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GROUP INDEX 1 2 3 4 5 6 7

1. 3 44 STARTER CLUTCH nnne aii 3 45 MAGNETO COVER eee 3 46 KICK STARTER 526 esto Dru HERI 3 47 REDUCTION GEAR eee 3 49 BEARING INSPECTION nennen senna 3 51 RIGHT CRANKCASE nnne 3 51 ENGINE MOUNTING BUSHING nnnm 3 51 LEFT CRANKCASE nennen ia n 3 52 ENGINE MOUNTING BUSHINGS nnnm 3 54 CRANKSHAFT SHIM SELECTION nnnm 3 55 ENGINE REASSEMB LY uv eee 3 56 PAIR AIR SUPPLY SYSTEM eere nn 3 73 PAIR HOSES INSPECTION nnne 3 73 PAIR REED VALVE INSPECTION nnnm 3 73 PAIR CONTROL VALVE INSPECTION nnnm 3 73 htto www motorcycle in th ENGINE 3 1 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 R efer to page listed in each section for removal and reinstallation instructions ENGINE CENTER REMOVAL INSTALLATION Starter motor 53 10 3 71 Cylinder head cover 3 11 3 70 Camshaft 3 22 273 32 Camshaft sprocket 3 12 3 68 Carburetor 273 4 4 8 Cam chain tension adjuster 53 12 3 69 PAIR cut valve 3 11 3 71 Cylinder head 3 12 3 67 Cylinder 3 12 3 67 Pisto
2. 9 x htto www motorcycle in th 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 DEFINITION DEFINITION Torque control required Data beside it indicates specified torque Apply THREAD LOCK SUPER 1360 99000 32130 Apply oil Use engine oil unless other wise specified Use fork oil 99000 99044 10G Apply molybdenum oil solution Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 1 Apply or use brake fluid Apply SUZUKI SUPER GREASE 99000 25010 gt T e o Measure in voltage range Apply SUZUKI SILICONE GREASE 99000 25100 gt cC o Measure in current range Apply SUZUKI MOLY PASTE 99000 25140 o LU Measure in resistance range 9 AGH Apply SUZUKI BOND 1215 99000 31110 H p Measure in diode test range Apply SUZUKI BOND 1207B 99000 31140 Measure in continuity test range Q2 N N Apply THREAD LOCK SUPER 1322 99000 32110 C Be 0 4 Q Use special tool Apply THREAD LOCK 1342 99000 32050 gt htto www motorcycle in th Indication of service data
3. 4 2 INSPECTION enn ra DR ERR ER ER RR 4 3 RE usi gg ic 4 4 FUEL LEVEL GAUGE EE Rud nr AME oC 4 5 REMOVAL 5 bsssseikiv E nasci sid a ERREUR S EFI Fa 4 5 INS PEC TION 4 6 a ED 4 7 CONSTRUCTION nennen n 4 7 SPECIFICATIONS aos e CLER cKEKI EUR EIE NP EKEKR ARMS 4 8 lD LOCATION Mer 4 8 TS 4 8 DISASSEMBLY 4 9 CARBURETOR CLEANING uve 4 12 CARBURETOR J ET INSPECTION nnnm 4 12 NEEDLE VALVE INSPECTION sti 4 13 FLOAT HEIGHT ADJ USTMENT nnne 4 13 REASSEMBLY AND REMOUNTING seni 4 13 LUBRICATION SYSTEM renes 4 15 OIL FILTER 4 15 OIL SUMP FILTER ssssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnan 4 15 ENGINE LUBRICATION SYSTEM CHART 4 16 htto www motorcycle in th 42 FUEL AND LUBRICATION SYSTEM FUEL TANK AND FUEL TAP REMOVAL Remove the frame front cover 75 8 Remove the luggage box 7 5 9 Remove the E ring D and 2 Disconnect the fuel hose
4. 7 36 CHASSIS dis e 7 37 TIGHTENING TORQUE CHART rne nnnm 7 38 E SER RR SER FANE 7 39 htto www motorcycle in th 7 SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low start or is hard to Out of adjustment valve clearance Adjust start Worn valve guides or poor seating of valves Repair or replace Mistimed valves Adjust Excessively worn piston rings Replace Worn down cylinder bore Replace or rebore Starter motor cranks too slow See electrical section Poor seating of spark plug R etighten Gas leaks from the joint in crankcase cylinder or or replace cylinder head Plugs not sparking 1 Fouled spark plug Clean Wet spark plug Clean and dry Defective ignition coil Replace Open or short in high tension cord Replace Defective pick up coil or CDI unit Replace Open or short circuited wiring connections Repair or replace Defective spark plug Replace Defective spark plug cap Replace No fuel reaching the carburetors Clogged hole in the fuel tank cap Clean or replace Clogged or defective fuel pump Clean or replace Defective carburetor needle valve Replace Clogged fue
5. CYLINDER HEAD CAMSHAFT PISTON DONE e e AND CYLINDER SMALL ROCKER PISTON WALL END ROCKER ARM CAM PIN CYLINDER ARM SHAFT CHAIN i UU ORIFICE GALLERY 22 CRANK PIN m CRANK BEARING L 5 OIL FILTER BIG END BYPASS 4 OIL SUMP FILTER N OIL PAN htto www motorcycle in th CHASSIS 5 1 CHASSIS CONTENTS EXTERIOR PARTS nere ia 5 2 FASTENER REMOVAL AND 5 5 2 REMOVAL ELIT 5 3 FRONT WHEEL AND FRONT BRAKE UY125 emn 5 10 REMOVAL TETTE 5 10 INSPECTION AND DISASSEMBLY nnne 5 12 REASSEMBLY AND INSTALLATION rnm 5 15 FRONT WHEEL UY 1258 5 18 REMOVAL rere n nnn 5 18 INSPECTION AND DISASSEMBLY nnnm 5 19 REASSEMBLY AND INSTALLATION rne 5 20 FRONT BRAKE UY125S u eee ennemi 5 22 BRAKE FLUID REPLACEMENT ssssssssssnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 5 23 BRAKE PAD REPLACEMENT nnrnnennenn nna 5 23 CALIPER REMOVAL nnne nn 5 24 CALIPER DISASSEMBLY uv 5 24 CALIPER INSPECTION errem nn 5 25 CALIPER REASSEMB LY nennen nn 5 26 CALIPER INSTALLATION nennen nnn 5 27 BRAKE DISC INSPECTION
6. Replace the brake shoes as a set otherwise braking performance will be adversely affected BRAKE DRUM Inspect the brake drum and measure the brake drum 1 0 to determine the extent of wear If the measurement exceeds the service limit replace the brake drum with a new one Brake drum I D Service Limit 110 7 mm htto www motorcycle in th 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 CHASSIS 5 15 WHEEL BEARING Apply SUZUKI SUPER GREASE A to the wheel bearings 99000 25010 SUZUKI SUPER GREASE A nstall the wheel bearings using the special tool 55 09924 84521 Bearing installer set CAUTION First install the left wheel bearing and then install the right wheel bearing The sealed cover on the bearing must face out gt Clearance htto www motorcycle in th 5 16 CHASSIS Install the pinion gear washer and pinion outer bush Apply SUZUKI SUPER GREASE A to the gear and the inside of gear box 99000 25010 SUZUKI SUPER GREASE Apply SUZUKI SUPER GREASE A to the camshaft AH 99000 25010 SUZUKI SUPER GREASE A Install the spring into the brake panel hole Install the indicator plate NOTE When installing the indicator plate align
7. Install the spark plug to the cylinder head by finger tight and then tighten itto the specified torque V Spark plug 11 N m 1 1 kgf m 09930 10121 Spark plug wrench set FUEL LINE Inspect every 4 000 km 20 months thereafter Replace every 4 years Inspect the fuel hoses for damage and fuel leakage If any defects are found the fuel hoses must be replaced ENGINE OIL AND OIL FILTER ENGINE OIL REPLACEMENT Replace initially at 1 000 km 5 months and every 4 000 km 20 months thereafter Keep the motorcycle upright Place an oil pan below the engine Drain oil by removing the engine oil drain plug D Remove the oil filler cap 2 Tighten the engine oil drain plug to the specified torque Pour new oil through the oil filler hole When performing an oil change without oil filter replacement the engine will hold about 950 ml of oil Use an engine oil that meets API service classifications SF or SG and that has a viscosity rating of SAE 10W 40 5 Engine oil drain plug 18 N m 1 8 kgf m Make sure that the engine is cooled Place the motorcycle on level ground and hold it vertically Install the oil filler cap 2 Startthe engine and allow itto run for a few minutes at idling speed htto www motorcycle in th 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
8. Remove the wheel bearings as follows Insert the bearing remover attachment 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 Bearing remover CAUTION Replace the removed bearings with new ones FRONT AXLE Measure the front axle runout using the dial gauge If the runout exceeds the service limit replace the front axle with a new one Front axle runout Service Limit 0 25 mm 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set WHEEL RIM Make sure that the wheel rim runout does not exceed the ser vice limit when checked as shown An excessive runout is usu ally due to worn or loose wheel bearings and can be corrected by replacing the bearings If bearing replacement fails to reduce the runout replace the wheel with a new one Wheel rim runout axial and radial Service Limit 2 0 mm htto www motorcycle in th CHASSIS 5 13 5 14 CHASSIS SPOKE NIPPLE Make sure that all nipples are tight If necessary tighten them with a spoke nipple wrench V Spoke nipple 4 5 0 45 kgf m 09940 60113 Spoke nipple wrench BRAKE SHOE Inspect the brake shoes wear or damage If any wear or dam ages are found replace the brake shoes as a set CAUTION
9. D Nut Clutch shoe assembly 8 Spring Remove the movable driven face seat with a thin blade screwdriver htto www motorcycle in th 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 CAUTION The removed bearing should be replaced with a new one Remove the snap ring Remove the bearing with the special tool 09913 70210 Bearing remover CAUTION The removed bearing should be replaced with a new one Remove the oil seals 8 and O rings 9 CAUTION The removed oil seals and O rings should be replaced with new ones htto www motorcycle in th 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 calipers Clutch shoe thickness Service Limit 2 5 mm Inspect the clutch springs for stretched or broken coils If any damages are found replace the clutch shoe assembly CAUTION Replace the clutch shoe assembly Inspect the clutch housing surface for scrolling cracks or uneven wear and measure the insi
10. Recharging time 3 A for 0 5 hour or 0 4 A for 5 to 10 hours CAUTION Be careful not to permit the charging current to exceed 5 A atany time After recharging wait for 30 minutes and more and check the battery voltage with a multi circuit tester f the battery voltage is the 12 5 V and less recharge the bat tery again f battery voltage is still 12 5 V and less after recharging replace the battery with a new one When the motorcycle is not used for a long period check the battery every 1 month to prevent battery discharge REMOVAL Remove the battery box lid 7776 10 Remove the battery rubber band 4 Remove the battery NOTE First disconnect the C battery lead wire REMOUNTING Remount the battery in the reverse order of removal htto www motorcycle in th ELECTRICAL SYSTEM 6 37 Time Minutes 100 75 50 25 0 0 96 Battety charged condition htto www motorcycle in th SERVICING INFORMATION 7 1 SERVICING INFORMATION CONTENTS TROUBLESHOOTING rnm 7 2 T 7 2 CARBURETOR EE S ERR SEE NHAU REY RE 7 5 CHASSIS 7 6 BRAKES a UI EUR AN MESS ERUNT UU ME FLUR IR UE 7 6 ELECTRICAL connexes nidis s niin cR UE FEIN YE KR VANS ERI QS SEE E
11. e O Fuel gauge a UA B Turn signal L htto www motorcycle in th 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 7775 8 Disconnect the fuel level gauge coupler L7 4 2 Connect a jumper wire between the Y B and B W lead wires coming from the wire harness Turn the ignition switch to the ON position fuel meter should indicate F full Test 2 This test will determine the accuracy of the fuel meter in the E empty and full positions Connect a 90 ohm resistor between the Y B and B W lead wires The fuel meter is operating correctly if the needle moves to E empty when the ignition switch is turned on Replace the 90 ohm resistor with a 10 ohm resistor The fuel meter is operating correctly if the needle moves to F full when the ignition switch is turned on If either test detects a malfunctioning fuel meter replace the fuel meter with a new one FUEL LEVEL GAUGE INSPECTION 4 6 htto www motorcycle in th 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 sign
12. 12 V 18 5 W Speedometer light 12V3 4W High beam indicator light 12V1 7W Turn signal indicator light 12V1 7W CAPACITIES Fueltank dal 3 7L Engine oil oil change veer mmm 950 ml with filter Chatear rtr rrt eee 1050 ml overhaul eec te o tek es 1100 ml Reduction gear oil oil 100 ml 1 0 4 enn 110 These specifications are subject to change without notice htto www motorcycle in th htto www motorcycle in th PERIODIC MAINTENANCE 2 1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE nme 2 2 PERIODIC MAINTENANCE CHART nnnm 2 2 LUBRICATION POINTS rennen nnn 2 3 MAINTENANCE AND TUNE UP PROCEDURES nnm 2 4 AIR CLEANER ce 2 4 EXHAUST PIPE BOLT AND MUFFLER MOUNTING NUT 2 5 COOLING FAN FILTER nnnm 2 5 VALVE CLEARANCE nnnm nn 2 6 SPARK PLUG RE ane SYM RENS 2 7 FUEL LINE c eni i n eco da Ere ER 2 8 ENGINE OIL AND OIL FILTER 2 8 ENGINE IDLE SPEED nnnm 2 10 THROTTLE CABLE PLAY eee 2 10 DRIVE DUE vaesannasesansusnusnaueuniasanvanenets 2 11 REDUCTION GEAR BOX OIL une 2 11 idquc 2 12 BRAKE HOSE AND BRAKE FLUID U
13. errem a 6 21 INS PEC TION rue 6 23 SPEEDOME VER 6 26 REMOVAL AND DISASSEMBLY nnne 6 26 5 RE 6 27 FUEL METER AND FUEL LEVEL GAUGE nre 6 28 FUEL METER INSPECTION nnnm 6 28 FUEL LEVEL GAUGE INSPECTION nnnm 6 28 RELAYS i 6 29 TURN SIGNAL RELAY uence 6 29 STARTER Bae C YRE ME ERE xk ru 6 29 htto www motorcycle in th 6 2 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS LAMPS CY RES FR AA IRIURE DU BUE Di 6 30 LI Tepelcipgeer TRE 6 30 FRONT TURN SIGNAL LIGHT uence 6 31 BRAKE LIGHT TAILLIGHT AND REAR TURN SIGNAL LIGHT 6 32 i pel ct CERE 6 34 Ly waicisdgec eT 6 35 SPECIFICATION ERES 6 35 INITIAL CHARGING nnn 6 35 E 6 37 RECHARGING OPERATION rennen nn 6 37 6 37 RE MOUNTING usec 6 37 htto www motorcycle in th 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 i
14. htto www motorcycle in th GENERAL INFORMATION 1 1 GENERAL INFORMATION CONTENTS WARNING CAUTION NOTE rernm 1 2 GENERAL PRECAUTIONS ue 1 2 SUZUKI UY125K6 SK6 06 MODEL rnm 1 4 SERIAL NUMBER LOCATION nnne nnn 1 4 FUEL AND OIL RECOMMENDATION nnne nnn 1 5 A 1 5 ENGINE eT 1 5 REDUCTION GEAR OIL nnnm 1 5 BRAKE FLUID UY125S ssssssssssssnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnna 1 5 M 1 5 BREAK IN PROCEDURES nennen a 1 5 SPECIFICATIONS in n aiia S RE YR tu ERR HR RBS E ER EAR Rn SRRER ENS 1 6 COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s CODE COUNTRY or AREA EFFECTIVE FRAME NO P 14 UY 125 Thailand CF48A TH P 14 UY 1255 Thailand CF48B TH htto www motorcycle in th 12 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 Indicates a potential hazard that could result in death or injury CAUTION Indicates a potential hazard that co
15. nnnm 5 27 MASTER CYLINDER REMOVAL AND 5 55 5 28 MASTER CYLINDER INSPECTION nnns 5 29 MASTER CYLINDER REASSEMBLY AND INSTALLATION 5 29 FRONT FORK 3E EE XAR DEPI ML RESEE PAVESE sive AREA ELATUM RENATO LN ANG 5 32 REMOVAL AND DISASSEMBLY nnnm 5 32 5 mc 5 34 REASSEMBLY AND INSTALLATION rnm 5 35 1 Pana ka nS E ERR M EE NR Ma 5 38 REMOVAL TR 5 38 INSTALLATION nnne 5 39 Aa cilc S 5 42 REMOVAL AND DISASSEMBLY nnnm 5 42 INS PEC TION eme RR 5 44 REASSEMBLY AND INSTALLATION nnnm 5 45 REAR WHEEL AND REAR BRAKE nnne 5 47 CONSTRUCTION ut rennen aa 5 47 REMOVAL AND DISASSEMBLY nnne 5 47 INS PEC TION PS 5 48 REASSEMBLY AND REMOUNTING nnnm 5 49 REAR SUSPENSION ennemi a 5 51 CONSTRUCTION nra rnm rns nana rn arr r a 5 51 n nn 5 51 INSPECTION AND DISASSEMBLY uve 5 52 REASSEMBLY AND REMOUNTING nnnm 5 52 htto www motorcycle in th 5 2 CHASSIS EXTERIOR PARTS FASTENER REMOVAL AND INSTALLATION REMOVAL Turn the head of fastener center piece 0 Pull outthe fastener INSTALLATION Let the center piece stick out toward the head so that the pawls 2 close Inse
16. Disconnect the speedometer cable Remove the front axle nut Raise the front wheel off the ground with a jack or wooden block Remove the front axle and front wheel CAUTION Do not operate the brake lever after front wheel removal htto www motorcycle in th Remove the brake disc by removing its bolts INSPECTION AND DISASSEMBLY WHEEL BEARING mmn 5 14 FRONT AXLE ee 5 15 WHEEL 2 mme n 5 15 TIRE ween 2 15 SPEEDOMETER GEARBOX Turn the speedometer gear and check to see that the gear turns smoothly together with the speedometer pinion htto www motorcycle in th CHASSIS 5 19 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 75 17 AO 99000 25010 SUZUKI SUPER GREASE A Install the wheel bearings using the special tool 09924 84521 Bearing installer set CAUTION First install the left wheel bearing and then install the right wheel bearing The sealed cover on the bearing must face out 27771 Clearance 1mm BRAKE DISC Apply THREAD LOCK SUPER to the brake disc bolts 4 52 99000 32130 THREAD LOCK SUPER 1360 Tighten the brake disc bolts to the speci
17. Inspect initially at 1 000 km 5 months and every 4 000 km 20 months thereafter NOTE Make this adjustment when the engine is hot Connectan 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 Tachometer THROTTLE CABLE PLAY Inspect initially at 1 000 km 5 months and every 4 000 km 20 months thereafter Adjust the throttle cable play with the following procedures Loosen the lock nut of the throttle cable Turn the adjuster or out until the throttle cable play should be 2 0 4 0 mm atthe throttle grip Tighten the lock nut while holding the adjuster Throttle cable play 4 2 0 4 0 mm After the adjustment is completed check that handle bar movement does not raise the engine idle speed and that the throttle grip returns smoothly and auto matically NOTE Major adjustment can be made by the carburetor side adjuster SNB E y htto www motorcycle in th PERIODIC MAINTENANCE 2 11 DRIVE BELT Inspect every 4 000 km 20 months thereafter Keep the motorcycle upright Remove the clutch cover 773 10 Check the contact surface for crack or other damage If crack or other damage exists replace the belt with a new one CAUTION If grease or oil is present on the sur
18. Install the bearing with the special tool 09924 84510 Bearing installer NOTE Face the stamped side of the bearing out Apply SUZUKI SUPER GREASE A between the sliding sur face of the fixed driven face and movable driven face 99000 25010 SUZUKI SUPER GREASE NOTE When installing the movable face to the fixed face make sure the oil seal is positioned properly htto www motorcycle in th Install the pins 3 atthree 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 Install the new O rings 4 Apply SUZUKI SUPER GREASE A to the O rings Install the movable driven face spring guide 5 Slowly turn the special tool handle to tighten and align the flats atthe movable driven face end with clutch shoe plate hole B 09922 31430 Clutch spring compressor Check that the special tool dogs are engaged with the clutch shoe plate holes and screw the clutch shoe nut Tighten the clutch shoe nut to the specified torque with the special tool 09930 40113 Rotor holder 09930 40120 Rotor holder attachment A V Clutch shoe nut 60 N m 6 0 kgf m htto www motorcycle in th ENGINE 3 43 3 44 ENGINE DRIVE BELT Remove the drive belt and check for cracks wear and separa tion and measure the d
19. Place the crankshaft onto the V blocks so that it becomes hor izontally Measure the runout from the tips of the crankshaft htto www motorcycle in th REASSEMBLY When rebuilding the crankshaft the width between the weds should be within the standard range Crank wed to wed width 48 9 49 1 mm OIL PUMP DISASSEMBLY Remove the circlip CD washer 2 oil pump driven gear 3 and pin 4 INSPECTION Rotate the oil pump shaft by finger to inspect for abnormal play noise and smooth rotation If there is anything unusual replace the oil pump CAUTION Do notattempt to disassemble the oil pump assembly It is available only as an assembly REASSEMBLY Reassemble the oil pump driven gear in the reverse order of disassembly When installing a new circlip pay attention to the direction of the circlip Fit it to the side where the thrust is as shown in the illustration MOVABLE DRIVE FACE SPACER INSPECTION Remove the spacer Check the spacer for any damage or wear If any defects are found replace the spacer with a new one htto www motorcvcle in th ENGINE 3 37 Thrust Sharp edge 7 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
20. Safety valve Stopper Anode plates Filter Separator Fiberglass plate INITIAL CHARGING Filling electrolyte Remove the aluminum tape D sealing the battery electrolyte filler holes 4 NOTE When filling electrolyte the battery must be removed from the motorcycle and must be put on the level ground Remove the caps NOTE After filling the electrolyte completely use the removed cap 2 as sealing caps of battery filler holes Do not remove or pierce the sealed areas 3 of the electrolyte container Insert the nozzles of the electrolyte container into the bat tery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any of the fluid to spill Make sure air bubbles 5 are coming up each electrolyte con tainer and leave in this position for about more than 20 min utes htto www motorcycle in th ELECTRICAL SYSTEM 6 35 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 from the bat tery Wait for about 20 minutes Insert the caps into the filler holes pressing in firmly so that the top ofthe caps do not protrude above the upper s
21. 6 24 Is the ignition coil OK Go to Step 6 Poor connection of the ignition coil Faulty ignition coil Step 6 1 Measure the pickup coil peak voltage and its resistance 7 6 24 25 NOTE The pickup coil peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Is the peak voltage and its resistance OK Faulty CDI unit e Open or short circuit in wire harness Poor connection of ignition couplers Faulty pickup coil htto www motorcycle in th INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE Remove the leg rear shield 7 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 and spark plug are connected properly Measure ignition coil primary peak voltage using the multi circuit tester in the following procedure Connect the multi circuit tester with the peak voltage adaptor as follows Probe Black White lead wire Probe White Blue lead wire NOTE Do not disconnect the ignition coil lead wires 09900 25008 Multi circuit tester set CAUTION Before using the multi circuit tester and peak volt adaptor be sure to refer to the appropriate instruction manual Turn the ignition switch to the ON position Squeez the brake lever Press the starter button and allow the engine to crank for a
