Home

2 - Pour RV 125

1. 5 PERIODIC MAINTENANCE SCHEDULE 6 PERIODIC MAINTENANCE CHART 6 MAINTENANCE AND TUNE UP PROCEDURES 7 THROTTLE CABLE PLAY 7 FUEL LINE 8 SDS CHECK 9 FI SYSTEM DIAGNOSIS 13 PRECAUTIONS IN SERVICING 13 FI SYSTEM TECHNICAL FEATURES 20 ECM TERMINAL 29 SELF DIAGNOSIS FUNCTION 30 FAIL SAFE FUNCTION 32 FI SYSTEM TROUBLESHOOTING 33 SENSORS 79 CKP SENSOR INSPECTION
2. 79 CKP SENSOR REMOVAL AND INSTALLATION 79 IAP TP IAT SENSOR INSPECTION 79 ET SENSOR INSPECTION 79 ET SENSOR REMOVAL AND INSTALLATION 80 TO SENSOR INSPECTION 80 TO SENSOR REMOVAL AND INSTALLATION 81 HO2 SENSOR INSPECTION 81 HO2 SENSOR REMOVAL AND INSTALLATION 81 2 RV125K7 07 MODEL RV125K7 07 MODEL CONTENTS FUEL SYSTEM 83 FUEL TANK 83 FUEL LEVEL INDICATOR CHECK RELAY 85 FUEL FILTER 86 THROTTLE BODY 87 WIRING DIAGRAM 93 CABLE AND HOSE ROUTING
3. 1 857 26 14 3rd 1 368 26 19 4th 1 095 23 21 5th 0 923 24 26 Top 0 833 20 24 Final reduction ratio 3 500 49 14 Drive chain D I D 428 134 links RV125K7 07 MODEL 5 CHASSIS Front suspension Telescopic coil spring oil damped Rear suspension Swingarm type coil spring oil damped Front suspension stroke 110 mm Rear wheel travel 136 mm Caster 26 Trail 91 mm Steering angle 45 right amp left Turning radius 2 1 m Front brake Disc brake Rear brake Drum brake Front tire size 130 80 18 M
4. 94 SPECIAL TOOLS 97 TIGHTENING TORQUE 97 SERVICE DATA 98 COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s MODEL CODE COUNTRY or AREA EFFECTIVE FRAME NO RV125 E 02 E 19 U K E U JS1BT111200101909 JS1BT111100111063 RV125K7 07 MODEL 3 ABBREVIATIONS USED IN THIS MANUAL A ABDC After Bottom Dead Center AC Alternating Current ACL Air Cleaner Air Cleaner Box API American Petroleum Institute ATDC After Top Dead Center A F Air Fuel Mixture B BBDC Before Bottom Dead Center BTDC Before Top Dead Center B Battery Positive Voltage C CKP Sensor Crankshaft Position Sensor CKPS CKT Circuit CLP Switch Clutch Lever Position Switch Clutch Switch CO Carbon Monoxide CPU Central Processing Unit D DC Direct Current DMC Dealer Mode Coupler DRL Daytime Running Light DTC Diagnostic Trouble Code E ECM Engine Control Module Engine Control Unit ECU FI Control Unit ECT Sensor Engine Coolant Temperature Sensor ECTS Water Temp Sensor WTS ET sensor Engine Temperature sensor F FI Fuel Injectio
5. 770 mm Dry mass 118 kg ENGINE Type Four stroke air cooled OHC Number of cylinders 1 Bore 57 0 mm Stroke 48 8 mm Displacement 125 cm Compression ratio 9 2 1 Fuel system Fuel injection Air cleaner Polyurethane foam element Starter system Electric Lubrication system Wet sump Idle speed 1 500 100 r min DRIVE TRAIN Clutch Wet multi plate type Transmission 6 speed constant mesh Gearshift pattern 1 down 5 up Primary reduction ratio 3 470 59 17 Gear ratios Low 3 000 33 11 2nd
6. Open or short circuit in the G B wire If the wire are OK replace the throttle body assembly with a new one When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend 2 V 2 ECM coupler Harness side 52 RV125K7 07 MODEL 14 P0120 H L TP SENSOR CIRCUIT MALFUNCTION NOTE TP sensor is incorporated in the IAP sensor IAT sensor INSPECTION Step 1 When indicating 14 1 Turn the ignition switch to OFF 2 Check the TP sensor coupler 1 for loose or poor contacts If OK then measure the TP sensor input voltage DETECTED CONDITION POSSIBLE CAUSE 14 Output voltage is not within the following range Difference between actual throttle open ing and opening calculated by ECM is larger than specified value 0 3 V Sensor voltage lt 4 7 V TP sensor maladjusted TP sensor circuit open or short TP sensor malfunction ECM malfunction P0120 H Sensor voltage is higher than specified value TP sensor circuit shorted to VCC or ground circuit open TP sensor circuit open or shorted to ground or VCC circuit open L Sensor voltage is lower than specified value ECM TP sensor B Br R P TP sensor E2 VCC 1 RV125K7 07 MODEL 53 3 Disconnect the TP sensor coupler 4 Turn the ignition switch ON 5 Measure the voltage at the R wire and ground
