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Suzuki UY125 Service Manual

Summary of UY125

  • Page 1

    Group index general information 1 periodic maintenance 2 engine 3 fuel and lubrication system 4 chassis 5 electrical system 6 servicing information 7 foreword this manual contains an introductory description on the suzuki uy125/s and procedures for its inspec- tion/service and overhaul of its main c...

  • Page 2: 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 3

    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 thread loc...

  • Page 4

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  • Page 5: General Information

    General information 1-1 1 general information contents warning/caution/note........................................................................ 1- 2 general precautions ......................................................................... 1- 2 suzuki uy125k6/sk6 (’06-model) ....................

  • Page 6: Warning/caution/note

    1-2 general information warning/caution/note 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 mes- sages highlighted by these signal words. ! Indicat...

  • Page 7

    General information 1-3 " * if parts replacement is necessary, replace the parts with suzuki genuine parts or their equiva- lent. * when removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. * be sure to use...

  • Page 8: Serial Number Location

    1-4 general information suzuki uy125k6/sk6 (’06-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 requir...

  • Page 9: Break-In Procedures

    General information 1-5 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 of sf/sg ...

  • Page 10: Specifications

    1-6 general information specifications dimensions and dry mass overall length.......................................................................... 1 859 mm overall width ........................................................................... 654 mm overall height...............................

  • Page 11

    General information 1-7 electrical ignition type ............................................................................. Electronic ignition (cdi) ignition timing .......................................................................... 10° b.T.D.C.At 1 600 rpm spark plug .......................

  • Page 12

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  • Page 13: Periodic Maintenance

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

  • Page 14

    2-2 periodic maintenance 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. No...

  • Page 15

    Periodic maintenance 2-3 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 16: Maintenance And Tune-Up

    2-4 periodic maintenance maintenance and tune-up procedures this section describes the servicing procedures for each item of the periodic maintenance requirements. Air cleaner • place the motorcycle on the side stand. • remove the frame cover (left and right). ( !5-10) • remove the hook 1. • remove ...

  • Page 17

    Periodic maintenance 2-5 • remove the drain plug from the air cleaner box to allow any water to drain out. Exhaust pipe bolt and muffler mounting nut • tighten the exhaust pipe bolts 1 and muffler mounting bolts 2. Cooling fan filter • remove the cooling fan cover 1. • remove the holder 2 and coolin...

  • Page 18

    2-6 periodic maintenance valve clearance removal • remove the frame front cover. ( !5-8) • remove the spark plug. ( !2-7) • disconnect the breather hoses 1 and remove the head cover 2. Inspection the valve clearance specification is same for both valves. Valve clearance adjustment must be checked an...

  • Page 19

    Periodic maintenance 2-7 • after finishing the valve clearance adjustment, reinstall the fol- lowing items. * cylinder head cover ( !3-11) * spark plug and plug cap ( !2-7) * frame front cover ( !5-8) spark plug removal • remove the frame front cover. ( !5-8) • disconnect the spark plug cap and remo...

  • Page 20

    2-8 periodic maintenance 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 inspect the fuel hoses for damage and fuel leakage. If any defects are f...

  • Page 21

    Periodic maintenance 2-9 • turn off the engine and wait minute, then check the oil level by removing the filler cap 2. If the level is below mark “l”, add oil to “f” level. (off the center stand, do not screw the filler cap.) if the level is above mark “f”, drain oil to “f” level. Oil filter replace...

  • Page 22

    2-10 periodic maintenance engine idle speed note: make this adjustment when the engine is hot. • connect an electric tachometer. • start up the engine and set its speed at anywhere between 1 500 and 1 700 rpm by turning throttle stop screw. Engine idle speed: 1 600 ± 100 rpm $ 09900-26006: tachomete...

  • Page 23

    Periodic maintenance 2-11 drive belt • keep the motorcycle upright. • remove the clutch cover. ( !3-10) • check the contact surface for crack or other damage. If crack or other damage exists, replace the belt with a new one. " • install the clutch cover. ( !3-72) note: drain water from the clutch co...

  • Page 24

    2-12 periodic maintenance brake brake lever play • adjust the brake lever play by turning the adjusting nut 1 so that the play a is 15 – 25 mm as shown. # brake lever play a: 15 – 25 mm front brake pads (uy125s) the extent of brake pad wear can be checked by observing the grooved limit line a on the...

  • Page 25

    Periodic maintenance 2-13 brake hose and brake fluid (uy125s) brake hose check the brake hose for leakage, cracks, wear and damage. If any damages are found, replace the brake hose with a new one. Brake fluid level check • keep the motorcycle upright and place the handlebars straight. • check the br...

  • Page 26

    2-14 periodic maintenance front brake fluid replacement • remove the handlebar cover. ( !5-5) • place the motorcycle on a level surface and keep the handle- bar straight. • remove the front master cylinder reservoir cap and dia- phragm. • suck up the old brake fluid as much as possible. • fill the r...

  • Page 27

    Periodic maintenance 2-15 • squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle; this will remove the tension of the brake l...

  • Page 28

    2-16 periodic maintenance tire pressure if the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, main- tain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. " wheel make ...

  • Page 29

    Periodic maintenance 2-17 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 30

    2-18 periodic maintenance chassis bolts and nuts check that all chassis bolts and nuts are tightened to their specified torque. (refer to page 2-19 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 31

    Periodic maintenance 2-19 http://mototh.Com.

  • Page 32: Compression Pressure Check

    2-20 periodic maintenance 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 33: Oil Pressure Check

    Periodic maintenance 2-21 oil pressure check check the oil pressure periodically. This will give a good indication of the condition of the moving parts. Oil pressure specisfication if the oil pressure is lower or higher than specification, the following causes may be considered. Low oil pressure * c...

  • Page 34: Automatic Clutch Inspection

    2-22 periodic maintenance automatic clutch inspection this motorcycle is equipped with an automatic clutch and vari- able ratio belt drive transmission. The engagement of the clutch is governed by engine rpms and centrifugal mechanism located in the clutch. To insure proper performance and longer li...

  • Page 35: Engine

    Engine 3-1 engine contents 3 engine components removable with the engine in place .. 3- 2 engine removal and installation ................................................. 3- 4 engine removal............................................................................... 3- 4 engine remounting .........

  • Page 36

    3-2 engine 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 starter motor !...

  • Page 37

    Engine 3-3 engine right side parts removal installation muffler !3-5 !3-9 fan cowling cover !3-11 !3-71 cooling fan !3-13 !3-65 starter idle gear !3-15 !3-63 magneto cover !3-14 !3-63 magnetorotor !3-15 !3-62 oil pump !3-16 !3-61 cylinder cowling right cover !3-11 !3-71 http://mototh.Com.

  • Page 38

    3-4 engine engine removal and installation engine removal before taking the engine out of the frame, wash the engine using a steam cleaner. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • remove the front frame cover. ( !5-8...

  • Page 39

    Engine 3-5 • remove the air cleaner box. • disconnect the magneto lead wire coupler 4 and pick-up coil lead wire coupler 5. • remove the engine ground bolt. • disconnect the spark plug cap 6. • remove the exhaust pipe bolts. Http://mototh.Com.

  • Page 40

    3-6 engine • remove the muffler mounting bolts and then remove the muf- fler 7. • remove the rear brake cable clamp bracket 8. • remove the rear brake cable adjuster nut 9, spring 0 and pin a. • remove the rear brake cable clamp. • remove the clutch upper cover b. • remove the crankcase tube c. Http...

  • Page 41

    Engine 3-7 • support the engine using a jack. • remove the rear shock absorber lower mounting bolt. • remove the engine mounting bolt and nut. Note: never remove the crankcase bracket d from the frame. • remove the engine from the frame. Http://mototh.Com.

  • Page 42

    3-8 engine engine remounting remount the engine in the reverse order of removal. Pay atten- tion to the following points: • install the crankcase bracket 1 to the frame and insert the crankcase bracket mounting shaft. • push up on the rear part of the crankcase bracket 1 and have the damper b touch ...