22. Disconnect the battery lead wire Remove the cooling fan duct 7 3 44 Remove the crankcase grommet No 1 and No 2 3 10 Disconnect the starter motor lead wire 1 Remove the starter motor 2 htto www motorcycle in th STARTER MOTOR DISASSEMBLY Disassemble the starter motor as shown in the illustration ELECTRICAL SYSTEM 6 15 D O ring 4 Armature 2 Housing end inside 5 Housing end outside 3 Starter motor case Remove the housing end inside 1 Remove the slip washer 2 thrust washer 3 t 0 2 thrust washer 24 0 5 and starter motor case htto www motorcycle in th 6 16 ELECTRICAL SYSTEM Remove the armature 6 Remove the thrust washer t 0 8 thrust washer 8 t 0 2 and brush holder Remove the insulators 40 Remove the nut 40 washer 2 slip washer No 1 43 slip washers No 2 49 O ring 45 brush 6 and terminating holder v D Remove the supporter 49 htto www motorcvcle in th 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 is not less than 3 5 mm If this length becomes less than 3 5 mm replace the brush Starter motor brush length Service Limit 3 5 mm COMMUTATOR Inspect the commutat
23. FUEL AND LUBRICATION SYSTEM 4 9 Disconnectthe starter cable 3 Disconnect the throttle cable 4 Remove the carburetor DISASSEMBLY Disconnect the fuel hose CD air vent hose 2 fuel drain hose and vacuum hose 4 Remove the throttle stop screw Remove the carburetor top cap 6 CAUTION Do not blow the carburetor body with compressed air before removing the diaphragm It may cause a dam age to the diaphragm htto www motorcvcle in th 410 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 Holder 17 Spring 40 Washers Jetneedle Remove the float chamber body 40 Remove the float assembly 45 and needle valve 46 by remov ing the pin CAUTION Do not use a wire for cleaning the valve seat htto www motorcycle in th FUEL AND LUBRICATION SYSTEM 4 11 Remove the following parts Main jet Pilot jet Needle jet holder 0 Needle jet CAUTION Do not use a wire for cleaning of passage and jets Remve the starter body Q2 Remove the pilot screw Q3 spring washer and O ring 06 Before removing the pilot screw Q3 determine the setting slowly turning it clockwise and count the number of turns required to lightly seat screw This counted number is imp
24. 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 specified brake fluid Thoroughly wash the dust seal grooves and piston seal grooves CAUTION Wash the brake caliper components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components with a rag Replace the removed piston seals and dust seals with new ones Apply brake fluid to all of the seals brake caliper bores and pistons before reassembly Specification and classification DOT 4 PISTON SEAL Install the piston seal and dust seal as shown BRAKE CALIPER HOLDER Apply SUZUKI SILICON GREASE to the brake caliper holder pin 99000 25100 SUZUKI SILICONE GREASE htto www motorcycle in th Dust seal Piston seal Install the brake pad D 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 V Brake caliper mounting bolt 25 N m 2 5 kgf m Tighten the brake pad mounting pin With the hose and contacted to the stopper D tighten the union bolt 2 V Brake hose union bolt 23 N m 2 3 kgf m Fill the system with brake flui
25. which the motorcycle begins to move forward 09900 26006 Tachometer Engagement rpm 2 900 3 500 rpm 2 CLUTCH LOCK UP INSPECTION Perform this inspection to determine if the clutch is engaging fully and not slipping Apply the front and rear brakes as firm as possible Briefly open the throttle fully and note the maximum engine RPMs sustained during the test cycle CAUTION Do not apply full power for more than x seconds or damage to the clutch or engine may occur Lock up rpm 4 500 5 500 rpm htto www motorcycle in th CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE 3 2 ENGINE REMOVAL AND 3 4 ENGINE REMOVAL nnne 3 4 ENGINE REMOUNTING ennemi 3 8 ENGINE DISASSEMBLY nnnm 3 10 ENGINE COMPONENT INSPECTION AND SERVICE 3 20 CYLINDER HEAD COVER nnnm n 3 20 CYLINDER HEAD nnnm nnn 3 21 CYLINDER 5 NA ERREUR IA UA NE 3 33 PISTON em 3 34 CRANKSHAFT enrnnmeneennn enia n 3 36 LA Ra EVITAR 3 37 MOVABLE DRIVE nnn 3 37 CLUTCH SHOE MOVABLE DRIVEN FACE nmm 3 39 DRIVE ger 3 44 DRIVE FILTER
26. ye Clamp coupler Assemble lock CDI unit BT i E gt Clamp Main harness Rectifire Magneto coupler Crankshaft 5 cover bolt MN Magneto 9 AG Harness wire i y an Clamp Brake cable A P ASA Starter cable Throttle cable Harness Cushion Speedometer UY125 Speedometer Rear brake switch coupler Handlebar Clamp AC Harness Front brake switch NS Starter r 7 1 cable bbs di Rear brake ead lamp coupler cable Speedometer 1 cable cable Steering lock Front brake Speedometer cable cable Speedometer Cushion UY125S Rear brake switch a Handlebar j LG lt lt 7 7 gne Front brake switch E y Starter x1 cable SSS t D 2 Steering lock Speedometer cable cable Front brake Speedometer cable hose Front brake hose htto www motorcycle in th 7 14 SERVICING INFORMATION CABLE ROUTING UY125 Handlebar Harness Starter cable m 59 ies brake Speedometer cable Front brake cable Throttle cable Pass through the guide Starter cable T e TN T Clamp Throttle cable Clamp Rear brake cable Clamp starter cable firmly LI 170 9 ZZ Strike
27. 19 9 Movable driven face spring free length 105 0 htto www motorcycle in th CARBURETOR ITEM SERVICING INFORMATION 7 41 SPECIFICATION Carburetor type BS26 Bore size 26 mm 1 0 No 46G0 Idle rpm 1600 100 rpm Fuel level mm Float height mm Main jet 95 Main air jet P ress fitted J et needle 4C 11 2 Needle jet E 3M Throttle valve 105 Pilot jet 15 Pilot screw 2 1 4 turns back Throttle cable play ELECTRICAL 2 0 4 0 mm SPECIFICATION Unit mm Spark plug NGK CR6HSA DENSO U20FSR U 0 6 0 7 Spark performance 8 0 mm and over at 1 atm Pick up coil resistance 180 280 Q BI Y Ground Pick up coil peak voltage 2 0 V and more BI Y Q B W Ignition coil resistance Primary 0 2 0 9 0 WJBI B W Secondary 11 20 kQ Plug cap B W Ignition coil primary peak voltage 150 V and more Ground W BI Stator coil resistance 0 4 0 9 0 YW Ground 06 110 9 WIR Ground Stator coil no load voltage when cold 4 V and more at 5 000 rpm YW Ground 6 V and more at 5 000 rpm 9 WIR Ground Starter motor bursh length 7 Charging output 13 5 15 2 V at X 5 000 rpm Starter relay resista
28. 2 3 29 2 9 50 5 0 45 4 5 85 8 5 65 5 135 13 5 105 10 5 210 21 0 160 16 0 240 24 0 htto www motorcycle in th SERVICE DATA VALVE GUIDE SERVICING INFORMATION 7 39 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 IN 0 010 0 037 clearance EX 0 030 0 057 Valve guide I D IN amp EX 5 000 5 012 Valve stem O D IN 4 975 4 990 4 955 4 970 Valve stem deflection IN amp EX 0 35 Valve stem runout IN amp EX 0 05 Valve head thickness IN amp EX 0 5 Valve stem end length IN amp EX 2 2 Valve seat width IN 0 90 1 10 EX 0 92 1 12 Valve head radial runout IN amp EX 0 03 Valve spring free length IN amp EX 32 9 Valve spring tension IN amp EX _ CAMSHAFT CYLINDER HEAD Unit mm STANDARD Cam height 27 92 28 02 27 77 27 87 Rocker arm I D 10 003 10 018 Rocker arm shaft O D 9 981 9 990 Cylinder head distortion CYLINDER PISTON PISTON RING ITEM STANDARD Unit mm LIMIT Compression pressure 750 1200 kPa 7 5 12 kgf cm 650 kPa 6 5 kgf cm Piston to cylinder clearance 0 020 0 030 0 120 Cylinder bore 53 5
29. 814 232 M 92 1461 61 5 ng wer H31HVLS 0 19 5 er M AuaLivg SHO109 M lt lt B eae 2 Em lt 29 1 1H5 r1 TWNDIS x a 4 8 1 49 wa 4 4 LHOM NYNL LNOH A 19 M M l T T 1HSITIIVL LHOTI 35i VH8 51 T wa wa L__ 65 61 TWNOIS NUN LH917 LNOH4 2 lt lt lt lt Lr 229895 lt m us HOLIMS o ualuvis wee LINN 109 109 HOLIMS HOLIMS HOLIMS 39nv9 gt NOILINDI 1 uardWoqaads TVNSIS NYNL NL 1H917 www motorcvcle in th htto SERVICING INFORMATION 7 11 UY125S HOLIMS 5 NYNL YOLOW H31HVIS OL3NOVIN 43921 IM MOJI9A 4 1 MOLIA NHOH Nonna 13921 en
30. Brake hose UY 125S Replace every four years Bro eee qe ctam Replace every two years Tire and wheels Steering Front fork Rear suspension Chassis bolt and nut NOTE 2 Inspectand adjust clean lubricate or replace as necessary Replace T Tighten htto www motorcycle in th 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 AGH Rear brake lever holder a AGH Footrest pivot Speedometer AGH Side stand pivot cable and spring hook Throttle cabl B OTE CESE AOH Front brake DANN lever holder CES S Center stand pivot and spring hook AGH Speedometer gearbox NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle has been operated under wet or rainy conditions htto www motorcycle in th 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 Inspect every 4 000 km 20 months and replace every 12 000 km thereafter Place the motorcycle on the side stand Remove the frame
31. NOTE The piston must be at TDC on the compression stroke CAM CHAIN TENSION ADJ USTER Remove the cam chain tension adjuster 7 and gasket CAMSHAFT SPROCKET Remove the decompression cam assembly and camshaft sprocket 2 CYLINDER HEAD Remove the cylinder head side nuts D and cylinder head nuts 2 Remove the cylinder head NOTE When loosening the cylinder head nuts loosen each nut little by little diagonally the cylinder head does not come off lightly tap on the finless portion of it with a plastic hammer CYLINDER Remove the dowel pins D gasket 2 and cam chain guide 3 Remove the cylinder NOTE If the cylinder does not come off lightly tap on the finless portion of it with a plastic hammer htto www motorcycle in th ENGINE 3 13 Remove the dowel pins and gasket A 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 Remove the cooling fan holder nut with the special tool 09930 40113 Rotor holder Remove the washer 2 and cooling fan holder 3 htto www motorcvcle in th 3 4 ENGINE REAR WHEEL REAR BRAKE Remove the rear wheel Remove the brake shoes CENTER STAND Remove the center stand spring D Remove the cotter pin 2 washer 3 sh
32. and plug cap 72 7 Frame front cover 75 8 SPARK PLUG Inspect at 4 000 km 20 months and replace every 8 000 km 40 months thereafter REMOVAL Remove the frame front cover 5 8 Disconnectthe spark plug cap and remove the spark plug 09930 10121 Spark plug socket wrench set Standard CR6HSA U20FSR U CARBON DEPOSIT Check to see the carbon deposit on the plug If the carbon is deposited remove it with a spark plug cleaner machine or carefully using a tool with a pointed end SPARK PLUG GAP Measure the plug gap with a thickness gauge if it is correct If not adjust it to the following gap Spark plug gap Standard 0 6 0 7 mm 09900 20803 Thickness gauge ELECTRODE S CONDITION Check to see the worn or burnt condition of the electrodes If it is extremely worn or burnt replace the plug And also replace the plug if ithas a broken insulator damaged thread etc CAUTION Confirm the thread size and reach when replacing the plug If the reach is too short carbon will be deposited on the screw portion of the plug hole and engine dam age may result htto www motorcycle in th PERIODIC MAINTENANCE 2 7 0 6 0 7 mm 2 8 PERIODIC MAINTENANCE INSTALLATION CAUTION Before using a spark plug wrench carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage the aluminum threads
33. axle Front axle nut 6 6 ea 5 Front brake cam lever bolt S OR R 5 SU sZ vs 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 htto www motorcycle in th CHASSIS 5 11 Remove the front brake panel 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 htto www motorcvcle in th 5 12 CHASSIS Replace the indicator plate 4 dust seal spring brake camshaft 7 Pull outthe pinion outer bush 6 Remove the washer 9 and pinion gear 40 INSPECTION AND DISASSEMBLY DUST SEAL Remove the spacer D Inspect the dust seal 2 for damage If any defects are found replace the dust seal with a new one WHEEL BEARING Play Inspect the play of wheel bearings by hand while they are in the wheel Play Rotate the inner race by hand to inspect for abnormal noise and smooth rotation If any abnormal noise occurs or rough move ment is noted replace the wheel bearings with new ones htto www motorcycle in th
34. check if the brake system is properly adjusted While operating the brake check to see that the tip of indica tor D is within the range 2 on the brake panel f the tip of indicator D is beyond the range the brake shoe assembly should be replaced with a new set of shoe 5 13 and 49 Rear htto www motorcycle in th PERIODIC MAINTENANCE 2 13 BRAKE HOSE AND BRAKE FLUID UY125S Inspect every 4 000 km 20 months Replace hoses every 4 years Replace fluid every 2 years 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 brake fluid level relative to the lower limit lines on the front brake fluid reservoirs When the level is below the lower limit line replenish with brake fluid that meets the following specification Specification and classification DOT 4 The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based and petro leum based fluids Do not use any brake fluid taken from old used or unsealed containers Never re use brake fluid left over from the last servicing or stored for a long period of time Brake fluid if it leaks will interfere with safe running and immediately discolor painted sur
35. krob indication Resistance Starter relay resistance 3 6 Q htto www motorcycle in th ELECTRICAL SYSTEM 6 21 IGNITION SYSTEM R Fuse CDI unit Regulator R a O Battery T rectifier laniti PEE LE gnition coil 7 YIN B W BI Y W BI W R Spark 7 BAN 7 V B W 7 Generator 7 TROUBLESHOOTING NOTE Make sure thatthe 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 YES Go to Step 2 NO Poor connection of couplers Step 2 1 Measure the battery voltage between inputlead wires O and B W atthe CDI unit with the ignition switch in the ON position Is the voltage OK Go to Step 3 Faulty ignition switch Faulty wire harness Broken wire harness or poor connection of related circuit couplers htto www motorcycle in th 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 YES Go to Step 4 NO Go to Step 5 Step 4 1 Inspect the spark plug 2 7 Is the spark plug OK Poor connection of the spark plug Go to Step 5 Faulty spark plug Step 5 1 Inspect the ignition coil
36. of specification replace the piston pin Piston pin O D Service Limit 13 980 mm 09900 20205 Micrometer 0 25 mm htto www motorcycle in th ENGINE 3 35 3 36 ENGINE CRANKSHAFT CONROD SMALL END 1 0 Using a caliper gauge measure the conrod small end inside diameter Conrod small end 1 0 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 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 rod 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 09900 20701 Magnetic stand 09900 20607 Dial gauge 1 100 mm 09900 21304 V block Push the big end of the conrod to one side and measure the side clearance using a thickness gauge Conrod big end side clearance Service Limit 1 0 mm 09900 20803 Thickness gauge If the clearance exceeds the service limit replace crankshaft assembly or bring the deflection and side clearance into specifi cation by replacing the worn parts conrod big end bearing and crank pin CRANKSHAFT RUNOUT Measure the crankshaft runout with V blocks and dial gauge Crankshaft runout Service Limit 0 08 mm 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block NOTE
37. on the cam face Measure the cam height with a micrometer Replace the camshaft if found worn down to the service limit Cam height Service Limit IN 27 62 mm EX 27 47 mm 09900 20202 Micrometer 25 50 mm CAMSHAFT BEARING Rotate the camshaft bearing outer race by finger to inspect for abnormal play noise and smooth rotation Replace the bearing in the following procedure if there is any thing unusual htto www motorcycle in th 118 N 12 0 kgf 2 n Remove the bearings and cam sprocket flange with a bearing puller 09913 60910 Bearing amp 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 CAUTION The removed bearing should be replaced with a new one Press in the bearings to the camshaft with a bearing installer 09951 16080 Bearing installer 549 mm 09913 70210 Bearing installer 32 mm CAM CHAIN TENSIONER Inspect the cam chain tensioner for damage If any damage are found replace the cam chain tensioner with a new one REASSEMBLY Insert the valves with their stems coated with molybdenum oil solution all around and along the full stem length without any break Similarly oil the lip of the stem seal MOLYBDNUM OIL SOLUTION CAUTION When inserting each valve take care not to damage th
38. or e 4 seat width is not uniform reface the seat using seat cutter m Valve seat width 0 Standard IN 0 90 1 10 mm EX 0 92 1 12 mm Service Limit Reface if measurement does not agree with standard valve 09916 10911 Valve lapper set If either requirement is not met correct the seat by servicing it as follows htto www motorcycle in th ENGINE 3 27 VALVE SEAT SERVICE The valve seats for both the intake and exhaust valves are machined to four different angles The seat contact surface is cut at 45 INTAKE SIDE EXHAUST SIDE N 122 N 122 N 121 09916 21111 Valve seat cutter set 09916 20610 Valve seat cutter N 121 09916 20620 Valve seat cutter N 122 09916 20630 Valve seat cutter N 126 09916 24311 Solid pilot N 100 5 0 NOTE Use the solid pilot N 100 5 0 along with the valve seat cutter N 121 122 and 126 For exhaust CAUTION The valve seat contact area must be inspected after _ 5 lt When installing the solid pilot rotate it slightly htto www motorcycle in th 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 valve seat is pitted or bur
39. points CAUTION Thoroughly wash all the component parts being assembled When reassembling the front fork use new fork oil Use the specified fork oil for the front fork When reassembling replace the oil seal dust seal and damper rod bolt gasket with new ones Insert the oil seal to the outer tube NOTE Apply fork oil to the oil seal lightly before installing it 99000 99044 10G SUZUKI FORK OIL G10 or equivalent fork oil OIL SEAL Install the oil seal D into the outer tube using the front fork oil seal installer 09940 52861 Front fork oil seal installer set CAUTION Wash clean the front fork oil seal installer before using If dirt is on the installer the inner tube may possibly be damaged during press fitting work When install the oil seal the stamped mark on the oil seal must face upper side Install the oil seal stopper ring and dust seal 3 4 A CAUTION BW Make sure that the oil seal stopper ring is fitted securely 1 2 A DAMPER ROD Fit the rebound spring D to the damper rod and install them to the inner tube htto www motorcycle in th 5 36 CHASSIS Fit gasket 3 coat the damper rod bolt with the thread lock and tighten the bolt to the specified torque CAUTION Use a new damper rod bolt gasket 3 to prevent oil leak
40. reading at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder Cylinder distortion Service Limit 0 05 mm 09900 20803 Thickness gauge CYLINDER BORE Inspect the cylinder wall for any scratches nicks or other damage Measure the cylinder bore diameter at six places Cylinder bore Service Limit 53 610 mm 09900 20530 Cylinder bore gauge set CAM CHAIN TENSION ADJ USTER Make sure the push rod movement If the push rod is stuck or spring mechanism failed replace the cam chain tension adjuster assembly with a new one CAM CHAIN GUIDE Inspect the cam chain guide for damage If any damage are found replace the cam chain guide with a new one htto www motorcycle in th ENGINE 3 33 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 CYLINDER CLEARANCE Subtract the piston diameter from the cylinder bore diameter 3 33 the piston to cylinder clearance exceeds service limit replace the crankcase set or the piston or both Piston to cylinder clearance Service Limit 0 120 mm PISTON RING TO GROOVE CLEARANCE Measure the side clearances of the 1st and 2nd p
41. receptacle Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system Close the air bleeder valve and disconnect a clear hose Fill the reservoir with new brake fluid to the upper level of the res ervoir CAUTION Never reuse the brake fluid left over from previous servicing and which has been stored for long peri ods of time Bleed air from the brake system C7 2 14 BRAKE PAD REPLACEMENT Remove the cap D and loosen the brake pad mounting pin 2 Remove the brake caliper 3 htto www motorcycle in th 5 24 CHASSIS Remove the brake pad mounting pin and brake pads 4 CAUTION Do not operate the brake lever after brake pad removal Replace the brake pad as a set otherwise braking performance will be adversely affected Install the new brake pads Temporarily tighten the brake pad mounting pin 2 Tighten the brake caliper mounting bolts and brake pad mounting pin V Brake caliper mounting bolt 25 2 5 kgf m Install the cap NOTE After replacing the brake pads pump the brake lever a few times to check for proper brake operation and then check the brake fluid level CALIPER REMOVAL Loosen the brake pad mounting pin 5 25 Remove the brake hose union bolt CD NOTE Place a rag underneath the union bolt on the brake caliper to catch any spilt bra