7. Page 40 1 When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend YES Go to Step 2 NO O or B Br wire open ECM coupler Harness side 1 RV125K7 07 MODEL 59 Step 1 When indicating P0115 L 1 Turn the ignition switch OFF 2 Check the ET sensor coupler 1 for loose or poor contacts If OK then measure the output voltage 3 Disconnect the ET sensor coupler 4 Check the continuity between O wire A and ground If the sound is not heard from the tester the circuit condition is OK Tester knob indication Continuity test Are the continuity and voltage OK 5 After repairing the trouble clear the DTC using SDS tool Page 40 1 1 YES Go to Step 2 NO O wire shorted to ground If wire is OK go to Step 2 60 RV125K7 07 MODEL Step 2 1 Turn the ignition switch OFF 2 Disconnect the ET sensor coupler 3 Measure the ET sensor resistance between B wires ET sensor resistance Approx 5 13 k at 20 40 C B B 09900 25008 Multi circuit tester set Tester knob indication Resistance Refer to page 79 for details Is the resistance OK 4 After repairing the trouble clear the DTC using SDS tool Page 40 ET sensor specification YES O or B Br wire open or shorted to ground or poo
8. I I Steering I I Front fork I Rear suspension I Chassis nuts and bolts T T T RV125K7 07 MODEL 7 MAINTENANCE AND TUNE UP PROCEDURES This section describes the servicing procedures for each Peri odic Maintenance item which differ from those of the RV125K6 06 MODEL For details other than the following items refer to the RV125 Service Manual THROTTLE CABLE PLAY Adjust the throttle cable play A with the following three steps First step Loosen the lock nut 2 of the throttle returning cable 1 Turn in the adjuster 3 fully Second step Loosen the lock nut 5 of the throttle pulling cable 4 Turn the adjuster 6 in or out until the throttle cable play A should be 2 0 4 0 mm at the throttle grip Tighten the lock nut 5 while holding the adjuster 6 Third step While holding the throttle grip at the fully closed position slowly turn out the adjuster 3 of the throttle returning cable 1 to feel resistance Tighten the lock nut 2 while holding the adjuster 3 Throttle cable play A 2 0 4 0 mm Inspect initially at 1 000 km 5 months and every 4 000 km 20 months thereafter After the adjustment is completed check that handle bars movement does not raise the engine idle speed and that the throttle grip returns smoothly and auto matically 8 RV125K7 07 MODEL FUEL LINE Inspect the fuel hoses for damage and fuel leakage I
9. NOTE As the zirconia element is not conductive below 250 C HO2 sensor will not function properly until the engine is at normal operating temperature ISC valve ISC Idle Speed Control valve controls the cold engine fast idle speed as well as warmed engine idle speed The air volume is adjusted by opening or closing the bypass port provided in the throttle port By controlling the fuel injection volume and air flow the idle speed is maintained at a constant level eliminating the need of manual adjustment RV125K7 07 MODEL 29 ECM TERMINAL TERMINAL NO CIRCUIT TERMINAL NO CIRCUIT 1 Power ground E0 D Ignition coil 2 ISC valve E FI indicator light 3 Control ground E1 F Fuel injector 4 Sensor ground E2 G Mode select switch 5 Power source B H Fuel injector 6 HO2 sensor heater I 7 J Neutral switch 8 Clutch switch K ET sensor ET 9 Power source for sensors VCC L IAT sensor IAT 0 M TP sensor TP A TO sensor TO N IAP sensor IAP B O C HO2 sensor HO2 P CKP sensor CKP ECM coupler 30 RV125K7 07 MODEL SELF DIAGNOSIS FUNCTION The self diagnosis function is incorporated in the ECM The function has two modes User mode and Dealer mode The user can only be notified by the FI indicator light To check the function of the individual FI system devices the dealer mode is provided In this check the special tool is necessary
10. 2 Current DTC example FI indicator light ON OFF Sec RV125K7 07 MODEL 37 DTC INDICATION CHART FLASHING PATTERN DTC No MALFUNCTION PART REMARKS 00 None 12 CKP sensor Page 44 Pick up coil signal 13 IAP sensor Page 47 14 TP sensor Page 52 15 ET sensor Page 57 21 IAT sensor Page 61 23 TO sensor Page 65 24 Ignition coil Page 68 32 Fuel injector Page 69 40 ISC valve Page 71 42 Ignition switch Page 74 44 HO2 sensor Page 75 1 2 1 3 1 4 1 5 2 1 2 3 4 2 2 3 4 0 2 4 4 4 38 RV125K7 07 MODEL 40 C40 code has no first digit display For this reason the interval A between the displays as shown below is longer than the others SELF DIAGNOSIS RESET PROCEDURE After repairing the trouble turn OFF the ignition switch and turn ON again If the FI indicator light turns OFF the malfunction is cleared Disconnect the special tool from the dealer mode coupler NOTE Even though the Current DTC is cleared Past DTC previous malfunction history code still remains stored in the ECM Therefore erase the Past DTC memorized in the ECM using SDS DTC is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when a wire coupler has been disconnected at the time of diagnosis erase the stored DTC Past DTC using S