  • Page 43

    Engine 3-9 • install the muffler. # • after installing the engine, properly route the wire harness, cables, and hoses. Refer to the wire and cable routing sec- tions. ( !7-12 to -19) • refer to the following sections to adjust the respective items to specification. * engine oil ( !2-8) * reduction g...

  • Page 44: Engine Disassembly

    3-10 engine engine disassembly # clutch cover • remove the kick starter lever. • remove the clutch cover assembly 1. Crankcase tube grommet • remove the crankcase tube grommet no.1 1 and no.2 2. Starter motor • remove the starter motor 1. Identify the position of each removed part. Organize the part...

  • Page 45

    Engine 3-11 pair cut valve • disconnect the pair hose 1 and vacuum hose 2. • remove the pair cut valve 3. Fan cowling cover/cylinder cowling/intake pipe • remove the fan cowling cover 1 and cylinder cowling right cover 2. • remove the intake pipe 3 and cylinder cowling left cover 4. Spark plug • rem...

  • Page 46

    3-12 engine • turn the crankshaft clockwise with a box wrench and align the “top” mark a on the cooling fan with the index mark b on the magneto cover. Note: the piston must be at tdc on the compression stroke. Cam chain tension adjuster • remove the cam chain tension adjuster 1 and gasket. Camshaft...

  • Page 47

    Engine 3-13 • remove the dowel pins 4 and gasket 5. Piston • remove the piston pin circlip. • remove the piston by driving out the piston pin. Note: place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase. Cooling fan • remove the cooling fan 1. • remove ...

  • Page 48

    3-14 engine rear wheel/rear brake • remove the rear wheel. • remove the brake shoes. Center stand • remove the center stand spring 1. • remove the cotter pin 2, washer 3, shaft 4 and center stand 5. Magneto cover • remove the magneto cover 1. Http://mototh.Com.

  • Page 49

    Engine 3-15 • remove the dowel pins 2 and gasket 3. Starter idle gear • remove the starter idle gear 1 and shaft 2. Magnetorotor • hold the fixed drive face with the special tool. $ 09930-40113: rotor holder • remove the magnetorotor nut. • remove the magnetorotor 1 with the special tool. $ 09930-34...

  • Page 50

    3-16 engine • remove the key 3. Oil pump • remove the oil pump cover 1. • turn the oil pump sprocket and align the oil pump sprocket hole on the oil pump mounting screw 2. • remove the oil pump screw 2. • remove the oil pump assembly 3 along with the chain 4. Note: the oil pump assembly is a non-dis...

  • Page 51

    Engine 3-17 fixed drive face • remove the fixed drive face nut with the special tool. $ 09930-40113: rotor holder • remove the washer 1, kick starter 2 and fixed drive face 3. Movable driven face/clutch housing • remove the clutch housing nut with the special tool. $ 09930-40113: rotor holder • remo...

  • Page 52

    3-18 engine reduction gear • drain the reduction gear oil. ( !2-11) • remove the reduction gear cover 1. • remove the gasket 2 and dowel pins 3. • remove the washer 4, idle driven gear 5 and rear axle shaft 6. Oil filter • remove the oil filter cap 1. • remove the oil filter 2 and o-ring 3. Http://m...

  • Page 53

    Engine 3-19 oil sump filter • remove the oil sump filter cap 1 and oil sump filter 2. Brake cam lever • remove the rear brake cam lever 1, brake lining wear indica- tor 2 and brake cam 3. Crankcase • remove the crankcase bolts. • separator the crankcase into 2 parts, right and left with the crankcas...

  • Page 54: And Service

    3-20 engine engine component inspection and service cylinder head cover disassembly • remove the pair reed valve cover 1 and pair reed valve 2. • remove the breather cover 3, oil separator 4 and gasket 5. Inspection reed valve • inspect the reed valve for the carbon deposit. • if the carbon deposit ...

  • Page 55

    Engine 3-21 reassembly • reassembly the cylinder head cover in the reverse order of disassembly. Pay attention to the following points: • install the breather cover gasket 1. # • tighten the breather cover bolts to the specified torque. " breater cover bolt: 10 n·m (1.0 kgf-m) • apply thread lock to...

  • Page 56

    3-22 engine • pull out the intake and exhaust rocker arm shafts 3 by using an 8-mm thread bolt. • remove the intake and exhaust rocker arms 4. • remove the camshaft 5. • compress the valve spring with the valve spring compressor. • remove the valve cotters from the valve stem. $ 09916-14510: valve s...

  • Page 57

    Engine 3-23 • remove the valve stem seal 9 and valve spring seat 0. 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 checking the valve rocker arm, the inside diam...

  • Page 58

    3-24 engine 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 59

    Engine 3-25 valve stem wear if the valve stem is worn down to the limit, when measured with a micrometer, and the clearance is found to be in excess of the limit indicated previously, replace the valve, if the stem is within the limit, then replace the guide. After replacing valve or guide, be sure ...

  • Page 60

    3-26 engine • after fitting the valve guides, re-finish their guiding bores with the handle and reamer. Be sure to clean and oil the guides after reaming. $ 09916-34542: handle 09916-34570: valve guide reamer (5.0 mm) valve seat width inspection visually check for valve seat width on each valve face...

  • Page 61

    Engine 3-27 valve seat service the valve seats 1 for both the intake and exhaust valves are machined to four different angles. The seat contact surface is cut at 45°. $ 09916-21111: valve seat cutter set 09916-20610: valve seat cutter (n-121) 09916-20620: valve seat cutter (n-122) 09916-20630: valve...

  • Page 62

    3-28 engine • seat the pilot snugly. Install the 45° cutter 3, attachment and t-handle 4. Initial seat cut • using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. • measure the valve seat width w after every cut. • if the valve seat is pitted or burned, use the 45°...

  • Page 63

    Engine 3-29 final seat cut • if the contact area w is too low or too narrow, use the 45° cut- ter to raise and widen the contact area. Note: after cutting the 15° and 30° angles, it is possible that the valve seat (45°) is too narrow. If so, re-cut the valve seat to the correct width. • after the de...

  • Page 64

    3-30 engine valve spring inspection the force of the coil spring keeps the valve seat tight. A weak- ened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mecha- nism. Check the valve springs for proper strength by measuring their free l...

  • Page 65

    Engine 3-31 • remove the bearings and cam sprocket flange with a bearing puller. $ 09913-60910: bearing & gear puller note: avoid removing the cam sprocket flange and bearing from the camshaft unless it is really necessary to do so, for example, removing the damaged bearing. # • press in the bearing...

  • Page 66

    3-32 engine • install the valve spring, making sure that the close-pitch end a of each spring goes in first to rest on the head. The coil pitch of spring vary: the pitch decreases from top to bottom, as shown in the illustration. • put on the valve spring retainer, and using the valve lifter, press ...

  • Page 67

    Engine 3-33 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 cylinder distortion check the gasketed surface of the cylinder for distortion with a straightedg...

  • Page 68

    3-34 engine piston piston diameter using a micrometer, measure the piston outside diameter at the place 10 mm from the skirt end as shown. If the measurement is less than the limit, replace the piston. & piston diameter service limit: 53.380 mm $ 09900-20203: micrometer (50 – 75 mm) piston-to-cylind...

  • Page 69

    Engine 3-35 piston ring end gap • measure the piston ring end gap using the vernier calipers. • next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. • if any of the measurements exceeds the service limit, replace the piston ring with a n...

  • Page 70

    3-36 engine crankshaft conrod small end i.D. Using a caliper gauge, measure the conrod small end inside diameter. & conrod small end i.D. Service limit: 14.064 mm $ 09900-20605: dial calipers if the conrod small end bore inside diameter exceeds the limit, replace the conrod. Conrod deflection and co...

  • Page 71

    Engine 3-37 reassembly • when rebuilding the crankshaft, the width between the weds a should be within the standard range. & crank wed to wed width a: 48.9 – 49.1 mm oil pump disassembly • remove the circlip 1, washer 2, oil pump driven gear 3 and pin 4. Inspection rotate the oil pump shaft by finge...