42. th FUEL AND LUBRICATION SYSTEM 4 13 CORRECT INCORRECT 414 FUEL AND LUBRICATION SYSTEM Install the pilot screw D NOTE Turn in the pilot screw until it lightly seats then back it out the counted number of turns 4 11 CAUTION Replace the removed O ring with a new one Install the gasket to the starter body 3 C77 4 11 CAUTION Replace the removed gasket with a new one Install the gasket to the float chamber body 374 10 CAUTION Replace the removed gasket with a new one Reassemble the clip ring D and washers 8 7 4 10 Fitthe jet needle assembly and spring to the piston valve Install the holder by turning it clockwise with a screwdriver htto www motorcvcle in th 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 Adjustthe following items to the specification Idling 7772 10 Throttle cable 7772 10 LUBRICATION SYSTEM OIL PRESSURE 372 21 OIL FILTER 2 9 OIL SUMP FILTER 3 57 OIL PUMP 3 3 37 htto www motorcycle in th 4 16 FUEL AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART
43. the ignition switch to the ON position when measuring current CHARGING OUTPUT Open the seat 7775 8 Remove the battery box lid above Start the engine and keep it running at 5 000 rpm with the dimmer switch turned HI position Measure the DC voltage between the and battery termi nals using the multi circuit tester If the voltage is not within the specified value inspect the stator coil and AC DC rectifier 76 11 12 NOTE When making this test be sure thatthe battery is in fully charged condition 09900 25008 Multi circuit tester set Tester knob indication Voltage Charging output Regulated voltage 13 5 15 2 V at 5 000 rpm htto www motorcycle in th ELECTRICAL SYSTEM 6 11 STATOR COIL RESISTANCE Remove frame front cover 5 8 Disconnectthe 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 25008 Multi circuit tester set Tester knob indication Resistance Stator coil resistance Charge side 0 6 1 1 White Red Ground Lamp side 0 4 0 9 Q Yellow White Ground YAN STATOR NO LOAD PERFORMANCE Remove the frame front cover 5 8 Disconnect the stator coupler C above Start the engine and keep it running at 5 000 rpm Using the mult
44. to the following points NOTE Apply engine oil to each running and sliding part before reas sembling CAUTION Make sure to coat the rotating and sliding sections with engine oil Care must be taken so that the drive belt drive face and driven face are completely free from oil and grease CRANKSHAFT Mount the crankshaft into the right crankcase by pulling its right end into the crankcase with the special tools 09910 32812 Crankshaft installer 09910 20116 Conrod holder 09911 11310 Attachment CAUTION Never fit the crankshaft into the crankcase by striking it with a plastic hammer Always use the special tool otherwise the crankshaft may be misaligned CRANKCASE Clean and degrease the crankcase mating surfaces both sur faces with a cleaning solvent Fitthe dowel pins D into the left crankcase Install the shim 73 55 htto www motorcycle in th ENGINE 3 57 Apply sealantto the right crankcase 99000 31110 SUZUKI BOND 1215 CAUTION Coatthe sealant evenly without break Application of sealant must be performed within a short period of time Take extreme care not to let sealant enter into the oil hole or bearing Tighten the crankcase bolts to the specified torque V Crankcase bolt 10 N m 1 0 kgf m NOTE After the crankcase bolts have been tightened make sure that the crank
45. valve or guide be sure to re check the clearance Valve stem O D Standard IN 4 975 4 990 mm EX 4 955 4 970 mm 09900 20205 Micrometer 0 25 mm VALVE GUIDE SERVICE Remove the valve guide with the valve guide remover 09916 44310 Valve guide remover Re finish the valve guide holes in cylinder head with the han dle and reamer 09916 34542 Handle 09916 34580 Valve guide reamer 10 8 mm Fita ring to each valve guide Lubricate each valve guide with oil and drive the guide into the guide hole with the special tool 09916 44310 Valve guide installer NOTE Install the valve guide until the ring contacts with the cylinder head CAUTION ENGINE 3 25 Be sure to use new ring and valve guide htto www motorcycle in th 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 If the valve face has worn abnormally replace the valve Coat the valve seat with Prussian Blue and set the valve in place Rotate the valve with light pressure Check that the transferred blue on the valve face is uniform all around and in center of the valve face m If the seat width measured exceeds the standard value
46. 00 53 515 53 610 Nicks or Scratches Piston diam 53 475 53 490 Measure at 10 mm from the skirt end 53 380 Cylinder distortion 0 05 Piston ring end gap Ist 0 05 0 15 0 50 2nd 0 05 0 15 0 50 Piston ring to groove clearance lst 0 180 htto www motorcycle in th 0 150 740 SERVICING INFORMATION ITEM STANDARD Piston ring groove width 1 01 1 03 1 01 1 03 2 01 2 03 Piston ring thickness 0 97 0 99 0 97 0 99 Piston pin bore I D 14 002 14 008 Piston pin O D CONROD CRANKSHAFT ITEM 13 996 14 000 STANDARD Conrod small end I D 14 006 14 024 Conrod deflection Conrod big end side clearance 0 10 0 45 Conrod big end width 16 95 17 00 Crank web to web width 48 9 49 1 Crankshaft thrust clearance 0 02 0 07 Crankshaft runout OIL PUMP ITEM STANDARD Oil pressure at 60 C 18 40 kPa 0 18 0 40 kgf cm at 3 000 rpm CLUTCH Unit mm ITEM STANDARD LIMIT Clutch housing 1 0 125 0 1252 125 5 Clutch shoe thickness 2 5 Clutch engagement 2 900 3 500 rpm Clutch lock up TRANSMISSION DRIVE BELT ITEM 4 500 5 500 rpm STANDARD Reduction ratio 2 700 0 825 Variable change Final reduction ratio 9 264 49 17 x 45 14 Drive V belt width
47. 18 ENGINE REDUCTION GEAR Drain the reduction gear oil C 572 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 D Remove the oil filter and O ring 3 htto www motorcvcle in th ENGINE 3 19 OIL SUMP FILTER Remove the oil sump filter cap D and oil sump filter 2 P BRAKE CAM LEVER e Remove the rear brake cam lever CD brake lining wear indica tor 2 brake 3 O i CRANKCASE Remove the crankcase bolts Separator the crankcase into 2 parts right and left with the crankcase separating tool 09920 13120 Crankcase separating tool NOTE Fitthe crankcase separating tool so that the tool arms are in parallel with the side of crankcase The crankshaft component should remain in the left crankcase half CRANKSHAFT Remove the crankshaft with the special tool 09920 13120 Crankcase separating tool htto www motorcvcle in th 3 20 ENGINE ENGINE COMPONENT INSPECTION AND SERVICE CYLINDER HEAD COVER DISASSEMBLY Remove the PAIR reed valve cover D and PAIR reed valve Q 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 is found in the reed valve replace the PAIR ree
48. ASE Install the brake shoes with spring hooks faced inside CAUTION Be careful not to apply too much grease to the cam shaft and pin If grease gets on the lining brake effec tiveness will be lost Tighten the rear axle nut to the specified torque V Rear axle nut 120 N m 12 0 Install the muffler 73 9 Adjust the rear brake cable play 7 2 12 htto www motorcvcle in th CHASSIS 5 51 REAR SUSPENSION CONSTRUCTION Rear shock absorber Washer Rear shock absorber mounting nut Upper Rear shock absorber mounting bolt Lower REMOVAL Remove the luggage box 5 9 Remove the clutch upper cover D Remove the rear shock absorber 2 htto www motorcycle in th 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 If any defects are found replace the spacer or bushing with a new one REASSEMBLY AND REMOUNTING Reassemble and remount the rear shock absorber in the reverse order of removal and disassembly Pay attention to the following points Tighten the rear shock absorber mounting bolt and nut to the specified torque V Rear sh
49. E A CAUTION side Install the oil seal D with the marked code toward out When replacing the stator coil 2 or pick up coil 3 apply THREAD LOCK to the stator coil set bolts and pick up coil set screws and tighten them to the specified torque V stator coil bolt 6 N m 0 6 kgf m 99000 32110 THREAD LOCK SUPER 1322 KICK STARTER DISASSEMBLY Remove the clutch cover air intake plate Remove the oil seal 2 snap ring 3 and washer 4 CAUTION Replace the removal oil seal with a new one htto www motorcycle in th ENGINE 3 47 3 48 ENGINE Remove the kick starter driven gear spring and kick starter shaft 2 6 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 Play smoothly or if there are signs of any abnormalities the bearing is defective and must be replaced with a new one Remove the kick starter shaft bearing with the special tool 09921 20240 Bearing remover set 10 mm S DM 2 4 D oom REASSEMBLY i Reassemble the kick starter in the reverse order of disassem bly Pay attention to the following points N Apply SUZUKI SUPER GREASE A onto the inside of the kick starter shaft spacer lt y 99000 25010 SUZUKI
50. FOREWORD This manual contains an introductory description on the SUZUKI UY125 S and procedures for its inspec tion service and overhaul of its main components Other information considered as generally known is not included Head the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its main tenance Use this section as well as other sections to use as a guide for proper inspection and service This manual will help you know the motorcycle bet ter so that you can assure your customers of fast and reliable service This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have been made since then differences may exist between the con tent of this manual and the actual motorcycle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual motorcycle exactly in detail This manual is written for persons who have enough knowledge skills and tools including special tools for servicing SUZUKI motorcy cles If you do not have the proper knowledge and tools ask your authorized SUZUKI motorcycle dealer to help you Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the ri
51. G 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 starter relay when the starter button is pushed Is a click sound heard YES Go to Step 2 NO Go to Step 3 Step 2 1 Check if the starter motor runs when its terminal is connected to the battery terminal Do not use thin wire because a large amount of current flows Does the starter motor run Faulty starter relay Loose or disconnected starter motor lead wire Loose or disconnected between starter relay and battery terminal Faulty starter motor Step 3 1 Measure the starter relay voltage at the starter relay connectors between Y G and B W when the starter button is pushed Is a voltage OK Go to Step 4 Faulty starter button Faulty ignition switch Faulty brake light switches front and rear brakes Poor contact of connector Open circuit in wire harness htto www motorcycle in th 6 4 ELECTRICAL SYSTEM Step 4 1 Check the starter relay L7 6 20 Is the starter relay OK YES Poor contact of the starter relay NO Faulty starter relay Starter motor runs but does not crank the engine Step 1 1 Check the starter clutch Is the starter clutch OK YES Faulty starter motor NO Faulty starter clutch STARTER MOTOR REMOVAL
52. INE ENGINE REMOUNTING Remount the engine in the reverse order of removal Pay atten tion to the following points Install the crankcase bracket D to the frame and insert the crankcase bracket mounting shaft Push up on the rear part of the crankcase bracket D and have the damper B touch the stopper 4 While holding the damper tighten the engine mounting bracket nut to the specified torque V Crankcase bracket nut 102 N m 10 2 kgf m Install the engine and tighten the engine mounting nut 3 to the specified torque V Engine mounting nut 85 N m 8 5 kgf m NOTE When tightening the engine mounting nut make sure that the WEEE 7 front wheel is elevated 6 Tighten rear shock absorber lower mounting nut to the specified torque 5 Rear shock absorber mounting bolt 29 N m 2 9 kgf m NOTE Place 65 kg on the seat after installing the engine Check that clearance and D are equal If clearances and D are not equal repeat the engine installation procedures Install the crank case tube 5 2 NOTE 3 Set the crankcase tube to crankcase tube grommet 7777 23 SQ htto www motorcycle in th ENGINE 3 9 Install the muffler CAUTION Replace the gasket with new one After installing the engine properly route the wire harness cables and hoses Refer to the wire and c
53. Is the charging output OK Faulty battery Abnormal driving condition Go to Step 4 Step 4 1 Measure the resistance of the stator coil 6 11 Is the resistance of stator coil OK Go to Step 5 Faulty stator coil Disconnected lead wires Step 5 1 Measure the stator no load performance 7776 11 Is the stator no load performance OK YES Go to Step 6 NO Faulty stator Step 6 1 Inspect the AC DC rectifier 7 6 12 Is the AC DC rectifier OK YES Go to Step 7 NO Faulty AC DC rectifier Step 7 1 Inspect wirings Is the wirings OK Faulty battery e Short circuit of wire harness Poor contact of couplers Battery overcharges Faulty AC DC rectifier Faulty battery Poor contact of stator lead wire coupler htto www motorcycle in th 6 10 ELECTRICAL SYSTEM INSPECTION BATTERY CURRENT LEAKAGE Turn the ignition switch to the OFF position Open the seat 7775 8 Remove the battery box lid Disconnect the battery lead wire Measure the current between battery terminal and the battery lead wire using the multi circuit tester If the reading exceeds the specified value leakage is evident 09900 25008 Multi circuit tester set Tester knob indication Current 20 mA Battery current leak Under 1 mA CAUTION n case of a large current leak turn the tester to high range first to avoid tester damage Do not turn
54. KI MOLY PASTE Fitthe depression of the starter motor case to the projection of the terminating holder Align the line on the starter motor case with the line on the housing end inside htto www motorcycle in th ELECTRICAL SYSTEM 6 19 Apply SUZUKI SUPER GREASE to the O ring AO 99000 25010 SUZUKI SUPER GREASE A Install the crankcase grommet No 1 and No 2 3 72 Install the cooling fan duct L7 3 45 htto www motorcycle in th 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 CD battery lead wire 2 and starter relay coupler 3 Remove the starter relay 4 Apply 12 V to and terminals and check for continuity between the positive and negative terminals using the multi circuit tester If the starter relay clicks and continuity is found the relay is OK 09900 25008 Multi circuit tester set N Tester knob indication Continuity test 4 D CAUTION Do not apply battery voltage to the starter relay for more than five seconds since the relay coil may over heat and get damaged Measure the relay coil resistance between the terminals using pr the multi circuit tester If the resistance is not within the specified value replace the starter relay with a new one 09900 25008 Multi circuit tester set Tester
55. Notenough oil in the engine Defective oil pump or clogged oil circuit Too low in float chambers fuel level Sucking air from intake pipe Use of incorrect engine oil Clogged air intake with dust htto www motorcycle in th Clean Add oil Replace or clean Adjust R etighten or replace Change Clean CARBURETOR Complaint Symptom and possible causes SERVICING INFORMATION 7 5 Remedy Starting difficulty Clogged starter jet Clogged starter jet passage Air leaking from joint between starter body and carburetor Air leaking from carburetor joint or vacuum hose joint Improperly working starter cable Clean Clean Tighten adjust or replace gasket Tighten or replace defective part Adjust Idling or low speed trouble Clogged or loose pilot jet Clogged or loose pilot air jet Air leaking from carburetor joint Clogged pilot outlet port Clogged bypass port Starter cable not fully closed Clean or tighten Clean or tighten Tighten or replace defective part Clean Clean Adjust Medium or high speed trouble Clogged main jet Clogged main air jet Clogged needle jet Improperly working throttle valve Clogged fuel filter Clean Clean Clean Adjust Clean or replace Overflow and fuel level fluctuations Worn or damaged needle valve Broken needle valve spring Improperly worki
56. PI RM 7 8 BATTERY ecce Mm seanssisduaudescudsavusnasedsectavieanecsavasnenadi 7 9 WIRING DIAGRAM ennemi 7 10 7 10 UY 1258 ricas tpi er MERDA 7 11 WIRING HARNESS CABLE AND HOSE ROUTING nnnm 7 12 WIRING HARNESS ROUTING nnnm 7 12 CABLE ROUTING UY 125 7 14 CABLE ROUTING UY 12585 wet 7 15 ENGINE ELECTRIC PARTS INSTALLATION nmn 7 16 FRONT BRAKE HOSE ROUTING UY125S emm 7 17 PAIR AIR SUPPLY SYSTEM HOSE ROUTING nmm 7 18 FUEL HOSE ROUTING nennen nn 7 19 CLUTH TRANSMISSION DRIVE BELT INSTALLATION 7 20 COOLING FAN INSTALLATION nnne 7 21 FUEL TANK INSTALLATION nnnm 7 22 CRANKCASE INSTALLATION cece 7 23 EXTERIOR PARTS CONSTRUCTION nnne 7 24 PROP STAND INSTALLATION nnnm 7 26 CENTER STAND INSTALLATION nnnm 7 26 REAR BRAKE CAM LEVER INSTALLATION 7 27 BATTERY INSTALLATION vv 7 28 SEAT HINGE INSTALLATION nnnm nnn 7 29 FRONT WHEEL UY 125 mnnera 7 30 FRONT WHEEL UY 1258 nnn 7 31 REAR WHEEL o nua a TU FRE 7 32 SPECIAL TOOL 5 5 RECHTIM EEERN IARE G IRAE 7 33 TIGHTENING TORQUE cence 7 36
57. S STEERING Washer Steering stem nut Inner upper race Inner lower race 3 4 Steel ball 7 9 Steering stem Outer lower race Steering stem lock nut ITEM kgf m 90 9 0 REMOVAL AND DISASSEMBLY Remove the handlebars 7575 40 Remove the front wheel CC UY 125 5 12 CC UY 1255 5 20 Remove the front fender and front forks 75 34 Remove the cable guide 1 Remove the steering stem lock nut with the special tool 09910 60611 Universal clamp wrench htto www motorcycle in th 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 upper and lower steel balls Upper 22 pcs Lower 27 pcs Remove the outer lower race with a chisel CAUTION The removed outer lower race should be replaced with a new one htto www motorcycle in th 5 44 CHASSIS Drive outthe 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 htto www motorcycle in th CHASSIS 5 45 REASSEMBLY AND INSTALLATION Reassemble and i
58. SUPER GREASE A Apply a light coat of SUZUKI SUPER GREASE A onto the D end of kick starter shaft SA AO 99000 25010 SUZUKI SUPER GREASE A AH Install the kick starter return spring D kick starter shaft 3 WS and kick starter spring hook its end D onto the clutch cover 7 boss 2 cS 7 289 htto www motorcycle in th Apply SUZUKI SUPER GREASE A onto the shaft and gear of the kick starter drive gear AO 99000 25010 SUZUKI SUPER GREASE A Install the kick starter driven gear 4 Apply SUZUKI SUPER GREASE A to the oil seal lip AGH 99000 25010 SUZUKI SUPER GREASE A Install the kick starter shaft new oil seal with the special tool 09925 98221 Bearing installer REDUCTION GEAR DISASSEMBLY Remove the driveshaft D Remove the driveshaft oil seal with the special tool 09913 50121 Oil seal remover CAUTION Replace the removed oil seal with a new one INSPECTION Drive gear idle gear and driveshaft damage or wear Improper tooth contact Shaft spline damage htto www motorcycle in th ENGINE 3 49 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 a
59. T Remove the rear combination light lens and brake light tail light lens 2 htto www motorcycle in th ELECTRICAL SYSTEM 6 33 Remove the brake light taillight bulb 3 CAUTION 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 REAR TURN SIGNAL LIGHT BULB REPLACEMENT Remove the rear combination light lens and brake light tail light lens C 5776 32 Remove the rearturn signal light bulb CAUTION 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 htto www motorcycle in th 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 IGNITION SWITCH HORN BUTTON STARTER BUTTON B G B W W B Y G Y W WIRE COLOR Black Lg Light green W White Green Orange Y Yellow Lightblue R Red Black with White tracer White with Black tracer Yellow with Green tracer Yellow with White tracer htto www motorcycle in th BATTERY SPECIFICATIONS Type designation FTZ5S Capacity 12 V 12 6 kC 3 5 Ah 10 HR CD Upper cover breather Terminal Cathode plates
60. VICING INFORMATION 7 25 D Battery box lid Luggage box Rear front fender Pillion rider handle 5 Rear fender 6 Frame cover R 7 Frame cover L Frame front cover htto www motorcycle in th 7 206 SERVICING INFORMATION PROP STAND INSTALLATION V 10 Nm 1 0 kgf m j OUTSIDE CENTER STAND INSTALLATION Long 9 htto www motorcycle in th REAR BRAKE CAM LEVER INSTALLATION 7 28 SERVICING INFORMATION BATTERY INSTALLATION Battery Starter relay Protector Front rear fender htto www motorcycle in th SERVICING INFORMATION 7 29 SEAT HINGE INSTALLATION RH LH Seat Assy SASH NAAN htto www motorcycle in th 7 30 SERVICING INFORMATION FRONT WHEEL UY 125 A D k k AGH T SSS ES R T iD htto www motorcycle in th SERVICING INFORMATION 7 31 FRONT WHEEL UY 125S B bu EM i TEE mmm uds COI Clearance a 1mm htto www motorcycle in th 7 32 SERVICING INFORMATION REAR WHEEL SPECIAL TOOLS Ecc S 09900 00410 09900 06107 Snap ring pliers 09900 06108 Snap ring pliers SERVICING INFORMATION 7 33 09900 09004 Impact driver set 09900 20101 09900 20102 Vernier calipers Hexagon w