11. 15 P0115 is indicated ET sensor lead wire coupler connection P0115 H Sensor voltage is higher than specified value ECT sensor circuit open or ground circuit open L Sensor voltage is lower than specified value ECT sensor circuit shorted to ground 21 IAT sensor The sensor voltage should be the fol lowing 0 1 V sensor voltage lt 4 6 V In other than the above range 21 P0110 is indicated IAT sensor lead wire coupler connection P0110 H Sensor voltage is higher than specified value IAT sensor circuit open or ground circuit open L Sensor voltage is lower than specified value IAT sensor circuit shorted to ground RV125K7 07 MODEL 43 DTC No DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR 23 TO sensor The sensor voltage should be the fol lowing for 2 sec and more after igni tion switch is turned ON 0 2 V sensor voltage lt 4 6 V In other than the above value 23 P1651 is indicated TO sensor lead wire coupler connection P1651 H Sensor voltage is higher than specified value TO sensor circuit shorted to VCC or ground circuit open L Sensor voltage is lower than specified value TO sensor circuit open or shorted to ground or VCC circuit open 24 Ignition signal CKP sensor pick up coil signal is pro duced but signal from ignition coil is interrupted 10 times or more continu ously In this case the code 24 P0351 is indicated Ignition coil
12. C 66P tube type Rear tire size 180 80 14 M C 78P tube type ELECTRICAL lgnition type Electronic ignition Transistorized lgnition timing 13 B T D C at 1 500 r min Spark plug NGK CR8E or DENSO U24ESR N Battery 12 V 21 6 kC 6 Ah 10 HR Generator Three phase A C generator Fuse 20 A Headlight 12 V 60 55 W Brake light Taillight 12 V 21 5 W Position light 12 V 4 W E 19 12 V 5 W E 02 Turn signal light 12 V 21 W Speedometer light 12 V 1 7 W Neutral indicator light 12 V 3 4 W High beam indicator light 12 V 1 7 W Turn signal indicator light 12 V 3 4 W FI indicator light 12 V 3 W Fuel lev
13. IG SWITCH CIRCUIT MALFUNCTION Refer to the RV125K3 6 28 for details RV125K7 07 MODEL 75 44 P0130 P0135 HO2 SENSOR HO2S CIRCUIT MALFUNCTION INSPECTION Step 1 When indicating 44 P0130 1 Turn the ignition switch OFF 2 Remove the seat 3 Check the HO2 sensor coupler 1 for loose or poor contacts If OK then check the HO2 sensor lead wire continuity 4 Disconnect the HO2 sensor coupler 5 Check the continuity between W G wire A and ground 6 Also check the continuity between W G wire A and B Br wire B If the sound is not heard from the tester the circuit condi tion is OK 09900 25008 Multi circuit tester set Tester knob indication Continuity test DETECTED CONDITION POSSIBLE CAUSE 44 P0130 HO2 sensor output voltage is not input to ECM during engine operation and running condition Sensor voltage lt 0 60 V HO2 sensor circuit open or shorted to ground Fuel system malfunction ECM malfunction 44 P0135 The heater can not operate so that heater operation voltage is not supply to the oxygen heater circuit Battery voltage supply to the HO2 sensor ECM Side stand relay Ignition switch Engine stop switch B O W Gr B W B Br W G W HO2 sensor HO2S HO2 H E2 To side stand switch 1 1 76 RV125K7 07 MODEL 7 Disconnect the ECM coupler 8 Check the continuity between W G wire A and terminal C 9 Als