  • Page 72

    3-38 engine movable drive face inspection check the drive face for any abnormal condition such as stepped wear or discoloration caused by burning. If any defects are found, replace the movable drive face with a new one. • remove the movable drive face plate 1. • remove the dampers 2. • pull out the ...

  • Page 73

    Engine 3-39 clutch shoe/movable driven face disassembly • loosen the clutch shoe nut with the special tool. $ 09930-40113: rotor holder 09930-40120: rotor holder attachment (a) # • lock the clutch shoe assembly with the special tool handle turned in. • remove the clutch shoe nut 1. $ 09922-31430: cl...

  • Page 74

    3-40 engine • remove the pins 5, movable driven face 6, and fixed driven face 7. • remove the bearing with the special tool. $ 09921-20240: bearing remover set # • remove the snap ring. • remove the bearing with the special tool. $ 09913-70210: bearing remover # • remove the oil seals 8 and o-rings ...

  • Page 75

    Engine 3-41 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. $ 09900-20101: vernier ca...

  • Page 76

    3-42 engine driven face inspection inspect the drive belt contacting surface of both driven faces for any scratches, wear or damage. If any damages are found, replace the driven faces with new ones. Reassembly reassemble the clutch shoe assembly and movable driven face in the reverse order of disass...

  • Page 77

    Engine 3-43 • install the pins 3 at three places on the drive face hub. • apply as small amount of suzuki super grease “a” to the cam where the pins are placed. * 99000-25010: suzuki super grease “a” • install the new o-rings 4. • apply suzuki super grease “a” to the o-rings. • install the movable d...

  • Page 78

    3-44 engine drive belt remove the drive belt and check for cracks, wear and separa- tion and measure the drive belt width with vernier calipers. If any damages are found or if the width of the drive belt is less than the service limit, replace the drive belt with a new one. & drive belt width servic...

  • Page 79

    Engine 3-45 reassembly • reassemble the drive belt filter in the reverse order of disas- sembly. Pay attention to the following points: • install the plate after aligning the cooling belt cover holes a with the plate pins b. • apply grease to the new o-ring and install the duct 1. * 99000-25010: suz...

  • Page 80

    3-46 engine • remove the roller 3, spring 4 and push pieces 5. Inspection inspect the rollers 1 and push pieces 2 for damage and exces- sive wear. If any defects are found, replace the new one. Reassembly • reassemble the starter clutch in the reverse order of disas- sembly. Pay attention to the fol...

  • Page 81

    Engine 3-47 reassembly • reassemble the magneto cover in the reverse order of disas- sembly. Pay attention to the following points: • install the oil seal with the special tool. $ 09913-70210: bearing installer set (35 mm) • apply a small quantity of suzuki super grease “a” to the lip of the oil sea...

  • Page 82

    3-48 engine • remove the kick starter driven gear 5, spring 6 and kick starter shaft 7. Bearing inspection wash the bearing with a cleaning solvent and lubricate it with motor oil before inspection. Rotate the inner race and check to see that it turns smoothly. If it does not turn quietly and smooth...

  • Page 83

    Engine 3-49 • apply suzuki super grease “a” onto the shaft and gear of the kick starter drive gear. * 99000-25010: suzuki super grease “a” • install the kick starter driven gear 4. • apply suzuki super grease “a” to the oil seal lip. * 99000-25010: suzuki super grease “a” • install the kick starter ...

  • Page 84

    3-50 engine bearing inspection wash the bearing with a cleaning solvent and lubricate it with motor oil before inspection. Rotate the inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defective and...

  • Page 85

    Engine 3-51 bearing inspection wash the bearing with a cleaning solvent and lubricate it with motor oil before inspection. Rotate the inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defective and...

  • Page 86

    3-52 engine • install the engine mounting bushing using two steel tubes of the appropriate size and a vise. Press the mounting bushing into the crankcase holes. ( !7-23) left crankcase bearing/oil seal removal • remove the bearing retainer 1. • remove the rear axle shaft bearing with the special too...

  • Page 87

    Engine 3-53 • remove the crankshaft oil seal with the special tool. $ 09913-50121: oil seal remover # • remove the crankshaft bearing with the special tool. $ 09913-70210: bearing installer set (35 mm) # bearing/oil seal installation • install the driveshaft bearing 1 and idle shaft 2 bearing with t...

  • Page 88

    3-54 engine • install the crankshaft bearing with the special tool. $ 09913-70210: bearing installer set (52 mm) • install the crankshaft oil seal with the special tool. $ 09913-70210: bearing installer set (42 mm) • install the bearing retainer. Note: when installing the bearing retainers, apply th...

  • Page 89

    Engine 3-55 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) cut out about 10 mm on the shim as shown. $ 09900-22302: plasti-gauge • install th...

  • Page 90: Engine Reassembly

    3-56 engine engine reassembly reassemble the engine in the reverse order of disassembly. Pay attention to the following points: note: apply engine oil to each running and sliding part before reas- sembling. # crankshaft • mount the crankshaft into the right crankcase by pulling its right end into th...

  • Page 91

    Engine 3-57 • apply sealant to the right crankcase. , 99000-31110: suzuki bond “1215” # • tighten the crankcase bolts to the specified torque. " crankcase bolt: 10 n·m (1.0 kgf-m) note: * after the crankcase bolts have been tightened, make sure that the crankshaft rotates smoothly. * if the cranksha...

  • Page 92

    3-58 engine # • install the oil sump filter cap 3. • tighten the oil sump filter cap bolts to the specified torque. " oil sump filter cap bolt: 10 n·m (1.0 kgf-m) oil filter • fit the o-ring 1. • position the oil filter 2. • fit the o-ring 3 and spring 4. # # • install the oil filter cap 5. * the li...

  • Page 93

    Engine 3-59 reduction gear • install the driveshaft 1 to the case. • install the rear axle shaft 2. • install the idle driven gear 3 and washer 4. # • install the dowel pins 5 and new gasket 6. • install the reduction gear cover 7. • tighten the reduction gear cover bolts to the specified torque. " ...

  • Page 94

    3-60 engine movable driven face • check that no roller inside the movable drive face is out of position from the slot. • install the movable drive face 1 and spacer 2. # • with the clutch shoe spring compressed by hands, the mov- able driven face towards the clutch, install the drive belt 3 to the m...

  • Page 95

    Engine 3-61 • install the fixed drive face 7. • install the kick starter 8. • install the washer 9 and nut 0. # • with the fixed drive face locked, tighten the fixed drive face nut to the specified torque. " fixed drive face nut: 50 n·m (5.0 kgf-m) $ 09930-40113: rotor holder • turn the fixed drive ...

  • Page 96

    3-62 engine • with the other side of the chain engaged with the crankshaft gear, install the oil pump assembly after applying thread lock to the screw. + 99000-32110: thread lock super “1322” • tighten the oil pump mounting screws to the specified torque. " oil pump mounting bolt: 8 n·m (0.8 kgf-m) ...

  • Page 97

    Engine 3-63 starter idle gear • install the starter idle gear 1 onto the starter idle gear shaft 2. # magneto cover • install the dowel pins 1 and gasket 2. # • install the magneto cover bolts to the specified torque. Note: fit the clamp to the bolt a as shown. " magneto cover nut: 10 n·m (1.0 kgf-m...

  • Page 98

    3-64 engine • position the brake cam so that the punch mark a faces the rear axle shaft. ( !7-27) • align the tang 1 on the brake lining wear indicator plate 2 with the cutaway 3 on the brake cam. Then, slide the brake lining wear indicator plate 2 onto the brake cam. • install the return spring and...

  • Page 99

    Engine 3-65 • install the washer 2. • tighten the cooling fan holder nut to the specified torque with the special tool. " cooling fan holder nut: 33 n·m (3.3 kgf-m) $ 09930-40113: rotor holder • align the boss c of the cooling fan to the groove d of the cooling fan holder. • tighten the cooling fan ...