61. Y125S mm 2 13 AND WHEELS nennen 2 15 2 0 CER Y IR UFU MESE UMANE RUE 2 17 uie nie 2 17 REAR SUSPENSION ennemi 2 17 CHASSIS BOLTS AND NUTS wwii 2 18 COMPRESSION PRESSURE CHECK rne nn 2 20 COMPRESSION TEST PROCEDURE nnnm nn 2 20 OIL PRESSURE CHECK ennemi 2 21 OIL PRESSURE TEST PROCEDURE nme nnn 2 21 AUTOMATIC CLUTCH INSPECTION nnnm 2 22 INITIAL ENGAGEMENT INSPECTION nnnm 2 22 2 CLUTCH LOCK UP INSPECTION nmm 2 22 htto www motorcycle in th 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 NOTE More frequent servicing may be performed on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART Interval Item 20 Replace every 12 000 km Exhaust pipe bolt and muffler bolt Air cleaner Cooling fan filter Clean every 3 000 km Valve clearance Spark plug Replace every four yea Fuel line Engine oil Engine oil filter Idle rpm Throttle cable play Drive belt Final reduction gear box oil Brake
62. able routing sec tions 7 12 to 19 Refer to the following sections to adjust the respective items to specification ENGINE OIL 2 8 REDUCTION GEAR OIL 7 2 11 THROTTLE CABLE PLAY 7 2 10 ENGINE IDLE SPEED 7 2 10 REAR BRAKE CABLE ADJ USTMENT 7 2 12 Check for leakage of the engine oil and reduction gear oil htto www motorcycle in th 3 10 ENGINE ENGINE DISASSEMBLY CAUTION Identify the position of each removed part Organize the parts in their respective groups so thatthey can be reinstalled in their original positions CLUTCH COVER Remove the kick starter lever Remove the clutch cover assembly CRANKCASE TUBE GROMMET Remove the crankcase tube grommet No 1 D and No 2 2 STARTER MOTOR Remove the starter motor D htto www motorcvcle in th ENGINE 3 1 PAIR CUT VALVE Disconnectthe PAIR hose D and vacuum hose 2 Remove the PAIR cut valve 3 FAN COWLING COVER CYLINDER COWLING INTAKE PIPE Remove the fan cowling cover and cylinder cowling right cover Remove the intake pipe 3 and cylinder cowling left cover 4 SPARK PLUG Remove the spark plug CYLINDER HEAD COVER Remove the cylinder head cover and gasket htto www motorcvcle in th 3 12 ENGINE Turn the crankshaft clockwise with a box wrench and align the Top mark on the cooling fan with the index mark B on the magneto cover
63. ace Replace Repair or replace Replace Replace Replace Replace Replace Replace Replace Replace Replace Slipping clutch Worn or damaged clutch shoes Weakened clutch shoe springs Worn clutch housing Worn or slipping drive belt Replace Replace Replace Replace Engine idles poorly Valve clearance out of adjustment Poor seating of valves Defective valve guides Worn down camshaft Too wide spark plug gap Defective ignition coil Defective CDI unit Defective stator coil Clogged caburetor jet Idle adjust screw and pilot screw out of adjust ment Damaged or cracked vacuum hose Clogged air cleaner element Incorrect float chamber fuel level amp QJ N L UJ N NJ I htto www motorcycle in th Adjust Repair or replace Replace Replace Adjust or replace Replace Replace Replace Clean or replace Adjust Replace Clean or replace Adjust float height 74 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine runs poorly in high speed range oO ON m Weakened valve spring Worn camshaft Valve timing out of adjustment Too narrow spark plug gap Ignition not advanced sufficiently due to poorly working timing advance circuit Defective ignition coil Defective pick up coil or CDI unit Too low float chamber fuel leve
64. aft 4 and center stand MAGNETO COVER Remove the magneto cover htto www motorcvcle in th Remove the dowel pins 2 and gasket 3 STARTER IDLE GEAR Remove the starter idle gear D and shaft 2 MAGNETOROTOR Hold the fixed drive face with the special tool 09930 40113 Rotor holder Remove the magnetorotor nut Remove the magnetorotor D with the special tool 09930 34980 Rotor remover Remove the starter clutch htto www motorcvcle in th ENGINE 3 15 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 disassemblable type Remove the cam chain 5 htto www motorcvcle in th ENGINE 3 17 FIXED DRIVE FACE Remove the fixed drive face nut with the special tool 09930 40113 Rotor holder Remove the washer 2 kick starter 2 and fixed drive face MOVABLE DRIVEN FACE CLUTCH HOUSING Remove the clutch housing nut with the special tool 09930 40113 Rotor holder Remove the clutch hosing 4 Remove the clutch shoe movable driven face assembly 9 along with the drive belt 3 E Remove the movable drive face assembly 4 and spacer 5 htto www motorcvcle in th 3
65. age 5 Damper rod bolt 23 N m 2 3 kgf m 4 222 99000 32110 THREAD LOCK SUPER 1342 09940 34520 T handle 09940 34561 Attachment D FORK OIL Pour the specified fork oil into the inner tube Front fork oil capacity each leg 55 ml 99000 99044 10G SUZUKI FORK OIL G10 or equivalent fork oil Hold the front fork leg in a vertical position and adjust the fork oil level by using the special tool When adjusting the oil level remove the fork spring and com press the inner tube fully Front fork oil level without spring 93 mm 09943 74111 Fork oil level gauge FORK SPRING end of the fork spring with the smaller pitch should be atthe top of the front fork htto www motorcycle in th CHASSIS 5 37 Fitthe O ring to the front fork cap bolt and apply fork oil CAUTION Use a new O ring to prevent oil leakage 99000 99044 10G SUZUKI FORK OIL G10 or equivalent fork oil Temporarily install the front fork to the motorcycle Tighten the front fork bolts to the specified torque Tighten the front fork cap bolt 2 to the specified torque V Front fork clamp bolt 28 N m 2 8 kgf m Front fork cap bolt 20 N m 2 0 kgf m Install the front brake caliper and front brake hose guide UY125S C 7775 29 Install the front fender and front wheel UY 125 5 19 34 C UY 1255 5 23 34 Move the f
66. al light If the turn signal light does not illuminate inspect the bulb turn signal switch and circuit connection If the bulb turn signal switch and circuit connection are OK the turn signal relay may be faulty In this case replace the turn sig nal relay with a new one NOTE Make sure that the battery is fully charged STARTER RELAY 6 20 htto www motorcycle in th ELECTRICAL SYSTEM 6 29 6 30 ELECTRICAL SYSTEM LAMPS HEADLIGHT Headlight bulb 12 V 30 30 W HEADLIGHT BULB REPLACEMENT Remove front handlebar cover 5 5 Remove the headlight bulb CAUTION 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 htto www motorcycle in th ELECTRICAL SYSTEM 6 31 FRONT TURN SIGNAL LIGHT NS 4 Turn signal light 12 V 10 W FRONT TURN SIGNAL LIGHT BULB REPLACEMENT Remove the front leg shield 75 6 Remove the front turn signal light bulb CAUTION 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 htto www motorcycle in th 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 REPLACEMEN
67. and vacuum hose 4 Gasoline is highly flammable and explosive Keep heat spark and flame away Remove the retainer 5 Disconnect the fuel level gauge coupler 6 htto www motorcycle in th 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 htto www motorcvcle in th 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 does not flow out replace the fuel tap with a new one Specified vacuum Approx 4 kPa 09917 47010 Vacuum pump gauge CAUTION Use a hand operated vacuum pump Do not apply high negative pressure to prevent the fuel tap damage REMOUNTING Remount the fuel tank and fuel valve in the reverse order of removal Replace the removed gasket 4 and seal washers with new ones to prevent leakage of fuel htto www motorcycle in th FUEL AND LUBRICATION SYSTEM 4 5 FUEL LEVEL GAUGE REMOVAL Open the seat 7775 8 Remove the retainer 4 Disconnectthe fuel level gauge coupler 2 Remove the rubber cushion Remove the f
68. ars with the front brake holder matching surface UY 125 Install the master cylinder UY 125S C77 5 33 htto www motorcycle in th 5 40 CHASSIS Apply SUZUKI SUPER GREASE A to the cable end and brake lever pivot MAH 99000 25010 SUZUKI SUPER GREASE Apply SUZUKI SUPER GREASE A onto the handlebars before installing the throttle grip MAH 99000 25010 SUZUKI SUPER GREASE Apply SUZUKI SUPER GREASE A to the throttle cable end and cable drum 99000 25010 SUZUKI SUPER GREASE Align the hole on the handlebars with the hole of the throttle grip case Tighten the throttle grip case screw HANDLEBAR LEFT SIDE PARTS Apply a handle grip bond onto the handlebars before installing the handlebar grip 39442 09D00 HANDLE GRIP BOND When remounting the rear brake holder onto the handlebars align the brake holders mating surface with the punched mark on the handlebars and tighten the upper clamp bolt first NOTE Be sure to face the UP mark B on the holder to the upside htto www motorcycle in th Apply SUZUKI SUPER GREASE A to the cable end and brake lever pivot MAH 99000 25010 SUZUKI SUPER GREASE After installing the handlebar route the wire harness properly gt 7 12 Adjust the throttle operation and cable play 72 10 htto www motorcycle in th CHASSIS 5 41 5 42 CHASSI
69. cover left and right 5 10 Remove the hook Remove the air cleaner element box cap 2 by removing the Screws Remove the air cleaner element 3 Inspect the air cleaner element for clogging If the air cleaner element is clogged with dust replace the air cleaner element with a new one CAUTION Do not blow the air cleaner element with compressed air NOTE If driving under dusty conditions replace the air cleaner element more frequently Make sure thatthe air cleaner is in good condi tion at all times The life of the engine depends largely on this D removal htto www motorcycle in th 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 initially at 1 000 km 5 months and every 8 000 km 40 months thereafter Tighten the exhaust pipe bolts D and muffler mounting bolts 2 COOLING FAN FILTER Clean every 3 000 km Remove the cooling fan cover D Remove the holder 2 and cooling fan filter 3 Clean the fan filter in the same manner of the air cleaner ele ment Reinstall the cleaned or new filter in the reverse order of removal CAUTION Do not apply engine oil to the filter after cleaning it htto www motorcvcle in th 2 6 PERIODIC MAINTENANCE VALVE CLEARANCE Inspect
70. ct the motorcycle to full throttle operation for short periods of time htto www motorcycle in th 1 6 GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall Dto oat oe ERE 1859 mm terret erret eene ce eren et 654 mm Overall height 1046 mm Wheelbase uie t e a e red e cd s 1244 mm Ground emen 145 mm Diy MASS iet ER 94 2 UY 125 95 5 UY 1255 ENGINE TeV DO i cete cometen dere enti ebbe ba dude en a tete Four stroke forced air cooled OHC Number of cylinders 1 1 mm 1 BOG entree ET ten AN 53 5 mm ii edm e eR DEN rr a EE 55 2 mm ddp d P e as 124 cm Compression rat n ee ianiai memes 9 6 1 vehe derer ir ieee MIKUNI BS26 Alt Starter systemic esed ecd ede ee e ed ne Electric and kick Lubrication 5 0 1 memes Wet sump Idle Speed 1600 100 rpm TRANSMISSION GlUtC bee rect e REPRE ERR NER Dry shoe automatic centrifugal type se are vv vd Variable change 2 700 0 825 Final reduction ratio 9 264 49 17 x 45 14 BYTE ic V belt drive CHASSIS Frontsusp
71. cycle 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 specifica tion 09900 20805 Tire depth gauge Tire tread depth Service Limit FRONT 1 6 mm REAR 1 6mm htto www motorcycle in th PERIODIC MAINTENANCE 2 15 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 COLD INFLATION TIRE PRESSURE FRONT REAR CAUTION The standard tire fitted on this motorcycle is a 70 90 14M C 34P for the front and a 80 90 14M C 40P for the rear The use of tires other than those specified may cause instability It is highly recommended to use the specified tires 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 reduce the runout replace the wheel Wheel runout Service Limit axial and radial 2 0 mm SPOKE NIPPLES Make sure that the nipples are
72. d and bleed air 72 14 BRAKE DISC INSPECTION Check the brake disc for cracks or damage and measure the thickness using the micrometer Replace the disc if the thickness is less than the service limit or if damage is found 5 21 22 Brake disc thickness Service Limit 3 0 mm 09900 20205 Micrometer 0 25 mm Measure the runout with a dial gauge f either measurement exceeds the service limit replace the brake disc with a new one 5 21 22 Brake disc runout Service Limit 0 30 mm 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand htto www motorcycle in th CHASSIS 5 27 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 D on the master cylinder to catch any spilt brake fluid 5 25 CAUTION Immediately wipe off any brake fluid contacting any part of the motorcycle The brake fluid reacts chemi cally with paint plastics rubber materials etc and will damage them severely Disconnect the front brake light switch lead wires 2 Remove the front brake master cylinder 3 Remove the brake lever 4 and brake switch 5 Remove the reservoir cap 6 diaphragm plate 2 and dia phragm 8 htto www motorcycle in th Pull outthe dust seal boot 9 and remove the snap ring 40 Remove the plate 42 pi
73. d assemble the head and valve components F ill the intake and exhaust ports with gasoline to check for leaks If any leaks occur inspect the valve seat and face for burrs or other things that could preventthe valve from sealing Always use extreme caution when handling gasoline 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 amp is notless than 2 2 mm If this length becomes less than 2 2 mm replace the valve Valve stem end length Service Limit 2 2 mm htto www motorcycle in th ENGINE 3 29 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 length and also by the force required to compress them If the spring length is less than the service limit or if the force required to compress the spring does not fall within the specified range replace both the inner and outer springs as a set Valve spring free length IN amp EX Service Limit 32 9 mm 09900 20102 Vernier calipers Valve spring tension IN amp EX Standard 118 N 12 0 kgf 26 8mm CAMSHAFT CAM WEAR Check for abnormal surface damage or wear
74. d valve spring 7 Remove the valve 8 from the combustion chamber side htto www motorcycle in th Remove the valve stem seal 9 and valve spring seat 40 ROCKER ARM SHAFT O D Measure the diameter of rocker arm shaft Rocker arm shaft O D IN amp 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 diameter of the valve rocker arm and wear of the camshaft contacting surface should be checked Rocker arm 1 0 IN amp EX Standard 10 003 10 018 mm 09900 20605 Dial calipers CYLINDER HEAD DISTORTION Decarbon the combustion chamber Check the gasketed surfaced of the cylinder head for distortion with a straightedge and thickness gauge taking a clearance reading at several places as indicated If the largest reading at any position of the straightedge exceeds the limit replace the cylinder head Cylinder head distortion Service Limit 0 05 mm 09900 20803 Thickness gauge htto www motorcycle in th ENGINE 3 23 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 D if itis out of specification replace the valve with a new one Valve head thickness IN amp EX Service Limit T 0 5 mm 09900 20101 V
75. d valve with a new one OIL SEPARATOR Check the oil separator for any damage or clogs If they are clogged clean the oil separator with a compressed air or replace htto www motorcycle in th REASSEMBLY Reassembly the cylinder head cover in the reverse order of disassembly P ay attention to the following points Install the breather cover gasket CAUTION Replace the removed breather gasket with a new one Tighten the breather cover bolts to the specified torque V Breater cover bolt 10 N m 1 0 kgf m Apply THREAD LOCK to the PAIR reed valve cover bolts and tighten them 99000 32050 THREAD LOCK 1342 CYLINDER HEAD CAUTION Identify the position of each removed part Organize the parts in their respective groups i e intake or exhaust so that they can be installed in their original locations DISASSEMBLY Remove the cam chain tensioner D Remove camshaft retainer 2 htto www motorcycle in th ENGINE 3 21 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 camshaft 5 Compress the valve spring with the valve spring compressor Remove the valve cotters from the valve stem 09916 14510 Valve spring compressor 09916 14521 Attachment 09916 84511 Tweezers Remove the valve spring retainer 6 an
76. de diameter of the clutch housing with inside calipers Measure the diameter at several points to check for out of round and wear If any damages are found or if the inside diameter exceeds the service limit replace the clutch housing with a new one Clutch housing 1 0 Service Limit 125 5 mm DRIVEN FACE SPRING INSPECTION Measure the free length of the driven face spring If the length is shorter than the service limit replace the spring with a new one Driven face spring length Service Limit 99 8 mm DRIVEN FACE PINS INSPECTION Rotate the driven faces and make sure they turn smoothly If they stick or do not turn smoothly inspect the sliding pins CD for wear or damage If any damages are found replace the driven face with a new one htto www motorcycle in th ENGINE 3 41 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 disassembly Pay attention to the follow ing points Install the bearing in the fixed driven face D with the spe cial tool 09943 88211 Bearing installer Apply SUZUKI SUPER GREASE A to the bearing 2 99000 25010 SUZUKI SUPER GREASE Securely install the snap ring
77. der and passenger THAI SUZUKI MOTOR LTD COPYRIGHT THAI SUZUKI MOTOR CO LTD 2005 GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE ENGINE FUEL AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION htto www motorcycle in th HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR 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 The contents are listed on the first page of each section to help you find the item and page you need A COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instructions and other service information such as the tightening torque lubricating points and locking agent points are provided Example Front wheel Spacer Dust seal Bearing Front wheel spacer Front wheel Bearing Front brake shoe Speedometer drive LT Front brake camshaft 22 7 7 8 Front brake panel 4 e Speedometer driven Front brake cam lever Front axle fF Front axle nut Spoke nipple 4 Front brake cam lever N bolt 42 Dust seal d
78. e When measuring the resistance make sure that no voltage is applied If voltage is applied the tester will be damaged After using the tester be sure to turn the switch to the OFF position 09900 25008 Multi circuit tester set CAUTION Before using the multi circuit tester read its instruc tion manual htto www motorcycle in th 66 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Horn 2 Turn signal relay 3 Regulator rectifier 4 Magneto 5 Battery 6 Fuse 7 CDI unit htto www motorcycle in th ELECTRICAL SYSTEM 6 7 Ignition coil 9 Starter relay Starter motor htto www motorcvcle in th 6 8 ELECTRICAL SYSTEM CHARGING AND LIGHTING SYSTEM Magneto B AC DC Su E iss 9 9 9 a il Battery HL M L e 3 3 H FH CDI unit TROUBLESHOOTING Battery runs down quickly Step 1 1 Check accessories which use excessive amounts of electricity Are accessories being installed YES Remove accessories NO Go to Step 2 Step 2 1 Check the battery for current leaks 6 10 Is the battery for current leaks OK YES Go to Step 3 Short circuit of wire harness N 9 Faulty electrical equipment htto www motorcycle in th ELECTRICAL SYSTEM 6 9 Step 3 1 Measure the charging output between the battery terminals 6 10
79. e CDI unit coil coupler Measure the pickup coil peak voltage in the following procedure Connect the multi circuit tester with the peak volt adaptor as follows Probe Blue Yellow lead wire Probe Ground Peak volt 09900 25008 Multi circuit tester set 208001 ep 79 CAUTION C _ Before using the multi circuit tester and peak volt adaptor be sure to refer to the appropriate instruction manual Magneto Turn the ignition switch to the ON position Measure the pickup coil peak voltage while squeezing the front or rear brake lever and pressing the starter button to turn the engine for a few seconds Repeat the above procedure a few times and measure the highest pickup coil peak voltage Tester knob indication Voltage Pickup coil peak voltage 2 0 V and more htto www motorcycle in th 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 7775 8 Disconnectthe pickup coil coupler Connect the multi circuit tester with the peak volt adaptor as follows Probe Blue Yellow lead wire Probe Ground Measure the pickup coil peak voltage in the same manner as on the CDI unit coupler 09900 25008 Multi circuit tester set Tester knob indication Voltage Pickup coil peak voltage 2 0 V and more If the peak vol
80. e circlip over the shaft After installing a circlip always ensure that it is completely seated in its groove and securely fitted Use a torque wrench to tighten fasteners to the specified torque Wipe off grease and oil if a thread is smeared with them After reassembling check parts for tightness and proper operation To protect the environment do not unlawfully dispose of used motor oil and other fluids bat teries and tires To protect Earth s natural resources properly dispose of used motorcycle and parts htto www motorcycle in th 14 GENERAL INFORMATION SUZUKI UY125K6 SK 6 06 MODEL LEFT SIDE UY125 SERIAL NUMBER LOCATION The frame serial number or V I N Vehicle Identification Number D is stamped on the left side of the steer ing head pipe The engine serial number is located on the left side of the crankcase These numbers are required especially for registering the machine and ordering spare parts htto www motorcycle in th 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 or SH SJ in API with MA inJASO MULTIGRADE vary j 10W 40 TOW 50 Suzuki recommends use of SAE 10W 40 engine oil If SAE 10W 40 engin
