuit tester set 09900-25009 needle pointed probe set 09904-41010 sds set tool 09930-82720 mode select switch 99565-01010-011 cd-rom ver. 11 item n·m k...

  • Page 391: Fl125Sdw     8-116

    Fl125sdw 8-116 service data valve + guide unit: mm camshaft + cylinder head unit: mm item standard limit valve diam. In. 24.9 – 25.1 — ex. 21.9 – 22.1 — valve clearance (when cold) in. 0.03 – 0.08 — ex. 0.08 – 0.13 — valve guide-to-valve stem clearance in. 0.010 – 0.037 — ex. 0.030 – 0.057 — valve g...

  • Page 392: 8-117     Fl125Sdw

    8-117 fl125sdw cylinder + piston + piston ring unit: mm conrod + crankshaft unit: mm oil pump first clutch unit: mm item standard limit compression pressure 750 – 1 200 kpa (7.5 – 12 kgf/cm²) 650 kpa (6.5 kgf/cm²) piston-to-cylinder clearance * 0.020 – 0.030 0.120 cylinder bore * 53.500 – 53.515 53....

  • Page 393: Fl125Sdw     8-118

    Fl125sdw 8-118 gear shift clutch unit: mm transmission + drive chain unit: mm (in) (except ratio) * fuel injector + isc valve item standard limit drive plate thickness 2.9 – 3.1 2.6 drive plate claw width 11.80 – 12.00 11.0 driven plate distortion — 0.10 clutch spring free length — 32.0 item standar...

  • Page 394: 8-119     Fl125Sdw

    8-119 fl125sdw * fi sensors * throttle body item specification note ckp sensor resistance 180 – 280 Ω ckp sensor peak voltage 2.0 v (when cranking) or more + bl/y – - g/w iap sensor input voltage 4.5 – 5.5 v iap sensor output voltage approx. 2.0 – 3.5 v at idle speed + g/b – - br/b tp sensor input v...

  • Page 395: Fl125Sdw     8-120

    Fl125sdw 8-120 electrical unit: mm item specification note spark plug type * ngk: cr6hsa * denso: u20fsr-u gap 0.6 – 0.7 spark performance 8.0 mm or more at 1 atm. Ignition coil resistance primary * 2 – 5 Ω + terminal – - terminal secondary * 25 – 40 k Ω plug cap – - terminal ignition coil primary p...

  • Page 396: 8-121     Fl125Sdw

    8-121 fl125sdw wattage unit: w brake + wheel unit: mm suspension unit: mm item specification headlight hi * 35 lo * 35 position/parking light 5 brake light/taillight * 21/5 license plate light 5 turn signal light * 21 speedometer light 1.7 high beam indicator light 1.7 turn signal indicator light * ...

  • Page 397: Fl125Sdw     8-122

    Fl125sdw 8-122 tire fuel + oil item standard limit cold inflation tire pressure (solo riding) front 175 kpa (1.75 kgf/cm²) — rear 200 kpa (2.00 kgf/cm²) — cold inflation tire pressure (dual riding) front 175 kpa (1.75 kgf/cm²) rear 280 kpa (2.80 kgf/cm²) tire size front * 70/90-17 m/c 38p — rear * 8...

  • Page 398: Notice

    Prepared by march, 2007 part no. 99500-31371-01e printed in japan 396 notice please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words warning, caution and note have special meanings. Pay special attention to the messages highlighted by...

  • Page 399: Printed In Japan

    Printed in japan k7 dic120 top bottom (back: 13mm) 9 9 5 0 0 - 3 1 3 7 1 - 0 1 e.