  • Page 100

    3-66 engine # • top ring and 2nd ring differ in the shape of ring face, and the face of top ring is chrome-plated whereas that of 2nd ring is not. The color of 2nd ring appears darker than that of the top one. • the 1st and 2nd piston rings should be installed with their marks facing up. • position ...

  • Page 101

    Engine 3-67 • after the piston pin 1 has been inserted through the conrod, install the circlip 2. # cylinder • before installing the cylinder, oil the big end and small end of the conrod and also the sliding surface of the piston. • install the dowel pins and a new gasket 1. # • hold each piston rin...

  • Page 102

    3-68 engine • install the cylinder head and the oil separator plate 4 and washer 5. • tighten the cylinder head nuts to the specified torque diago- nally. " cylinder head nut: 25 n·m (2.5 kgf-m) • tighten the cylinder head side nuts to the specified torque. " cylinder head side nut: 10 n·m (1.0 kgf-...

  • Page 103

    Engine 3-69 • install the spring 6 and plastic washer 7 to the decompres- sion cam. • hook the part e of the spring onto the cam and fit the part f to the washer’s slit and hole of cam sprocket 8. • turn the decompression cam 9 clockwise, and install the decomp cam stopper 0. • tighten the camshaft ...

  • Page 104

    3-70 engine • fit a new gasket 1 to the cam chain tension adjuster body 2. # • install the cam chain tension adjuster body to the cylinder and tighten the bolts to the specified torque. " cam chain tension adjuster mounting bolt: 10 n·m (1.0 kgf-m) • turn the adjusting screw counterclockwise with a ...

  • Page 105

    Engine 3-71 cylinder cowling • install the cylinder cowling left cover 1. Intake pipe • install the intake pipe. # • tighten the intake pipe mounting bolts to the specified torque. " intake pipe mounting bolt: 10 n·m (1.0 kgf-m) fan cowling cover • install the fan cylinder cowling right cover 1 and ...

  • Page 106

    3-72 engine • mount the starter motor 2 on the engine. • tighten the starter motor bolts to the specified torque. " starter motor mounting bolt: 10 n·m (1.0 kgf-m) crankcase tube grommet • install the crankcase tube grommet no.1 1 and no.2 2. Note: the boss a of the crankcase tube grommet faces fron...

  • Page 107: Pair (Air Supply) System

    Engine 3-73 pair (air supply) system pair hoses inspection • remove the frame front cover. ( !5-8) • inspect the pair hoses for wear or damage. • inspect the pair hoses are securely connected. Pair reed valve inspection • remove the pair reed valve cover. ( !3-20) • inspect the reed valve for the ca...

  • Page 108

    White page http://mototh.Com.

  • Page 109

    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 110: Fuel Tank And Fuel Tap

    4-2 fuel and lubrication system fuel tank and fuel tap removal • remove the frame front cover. ( !5-8) • remove the luggage box. ( !5-9) • remove the e-ring 1 and pin 2. • disconnect the fuel hose 3 and vacuum hose 4. " • remove the retainer 5. • disconnect the fuel level gauge coupler 6. Gasoline i...

  • Page 111

    Fuel and lubrication system 4-3 • remove the fuel tank 7. • remove the fuel tap 8. Inspection fuel filter if the 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 check the fuel filter for cracks....

  • Page 112

    4-4 fuel and lubrication system fuel tap connect the vacuum pump gauge to the vacuum port of the fuel tap. Apply negative pressure to the fuel tap and breathe the fuel outlet port. If air a does not flow out, replace the fuel tap with a new one. # specified vacuum: approx. 4 kpa $ 09917-47010: vacuu...

  • Page 113: Fuel Level Gauge

    Fuel and lubrication system 4-5 fuel level gauge removal • open the seat. ( !5-8) • remove the retainer 1. • disconnect the fuel level gauge coupler 2. • remove the rubber cushion 3. • remove the fuel level gauge 4. Http://mototh.Com.

  • Page 114

    4-6 fuel and lubrication system inspection measure resistance between the terminals when the float is at the position listed below. $ 09900-25008: multi-circuit tester if the resistance measured is out of the specification, replace the gauge assembly with a new one. Float position resistance between...

  • Page 115: Carburetor

    Fuel and lubrication system 4-7 carburetor construction 1 top cap 6 starter body a needle valve 2 spring 7 pilot screw b float 3 holder 8 air vent hose c pilot jet 4 jet needle 9 needle jet holder d float chamber 5 piston valve assembly 0 main jet e throttle stop screw http://mototh.Com.

  • Page 116

    4-8 fuel and lubrication system specifications removal • remove the frame front cover. ( !5-8) • remove the luggage box. ( !5-9) • remove the fuel tank. ( !4-3) • disconnect the pair hose 1 and pcv hose 2. • remove the air cleaner mounting bolts. • slightly move the air cleaner box backward. • loose...

  • Page 117

    Fuel and lubrication system 4-9 • disconnect the starter cable 3. • disconnect the throttle cable 4. • remove the carburetor. Disassembly • disconnect the fuel hose 1, air vent hose 2, fuel drain hose 3 and vacuum hose 4. • remove the throttle stop screw 5. • remove the carburetor top cap 6. % do no...

  • Page 118

    4-10 fuel and lubrication system • remove the spring 7 and diaphragm 8. • remove the holder 9 by turning it counterclockwise with a screwdriver. • remove the following parts. 0 holder a spring b washers c jet needle • remove the float chamber body d. • remove the float assembly e and needle valve f ...

  • Page 119

    Fuel and lubrication system 4-11 • remove the following parts. H main jet i pilot jet j needle jet holder k needle jet % • remve the starter body l. • remove the pilot screw m, spring n, washer o and o-ring p. Note: before removing the pilot screw m, determine the setting by slowly turning it clockw...

  • Page 120

    4-12 fuel and lubrication system 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 121

    Fuel and lubrication system 4-13 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 122

    4-14 fuel and lubrication system • install the pilot screw 1. Note: turn in the pilot screw 1 until it lightly seats, then back it out the counted number of turns. ( !4-11) % • install the gasket 2 to the starter body 3. ( !4-11) % • install the gasket 4 to the float chamber body 5. ( !4-10) % • rea...

  • Page 123: Lubrication System

    Fuel and lubrication system 4-15 • position the diaphragm to the carburetor body properly. • align the lug on the carburetor with the intake pipe cutout a. • adjust the following items to the specification. * idling adjustment................................................... !2-10 * throttle cable...

  • Page 124

    4-16 fuel and lubrication system engine lubrication system chart piston and piston pin cylinder wall conrod small end orifice crank bearing (l) by-pass cylinder head cylinder main gallery oil filter oil pump oil sump filter camshaft rocker arm rocker arm shaft cam chain crank pin conrod big end http...

  • Page 125: Chassis

    Chassis 5-1 5 chassis contents exterior parts ...................................................................................... 5- 2 fastener removal and installation..................................... 5- 2 removal .................................................................................

  • Page 126: Exterior Parts

    5-2 chassis exterior parts fastener removal and installation removal • turn the head of fastener center piece 1. • pull out the fastener. Installation • let the center piece stick out toward the head so that the pawls 2 close. • insert the fastener into the installation hole. Note: to prevent the pa...

  • Page 127

    Chassis 5-3 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 remove the rear handlebar cover 5. • disconnect the speedometer coupler 6 and right and left handlebar switch co...

  • Page 128

    5-4 chassis front leg shield • remove the front leg shield mounting screws. !: hooked part • disconnect the front turn signal couplers 1. • remove the front leg shield 2. Front leg lower shield • remove the front leg shield. ( "abobe) • remove the front leg lower shield 1. Http://mototh.Com.

  • Page 129

    Chassis 5-5 leg lower shield • remove the leg lower shield. Leg shield cover • remove the frame front cover. ( "5-8) • remove the luggage box. ( "5-9) • remove the pillion rider handle. ( "5-9) • remove the frame cover assembly. ( "5-10) • remove the leg shield hook 1. • remove the ignition switch h...