81. e guide reamer 10 8 mm 09916 44310 Valve guide remover installer 09916 84511 Tweezers 09917 14910 Valve clearance adjusting driver 09917 47010 Vacuum pump 09920 13120 Crankcase separator 88 09921 20240 Bearing remover set 09922 31430 Clutch spring compressor 09923 73210 Bearing puller 17 20 mm 09924 84510 Bearing installer set htto www motorcycle in th 09924 84521 Bearing installer set C 09925 98221 Bearing installer 09930 10121 Spark plug socket wrench set 09930 30104 Sliding shaft SERVICING INFORMATION 7 35 09930 34980 Rotor remover 09930 40113 Rotor holder 09930 40120 Rotor holder attachment A 09940 34520 T handle 09940 34561 Attachment D 09940 51710 Bearing installer 09940 52861 Front fork oil seal installer set 09940 60113 Spoke nipple wrench NOTE 09941 34513 Steering outer race installer 09943 74111 Fork oil level gauge 09943 88211 Bearing installer Before placing order for the special tool please check for availability htto www motorcycle in th 09951 16080 Bearing installer 7 36 SERVICING INFORMATION TIGHTENING TORQUE ENGINE Cylinder head cover bolt Initial Final Crank case bracket nut Engine mounting nut Breather cover bolt Intake pipe mounting bolt Cylinder head nut Cylinder head side nut Spark plug Valve clearance adjuster locknut Ma
82. e in charging system Cell plates have lost much of their active material as a result of overcharging A short circuit condition exists within the battery Too low battery voltage Too old battery Check the generator regu lator rectifier and circuit connections and make nec essary adjustments to obtain specified charging operation Replace the battery and correct the charging sys tem Replace the battery Recharge the battery fully Replace the battery Battery sulfation Too low or too high charging rate When not in use battery should be checked at least once a month to avoid sulfation Leftunused the battery for too long in cold cli mate htto www motorcycle in th Replace the battery Replace the battery if badly sulfated WIRING DIAGRAM 7 10 SERVICING INFORMATION UY125 HOLIMS 1 5 NYNL HOLON H31HVlS OL3N5VIN 492811 MOJI9A WA PE MOII9A NHOH NOLLOS 1391 YUM PRESE NHOH 49981 en g YUM SUM Ig M xoa asnd 1927 AA OFO i 49981 xoelg Bes
83. e lip of the stem seal htto www motorcycle in th ENGINE 3 31 3 32 ENGINE Install the valve spring making sure that the close pitch end 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 down the spring fit the cotter halves to the stem end and release the lifter to allow the cotter D to wedge in between retainer and stem Be sure that the rounded lip of the cotter fits snugly into the groove O in the stem end 09916 14510 Valve lifter 09916 14521 Valve lifter attachment 09916 84511 Tweezers CAUTION Be sure to restore each spring and valve to their origi nal positions NOTE J ust before installing the camshaft into the cylinder head apply molybdenum oil solution to the cam faces MOLYBDNUM OIL SOLUTION Apply engine oil to the rocker arm shafts rocker arms and install them htto www motorcycle in th CAM CHAIN TENSIONER Install the cam chain tensioner D and washer 2 Tighten the cam chain tensioner bolt 3 to the specified torque V 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 straightedge and thickness gauge taking a clearance
84. e nut 120 N m 12 0 kgf m COOLING FAN Install the cooling fan holder NOTE When installing the cooling fan holder align the wide spline teeth and B htto www motorcvcle in th ENGINE 3 65 Install the washer 2 Tighten the cooling fan holder nut to the specified torque with the special tool V Cooling fan holder nut 33 N m 3 3 kgf m 09930 40113 Rotor holder Align the boss O of the cooling fan to the groove D of the cooling fan holder Tighten the cooling fan bolt to the specified torque V Cooling fan bolt 10 N m 1 0 kgf m POSTON RING Install the spacer into the oil ring groove first Then install both side rails 2 one on each side of the spacer The spacer and side rails do not have a specific top or bottom when they lt new When reassembling used parts install them their original place and direction htto www motorcvcle in th 3 66 ENGINE CAUTION When installing the spacer be careful not to allow its two ends to overlap in the groove 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 the gaps of the three rings as shown NOTE Before inserting piston into the cylind
85. e oil is not available select an alternative accord ing to the right chart 230 20 10 0 10 20 30 40 ej 22 4 14 32 50 68 86 104 REDUCTION GEAR OIL Use a good quality SAE 10W 40 multi grade motor oil 15W 40 15W 50 BRAKE FLUID UY125S Specification and classification DOT 4 Since the brake system of this motorcycle is filled with a glycol based brake fluid by the manu facturer do not use or mix different types of fluid such as silicone based and petroleum based fluid for refilling the system otherwise serious damage will result Do not use any brake fluid taken from old or used or unsealed containers Never re use brake fluid left over from a previous servicing which has been stored for a long period FRONT FORK OIL Use SUZUKI FORK OIL G10 10 or an equivalent fork oil BREAK IN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but itis still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised during its early life Refer to the following throttle position recommendations Keep to these break in throttle positions Initial 800 km Less than 1 2 throttle Up to 1 600 km Less than 3 4 throttle Upon reaching an odometer reading of 1 600 km you can subje
86. emoved bearing with a new one BEARING OIL SEAL INSTALLATION Install the driveshaft bearing D and idle shaft 2 bearing with the special tool 09913 70210 Bearing installer set 32 mm nstall the rear axle shaft oil seal with the special tool 09913 70210 Bearing installer set 40 mm nstall the rear axle shaft bearing with the special tool 09913 70210 Bearing installer set 42 mm htto www motorcycle in th 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 THREAD LOCK to the screws 99000 32110 THREAD LOCK SUPER 1322 ENGINE MOUNTING BUSHINGS 3 51 htto www motorcvcle in th CRANKSHAFT SHIM SELECTION Degrease the right crankshaft web shim and inner race of the right crankshaft bearing Place the removed shim D 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 the right crankcase and tighten the crankcase screws and bolts Remove the crankcase screws and bolts Separate the crankcase into 2 parts left and right with the special tool 3 19 09920 13120 Crankcase separator Measure the width of c
87. enier calipers VALVE STEM RUNOUT Support the valve using V blocks as shown and measure its runout with the dial gauge If the runout exceeds the limit replace the valve Valve stem runout IN amp EX Service Limit 0 05 mm 09900 20701 Magnetic stand 09900 20607 Dial gauge 1 100 mm 09900 21304 V block 100 mm VALVE HEAD RADIAL RUNOUT Place the dial gauge at right angles to the valve head and mea sure the valve head radial runout If it measures more than limit replace the valve Valve head radial runout IN amp EX Service Limit 0 03 mm 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm VALVE STEM DEFLECTION Lift the valve about 10 mm from the valve seat Measure the valve stem deflection in two directions X and Y perpendicu lar to each other by positioning the dial gauge as shown If the deflection measured exceeds the limit then determine whether the valve orthe guide should be replaced with a new one Valve stem deflection Service Limit IN amp EX 0 35 mm 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand htto www motorcycle in th 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
88. ension Replenish R etighten Wobbly rear wheel Distorted wheel rim Worn gearbox bearing Defective or incorrect tire Worn crankcase bushing Loose axle nut or engine mounting bolts nuts Replace Replace Replace Replace R etighten Rear suspension too soft Weakened shock absorber spring Leakage of oil from shock absorber Replace Replace Rear suspension too stiff e AU NEJIN U gt RB WYN mnm Worn crankcase bushing Replace Noisy rear suspension BRAKES Complaint Loose nuts or bolts on rear suspension Worn crankcase bushing Symptom and possible causes R etighten Replace Remedy Insufficient brake power UY125S Leakage of brake fluid from hydraulic system Worn pads or disc Oil adhesion on friction surface of pads Air in hydraulic system Excessive brake lever play Friction surfaces of pads are dirty with oil or dust Notenough brake fluid in the reservoir htto www motorcycle in th Repair or replace Replace Clean disc and pads Bleed air Adjust Replace Replenish Complaint Symptom and possible causes SERVICING INFORMATION 7 7 Remedy Insufficient brake power UY 125 Worn shoes or drum Too much brake lever play Excessive brake lever play Friction surfaces of shoes are dirty with oil or dust Excessively w
89. er check that the gaps are so located PISTON Rub a small quantity of molybdenum oil solution onto the pis ton pin Place a clean rag over the cylinder base to prevent the piston pin circlips from dropping into the crankcase Install the piston with the arrow mark 4 facing towards the exhaust side MOLYBDNUM OIL SOLUTION htto www motorcycle in th Y 4 INCORRECT CORRECT 8 ARAR gt 2nd ring EX Upper side rail Lower side rail Top ring IN Spacer ENGINE 3 67 After the piston pin D has been inserted through the conrod install the circlip 2 CAUTION Replace the circlip with a new one Place a piece of rag under the piston when installing the circlip to prevent it from falling into the crank case The circlip end gap must be positioned so as not to coincide with the piston pin bore cutaway 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 CAUTION Use a new gasket to prevent oil leakage Hold each piston ring with properly position and insert the piston into the cylinder NOTE When mounting the cylinder keep the camshaft drive chain taut Install the cam chain guide CYLINDER HEAD Install the dowel pins and a new gask
90. ernier calipers BRAKE SHOE Inspect the brake shoes for wear or damage If any defects are found replace the brake shoes as a set CAUTION Replace the brake shoes as a set otherwise braking performance will be adversely affected REAR AXLE Check the rear axle spline for damage or wear If any abnormal condition is noted replace the rear axle shaft 3 18 59 REAR WHEEL 5 15 TIRE ven 2 15 SPOKE 272 16 htto www motorcvcle in th CHASSIS 5 49 REASSEMBLY AND REMOUNTING Reassemble and remount the rear wheel and rear brake in the reverse order of removal and disassembly P ay attention to the following points When installing the camshaft apply SUZUKI SUPER GREASE A to the camshaft 99000 25010 SUZUKI SUPER GREASE A Turn the punched mark on the camshaft to the rear axle side Align the tang D on the brake lining wear indicator plate 2 with the cutaway 3 the brake cam Then slide the brake lining wear indicator plate onto the brake cam htto www motorcvcle in th 5 50 CHASSIS When installing the brake cam lever align the groove 4 of camshaft with the slit on cam lever 7 27 Tighten the brake cam lever nut to the specified torque V Brake cam lever nut 11 N m 1 1 kgf m Apply SUZUKI SUPER GREASE A to the camface and pin 99000 25010 SUZUKI SUPER GRE
91. ernslOnz e lere FREIER Telescopic coil spring oil damped Rear eene Swingarm type coil spring oil damped Erontfork stroke ace ut aeter s 85 mm Rear 2002 80 mm Steering angle siio mre ee eee beg ie e e ER RETE 45 right and left 25 6 CIT 100 TUNING tos tiet eh re er rr ht 1 9m Front Drake munito eo Fee Fes Drum brake UY 125 Disc brake UY 1255 Rear Drake it esent ete Pre EET REED REPE FEY EYE Drum brake Fronttire SiZe zwei e a ete ete n n eeu Eso dies 70 90 14 34 P tube type Rear Pv fe cete n D PR 80 90 14 M C 40 P tube type htto www motorcycle in th GENERAL INFORMATION 1 7 ELECTRICAL Ignition tpe rt ete reor edt en ra Fee P dr rs Electronic ignition CDI sce et i e ha Pe DER cod OR Ene 10 B T D C at 1 600 rpm Spark PlUG Ju sees terere reden e c ra rper P REPERI NGK CR6HSA or DENSO U20FSR U Battery ctr a E HEAR EE rer cec bu eas 12 V 12 6 kC 3 5 Ah 10 HR Generator evo e tei t RT gies Single phase A C generator 10 12 V 30 30 W TUNES IGM a ill Wits seo beate ei ete ettet e e Ratte 12V 10W Brake
92. et 3 CAUTION Use a new gasket to prevent gas leakage htto www motorcvcle in th 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 V Cylinder head nut 25 N m 2 5 kgf m Tighten the cylinder head side nuts to the specified torque V Cylinder head side nut 10 N m 1 0 kgf m MERO yo du Turn the crankshaft clockwise with a box wrench and align the TOP mark on the cooling fan with the index mark B on the magneto cover keeping the camshaft drive chain pulled upward CAUTION If crankshaft is turned without drawing the camshaft drive chain upward the chain will be caught between crankcase and cam chain drive sprocket Engage the chain on the cam sprocket with the locating pin at just top position Align the engraved line mark D on the cam sprocket so it is gt parallel with the surface of the cylinder head htto www motorcycle in th Install the spring 6 and plastic washer 2 to the decompres sion cam Hook the part of the spring onto the cam and fit the part 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 sprocket bolts to the specified torque V Camshaft sprocket b
93. everal 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 handle 09940 34561 Attachment D Remove the damper 5 and rebound spring 6 Remove the dust seal and the oil seal stopper ring CAUTION The removed dust seal must be replaced with a new one htto www motorcycle in th CHASSIS 5 33 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 CAUTION The removed oil seal must be replaced with a new one 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 the fork spring free length If the fork spring free length is shorter than the service limit replace the fork spring with a new one Front fork spring free length Service limit 285 8 mm DAMPER ROD RING Inspect the damper rod ring for wear or damage If itis worn or damaged replace the damper rod ring with a new one htto www motorcycle in th 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
94. face decrease the belt thoroughly Install the clutch cover 3 72 NOTE Drain water from the clutch cover by removing the drain bolt A REDUCTION GEAR BOX OIL Inspect every 8 000 km 40 months thereafter Keep the motorcycle upright Place an oil pan below the gear case and drain oil by remov ing the oil drain plug D and filler cap Tighten the drain plug D and pour fresh oil through the filler Oil viscosity and classification SAE 10W 40 with SF or SG NECESSARY AMOUNT OF REDUCTION GEAR OIL Oil change 100 ml Overhaul 110 ml htto www motorcycle in th 2 12 PERIODIC MAINTENANCE BRAKE Inspect initially at 1 000 km 5 months and every 4 000 km 20 months thereafter BRAKE LEVER PLAY Adjust the brake lever play by turning the adjusting nut D so that the play is 15 25 mm as shown Brake lever play 15 25 mm FRONT BRAKE PADS UY125S The extent of brake pad wear can be checked by observing the grooved limit line on the brake pad When the wear exceeds the grooved limit line replace the pads with new ones 5 25 CAUTION Replace the brake pads as a set otherwise braking performance will be adversely affected BRAKE SHOW WEAR This motorcycle is equipped with the brake lining wear limit indi cator on the brake To check wear of the brake lining perform the following steps First
95. faces Check the brake hoses and hose joints for cracks and fluid leakage before riding htto www motorcycle in th 2 14 PERIODIC MAINTENANCE FRONT BRAKE FLUID REPLACEMENT Remove the handlebar cover 75 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 reservoir with new brake fluid Specification and classification DOT 4 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a receptacle Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system Close the air bleeder valve and disconnectthe clear hose F ill the reservoir with new brake fluid to the upper end of the inspection window V Air bleeder valve 7 5 0 75 kgf m AIR BLEEDING FOR THE FRONT BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin der and thus interferes with the full braking performance of the brake caliper The presence of air is indicated by sponginess of the brake lever and also by lack of braking force Considering the danger to which such trapped air exposes the machine and rider it is essential that after remounting the brake and restor ing the brake system to the
96. few seconds and then measure the ignition coil primary peak voltage Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage Tester knob indication Voltage Ignition coil primary peak voltage 150 V and more While testing do not touch the tester probes and spark plug to prevent receiving an electric shock If the voltage is lower than the specified values inspect the igni tion coil 6 24 htto www motorcycle in th ELECTRICAL SYSTEM 6 23 WIBI New spark plug IW 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 resistance in both the primary and secondary windings is close to the speci fied values the windings are in sound condition 09900 25008 Multi circuit tester set Tester knob indication Resistance Ignition coil resistance Primary 0 2 0 9 Tap gt Tap Secondary 11 20 Spark plug cap Tap PICKUP COIL PEAK VOLTAGE Remove the luggage box 5 9 NOTE Make sure that all of the couplers are connected properly and the battery is fully charged Disconnect th
97. fied torque V Brake disc bolt 23 N m 2 3 kgf m Keep the brake disc clean free front dirt and grease htto www motorcycle in th CHASSIS 5 21 SPEEDOMETER GEARBOX Apply SUZUKI SUPER GREASE A to the speedometer gearbox 99000 25010 SUZUKI SUPER GREASE Align the lugs D on the speedometer gearbox with the recesses 2 on the front wheel FRONT WHEEL Make sure thatthe stopper 9 on the front fork and the speed ometer gearbox protrusion 4 are installed as shown CAUTION When installing the front wheel position the brake disc between the brake pads Be careful not to dam age the brake pads Tighten the front axle to the specified torque V Front axle nut 42 N m 4 2 kgf m Connectthe speedometer cable NOTE Move the front fork up and down four or five times After remounting the front wheel pump the brake lever a few times to check for proper brake operation htto www motorcvcle in th 5 22 CHASSIS FRONT BRAKE UY125S Reservoir cap Diaphragm Master cylinder Piston set Dust seal boot Brake hose Caliper holder Caliper holder pin Caliper holder pin Rubber parts Pad set Piston and dust seal Piston Caliper Pad spring Master cylinder mounting bolt Brake hose union bolt Brake caliper mounting bolt G S S m o eo ejc e e je me mo A
98. gf m htto www motorcvcle in th ENGINE 3 59 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 D and spacer 2 CAUTION The assembly work should be carefully performed so as notto allow the roller to dislocate With the clutch shoe spring compressed by hands the mov able driven face towards the clutch install the drive belt 3 to the movable driven face 4 CAUTION Position the drive belt so that the arrow points the engine rotating direction Degrease the drive belt contact surface pulley face Mountthe clutch shoes movable driven face assembly 5 CAUTION Pull the center area of upper and lower belt lines to be close to each other to prevent the belt from expand ing Install the clutch housing and lock the clutch housing uA with the special tool and tighten the clutch housing nut to the specified torque CAUTION Degrease the inner surface of the clutch housing 09930 40113 Rotor holder V Clutch housing nut 50 N m 5 0 kgf m Tor htto www motorcycle in th ENGINE 3 61 Install the fixed drive face Install the kick starter Install the washer and nut 10 CAUTION Check that the fixed drive face is not fouled with grease or other substance and if fo
99. gine removal is sequentially explained in the following steps Reinstall the engine by reversing the removal procedure Remove the front frame cover 75 8 Remove the luggage box 5 9 Remove the frame covers left and right 5 10 Disconnect the battery lead wire Remove the fuel tank 4 2 Drain engine oil 2 8 Disconnect the starter motor lead wire Remove the carburetor 77 4 8 Disconnect the head cover breather hose 2 and PAIR hose htto www motorcvcle in th 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 Remove the exhaust pipe bolts htto www motorcvcle in th 3 6 ENGINE Remove the muffler mounting bolts and then remove the muf fler Remove the rear brake cable clamp bracket 8 Remove the rear brake cable adjuster nut 9 spring 40 and pin 4 Remove the rear brake cable clamp Remove the clutch upper cover 42 Remove crankcase tube 3 htto www motorcvcle in th 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 0 from the frame Remove the engine from the frame htto www motorcycle in th 3 8 ENG