14. MODEL Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool Page 40 YES Bl or B Br wire open or shorted to ground Loose or poor contacts on the CKP sensor cou pler or ECM coupler terminal P or 4 If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Inspect that metal particles or foreign material stuck on the CKP sensor and rotor tip If there are no metal particles and foreign mate rial then replace the CKP sensor with a new one When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend 2 ECM coupler Harness side RV125K7 07 MODEL 47 13 P0105 H L IAP SENSOR CIRCUIT MALFUNCTION NOTE IAP sensor is incorporated in the TP sensor IAT sensor INSPECTION Step 1 When indicating 13 1 Turn the ignition switch OFF 2 Check the IAP sensor coupler 1 for loose or poor contacts If OK then measure the IAP sensor input voltage DETECTED CONDITION POSSIBLE CAUSE 13 IAP sensor voltage is not within the fol lowing range 0 2 V Sensor voltage lt 4 5 V NOTE Note that atmospheric pressure varies depending on weather conditions as well as altitude Take
15. MODEL DRIVE TRAIN DRIVE CHAIN Unit mm Except ratio FUEL INJECTOR ISC VALVE ITEM STANDARD LIMIT Primary reduction ratio 3 470 59 17 Final reduction ratio 3 500 49 14 Gear ratios Low 3 000 33 11 2nd 1 857 26 14 3rd 1 368 26 19 4th 1 095 23 21 5th 0 923 24 26 Top 0 833 20 24 Shift fork to groove clearance 0 10 0 30 0 50 Shift fork groove width No 1 5 0 5 1 No 2 5 5 5 6 Shift fork thickness No 1 4 8 4 9 No 2 5 3 5 4 Countershaft length Low to 2nd Drive chain Type DID 428 Links 134 20 pitch length 259 0 Drive chain slack 15 25 Gearshift lever height 20 between footrest top and gearshift lever top 88 0 0 1 0 ITEM SPECIFICATION NOTE Fuel injector resistance 1 9 at 20 C Fuel injector voltage Battery voltage 1 0 V and more ISC valve resistance Approx 35 ISC valve voltage Battery voltage RV125K7 07 MODEL 101 FI SENSORS THROTTLE BODY ITEM SPECIFICATION NOTE CKP sensor resistance 172 288 CKP sensor peak voltage 2 0 V When cranking and more G BI IAP sensor input voltage 4 5 5 5 V IAP sensor output voltage Approx 2 0 3 5 V at idle speed G B B Br TP sensor input voltage 4 5 5 5 V TP sensor output voltage Closed Approx 0 7 V P B Br Opened Ap
16. circuit in the R wire or B Br wire V 1 1 1 RV125K7 07 MODEL 49 5 Disconnect the ECM coupler 6 Check the continuity between G B wire C and terminal N 7 If OK then check the continuity between B Br wire B and ter minal 4 IAP sensor lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 8 After repairing the trouble clear the DTC using SDS tool Page 40 Step 1 When indicating P0105 L 1 Turn the ignition switch OFF 2 Check the IAP sensor coupler 1 for loose or poor contacts If OK then check the IAP sensor lead wire continuity 3 Disconnect the IAP sensor coupler 4 Check the continuity between G B wire and ground 5 Also check the continuity between G B wire and B Br wire If the sound is not heard from the tester the circuit condition is OK When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend YES Go to Step 2 NO G B wire shorted to VCC or B Br wire open 1 ECM coupler Harness side 1 1 50 RV125K7 07 MODEL 6 Disconnect the ECM coupler 7 Check the continuity between R wire A and terminal 9 8 Also check the continuity between G B wire C and terminal N IAP sensor lead wire con
17. fuel injector Light load When the engine load is light the fuel injection time volume is determined on the basis of intake air pressure and engine speed High load When the engine load is high the fuel injection time volume is determined on the basis of throttle valve opening and engine speed ET SENSOR ET Engine Temperature sensor sends the signal of engine temperature as thermistor ohmic value which is then detected by ECM When the engine temperature is low the injection vol ume increases The thermistor ohmic value increases with the engine tempera ture low and it decreases with the temperature high 1 3 way joint 1 From fuel tank 2 Fuel filter 2 Fuel tank return 3 Fuel injector 2 2 1 1 RV125K7 07 MODEL 27 TO SENSOR TO Tip Over sensor detects the vehicle inclination When the vehicle tips to more than 65 a signal is sent to ECM When this signal continues for more than 4 seconds ECM interrupts cur rent to fuel injector and ignition coil To restart the engine turn the ignition switch OFF once and then attempt starting in the normal procedure IAP TP IAT SENSOR The IAP sensor TP sensor IAT sensor are combined into one IAP sensor The value of intake air pressure is converted into an electrical signal and sent to ECM The base fuel injection time volume in light load is determined in accordance with this electrical signal output signal The higher the intake air pressure th