  • Page 130

    5-6 chassis frame front cover • open the seat 1 using the ignition key. • remove the frame front cover 2. Leg rear shield • remove the frame front cover. ( "5-8) • remove the luggage box. ( "5-9) • remove the pillion rider handle. ( "5-9) • remove the frame cover assembly. ( "5-10) • remove the leg ...

  • Page 131

    Chassis 5-7 luggage box • open the seat. ( "5-8) • remove the luggage box mounting screws. • remove the fuse box 1 from luggage box 2. • remove the luggage box 2. Pillion rider handle • remove the pillion rider handle 1. Http://mototh.Com.

  • Page 132

    5-8 chassis frame cover (r&l) • remove the frame front cover. ( "5-8) • remove the luggage box. ( "5-9) • remove the pillion rider handle. ( "5-9) • remove the frame cover assembly mounting screws. !: hooked part http://mototh.Com.

  • Page 133

    Chassis 5-9 • disconnect the seat lock cable 1. • disconnect the rear combination light coupler 2. • remove the frame cover assembly. • remove the right frame cover 3 and left frame cover 4. • pull the ignition key stopper plate 5. • remove the ignition key 6 from left frame cover 4. Http://mototh.C...

  • Page 134

    5-10 chassis front wheel and front brake (uy125) # removal • remove the speedometer cable and front brake cable. • remove the axle nut. • support the motorcycle with the jack or wooden block. • remove the front axle and front wheel with front brake. 1 collar 2 dust seal 3 bearing 4 front wheel space...

  • Page 135

    Chassis 5-11 • remove the front brake panel 1. • remove the brake shoes. • remove the dust seal with the special tool. $ 09913-50121: oil seal remover • remove the speedometer drive gear 2. • remove the brake cam lever 3. Http://mototh.Com.

  • Page 136

    5-12 chassis • replace the indicator plate 4, dust seal 5, spring 6 and brake camshaft 7. • pull out the pinion outer bush 8. • remove the washer 9 and pinion gear 0. Inspection and disassembly dust seal • remove the spacer 1. • inspect the dust seal 2 for damage. If any defects are found, replace t...

  • Page 137

    Chassis 5-13 remove the wheel bearings as follows: • insert the bearing remover attachment 1 into the wheel bear- ing. • insert the wedge bar 2 from the opposite side and lock it into the slit of the bearing remover attachment. • drive out the wheel bearing by striking the wedge bar. $ 09941-50111: ...

  • Page 138

    5-14 chassis spoke nipple make sure that all nipples are tight. If necessary tighten them with a spoke nipple wrench. # s poke nipple: 4.5 n·m (0.45 kgf-m) $ 09940-60113: spoke nipple wrench tire............................................................................. "2-15 brake shoe inspect th...

  • Page 139

    Chassis 5-15 reassembly and installation reassemble and install the front wheel and front brake in the reverse order of removal and disassembly. Pay attension to the following points: wheel bearing • apply suzuki super grease “a” to the wheel bearings. ' 99000-25010: suzuki super grease “a” • instal...

  • Page 140

    5-16 chassis • install the pinion gear 1, washer 2 and pinion outer bush 3. • apply suzuki super grease “a” to the gear and the inside of gear box. ' 99000-25010: suzuki super grease “a” • apply suzuki super grease “a” to the camshaft. ' 99000-25010: suzuki super grease “a” • install the spring 4 in...

  • Page 141

    Chassis 5-17 • apply suzuki super grease “a” to the inside and outside of drive gear. ' 99000-25010: suzuki super grease “a” • install the new dust seal 7. • apply suzuki super grease “a” to the camshaft, pin and lip of dust seal before installing the brake shoes. ' 99000-25010: suzuki super grease ...

  • Page 142: Front Wheel (Uy125S)

    5-18 chassis front wheel (uy125s) # removal • 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 and front wheel. % 1 spacer 2 bearing 3 front axle spacer 4 bearing 5 brake disc 6 speedometer ...

  • Page 143

    Chassis 5-19 • remove the brake disc by removing its bolts. Inspection and disassembly wheel bearing...................................................... "5-14 front axle ............................................................. "5-15 wheel .........................................................

  • Page 144

    5-20 chassis 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. ( "5-17) ' 99000-25010: suzuki super grease “a” • install the w...

  • Page 145

    Chassis 5-21 speedometer gearbox • apply suzuki super grease “a” to the speedometer gearbox. ' 99000-25010: suzuki super grease “a” • align the lugs 1 on the speedometer gearbox with the recesses 2 on the front wheel. Front wheel • make sure that the stopper 3 on the front fork and the speed- ometer...

  • Page 146: Front Brake (Uy125S)

    5-22 chassis front brake (uy125s) # ( % 1 reservoir cap 2 diaphragm 3 master cylinder 4 piston set 5 dust seal boot 6 brake hose 7 caliper holder 8 caliper holder pin 9 caliper holder pin 0 rubber parts a pad set b piston and dust seal c piston d caliper e pad spring a master cylinder mounting bolt ...

  • Page 147

    Chassis 5-23 brake fluid replacement • remove the front handlebar cover. ( "5-5) • 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 new br...

  • Page 148

    5-24 chassis • remove the brake pad mounting pin 2 and brake pads 4 . % • install the new brake pads. • temporarily tighten the brake pad mounting pin 2. • tighten the brake caliper mounting bolts and brake pad mounting pin. # brake caliper mounting bolt: 25 n·m (2.5 kgf-m) • install the cap. Note: ...

  • Page 149

    Chassis 5-25 • 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 seal 4 and piston seal 5. % caliper inspection caliper inspect the caliper cylinder wall and p...

  • Page 150

    5-26 chassis caliper holder inspect the caliper holder for damage. If any defects are found, replace it with a new one. Caliper reassembly reassemble the brake caliper in the reverse order of disassem- bly. Pay special attention to the following points: wash the caliper bores and pistons with the sp...

  • Page 151

    Chassis 5-27 • install the brake pad 1. • temporary tighten the brake pad mounting pin 2. Caliper installation install the caliper in the reverse order of removal. Pay attention to the following points: • tighten the brake caliper mounting bolts and brake pad mounting pin. # brake caliper mounting b...

  • Page 152

    5-28 chassis master cylinder removal and disas- sembly • remove the front and rear handlebar covers. ( "5-5) • place a rag underneath the brake hose union bolt 1 on the master cylinder to catch any spilt brake fluid. ( "5-25) % • disconnect the front brake light switch lead wires 2. • remove the fro...

  • Page 153

    Chassis 5-29 • pull out the dust seal boot 9 and remove the snap ring 0. • remove the plate a, piston b and spring c. Master cylinder inspection cylinder inspect the master cylinder bore for any scratches or damage. Piston and cup set inspect the piston surface for any scratches or other damage. Ins...

  • Page 154

    5-30 chassis • install the piston/cup set. • when installing the brake light switch, align the projection on the switch with the hole in the master cylinder. • apply suzuki super grease “a” to the piston and brake lever pivot. ' 99000-25010: suzuki super grease “a” • when installing the master cylin...

  • Page 155

    Chassis 5-31 • install the brake hose union as shown and tighten the union bolt to the specified torque. # brake hose union bolt: 23 n·m (2.3 kgf-m) • fill the master cylinder with brake fluid and bleed air. ( "2-14) http://mototh.Com.

  • Page 156: Front Fork

    5-32 chassis front fork # removal and disassembly • remove the front leg shield. ( "5-6) • remove the front wheel. ( "uy125: 5-12)("uy125s: 5-20) • remove the front fender 1. • remove the front brake hose guide and front brake caliper. (uy125s)( "5-25) • loosen the front fork top cap 2. • remove the...

  • Page 157

    Chassis 5-33 • remove the front fork cap bolt 2 and spring 4. • invert the fork and stroke it several times to drain out the fork oil. Note: hold the fork inverted for a few minutes to drain the oil. • remove the damper rod bolt using a 8-mm hexagon wrench and the special tools. $ 09940-34520: “t” h...