100. gnetorotor nut Clutch housing nut Clutch shoe nut Fixed drive face nut Stator coil bolt Crankcase bolt Magneto cover bolt Cam chain tensioner bolt Cam chain tension adjuster mounting bolt Oil drain plug Main oil gallery plug Camshaft sprocket bolt Starter motor mounting bolt Clutch cover bolt Oil pump mounting screw Reduction gear cover bolt Cooling fan holder nut Cooling fan bolt Oil sump filter cap bolt Oil filter cap bolt Oil pump cover bolt Kick starter lever bolt Starter clutch bolt htto www motorcycle in th SERVICING INFORMATION 7 37 CHASSIS Front axle nut Steering stem lock nut Handlebar clamp nut Brake cam lever nut Front UY 125 Rear Rear axle nut Rear shock absorber mounting nut Front fork clamp bolt Front fork cap bolt Damper rod bolt Front brake caliper mounting bolt UY 1255 Brake hose union bolt UY 125S Brake disc bolt UY 125S Air breeder valve UY 125S Brake master cylinder bolt UY 1255 S poke nipple htto www motorcycle in th 7 38 SERVICING INFORMATION TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page refer to this chart Bolt Diameter 4 Conventional or 4 marked bolt 7 marked bolt mm N m kgf m N m kgf m 1 5 0 15 2 3 0 23 3 0 3 4 5 0 45 5 5 0 55 10 1 0 13 1 3 23
101. i circuit tester measure the voltage between two lead wires the tester reads under the specified value replace the stator coil with a new one 09900 25008 Multi circuit tester set 4 Tester knob indication Voltage Stator no load performance Charge side 6 V and more at 5 000 rpm When engine is cold Lamp side 4 V and more at 5 000 rpm When engine is cold W R YAN htto www motorcycle in th 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 D Measure the voltage between the terminals using the multi cir cuit tester as indicated in the table below If voltage is not within the specified value replace the AC DC rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode test 44 Tester probe B W 8 B W W R 1 0 1 6 9 Y 1 4 V and more tester s battery voltage m i NOTE If the tester reads 1 4 V and below when the tester probes are not connected replace its battery htto www motorcycle in th ELECTRICAL SYSTEM 6 13 STARTER SYSTEM Starter relay Starter motor Front brake light switch Fuse Ignition switch y 6 6 9 4 O O YIG Starter button T Battery Rear brake light switch 7 7 TROUBLESHOOTIN
102. ified torque V Kick starter lever bolt 26 N m 2 6 kgf m htto www motorcvcle in th PAIR AIR SUPPLY SYSTEM PAIR HOSES INSPECTION Remove the frame front cover 7575 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 73 20 Inspect the reed valve for the carbon deposit f the carbon deposit is found in the reed valve replace the PAIR reed valve with a new one PAIR CONTROL VALVE INSPECTION Remove the PAIR control valve 3 11 Inspect that air flows through the PAIR control valve air inlet port to the air outlet port If air does not flow out replace the PAIR control valve with a new one Connect the vacuum pump gauge to the vacuum port of the control valve as shown in the photograph Apply negative pressure slowly to the control valve and inspect the air flow If air does not flow out the control valve and is in normal condition If the control valve does not func tion replace if with a new one Negative pressure range 51 kPa 0 5 mmHg 09917 47010 Vacuum pump gauge CAUTION Use a hand operated vacuum pump to prevent the control valvedamage htto www motorcycle in th ENGINE 3 73 htto www motorcycle in th FUEL AND LUBRICATION SYSTEM 4 1 FUEL AND LUBRICATION SYSTEM CONTENTS FUEL TANK AND FUEL ui 4 2 5
103. in th STARTER IDLE GEAR Install the starter idle gear D onto the starter idle gear shaft Q CAUTION Apply engine oil to each gear and shaft MAGNETO COVER Install the dowel pins D and gasket CAUTION Make sure to replace the gasket with a new one nstall the magneto cover bolts to the specified torque NOTE Fitthe clamp to the bolt as shown V Magneto cover nut 10 N m 1 0 kgf m CENTER STAND nstall the center stand Apply SUZUKI SUPER GREASE A to the center stand spring and shaft 7777 26 99000 25010 SUZUKI SUPER GREASE BRAKE CAM Apply SUZUKI SUPER GREASE A to the brake cam and then install the brake cam into the crankcase 99000 25010 SUZUKI SUPER GREASE htto www motorcvcle in th ENGINE 3 63 3 64 ENGINE Position the brake cam so that the punch mark faces the rear axle shaft 7 27 Align the tang D on the brake lining wear indicator plate 2 with the cutaway 9 on the brake cam Then slide the brake lining wear indicator plate 2 onto the brake cam Install the return spring and brake cam lever onto the brake cam and tighten the brake cam lever nut to the specified torque V Brake cam lever nut 11 N m 1 1 kgf m REAR WHEEL Install the brake shoes and rear wheel Install the washer and nut Tighten the rear axle nut to the specified torque V Rear axl
104. ing the lock nut check the steering movement again and adjust if necessary Install the front forks and front fender 5 39 Install the front wheel UY 125 5 19 C UY 125S 5 23 Install the handlebars 7 5 41 Perform the steering inspection after assembly has been completed 2 17 htto www motorcycle in th CHASSIS 5 47 REAR WHEEL AND REAR BRAKE CONSTRUCTION Rear wheel Washer Brake shoe E S pring 1 Brake camshaft Brake cam lever Brake cam lever bolt Brake lining wear indi cator Rear axle nut Rear brake cam lever nut amp D ITEM kgf m 120 12 0 11 1 1 REMOVAL AND DISASSEMBLY REAR WHEEL AND REAR BRAKE Support the motorcycle with the center stand Remove muffler 3 6 Remove the rear wheel Remove the rear brake shoes D htto www motorcvcle in th 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 1 0 to determine the extent of wear and if the limit is exceeded by the wear noted replace the wheel hub The value of this limit is indicated inside the drum Brake drum I D Service Limit 130 7 mm 09900 20101 V
105. initially at 1000 km 5 months and every 4 000 km 20 months thereafter REMOVAL Remove the frame front cover 5 8 Remove the spark plug 2 7 Disconnect the breather hoses D and remove the head cover Q INSPECTION The valve clearance specification is same for both valves Valve clearance adjustment must be checked and adjusted 1 at the time of periodic inspection 2 when the valve mechanism is ser viced and 3 when the camshaft is disturbed by removing it for servicing NOTE The piston must be at TDC on the compression stroke in order to check the valve clearance or to adjust valve clear ance The clearance specification is for COLD state To turn the crankshaft for clearance checking rotate in nor mal running direction The spark plug should be removed Turn crankshaft to bring the TDC mark on the cooling fan to the index mark B on the crankcase Inserta 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 range Valve clearance when cold IN 0 04 0 07 mm EX 0 10 0 15 mm 09900 20803 Thickness gauge 09917 13210 Valve adjusting driver Adjuster Lock nut htto www motorcycle in th After finishing the valve clearance adjustment reinstall the fol lowing items Cylinder head cover 3 11 Spark plug
106. ir bleeder valve gjo o This brake system is filled with an ethylene glycol based DOT 4 brake fluid Do not use mix different types of fluid such as silicone based or petroleum based Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for a long periods When storing the brake fluid seal the container completely and keep away from children When replenishing brake fluid take care not to get dust into fluid When washing brake components use fresh brake fluid Never use cleaning solvent A contaminated brake disc or brake pad reduces braking performance Discard contaminated pads and clean the disc with high quality brake cleaner or neutral detergent CAUTION Handle brake fluid with care the fluid reacts chemically with paint plastics rubber materials etc and will damage then severly htto www motorcycle in th CHASSIS 5 23 BRAKE FLUID REPLACEMENT Remove the front handlebar cover 7 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 brake fluid Specification and classification DOT 4 Connect a clear hose to the air bleeder valve and insert the other end of the hose into a
107. iston 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 mm Piston ring groove width Standard 1st 1 01 1 03 mm 2nd 1 01 1 03 mm Oil 2 01 2 03 mm Piston ring thickness Standard 1st amp 2nd 0 97 0 99 mm 09900 20205 Micrometer 0 25 mm 09900 20803 Thickness gauge NOTE Using a soft metal scraper decarbon the crown of the piston Clean the ring grooves similarly htto www motorcycle in th 10 mm PISTON RING END GAP Measure the piston ring end gap using the vernier calipers Next fitthe 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 new one 09900 20102 Vernier calipers Piston ring end gap Service Limit 1st 0 50 mm 2nd 0 50 mm 09900 20803 Thickness gauge PISTON PIN AND PIN BORE Measure the piston pin bore diameter using the small bore gauge measurementis out of specification replace the piston Piston pin bore 1 0 Service Limit 14 038 mm 09900 20602 Dial gauge 1 1000 mm 09900 22401 Small bore gauge 10 18 mm Measure the piston pin outside diameter at three positions using the micrometer f any of the measurements is out
108. jg HUM 19 M asn4 xoe g A M 49924 ang amp 5 M E lt MOURA 232 MUM M jt o 2 D Av 13H 1 18 Bex lt 2 5 227 5 SHO109 9 2 0 f m 7 z o 26 1 1 5 HV3H r wa T 1 1H5r11VN9IS LNOHA a M M T 61 i L 6s 61 LH917 TYN IS 1 IWNDIS NUNLLNOUS 34344 lt lt E DEBS 29 mo lt ml uz C wu o HOLIMS H LIMS LHI H31HVIS uni LINN 109 HOLIMS HOLIMS 35nvO NOLLINDI axvHdg Tana uaradwoqaads YOLVSIGNI 1VN9IS NYAL NL 1 NWW motorcvcle in th http 7 12 SERVICING INFORMATION WIRING HARNESS CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Fuel gauge OS Throttle cable Harness x clamp E eC OTA ROR 2 QA EES um Engine side Battery High tension cord htto www motorcycle in th SERVICING INFORMATION 7 13 Harness Turn signal coupler R amp L Harness WN Steering Wo Engine earth 9
109. ke fluid CAUTION Immediately wipe off any brake fluid contacting any part of the motorcycle The brake fluid reacts chemi cally with paint plastics rubber materials etc and will damage them severely Remove the brake caliper 2 CALIPER DISASSEMBLY Remove the brake pads above Remove the brake caliper holder D htto www motorcycle in th Remove the pad spring Remove the rubber parts 3 Place a rag over the pistons to prevent them from popping out and then force outthe pistons using compressed air CAUTION Do not use high pressure air to prevent piston dam age Remove the dust seal 4 and piston seal 5 CAUTION Do not reuse the removed dust seals and piston seals to prevent fluid leakage CALIPER INSPECTION CALIPER Inspect the caliper cylinder wall and piston surface for scratch corrosion or other damages If any abnormal condition is found replace the caliper or caliper piston with a new one PAD SPRING Inspect the brake pad spring for damage excessive bend If any damage is found replace it with a new one RUBBER PARTS Inspect the boots for damage and cracks If any defects are found replace the rubbers with new ones htto www motorcvcle in th CHASSIS 5 25 5 26 CHASSIS CALIPER HOLDER Inspect the caliper holder for damage If any defects are found replace it with a new one
110. key Remove the frame front cover LEG REAR SHIELD Remove the frame front cover 75 8 Remove the luggage box 5 9 Remove the pillion rider handle 7 5 9 Remove the frame cover assembly 5 10 Remove the leg rear shield htto www motorcycle in th CHASSIS 5 7 LUGGAGE BOX Open the seat 5 8 Remove the luggage box mounting screws Remove the fuse box D from luggage box Remove the luggage box PILLION RIDER HANDLE Remove the pillion rider handle 1 htto www motorcycle in th 5 8 CHASSIS FRAME COVER R amp L Remove the frame front cover 75 8 Remove the luggage box 75 9 Remove the pillion rider handle 7 5 9 Remove the frame cover assembly mounting screws xx Hooked part htto www motorcycle in th CHASSIS 5 9 Disconnectthe seat lock cable D 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 from left frame cover 4 htto www motorcycle in th 5 10 CHASSIS FRONT WHEEL AND FRONT BRAKE U Y125 Collar Dust seal Bearing Front wheel spacer Front wheel Bearing Front brake shoe Dust seal Speedometer drive gear Front brake camshaft Front brake panel Speedometer driven gear Front brake cam lever Front
111. l Clogged air cleaner element Clogged fuel hose resulting in inadequate fuel supply to carburetor Replace Replace Adjust Adjust Replace CDI unit Replace Replace Adjust Clean Clean and prime Dirty or heavy exhaust smoke Too much engine oil in the engine Worn piston rings or cylinder Worn valve guides Scored or scuffed cylinder wall Worn valves or stems Defective stem seals Worn oil ring side rails Check level and drain Replace Replace Rebore or replace Replace Replace Replace Engine lacks power HL HH Loss of valve clearance Weakened valve spring Outof adjustment valve timing Worn piston rings or cylinder Poor seating of valves Fouled spark plug Incorrect spark plug Clogged jets in carburetor Out of adjustment float chamber fuel level Clogged air cleaner element Slipping or worn drive belt Sucking air from intake pipe Too much engine oil Defective CDI unit Damaged worn rollers in the movable drive face Weakened movable drive face spring Adjust Replace Adjust Replace Repair Clean or replace Adjust or replace Clean Adjust Clean Replace Retighten or replace Drain out excess oil Replace Replace Replace Engine overheats Im Heavy carbon deposit on piston crown
112. l hose or fuel filter Clean or replace Fouled spark plug Clean Defective pick up coil or CDI unit Replace Clogged fuel hose or fuel tank cap Clean or replace Clogged jets in carburetor Clean Out of adjustment valve clearance Adjust Clogged exhaust pipe Clean Open or short circuited wiring connection Repair or replace cessive valve chatter Too large valve clearance Adjust Weakened or broken valve spring Replace Worn rocker arm or cam surface Replace Worn and burnt camshaft bearing Replace Engine stalls often Noisy engine E Noise seems from piston Worn down piston or cylinder Replace Fouled with carbon combustion chamber Clean Worn piston pin or piston pin bore Replace Worn piston rings or ring grooves Replace htto www motorcycle in th Complaint Symptom and possible causes SERVICING INFORMATION 7 3 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 Noise seems to come from crankshaft 1 Due to wear rattling bearings 2 Worn and burnt big end bearing 3 Worn and burnt journal bearings 4 Too large thrust clearance Noise seems to come from transmission 1 Worn or rubbing gears Badly worn splines Badly worn bearings Repl
113. lace the engine mounting bushing with a new one Press out the engine mounting bushings in a vise using two steel tubes of the appropriate size as shown CAUTION Replace the removed bushing with a new one Crankcase htto www motorcycle in th 3 52 ENGINE Install the engine mounting bushing using two steel tubes of 202 the appropriate size and a vise Press the mounting bushing al into the crankcase holes 77 23 5 LEFT CRANKCASE BEARING OIL SEAL REMOVAL Remove the bearing retainer Remove the rear axle shaft bearing with the special tool 09921 20240 Bearing remover set 20 mm CAUTION Replace the removed bearing with a new one Remove the rear axle shaft oil seal with the special tool 09913 50121 Oil seal remover CAUTION Replace the removed oil seal with a new one Remove the idle shaft bearing 2 and driveshaft bearing 3 with the special tool 09921 20240 Bearing remover set 2 15 mm 3 12 mm CAUTION Replace the removed bearing with a new one htto www motorcycle in th ENGINE 3 53 Remove the crankshaft oil seal with the special tool 09913 50121 Oil seal remover CAUTION Replace the removed oil seal with a new one Remove the crankshaft bearing with the special tool 09913 70210 Bearing installer set 35 mm CAUTION Replace the r
114. 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 REPLACEMENT Replace initially at 1 000 km 5 months and every 8 000 km 40 months thereafter Drain engine oil as described in the engine oil replacement procedure Remove the oil filter cap D and oil filter 2 Replace the oil filter with a new one Install the spring 9 correctly Apply engine oil lightly to the O rings and Install the oil filter cap and tighten the bolts securely V filter cap bolt 10 N m 1 0 kgf m NOTE Before installing the new oil filter and oil filter cap make sure that the spring and new O rings 4 are installed cor rectly The arrow mark on the oil filter cap should be positioned down Fitthe clamp to the bolt B Add new engine oil and check the oil level as described in the engine oil replacement procedure Oil viscosity and classification 10W 40 SAE SF or SG API NECESSARY AMOUNT OF ENGINE OIL Oil change 950ml Oil and filter change 1050 ml Engine overhaul 1 100 CAUTION Make sure that the oil filter is installed properly If the filter is installed improperly serious engine damage may result OIL SUMP FILTER CLEANING 7 3 19 and 57 htto www motorcycle in th PERIODIC MAINTENANCE 2 9 2 10 PERIODIC MAINTENANCE ENGINE IDLE SPEED
115. movable drive face with a new one Remove the movable drive face plate 1 Remove the dampers 2 Pull out the six rollers ROLLER INSPECTION Check that there is no abnormal wear or damage on the roller If any defects are found replace the rollers as a set REASSEMBLY Reassemble the movable drive face in the reverse order of disassembly Pay attention to the following points Mount the three dampers D on the movable drive plate 2 and install it onto the movable drive face NOTE Make sure the movable drive plate is fully positioned inside the movable drive face or the rollers may fall out htto www motorcycle in th fr 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 Do not remove clutch shoe nut at this time Lock the clutch shoe assembly with the special tool handle turned in Remove the clutch shoe nut D 09922 31430 Clutch spring compressor CAUTION Since a high spring force applies to the clutch shoe assembly care must be used so as not to cause the clutch shoe assembly and movable driven face to come off abruptly Loosen the special tool handle slowly and remove the clutch shoe assembly CAUTION Do not attempt to disassemble the clutch shoe assem bly
116. n 3 13 3 66 Intake pipe 573 11 3 71 Crankcase tube grommet 53 10 3 72 ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION Fixed drive face 3 17 3 61 Movable drive face assembly 3 17 3 60 Clutch housing 3 17 3 60 Clutch shoe movable driven face assembly 3 17 3 60 Drive belt 3 17 3 60 Reduction gear cover 3 18 3 59 Oil sump filter 3 19 3 57 Drive shaft 3 49 7 3 59 Air cleaner box 3 5 S park plug 3 11 2 7 Oil filter 3 18 53 58 Kick starter lever 3 10 3 72 Cooling belt cover and duct 53 44 3 45 Clutch cover 3 10 3 72 Cylinder cowling left cover 3 11 3 71 Idle driven gear 3 18 3 59 Clutch upper cover and crankcase tube 7773 6 htto www motorcycle in th ENGINE RIGHT SIDE REMOVAL ENGINE 3 3 INSTALLATION Muffler 2 3 5 27259 Fan cowling cover 3 11 27 93 71 Cooling fan 73 13 773 65 Starter idle gear 293 15 3 63 Magneto cover 3 14 3 63 Magnetorotor 27 3 15 7 3 02 Oil pump 3 16 3 61 Cylinder cowling right cover htto www motorcycle in th 27 3 11 7 3 71 3 4 ENGINE ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame wash the engine using a steam cleaner En
117. n distilled water replenishment During normal charging no hydrogen gas is produced How ever if the battery is overcharged hydrogen gas may be pro duced Therefore be sure there are no fire or spark sources 0 short circuit nearby when charging the battery Be sure to recharge the battery in a well ventilated and open area Note that the charging system for the MF battery is different from that of a conventional battery Do not replace the MF battery with a conventional battery CONNECTING THE BATTERY When disconnecting terminals from the battery for disassem bly or servicing be sure to disconnect the battery lead wire first When connecting the battery lead wires be sure to connect the battery lead wire first f the terminal is corroded remove the battery pour warm water over it and clean it with a wire brush After connecting the battery apply a light coat of grease to the battery terminals Install the cover over the 9 battery terminal WIRING PROCEDURE Properly route the wire harness according to the WIRING HARENESS ROUTING section 77 12 13 htto www motorcycle in th ELECTRICAL SYSTEM 6 5 USING THE MULTI CIRCUIT TESTER e Properly use the multi circuit tester and probes Improper use can cause damage to the motorcycle and tester f the voltage and current values are not known begin mea suring in the highest rang
118. n its cover COUPLER With a lock type coupler be sure to release the lock when dis connecting and push in fully to engage the lock when con necting When disconnecting the coupler be sure to hold the coupler itself and do not pull the lead wires Inspect each terminal on the coupler for being loose or bent Inspect each terminal for corrosion and contamination CLAMP Clamp the wire harness at such positions as indicated in WIRING HARNESS ROUTING 7 12 13 Bend the clamp properly so that the wire harness is clamped securely clamping the wire harness use care not to allow it to hang down Do not use wire or any other substitute for the band type clamp FUSE When a fuse blows always investigate the cause to correct it and then replace the fuse Do notuse a fuse of a different capacity Do notuse wire or any other substitute for the fuse htto www motorcycle in th ELECTRICAL SYSTEM 6 3 CORRECT INCORRECT 64 ELECTRICAL SYSTEM SEMI CONDUCTOR EQUIPPED PART Be careful notto drop the part which has a semi conductor INCORRECT built in such as a CDI unitand AC DC rectifier When inspecting these parts follow the instructions carefully Failure to follow the proper procedure can cause damage to these parts BATTERY The MF battery used in this motorcycle does notrequire main tenance e g electrolyte level inspectio
119. n th SERVICING INFORMATION 7 17 FRONT BRAKE HOSE ROUTING UY 125S Handlebar After brake hose touching to the stopper tighten the union bolt Front brake hose Brake hose After brake hose touching to the stopper tighten the union bolt htto www motorcycle in th 7 18 SERVICING INFORMATION PAIR AIR SUPPLY SYSTEM HOSE ROUTING Intake pipe Match mark Fuel tap vaccum hose htto www motorcycle in th SERVICING INFORMATION 7 19 FUEL HOSE ROUTING Fuel hose Fuel hose and vacuum hose must be wrap by clip at mark position Vacuum hose htto www motorcycle in th 7 20 SERVICING INFORMATION CLUTCH TRANSMISSION DRIVE BELT INSTALLATION 1 Remove excess grease htto www motorcycle in th SERVICING INFORMATION 7 21 COOLING FAN INSTALLATION 33 Nim 3 3 kgf m V 10 Nm 1 0 kgf m htto www motorcycle in th 7 22 SERVICING INFORMATION FUEL TANK INSTALLATION htto www motorcycle in th SERVICING INFORMATION 7 23 CRANKCASE INSTALLATION 37 mm 52 04 EN mm 34 63 04 34 mm 37 mm htto www motorcycle in th 7 24 SERVICING INFORMATION EXTERIOR PARTS CONSTRUCTION D Leg shield cover Leg shield rack Front leg shield 4 Leg rear shield Front leg lower shield Leg lower shield htto www motorcycle in th SER
120. nce 3 60 Battery Type des ignation ETZ55 Capacity 12 V 12 6 kC 3 5 Ah 10 HR Fuse size 10A htto www motorcycle in th 742 SERVICING INFORMATION WATTAGE SPECIFICATION Unit W Headlight 30 30 Brake light Taillight Turn signal light 10 Speedometer light 3 4 High beam indicator light 1 7 Turn signal indicator light BRAKE WHEEL ITEM 1 7 STANDARD Unit mm Front brake cable play UY 125 15323 Rear brake cable play 15 25 Brake drum 1 0 Front Rear Brake disc thickness UY 125S Front 3 5 50 2 Brake disc runout UY 1259 Front Master cylinder bore 0 1255 Front 11 000 11 043 Master cylinder piston diam UY 125S Front 10 957 10 984 Brake caliper cylinder bore UY 1255 Front 32 030 32 106 Brake caliper piston diam UY 125S Front 31 950 32 000 Brake fluid type UY 125S DOT 4 Wheel rim runout Axial Radial Wheel axle runout Wheel rim size SUSPENSION ITEM Front 114 x1 40 Rear 114 x1 60 STANDARD Front fork stroke 85 Front fork spring free length 291 7 Front fork oil level without ju outer tube fully 93 Front fork oil type SUZUKI FORK OIL G10 oran equivalent fork oil Front fork oil capacity each leg 55 ml Front fork in
121. nd by pass ports Pilot air jet Float Needle valve Starter passage Needle jet Pilot screw Needle jet holder htto www motorcycle in th Aa 4 gt NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the nee dle valve the gasoline will continue flowing and cause itto over flow If the valve seat and needle valve are worn beyond the permissible limits similar trouble will occur Conversely if the needle valve sticks the gasoline will notflow into the float cham ber Clean the float chamber and float parts with gasoline If the needle valve is worn as shown in the illustration replace it together with a valve seat Clean the fuel passage of the mixing chamber with compressed air FLOAT HEIGHT ADJ USTMENT To check the float height invert the carburetor body with the float arm kept free measure the height while the float arm is just in contact with needle valve by using venier calipers Bend the tongue as necessary to bring the height to this value Float height XX X mm 09900 20102 Vernier calipers REASSEMBLY AND REMOUNTING Reassemble and remount the carburetor in the reverse order of disassembly and removal Pay attention to the following points Apply SUZUKI SUPER GREASE A to thread part of the throttle stop screw then install the throttle stop screw to the carburetor 99000 25010 SUZUKI SUPER GREASE htto www motorcycle in
122. nd must be replaced with a new one Remove the bearing with the special tool 09921 20240 Bearing remover set 0 12 mm Q 20 mm 09923 73210 Bearing remover 3 17 mm 09930 30104 Sliding shaft CAUTION Replace the removed bearing with a new one REASSEMBLY Reassemble the reduction gear in the reverse order of disas sembly Pay attention to the following points Install the bearing with the special tool 09913 70210 Bearing installer set 1 40 mm 2 35 mm 47 mm Install the driveshaft oil seal with the special tool 09913 70210 Bearing installer set 30 mm htto www motorcycle in th 4 sA 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 must be replaced with a new one RIGHT CRANKCASE BEARING REMOVAL Remove the crankshaft right bearing with the special tool 09913 70210 Bearing installer set 42 mm CAUTION Replace the removed bearing with a new one BEARING INSTALL Install the bearing with the special tool 09913 70210 Bearing installer set 62 mm ENGINE MOUNTING BUSHING Inspect each engine mounting bushing D for damage If any damage is found rep
123. ned use the 45 cutter to con dition the seat some more NOTE Cut only the minimum amount necessary from the seat to pre vent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle TOP NARROWING CUT f the contact area W is too high on the valve or if it is too wide use the 15 for exhaust side and the 30 for the intake side to lower and narrow the contact area htto www motorcycle in th 42 15 For exhaust 30 For intake 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 cutthe valve seatto the correct width After the desired seat position and width is achieved use the 45 cutter very lightly to clean up any burrs caused by the pre vious cutting operations CAUTION Do not use lapping compound after the final cut is made The finished valve seat should have a velvety smooth finish but not a highly polished or shiny fin ish This will provide a soft surface for the final seat ing of the valve which will occur during the first few seconds of engine operation NOTE After servicing the valve seats be sure to check the valve clear ance after the cylinder head has been reinstalled 72 6 Clean an
124. ner tube diam 26 Rear wheel travel 80 S wingarm pivot shaft runout htto www motorcycle in th TIRE ITEM STANDARD SERVICING INFORMATION 7 43 Cold inflation tire pressure 175 kPa 1 75 kgf cm 225 kPa 2 25 kgf cm Tire size 70 90 14 80 90 14 40P Tire type IRC NF59 IRC NR76 Tire tread depth FUEL OIL SPECIFICATION Fuel type Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Fuel tank capacity 3 7 L Engine oil type SAE 10W 40 SF SG or SH SJ with ASO MA Engine oil capacity Change 950 ml Filter change 1050 ml Overhaul 1 100 ml Reduction gear oil type SAE 10W 40 Reduction gear oil capacity Change 100 ml Overhaul 110 ml htto www motorcycle in th Prepared by THAI SUZUKI MOTOR CO LTD August 2005 Part No 99500 31310 01E Printed in Thailand htto www motorcycle in th
125. ng float Foreign matter on the needle valve Incorrect float chamber fuel level htto www motorcycle in th Replace Replace Adjust or replace Clean or replace with nee dle valve seat Adjust float height 7 6 SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering Overtightened steering stem nut Broken bearing in steering stem Distorted steering stem Not enough pressure in tires Adjust Replace Replace Adjust Wobbly handlebars Loss of balance between right and left front forks Distorted front fork Distorted front axle or crooked tire Loose handlebar set bolt or clamp bolt Loose steering stem nut Worn or incorrect tire or wrong tire pressure Worn bearing race in steering stem Replace Repair or replace Replace R etighten Adjust Adjust or replace Replace Wobbly front wheel Distorted wheel rim Worn front wheel bearings Defective or incorrect tire Loose axle Incorrect front fork oil level Incorrect front wheel weight balance Replace Replace Replace R etighten Adjust Adjust Front suspension too soft Weakened Springs Not enough fork oil Wrong weight fork oil Replace Replenish Replace Front suspension too stiff Too viscous fork oil Too much fork oil Replace Drain excess oil Noisy front suspension Not enough fork oil Loose bolts on susp
126. normal condition the brake fluid cir cuit be purged of air in the following manner Fill up the master cylinder reservoir to the UPPER line Place the reservoir cap to prevent entry of dirt Connect a clear hose 4 to the air bleeder valve and insert the free end of the pipe into a receptacle Front brake Bleed the air from the air bleeder valve htto www motorcycle in th 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 lever causing it to touch the handle bar grip Then close the valve pump and squeeze the lever and open the valve Repeat this process until the fluid flowing into the receptacle longer contains air bubbles NOTE Replenish the brake fluid in the reservoir as necessary while bleeding the brake system Make sure thatthere is always some fluid visible in the reservoir Close the bleeder valve and disconnectthe clear hose V Air bleeder valve 7 5 N m 0 75 kgf m Fill the reservoir with brake fluid to the UPPER line CAUTION Handle brake fluid with care the fluid reacts chemi cally with paint plastics rubber materials and so on TIRE AND WHEELS TIRE TREAD CONDITION Inspect every 4 000 km 20 months Operating the motor
127. nstall 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 set Attachment Press in the outer lower race 2 with the special tools 09913 70210 Bearing installer set 3 09940 51710 Bearing installer 4 Apply SUZUKI SUPER GREASE A to the upper and lower races Install the steel balls 99000 25010 SUZUKI SUPER GREASE Upper 22 pcs Number of steel balls Lower 27 pcs Tighten the steering stem nut to the specified torque with the special tool 09910 60611 Universal clamp wrench V Steering stem nut 45 N m 4 5 kgf m htto www motorcycle in th 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 1 4 1 2 turn NOTE When installing the washer align the stopper lug to the groove of steering stem Tighten the steering stem lock nut to the specified torque with the special tool 09910 60611 Universal clamp wrench V Steering stem lock nut 90 N m 9 0 kgf m NOTE Tightening the lock nut can affect the steering stem nut adjust ment Therefore after tighten
128. ock absorber mounting bolt and nut 29 N m 2 9 kgf m htto www motorcycle in th ELECTRICAL SYSTEM 6 1 ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING rrr 6 3 rre ira a ra i rar a nnnnna 6 3 COUPLER 6 3 CLAMP T 6 3 FUSE 6 3 SEMI CONDUCTOR EQUIPPED PART nnnm 6 4 BATTERY ge 6 4 CONNECTING THE 6 4 WIRING PROCEDURE ues 6 4 USING THE MULTI CIRCUIT TESTER rennen 6 5 LOCATION OF ELECTRICAL COMPONENTS nmm 6 6 CHARGING AND LIGHTING SYSTEM nmn 6 8 TROUBLESHOOTING rernm a 6 8 INS PEC TION Pr 6 10 STARTER SYS TE Ms RR EEEIMKRERESKKUNE SEDE X ONRREE EUR KR C ERO 6 13 TROUBLESHOOTING errem nnn 6 13 STARTER MOTOR REMOVAL nnne 6 14 STARTER MOTOR DISASSEMBLY usenet ene 6 15 STARTER MOTOR INSPECTION nnnm nn 6 17 STARTER MOTOR REASSEMBLY nnnm 6 18 STARTER RELAY INSPECTION nnnm 6 20 IGNITION SYSTEM e 6 21 TROUBLESHOOTING
129. of the above items HIGH OIL PRESSURE Engine oil viscosity is too high Clogged oil passage Combination of the above items OIL PRESSURE TEST PROCEDURE Connect a tachometer to the high tension cord Remove the main oil gallery plug nstall the oil pressure gauge and adaptor into the main oil gallery Warm up the engine as follows Summer 10 minutes at 2 000 rpm Winter 20 minutes at 2 000 rpm After warming up the engine increase the engine speed to 3 000 rpm observe the tachometer and read the oil pres sure gauge 09915 74511 Oil pressure gauge 09915 74531 Adaptor 09900 26006 Tachometer V Main gallery plug 12 N m 1 2 kgf m htto www motorcycle in th 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 lifetime of the clutch assembly it is essential that the clutch engages smoothly and gradually The following inspections must be performed 1 INITIAL ENGAGEMENT INSPECTION Warm up the engine to normal operating temperature e Remove the front frame cover 5 8 Connectan electric tachometer to the high tension cord Seated on the motorcycle with the motorcycle on level ground increase the engine RPM slowly and note the RPM at
130. olt 11 N m 1 1 kgf m CAM CHAIN TENSION ADJ USTER Apply engine oil to the push rod Turn the adjusting screw clockwise with a flat bladed screw driver to lock htto www motorcvcle in th ENGINE 3 69 3 70 ENGINE Fita new gasket D to the cam chain tension adjuster body 2 CAUTION Use a new gasket to prevent oil leakage Install the cam chain tension adjuster body to the cylinder and tighten the bolts to the specified torque V Cam chain tension adjuster mounting bolt 10 1 0 kgf m Turn the adjusting screw counterclockwise with a flat bladed screw driver to unlock Install the rubber cap After installing the cam chain tension adjuster rotate the crankshaft some turns and recheck the positions of the cam shafts CAUTION Be sure to check the valve clearance gt 2 6 CYLINDER HEAD COVER Fita new gasket D to the cylinder head cover Apply sealantto cam end cap 99104 31140 SUZUKI BOND 1207B CAUTION Make sure to replace the gasket with a new one Place the cylinder head cover on the cylinder head Fita new gasket 2 to each head cover bolt 3 CAUTION Use a new gasket to prevent oil leakage Tighten the head cover bolts to the specified torque V Head cover bolt Intial 10 N m 1 0 kgf m Final 14 N m 1 4 kgf m Install
131. ompressed plasti gauge with the enve lope scale Crankshaft thrust clearance From 0 02 to 0 07 mm f the thrust clearance is not within specification select the proper size of shim The shim size is printed on the shim surface After selecting the proper size of shim place it on the right crankshaft LIST OF SHIMS Part number Shim thickness Thrust clearance 09181 35101 0 50 50 02 mm 0 50 0 55 mm 09181 35025 0 55 50 02 mm 0 55 0 60 mm 09181 35103 0 60 50 02 mm 0 60 0 65 mm 09181 35026 0 65 50 02 mm 0 65 0 70 mm 09181 35104 0 70 0 02 mm 0 70 0 75 mm 09181 35105 0 75 0 02 mm 0 75 0 80 mm 09181 35106 0 80 50 02 mm 0 80 0 85 mm 09181 35107 0 85 0 02 mm 0 85 0 90 mm 09181 35108 0 90 50 02 mm 0 90 0 95 mm 09181 35109 0 95 0 02 mm 0 95 1 00 mm 09181 35110 1 00 x 0 02 mm 1 00 1 05 mm 09181 35113 1 05 50 02 mm 1 05 1 10 mm 09181 35116 1 10 50 02 mm 1 10 1 15 mm 09181 35118 1 15 0 02 mm 1 15 1 20 mm 09181 35120 1 20 0 02 mm 1 20 1 25 mm 09181 35123 1 25 0 02 mm 1 25 1 30 mm 09181 35125 1 30 0 02 mm 1 30 1 34 mm htto www motorcycle in th ENGINE 3 55 3 56 ENGINE ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly Pay attention
132. or tant when reassembling pilot screw to original position Remove the throttle stop screw 07 washer Q9 and spring 09 htto www motorcvcle in th 4 12 FUEL AND LUBRICATION SYSTEM CARBURETOR CLEANING Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical man ufacturer s instructions on proper use handling and storage 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 and allow each circuitto soak if necessary to loosen dirt and varnish Blow the body dry using compressed air CAUTION Do not use a wire to clean the jets or passageways A wire can damage the jets and passageways If the components cannot be cleaned with a spray cleaner it may be necessary to use a dip type cleaning solution and allow them to soak Always follow the chemical manufacturer s instructions for proper use and clean ing of the carburetor components After cleaning reassemble the carburetor with new O ring and gaskets CARBURETOR J ET INSPECTION Check the following items for damage or clogging Pilot jet Needle jet air bleeding hole Main jet Diaphragm Main air jet Pilot outlet a
133. or for discoloration abnormal wear or undercut A If abnormal wear is found replace the armature with a new one If the commutator surface is discolored polish it with 4400 sand paper and wipe it using a clean dry cloth If there is no undercut scrape outthe insulator with a saw blade Insulator Segment ARMATURE COIL Check for continuity between each segment and between each segment and the armature shaft using the multi circuit tester If there is no continuity between the segments or there is conti nuity between the segments and shaft replace the armature with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test OIL SEAL AND BEARING Check the oil seal lip for damage or leakage Check the bearing for abnormal noise and smooth movement If any defects are found replace the housing end inside htto www motorcycle in th ELECTRICAL SYSTEM 6 17 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 the lip of the oil seal and bearing 99000 25010 SUZUKI SUPER GREASE Apply a small quantity of SUZUKI MOLY PASTE to the arma ture shaft 99000 25140 SUZU
134. orn brake drum Replace Adjust Adjust Replace Replace Brake squeaking UY 1255 Carbon adhesion on pad surface Tilted pad Damaged wheel bearing Loose front wheel axle or rear wheel axle Worn pads Foreign material in brake fluid Clogged return port of master cylinder Brake pad surface glazed Repair surface with sandpaper Correct pad fitting or replace Replace Tighten to specified torque Replace Replace brake fluid Disassemble and clean master cylinder Repair surface with sandpaper Brake squeaking UY 125 Carbon adhesion on shoe surface Tilted shoe Damaged wheel bearing Loose front or rear axle nut Brake pad surface glazed Worn shoe Repair surface with sandpaper Correct shoe fitting or replace Replace Tighten Repair surface with sandpaper Replace Excessive brake lever stroke UY125S 1 Air in hydraulic system Insufficient brake fluid Improper quality of brake fluid Worn brake cam lever Excessively worn shoes and or drum Bleed air Replenish fluid to specified level bleed air Replace with correct fluid Replace Replace Excessive brake lever or pedal stroke Worn brake cam lever Excessively worn shoes and or drum Replace Replace Leakage of brake fluid UY 125S Insufficient tightening of connection joints Cracked hose Worn piston and o
135. pecification Lead wires tend to get shorted or open circuited or loosely connected at terminals Grounded or open circuited stator coils Defective regulator rectifier Defective cell plates in the battery or retighten Replace Replace Replace the battery Overcharges Internal short circuit in the battery Damaged or defective resistor element in the reg ulator rectifier Poorly grounded regulator rectifier Replace the battery Replace Clean and tighten ground connection Unstable charging Lead wire insulation frayed due to vibration resulting in intermittent short circuiting Internally short circuited stator coils Defective regulator rectifier Repair or replace Replace Replace Starter button is not effective Run down battery Defective switch contacts Brushes not seating properly on starter motor commutator Defective starter relay 5 Defective main fuse htto www motorcycle in th Repair or replace Replace Repair or replace Replace Replace BATTERY Complaint Symptom and possible causes SERVICING INFORMATION 7 9 Remedy Sulfation acidic white powdery sub stance or spots on surface of cell plates Cracked battery case Battery has been left a run down condition for a long time Replace the battery Replace the battery Battery runs down quickly Troubl
136. placement 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 special tools when instructed Make sure that all parts used in reassembly are clean Lubricate them when specified Use the specified lubricant bond or sealant When removing the battery disconnect the negative cable first and then the positive cable When reconnecting the battery connect the positive cable first and then the negative cable and replace the terminal cover on the positive terminal When performing service to electrical parts if the service procedures do not require use of battery power disconnect the negative cable from the battery When tightening the cylinder head or case bolts and nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci fied tightening torque Whenever you remove oil seals gaskets packing O rings locking washers self locking nuts cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any left over material from the mating surfaces Never reuse a circlip When installing a new circlip take care not to expand the end gap larger than required to slip th
137. r cup htto www motorcycle in th Tighten to specified torque Replace Replace piston and or cup 7 8 SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor sparking Defective ignition coil or CDI unit Defective spark plug Defective pick up coil or startor coil Open circuited wiring connections Replace Replace Replace Check and repair Spark plug soon become fouled with carbon Mixture too rich Idling speed set too high Incorrect gasoline Dirty air cleaner element Too cold spark plug Adjust carburetor Adjust carburetor Change Clean Replace with hot type plug Spark plug become fouled too soon gt UC Worn piston rings Worn piston or cylinder Excessive clearance of valve stems in valve guides 4 Worn stem oil seal Replace Replace Replace Replace Spark plug elec trodes overheat or burn Too hot spark plug Overheated engine Loose spark plug Too lean mixture Replace with cold type plug Tune up R etighten Adjust carburetor Battery does not charge Open or short circuited lead wires or loose lead connections Short circuited grounded or open startor coils Short circuited or punctured regulator rectifier Repair or replace or retighten Replace Replace Battery does charge but charg ing rate is below the s