  • Page 158

    5-34 chassis • pull the inner tube out of the outer tube. • remove the oil seal by using 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 or damage. Front fork spring measure t...

  • Page 159

    Chassis 5-35 reassembly and installation reassemble and install the front fork in the reverse order of removal and disassembly. Pay attention to the following points: % • insert the oil seal 1 to the outer tube. Note: apply fork oil to the oil seal 1 lip lightly before installing it. , 99000-99044-1...

  • Page 160

    5-36 chassis • fit the gasket 3, coat the damper rod bolt 4 with the thread lock and tighten the bolt to the specified torque. % # damper rod bolt: 23 n·m (2.3 kgf-m) - 99000-32110: thread lock super “1342” $ 09940-34520: “t” handle 09940-34561: attachment “d” fork oil • pour the specified fork oil ...

  • Page 161

    Chassis 5-37 • fit the o-ring to the front fork cap bolt and apply fork oil. % , 99000-99044-10g: suzuki fork oil g10 or equivalent fork oil • temporarily install the front fork to the motorcycle. • tighten the front fork bolts 1 to the specified torque. • tighten the front fork cap bolt 2 to the sp...

  • Page 162: Handlebars

    5-38 chassis handlebars # removal • remove the front leg shield. ( "5-6) • remove the front and rear handlebar covers. ( "5-5) • remove the cable clamp. Handlebar left side parts • disconnect the rear brake cable 1 and brake switch 2. • remove the starter lever 3. • remove the rear brake lever holde...

  • Page 163

    Chassis 5-39 handlebar right side parts • remove the throttle cable by removing the throttle grip case 1. • remove the throttle grip 2. • disconnect the front brake cable 3 and brake switch 4. (uy125) • remove the front brake lever holder 5. (uy125) • disconnect the brake light switch lead wires, an...

  • Page 164

    5-40 chassis • apply suzuki super grease “a” to the cable end and brake lever pivot. ' 99000-25010: suzuki super grease “a” • apply suzuki super grease “a” onto the handlebars before installing the throttle grip. ' 99000-25010: suzuki super grease “a” • apply suzuki super grease“a” to the throttle c...

  • Page 165

    Chassis 5-41 • apply suzuki super grease “a” to the cable end and brake lever pivot. ' 99000-25010: suzuki super grease “a” • after installing the handlebar, route the wire harness properly. ( "7-12) • adjust the throttle operation and cable play ( "2-10) http://mototh.Com.

  • Page 166: Steering

    5-42 chassis steering # removal and disassembly • remove the handlebars. ( "5-40) • remove the front wheel. ( "uy125: 5-12)("uy125s: 5-20) • remove the front fender and front forks. ( "5-34) • remove the cable guide 1. • remove the steering stem lock-nut with the special tool. $ 09910-60611: univers...

  • Page 167

    Chassis 5-43 • remove the washer 2. • loosen the steering stem nut 3 with the special tool. $ 99000-60611: universal clamp wrench • remove the steering stem nut 3 and dust cover 4. Note: hold the steering stem bracket to prevent it from falling. • remove the upper bearing inner race 5. • remove the ...

  • Page 168

    5-44 chassis • drive out the upper and lower races. Inspection inspect the steering stem for any damage. Inspect the steel balls and race for corrosion, wear or other dam- age. Http://mototh.Com.

  • Page 169

    Chassis 5-45 reassembly and installation reassemble and install the steering in the reverse order of removal and disassembly. Pay attention to the following points: • press in the upper and lower outer races with the special tool. $ 09941-34513: steering race installer 09924-84510: bearing installer...

  • Page 170

    5-46 chassis • turn the steering stem bracket 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...

  • Page 171: Rear Wheel And Rear Brake

    Chassis 5-47 rear wheel and rear brake construction # removal and disassembly rear wheel and rear brake • support the motorcycle with the center stand. • remove the muffler. ( "3-6) • remove the rear wheel. • remove the rear brake shoes 1. 1 rear wheel 2 washer 3 brake shoe 4 spring 5 brake camshaft...

  • Page 172

    5-48 chassis • remove the brake cable plate 2. • remove the brake adjuster 3. • remove the brake cam lever nut and bolt 4. • remove the brake cam lever 5, brake lining wear indicator 6 and brake camshaft 7. Inspection brake drum measure the brake drum i.D. To determine the extent of wear and, if the...

  • Page 173

    Chassis 5-49 reassembly and remounting reassemble and remount the rear wheel and rear brake in the reverse order of removal and disassembly. Pay attention to the following points: • when installing the camshaft, apply suzuki super grease “a” to the camshaft. ' 99000-25010: suzuki super grease “a” • ...

  • Page 174

    5-50 chassis • when installing the brake cam lever, align the groove 4 of camshaft with the slit 5 on cam lever. ( "7-27) • tighten the brake cam lever nut to the specified torque. # brake cam lever nut: 11 n·m (1.1 kgf·m) • apply suzuki super grease “a” to the camface and pin. ' 99000-25010: suzuki...

  • Page 175: Rear Suspension

    Chassis 5-51 rear suspension construction # removal • remove the luggage box. ( "5-9) • remove the clutch upper cover 1. • remove the rear shock absorber 2. 1 rear shock absorber 2 washer a rear shock absorber mounting nut (upper) b rear shock absorber mounting bolt (lower) item n·m kgf-m a 29 2.9 b...

  • Page 176

    5-52 chassis inspection and disassembly • remove the spacer 3 and bushing 4. Rear 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 bushing inspect the spacer and bushing for wear and damage...

  • Page 177: Electrical System

    Electrical system 6-1 6 electrical system contents cautions in servicing ......................................................................... 6- 3 connector ........................................................................................ 6- 3 coupler........................................

  • Page 178: Electrical System

    Electrical system contents 6-2 electrical system lamps ........................................................................................................ 6-30 headlight .......................................................................................... 6-30 front turn signal light ........

  • Page 179: Cautions In Servicing

    Electrical system 6-3 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 180

    6-4 electrical system semi-conductor equipped part • be careful not to drop the part which has a semi-conductor built in such as a cdi unit and ac/dc rectifier. • when inspecting these parts, follow the instructions carefully. Failure to follow the proper procedure can cause damage to these parts. B...

  • Page 181

    Electrical system 6-5 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 182

    6-6 electrical system location of electrical components 1 horn 2 turn signal relay 3 regulator/rectifier 4 magneto 5 battery 6 fuse 7 cdi unit http://mototh.Com.

  • Page 183

    Electrical system 6-7 8 ignition coil 9 starter relay 0 starter motor http://mototh.Com.

  • Page 184: Charging and Lighting System

    6-8 electrical system charging and lighting system troubleshooting battery runs down quickly. Step 1 1) check accessories which use excessive amounts of electricity. Are accessories being installed? Step 2 1) check the battery for current leaks. ( !6-10) is the battery for current leaks ok? Yes remo...

  • Page 185

    Electrical system 6-9 step 3 1) measure the charging output between the battery terminals. ( !6-10) is the charging output ok? Step 4 1) measure the resistance of the stator coil. ( !6-11) is the resistance of stator coil ok? Step 5 1) measure the stator no-load performance. ( !6-11) is the stator n...

  • Page 186

    6-10 electrical system inspection battery current leakage • turn the ignition switch to the off position. • open the seat. ( !5-8) • remove the battery box lid 1. • disconnect the battery - lead wire. • measure the current between - battery terminal and the - battery lead wire using the multi-circui...

  • Page 187

    Electrical system 6-11 stator coil resistance • remove the frame front cover. ( !5-8) • disconnect the stator coupler. Measure the resistance between the lead wires using the multi-circuit tester. If the resistance is not within the specified value, replace the stator coil with a new one. " 09900-25...

  • Page 188

    6-12 electrical system ac/dc rectifier • remove the frame cover assembly. ( !5-11) • disconnect the ac/dc rectifier coupler. • remove the ac/dc rectifier 1. Measure the voltage between the terminals using the multi-cir- cuit tester, as indicated in the table below. If voltage is not within the speci...