138. r support bracket Vacuum hose Fuel hose Seat lock Pass through the rear brake cable inside guide Air cleaner Speedometer cable Front brake cable Pass through the guide Crankcase Oil filter cap X MAP d brake cable Clamp Rear brake cable htto www motorcycle in th 0 Crankcase L A filter cap 4 GG 5 Rear brake cable Clamp SERVICING INFORMATION 7 15 CABLE ROUTING UY 125S Harness Clamp starter cable firmly oe cable Qe gt Rear brake SY cable IGSS ser cable Front brake 2 lt Throttle cable Pass through the guide Starter cable Striker support bracket Vacuum hose i Ww Fuel hose H 5 Clamp Throttle cable Clamp Rear brake cable Seat lock Pass through the rear brake cable inside guide amp Air cleaner x Clamp starter cable firmly 2 gt Cylinder need Speedometer cable Front brake hose Pass through the guide L filter cap M filter cap bolt Crankcase L 1 3 a Plate yy Rear brake cable brake cable Rear brake cable Se Clamp htto www motorcycle in th 7 16 SERVICING INFORMATION ENGINE ELECTRIC PARTS INSTALLATION Avoid twisting the lead wire when grommet installation V 120 12 0 kgf m 7 6 0 6 kgf m htto www motorcycle i
139. re tightened to their specified torque Refer to page 2 19 for the loca tions of the following bolts and nuts on the motorcycle ITEM Handlebar clamp bolt Steering stem lock nut 3 Front fork clamp bolt Front fork cap bolt 5 Frontaxle nut 6 Engine mounting nut 7 Rear axle nut Front brake caliper mounting bolt UY 1255 9 Front brake hose union bolt UY 1255 Front brake disc bolt UY 1255 17 Air breeder valve UY 1255 40 Front brake master cylinder bolt UY 1255 43 Rear shock absorber mounting nut Upper amp Lower Front brake cam lever nut UY 125 Rear brake cam lever nut S poke nipple htto www motorcycle in th PERIODIC MAINTENANCE 2 19 o htto www motorcycle in th 2 00 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 P eriodic mainte nance records kept at your dealership should include compression readings for each maintenance service COMPRESSION PRESSURE SPECIFICATION Standard Limit 750 1200 kPa 650 kPa 7 5 12 kgf cm 6 5 kgf cm Low compression pressure can indicate any of the following conditions Excessively worn cylinder walls Worn piston or piston rings Piston rings stuck in grooves Poor valve seating Ruptu
140. red or otherwise defective cylinder head gasket NOTE When the compression pressure goes below specification check the engine for conditions listed above COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head nuts are tightened to the specified torque values and the valves are properly adjusted Warm up the engine before testing Make sure the battery is fully charged Remove the related parts and test the compression pressure in the following manner Remove the spark plug 2 7 Install the compression gauge and adaptor in the spark plug hole Make sure that the connection is tight Keep the throttle grip in the fully opened position Press the starter button and crank the engine for a few sec onds Record the maximum gauge reading as the cylinder compression 09915 64512 Compression gauge 09915 63311 Adaptor htto www motorcycle in th 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 18 40 kPa 0 18 0 40 kgf cm at 3 000 rpm Oil temp at 60 C If the oil pressure is lower or higher than specification the following causes may be considered LOW OIL PRESSURE Clogged oil filter Oil leakage from the oil passage Damaged O ring Defective oil pump Combination
141. rench set 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 1000 mm 1 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20607 Dial gauge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 20803 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block set 100 mm 09900 22301 09900 22302 Plastigauge 09900 22401 Small bore gauge 10 18 mm 09900 25008 Multi circuit tester set 09900 26006 Tachometer 09910 11310 Crankshaft installer attachment 09910 20116 Conrod stopper 09910 32812 Crankshaft installer htto www motorcycle in th 09910 60611 Universal clamp wrench 09913 50121 Oil seal remover 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 Nc 09916 10911 Valve lapper set 09916 14510 Valve lifter Corn S2 Valve lifter attachment 09916 20630 Valve seat cutter N 126 09916 21111 Valve seat cutter set N 09916 24311 Solid pilot N 100 5 0 09916 34542 Valve guide reamer handle 09916 34570 Valve guide reamer 09916 34580 Valv
142. rive 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 Service Limit 18 9 mm 09900 20101 Vernier calipers CAUTION Always keep the drive belt away from grease oil etc DRIVE BELT FILTER DISASSEMBLY Remove the cooling belt cover D and duct Remove the plate and filter 4 INSPECTION Check the drive belt filter for clogging If they are clogged clean or replace htto www motorcycle in th 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 with the plate pins Apply grease to the new O ring and install the duct AGH 99000 25010 SUZUKI SUPER GREASE A CAUTION Use the new O ring to prevent oil leakage b STARTER CLUTCH INSPECTION OF STARTER CLUTCH OPERATION Turn the starter clutch gear by hand in the direction of arrow as e shown and check that rotation is smooth Also check that the T i gear is locked when attempted to turn in the other direction XE D If a large resistance is felt or noise occurs when turning the gear E check the starter driven gear sliding surface for wear or damage wp gt If any abnormal condition is fo
143. ront fork up and down four or five times CAUTION After assembling the front fork check each tighten ing part for looseness play and other conditions Check for oil leakage htto www motorcycle in th 5 38 CHASSIS HANDLEBARS Handlebar clamp nut 9 kgf m 60 6 0 REMOVAL Remove the front leg shield 7775 6 Remove the front and rear handlebar covers 0575 5 Remove the cable clamp HANDLEBAR LEFT SIDE PARTS Disconnect the rear brake cable D and brake switch Remove the starter lever 3 Remove the rear brake lever holder and left handle grip htto www motorcycle in th CHASSIS 5 39 HANDLEBAR RIGHT SIDE PARTS Remove the throttle cable by removing the throttle grip case Remove the throttle grip 2 Disconnect the front brake cable 3 and brake switch 4 UY 125 Remove the front brake lever holder 5 UY 125 Disconnect the brake light switch lead wires and remove the front brake master cylinder UY 1255 75 30 Remove the handlebars by removing the handlebar clamp nut INSTALLATION Install the handlebars in the reverse order of removal Pay attention to the following points Tighten the handlebar clamp nutto the specified torque V Handlebar clamp nut 60 N m 6 0 kgf m HANDLEBAR RIGHT SIDE PARTS Align the punch mark amp on the handleb
144. rt the fastener into the installation hole NOTE To prevent the pawl 2 from damage insert the fastener all the way into the installation hole Push in the head of center piece until it becomes flush with the fastener outside face htto www motorcycle in th CHASSIS 5 3 REMOVAL HANDLEBAR COVERS Remove the rear view mirrors D Remove the front handlebar cover 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 couplers 7 htto www motorcycle in th 5 4 CHASSIS FRONT LEG SHIELD Remove the frontleg shield mounting screws yx Hooked part Disconnect the front turn signal couplers 0 Remove the front leg shield 0 FRONT LEG LOWER SHIELD Remove front leg shield Remove the front leg lower shield htto www motorcycle in th CHASSIS 5 5 LEG LOWER SHIELD Remove the leg lower shield LEG SHIELD COVER Remove the frame front cover 7575 8 Remove the luggage box 5 9 Remove the pillion rider handle 7 5 9 Remove the frame cover assembly 7775 10 Remove the leg shield hook 4 Remove the ignition switch holder 2 Remove the leg shield cover mounting screws htto www motorcycle in th 5 6 CHASSIS FRAME FRONT COVER Open the seat using the ignition
145. shaft rotates smoothly f the crankshaft does not rotate smoothly try to free it by tap ping it with a plastic hammer OIL SUMP FILTER Clean the oil sump filter using compressed air Fita new gasket D 4 ax i Install the oil sump filter 2 J A gt e e 2 o CE htto www motorcycle in th 3 58 ENGINE CAUTION The lip of the oil sump filter should be positioned downward The thinner side B of the oil sump filter should be positioned inside Install the oil sump filter cap 3 Tighten the oil sump filter cap bolts to the specified torque V Oil sump filter cap bolt 10 N m 1 0 kgf m OIL FILTER Fit the O ring Position the oil filter Fit the O ring and spring CAUTION Make sure to replace the O ring with a new one CAUTION Position the oil filter so that the valve comes out side Install the oil filter cap htto www motorcvcle in th REDUCTION GEAR Install the driveshaft CD to the case Install the rear axle shaft Install the idle driven gear and washer 4 CAUTION Apply engine oil to each gear and shaft Install the dowel pins and new gasket Install the reduction gear cover 7 Tighten the reduction gear cover bolts to the specified torque V Reduction gear cover bolt 10 N m 1 0 k
146. ston 42 and spring 3 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 Inspect the primary cup secondary cup and dust seal for wear or damage 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 CAUTION Wash the master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components with a rag When washing the components use the specified brake fluid Never use different types of fluid or cleaning solvents such as gasoline kerosine etc Apply brake fluid to the master cylinder bore and all of the master cylinder components before reassem bly Specification and classification DOT 4 htto www motorcycle in th CHASSIS 5 29 5 30 CHASSIS Install the piston cup set S econdary cup Spring Been Snap ring Primary plate Boot 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 When installing the master cylinder onto the handlebars align Mas
147. tage on the pickup coil coupler is within specifica tion but on the CDI unit coupler is not within specification replace the wire harness with a new one If both peak voltages are out of specification replace the pickup coil with a new one PICKUP COIL RESISTANCE Remove the frame front cover 7775 8 Disconnectthe pickup coil coupler Measure the resistance between the lead wires using the multi circuit tester If the resistance is not within the specified value the pickup coil must be replaced 09900 25008 Multi circuit tester set Tester knob indication Resistance Pickup coil resistance 180 280 Blue Yellow Ground htto www motorcycle in th ELECTRICAL SYSTEM 6 25 6 26 ELECTRICAL SYSTEM SPEEDOMETER REMOVAL AND DISASSEMBLY Remove the handlebar covers 7 5 5 Remove the speedometer Disassemble the speedometer as shown htto www motorcycle in th 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 2 Speedometer WIRE COLOR B Black Gr Gray Lg Light green Orange Y Yellow B W Black White Y B Yellow Black B W GND Y B Fuel gauge Y High beam Blank DDC Blank J Gr 4 Lg Turn signal
148. ter cylinder the master cylinder holder s mating surface with the Handlebar punched mark on the handlebars and tighten the upper 8 clamp bolt first clamp 5 Master cylinder bolt 10 N m 1 0 kgf m Connectthe front brake light switch lead wires UP mark Clearance htto www motorcycle in th CHASSIS 5 31 nstall the brake hose union as shown and tighten the union boltto the specified torque V Brake hose union bolt 23 N m 2 3 kgf m Fill the master cylinder with brake fluid and bleed air 2 14 htto www motorcycle in th 5 33 CHASSIS FRONT FORK O ring Spring Damper rod ring Damper rod Rebound spring Inner tube Dust seal Oil seal stopper ring Oil seal Outer tube Front fork cap bolt Damper rod bolt REMOVAL AND DISASSEMBLY Remove the front leg shield 7775 6 Remove the front wheel 220 125 5 12 2 gt 0 1255 5 20 Remove the front fender D Remove the front brake hose guide and front brake caliper UY 125S C5775 25 Loosen the front fork top cap Remove the front fork clamp bolts NOTE Hold the frontfork by the hand to prevent sliding out of the steer ing stem Remove the front fork 3 htto www motorcycle in th Remove the front fork cap bolt and spring 4 Invert fork and stroke it s
149. the spark plug 2 7 htto www motorcycle in th CYLINDER COWLING Install the cylinder cowling left cover INTAKE PIPE nstall the intake pipe CAUTION Use a new O ring to prevent sucking air from the joint Tighten the intake pipe mounting bolts to the specified torque V Intake pipe mounting bolt 10 N m 1 0 kgf m FAN COWLING COVER Install the fan cylinder cowling right cover D and fan cowling cover 2 PAIR CONTROL VALVE Install the PAIR control valve 777 18 STARTER MOTOR Fitthe O ring 0 to the starter motor Apply a small amount of grease to the O ring 1 99000 25010 SUZUKI SUPER GREASE htto www motorcvcle in th ENGINE 3 71 3 72 ENGINE Mount the starter motor on the engine Tighten the starter motor bolts to the specified torque V Starter motor mounting bolt 10 N m 1 0 kgf m gt Pio 28 fe mw CRANKCASE TUBE GROMMET Install the crankcase tube grommet No 1 and No 2 NOTE The boss of the crankcase tube grommet faces front side CLUTCH COVER Install the dowel pins and new gasket CAUTION Use a new gasket to the prevent oil leakage Install the clutch cover and its bolts to the specified torque 5 Clutch cover bolt 10 N m 1 0 kgf m KICK STARTER LEVER Install the kick starter lever and bolt to the spec
150. the wide spline teeth and B Install the brake lever 6 and tighten the brake cam lever nut NOTE Be sure to align the punch marks O on the brake cam lever and brake lever Vp rake cam lever nut 8 N m 0 8 kgf m htto www motorcycle in th CHASSIS 5 17 Apply SUZUKI SUPER GREASE A to the inside and outside of drive gear 99000 25010 SUZUKI SUPER GREASE 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 Be careful not to apply too much grease to the cam shaft and pin If grease gets on the lining brake slipage will result NOTE When installing the brake panel align groove D on the wheel hub with two drive pawls on speedometer drive gear Align the groove of the front brake panel with the lug of the front fork Tighten the front axle to the specified torque V Front axle nut 42 N m 4 2 kgf m nstall the speedometer cable and front brake cable certainly Adjust the front brake lever play 7772 12 htto www motorcvcle in th 5 18 CHASSIS FRONT WHEEL UY125S Spacer Bearing Front axle spacer Bearing Brake disc Speedometer gearbox Front axle Front axle nut Brake disc bolt ITEM kgf m 42 4 2 23 2 3 REMOVAL
151. tight If necessary tighten them with a spoke nipple wrench V Spoke nipple 4 5 N m 0 45 kgf m 09940 60113 Spoke nipple wrench htto www motorcycle in th STEERING Inspect initially at 1 000 km 5 months and every 8 000 km 40 months thereafter 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 motorcycle so that the front wheel is off the ground With the wheel facing straight ahead grasp the lower fork tubes near the axle and pull forward If play is found readjust the steering C 575 46 FRONT FORK Inspect every 8 000 km 40 months Inspect the front forks for oil leakage scoring or scratches on the outer surface of the inner tubes Replace any defective parts if necessary 75 34 REAR SUSPENSION Inspect every 8 000 km 40 months Inspect the rear shock absorber for oil leakage and mounting rubbers including engine mounting for wear and damage Replace any defective parts if necessary 5 53 htto www motorcycle in th PERIODIC MAINTENANCE 2 17 2 18 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km 5 months and every 4 000 km 20 months thereafter Check that all chassis bolts and nuts a
152. uel level gauge 4 htto www motorcvcle in th 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 Float position Resistance between terminals Full 4 100 1 2 Approx 38 O Empty 90 100 Q If the resistance measured is outofthe specification replace the gauge assembly with a new one 27 1 3 5 mm 73 1 3 5 mm htto www motorcycle in th FUEL AND LUBRICATION SYSTEM 4 7 CARBURETOR CONSTRUCTION cad ted 052 CLA Co CA 0 5 2 C C C C CL C7 02 E htto www motorcycle in th 48 FUEL AND LUBRICATION SYSTEM SPECIFICATIONS ITEM SPECIFICATION Carburetor type MIKUNI BS26 Bore size 26 mm 1 0 No 46G0 Idle rpm 1600 100 rpm Float height X X mm 95 4 11 2 E 3M Throttle valve 105 Pilot jet 15 Pilot screw 2 1 4 turns back Throttle cable play 2 0 4 0 mm REMOVAL Remove the frame front cover 7 5 8 Remove the luggage box 5 9 Remove the fuel tank 7 4 3 Disconnect the PAIR hose D and PCV hose 2 Remove the air cleaner mounting bolts Slightly move the air cleaner box backward Loosen the clamp screws htto www motorcycle in th 10 LOCATION The carburetor has 1 0 Number stamped on the carburetor body
153. uld result in motorcycle damage NOTE Indicates special information to make maintenance easier or instructions clearer Please note however that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing or lack of servicing of the motorcycle In addition to the WARN INGS and CAUTIONS stated you must use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice 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 to run the engine indoors make sure that exhaust gas is forced out doors When working with toxic or flammable materials make sure that the area you work in is well ventilated and that you follow all of the material manufacturer s instructions Never use gasoline as a cleaning solvent To avoid getting burned do not touch the engine engine oil radiator and exhaust system until they have cooled After servicing the fuel oil water exhaust or brake systems check all lines and fittings related to the system for leaks htto www motorcycle in th GENERAL INFORMATION 1 3 CAUTION If parts re
154. und clean and degrease completely Check that the parts are properly engaged with the spline With the fixed drive face locked tighten the fixed drive face nut to the specified torque V Fixed drive face nut 50 N m 5 0 kgf m 09930 40113 Rotor holder the fixed drive face 4 by hand until the drive belt is properly seated and both the drive and driven faces rotate together smoothly and without slipping x A 9 CHAIN Install the cam chain D OIL PUMP Install the cam chain D with the oil pump gear htto www motorcycle in th 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 4 422 99000 32110 THREAD LOCK SUPER 1322 Tighten the oil pump mounting screws to the specified torque V Oil pump mounting bolt 8 0 8 kgf m Install the oil pump cover 2 Tighten the oil pump cover bolts to the specified torque V Oil pump cover bolt 10 N m 1 0 kgf m MAGNETOROTOR Install the key NOTE Remove any grease from the tapered portion of the magnetoro tor and crankshaft Install the magnetorotor 2 together with the starter clutch gear 3 With the fixed drive face locked tighten the magnetorotor nut to the specified torque V Magnetorotor nut 120 N m 12 0 kgf m 09930 40113 Rotor holder htto www motorcycle
155. und replace the starter clutch with 1422887 a new one DISASSEMBLY Remove the starter clutch gear With the rotor held immovable remove the starter clutch bolts 09930 34980 Rotor holder Remove the starter clutch D from the rotor Remove the plate 2 htto www motorcycle in th 3 46 ENGINE Remove the roller 3 spring 4 and push pieces 5 Inspect the rollers and push pieces 2 for damage and exces INSPECTION M 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 following points Apply THREAD LOCK on the starter clutch bolts and tighten them to the specified torque V Starter clutch bolt 10 N m 1 0 kgf m 4 42 99000 32110 THREAD LOCK SUPER 1322 09930 34980 Rotor holder MAGNETO COVER DISASSEMBLY Remove the startor coil and pick up coil Remove the oil seal with the special tool 09913 50121 Oil seal remover CAUTION Replace the removed oil seal with a new one htto www motorcycle in th REASSEMBLY Reassemble the magneto cover in the reverse order of disas sembly Pay attention to the following points nstall 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 seal AH 99000 25010 SUZUKI SUPER GREAS
156. urface of the battery s top cover CAUTION Never use anything except the specified battery Once the caps have been installed to the battery do not remove the caps Do not tap the caps with a tool such as hammer when installing them CORRECT INCORRECT For initial charging use the charger specially designed for MF battery CAUTION For charging the battery make sure to use the charger specially designed for MF battery Other wise the battery may be overcharged resulting in shortened service life Do not remove the cap during charging Position the battery with the cap facing upward during charging htto www motorcycle in th 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 powdery substance clean the battery terminals with sandpaper RECHARGING OPERATION Using the multi circuit tester check the battery voltage If the voltage reading is the 12 0 V DC and less recharge the bat tery with a battery charger Charging period Stop charging CAUTION When recharging the battery remove the battery from the motorcycle Do not remove the caps on the battery top while recharging

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