  • Page 189: Starter System

    Electrical system 6-13 starter system troubleshooting make sure that the fuse is not blown and the battery is fully-charged before diagnosing. Starter motor will not run. Step 1 1) turn the ignition switch to the “on” position. 2) grasp the front or rear brake lever. Listen for a click from the star...

  • Page 190

    6-14 electrical system step 4 1) check the starter relay. ( !6-20) is the starter relay ok? Starter motor runs but does not crank the engine. Step 1 1) check the starter clutch. Is the starter clutch ok? Starter motor removal • disconnect the battery - lead wire. • remove the cooling fan duct. ( !3-...

  • Page 191

    Electrical system 6-15 starter motor disassembly • 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 o-ring 4 armature 2 housing end (inside) 5 ho...

  • Page 192

    6-16 electrical system • 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, brush f and terminating holder g. • remove the supporter h. ...

  • Page 193

    Electrical system 6-17 starter motor inspection 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 becomes less than 3....

  • Page 194

    6-18 electrical system bushing check the bushing for wear and damage. If any defects are found, replace the housing end (outside). Starter motor reassembly reassemble the starter motor in the reverse order of disassem- bly. Pay attention to the following points: • apply suzuki super grease “a” to th...

  • Page 195

    Electrical system 6-19 • apply suzuki super grease to the o-ring. . 99000-25010: suzuki super grease “a” • install the crankcase grommet no.1 and no.2. ( !3-72) • install the cooling fan duct. ( !3-45) http://mototh.Com.

  • Page 196

    6-20 electrical system starter relay inspection • remove the luggage box. ( !5-9) • disconnect the battery - lead wire from the battery. • disconnect the starter motor lead wire 1, battery lead wire 2 and starter relay coupler 3. • remove the starter relay 4. • apply 12 v to a and b terminals and ch...

  • Page 197: Ignition System

    Electrical system 6-21 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. Is there connection in the ignition switch couplers? Step ...

  • Page 198

    6-22 electrical system step 3 1) measure the ignition coil primary peak voltage. ( !6-23) note: this inspection method is applicable only with the multi-circuit tester and the peak volt adaptor. Is the peak voltage and its resistance ok? Step 4 1) inspect the spark plug. ( !2-7) is the spark plug ok...

  • Page 199

    Electrical system 6-23 inspection ignition coil primary peak voltage • remove the leg rear shield. ( !5-8) • remove the spark plug cap. • connect a new spark plug 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 prop...

  • Page 200

    6-24 electrical system ignition coil resistance • remove the leg rear shield. ( !5-8) • disconnect the ignition coil lead wires and spark plug cap. • remove the ignition coil. Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi-circuit tester. If the res...

  • Page 201

    Electrical system 6-25 if the peak voltage measured on the cdi unit coupler is lower than the standard value, measure the peak voltage on the pickup coil coupler as follows. • remove the frame front cover. ( !5-8) • disconnect the pickup coil coupler. • connect the multi-circuit tester with the peak...

  • Page 202: Speedometer

    6-26 electrical system speedometer removal and disassembly • remove the handlebar covers. ( !5-5) • remove the speedometer. • disassemble the speedometer, as shown. Http://mototh.Com.

  • Page 203

    Electrical system 6-27 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 (-) speedometer fuel meter high beam indicator light...

  • Page 204

    6-28 electrical system 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. ( !5-8) • disconnect the fuel level gauge coupler. ( !4-2) • connect a jumper wire betwee...

  • Page 205: Relays

    Electrical system 6-29 relays turn signal relay the turn signal relay is located behind the front leg shield. Inspection 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...

  • Page 206: Lamps

    6-30 electrical system lamps headlight headlight bulb: 12 v 30/30 w headlight bulb replacement • remove the front handlebar cover. ( !5-5) • remove the headlight bulb. # if you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature...

  • Page 207

    Electrical system 6-31 front turn signal light turn signal light: 12 v 10 w front turn signal light bulb replacement • remove the front leg shield. ( !5-6) • remove the front turn signal light bulb. # if you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or s...

  • Page 208

    6-32 electrical system brake light/taillight and rear turn signal light brake light/taillight: 12 v 18/5 w turn signal light: 12v 10 w brake light/taillight bulb replacement • remove the rear combination light lens 1 and brake light/tail- light lens 2. Http://mototh.Com.

  • Page 209

    Electrical system 6-33 • remove the brake light/taillight bulb 3. # rear turn signal light bulb replacement • remove the rear combination light lens and brake light/tail- light lens. ( !6-32) • remove the rear turn signal light bulb. # if you touch the bulb with your bare hands, clean the bulb with ...

  • Page 210: 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 lg : light green w : white g : green o : orange y : yellow lbl...

  • Page 211: 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 212

    6-36 electrical system 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 container from the battery. • after confirming that the electrolyte has entered the battery completely, remove the electrolyte containers ...

  • Page 213

    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 214

    White page http://mototh.Com.

  • Page 215: Servicing Information

    Servicing information 7-1 7 servicing information contents troubleshooting .................................................................................. 7- 2 engine .................................................................................................. 7- 2 carburetor ..................

  • Page 216: Troubleshooting

    7-2 servicing information troubleshooting engine complaint symptom and possible causes remedy engine will not start, or is hard to start. Compression too low 1. Out of adjustment valve clearance. 2. Worn valve guides or poor seating of valves. 3. Mistimed valves. 4. Excessively worn piston rings. 5....

  • Page 217

    Servicing information 7-3 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 or slipping drive belt. 2. Worn rollers in the movable drive face....

  • Page 218

    7-4 servicing information complaint symptom and possible causes remedy engine runs poorly in high speed range. 1. Weakened valve spring. 2. Worn camshaft. 3. Valve timing out of adjustment. 4. Too narrow spark plug gap. 5. Ignition not advanced sufficiently due to poorly working timing advance circu...

  • Page 219

    Servicing information 7-5 carburetor complaint symptom and possible causes remedy starting difficulty. 1. Clogged starter jet. 2. Clogged starter jet passage. 3. Air leaking from joint between starter body and carburetor. 4. Air leaking from carburetor joint or vacuum hose joint. 5. Improperly worki...

  • Page 220

    7-6 servicing information chassis brakes 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 b...

  • Page 221

    Servicing information 7-7 complaint symptom and possible causes remedy insufficient brake power. (uy125) 1. Worn shoes or drum. 2. Too much brake lever play 3. Excessive brake lever play. 4. Friction surfaces of shoes are dirty with oil or dust. 5. Excessively worn brake drum. Replace. Adjust. Adjus...

  • Page 222

    7-8 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 startor coil. 4. Open-circuited wiring connections. Replace. Replace. Replace. Check and repai...

  • Page 223

    Servicing information 7-9 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. Batter...

  • Page 224: Wiring Diagram

    7-10 servicing information wiring diagram uy125 speedometer hi tu sp fuel on off on off off on push fr ont brake light switch st ar ter switch l r hi lo push dimmer switch turn signal switch horn b utt on horn b a tter y ear th ignition switch rear brake switch ignition coil fuel ga uge cdi unit st ...

  • Page 225

    Servicing information 7-11 uy125s speedometer hi tu sp fuel on off off on push off on fr ont brake light switch st ar ter switch l r hi lo push dimmer switch turn signal switch horn b utt on horn b a tter y ear th b g gr lb l lg o r w y b/w bl/y w/b w/bl w/r y/b y/g y/w : : : : : : : : : : : : : : :...

  • Page 226

    7-12 servicing information wiring harness, cable and hose routing wiring harness routing guide throttle cable harness clamp fuel gauge guide harness harness clamp frame engine side high tension cord ig coil battery - fuse relay battery cap cap http://mototh.Com.

  • Page 227

    Servicing information 7-13 harness cdi unit rectifire main harness harness magneto coupler clamp magneto wire crankshaft cover bolt guide assemble mark assemble mark harness engine earth coupler clamp clamp engine earth steering lock horn turn signal coupler r & l clamp clamp clamp assemble mark har...

  • Page 228

    7-14 servicing information cable routing (uy125) throttle cable clamp rear brake cable stater cable clamp rear brake cable crankcase oil filter cap oil filter cap bolt clamp crankcase, l rear brake cable plate cylinder head clamp starter cable firmly. Air cleaner starter lever clamp speedometer cabl...

  • Page 229

    Servicing information 7-15 cable routing (uy125s) throttle cable clamp rear brake cable stater cable clamp rear brake cable crankcase oil filter cap oil filter cap bolt clamp crankcase, l rear brake cable plate cylinder head clamp starter cable firmly. Air cleaner starter lever clamp speedometer cab...

  • Page 230

    7-16 servicing information engine electric parts installation 6.9 n.M (0.69 kgf-m) 30˚ avoid twisting the lead wire when grommet installation. 6 n.M (0.6 kgf-m) 120 n.M (12.0 kgf-m) http://mototh.Com.

  • Page 231

    Servicing information 7-17 front brake hose routing (uy125s) handlebar front brake hose after brake hose touching to the stopper, tighten the union bolt. Set the brake hose firmly into the clamp. Brake hose after brake hose touching to the stopper, tighten the union bolt. Outside http://mototh.Com.

  • Page 232

    7-18 servicing information pair (air supply) system hose routing intake pipe breather hose match mark carburetor fuel tap vaccum hose air cleaner http://mototh.Com.

  • Page 233

    Servicing information 7-19 fuel hose routing fuel hose fuel tap fuel tap vacuum hose carburetor clip fuel hose and vacuum hose must be wrap by clip at mark position. Vacuum hose clip http://mototh.Com.

  • Page 234

    7-20 servicing information clutch/transmission/drive belt installation * 1 * 1 * 1 * 1 * 1 remove excess grease. Http://mototh.Com.

  • Page 235

    Servicing information 7-21 cooling fan installation 33 n.M (3.3 kgf-m) 10 n.M (1.0 kgf-m) http://mototh.Com.

  • Page 236

    7-22 servicing information fuel tank installation fuel tap vacuum hose fuel hose clip http://mototh.Com.

  • Page 237

    Servicing information 7-23 crankcase installation 37 mm 37 mm 2 mm 2 mm mm Ê 34 Ê 34 2 mm Ê 22.3 52 + 0.4 0 67 ± 0.2 mm 63 + 0.4 0 turn the projection with the assemble tube ahead. Apply suzuki bond “1215” to the gasket. 45˚ mm http://mototh.Com.

  • Page 238

    7-24 servicing information exterior parts construction 1 leg shield cover 2 leg shield rack 3 front leg shield 4 leg rear shield 5 front leg lower shield 6 leg lower shield http://mototh.Com.

  • Page 239

    Servicing information 7-25 1 battery box lid 2 luggage box 3 rear front fender 4 pillion rider handle 5 rear fender 6 frame cover (r) 7 frame cover (l) 8 frame front cover http://mototh.Com.

  • Page 240

    7-26 servicing information prop stand installation center stand installation 40 n.M (4.0 kgf-m) 10 n.M (1.0 kgf-m) outside rh lh long short http://mototh.Com.

  • Page 241

    Servicing information 7-27 rear brake cam lever installation 33 ˚ 40 ˚ 35 ˚ match match match set position http://mototh.Com.

  • Page 242

    7-28 servicing information battery installation starter relay battery 18 mm 18 mm 5 mm protector front rear fender http://mototh.Com.

  • Page 243

    Servicing information 7-29 seat hinge installation 96˚ seat assy. E-ring rh lh fwd http://mototh.Com.

  • Page 244

    7-30 servicing information front wheel (uy125) 5 ˚ http://mototh.Com.

  • Page 245

    Servicing information 7-31 front wheel (uy125s) clearance 1 mm http://mototh.Com.

  • Page 246

    7-32 servicing information rear wheel http://mototh.Com.

  • Page 247: Special Tools

    Servicing information 7-33 special tools 09900-00410 hexagon wrench set 09900-06107 snap ring pliers 09900-06108 snap ring pliers 09900-09004 impact driver set 09900-20101 09900-20102 vernier calipers 09900-20202 micrometer (25 – 50 mm) 09900-20203 micrometer (1/100 mm, 50 – 75 mm) 09900-20205 micro...

  • Page 248

    7-34 servicing information 09913-60910 bearing puller 09913-70210 bearing installer set 09915-63311 compression gauge adaptor 09915-64512 compression gauge 09915-74531 oil pressure gauge attachment 09915-74511 oil pressure gauge 09916-10911 valve lapper set 09916-14510 valve lifter 09916-14521 valve...

  • Page 249

    Servicing information 7-35 note: before placing order for the special tool, please check for availability. 09925-98221 bearing installer 09930-10121 spark plug socket wrench set 09930-30104 sliding shaft 09930-34980 rotor remover 09930-40113 rotor holder 09930-40120 rotor holder attachment (a) 09940...

  • Page 250: Tightening Torque

    7-36 servicing information tightening torque engine item n·m kgf-m cylinder head cover bolt initial 10 1.0 final 14 1.4 crank case bracket nut 102 10.2 engine mounting nut 85 8.5 breather cover bolt 10 1.0 intake pipe mounting bolt 10 1.0 cylinder head nut 25 2.5 cylinder head side nut 10 1.0 spark ...

  • Page 251

    Servicing information 7-37 chassis item n·m kgf-m front axle nut 42 4.2 steering stem lock-nut 90 9.0 handlebar clamp nut 60 6.0 brake cam lever nut front (uy125) 8 0.8 rear 11 1.1 rear axle nut 120 12.0 rear shock absorber mounting nut 29 2.9 front fork clamp bolt 28 2.8 front fork cap bolt 33 3.3 ...

  • Page 252

    7-38 servicing information 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 253: Service Data

    Servicing information 7-39 service data valve + guide unit: mm camshaft + cylinder head unit: mm cylinder + piston + piston ring unit: mm item standard limit valve diam. In. 25.0 — ex. 22.0 — valve clearance (when cold) in. 0.04 – 0.07 — ex. 0.10 – 0.15 — valve guide to valve stem clearance in. 0.01...

  • Page 254

    7-40 servicing information conrod + crankshaft unit: mm oil pump clutch unit: mm transmission + drive belt unit: mm (except ratio) piston ring groove width 1st 1.01 – 1.03 — 2nd 1.01 – 1.03 — oil 2.01 – 2.03 — piston ring thickness 1st 0.97 – 0.99 — 2nd 0.97 – 0.99 — piston pin bore i.D. 14.002 – 14...

  • Page 255

    Servicing information 7-41 carburetor electrical unit: mm item specification carburetor type bs26 bore size 26 mm i.D. No. 46g0 idle rpm 1 600 ± 100 rpm fuel level x.X ± x.X mm float height xx.X ± x.X mm main jet (m.J.) #95 main air jet (m.A.J.) press-fitted jet needle (j.N.) 4cj11-2 needle jet (n.J...

  • Page 256

    7-42 servicing information wattage unit: w brake + wheel unit: mm suspension unit: mm item specification headlight hi 30 lo 30 brake light/taillight 18/5 turn signal light 10 speedometer light 3.4 high beam indicator light 1.7 turn signal indicator light 1.7 item standard limit front brake cable pla...

  • Page 257

    Servicing information 7-43 tire fuel + oil item standard limit cold inflation tire pressure front 175 kpa (1.75 kgf/cm²) — rear 225 kpa (2.25 kgf/cm²) — tire size front 70/90-14 m/c (34p) — rear 80/90-14 m/c (40p) — tire type front irc: nf59 — rear irc: nr76 — tire tread depth front — 1.6 rear — 1.6...

  • Page 258

    Prepared by august, 2005 part no. 99500-31310-01e printed in thailand 260 thai suzuki motor co., ltd. Http://mototh.Com.