18. modified according to conditions and characteris tics of each market VISUAL INSPECTION Prior to diagnosis using the mode select switch or SDS perform the following visual inspections The rea son for visual inspection is that mechanical failures such as oil leakage cannot be displayed on the screen with the use of mode select switch or SDS Engine oil level and leakage RV125K3 2 10 Fuel level and leakage Page 8 and 84 Clogged air cleaner element RV125K3 2 4 Battery condition RV125K3 6 31 Throttle cable play Page 7 Broken fuse FI indicator light operation Page 30 Exhaust gas leakage and noise RV125K3 2 19 Each coupler disconnection MOTORCYCLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Hot Warm Cool Cold C Always Frequency Always Sometimes times day month Only once Under certain condition Road Urban Suburb Highway Mountainous Uphill Downhill Tarmacadam Gravel Other Motorcycle condition Engine condition Cold Warming up phase Warmed up Always Other at starting Immediately after start Racing without load Engine speed r min Motorcycle con dition During driving Constant speed Accelerating Decelerating Right hand corner Left hand corner At stop Motorcycle speed when problem occurs km h Other RV125K7 07 MODEL 35 SELF DIAGNOSTIC
19. signal Fuel injector ECM Basic fuel injection time Ultimate fuel injection time Compensation RV125K7 07 MODEL 21 COMPENSATION OF INJECTION TIME VOLUME The following different signals are output from the respective sensors for compensation of the fuel injection time volume INJECTION STOP CONTROL SIGNAL DESCRIPTION ENGINE TEMPERATURE SENSOR SIGNAL When engine temperature is low injection time volume is increased INTAKE AIR TEMPERATURE SENSOR SIGNAL When intake air temperature signal is low injection time vol ume is increased HEATED OXYGEN SENSOR SIGNAL Air fuel ratio is compensated to the theoretical ratio from density of oxygen in exhaust gasses The compensation occurs in such a way that more fuel is supplied if detected air fuel ratio is lean and less fuel is supplied if it is rich ENGINE RPM SIGNAL At high speed the injection time volume is increased When starting engine additional fuel is injected during cranking engine ACCELERATION SIGNAL DECELERATION SIGNAL During acceleration the fuel injection time volume is increased in accordance with the throttle opening speed and engine rpm During deceleration the fuel injection time vol ume is decreased FUEL INJECTOR DRIVE CURRENT SIGNAL ECM detects this current and compensates the injection time volume SIGNAL DESCRIPTION TIP OVER SENSOR SIGNAL FUEL SHUT OFF When the motorcycle tips over the tip over sensor sends a signa
20. that into consideration when inspecting voltage Clogged vacuum passage between throttle body and IAP sensor Air being drawn from vacuum passage between throttle body and IAP sensor IAP sensor circuit open or shorted to ground IAP sensor malfunction ECM malfunction P0105 H Sensor voltage is higher than specified value IAP sensor circuit open or shorted to VCC or ground circuit open IAP sensor circuit shorted to ground or VCC cir cuit open L Sensor voltage is lower than specified value ECM IAP sensor B Br G B R VCC IAP E2 1 48 RV125K7 07 MODEL 3 Disconnect the IAP sensor coupler 4 Turn the ignition switch ON 5 Measure the voltage at the R wire and ground 6 If OK then measure the voltage at the R wire and B Br wire IAP sensor input voltage 4 5 5 5 V R Ground R B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK Step 1 When indicating P0105 H 1 Turn the ignition switch OFF 2 Check the IAP sensor coupler 1 for loose or poor contacts If OK then check the IAP sensor lead wire continuity 3 Disconnect the IAP sensor coupler 4 Check the continuity between R wire and G B wire If the sound is not heard from the tester the circuit condition is OK YES Go to Step 2 NO Loose or poor contacts on the ECM coupler terminal 9 or 4 Open or short
21. the fuse SWITCH Never apply grease material to switch contact points to pre vent damage ECM VARIOUS SENSORS Since each component is a high precision part great care should be taken not to apply any sharp impacts during removal and installation Be careful not to touch the electrical terminals of the ECM The static electricity from your body may damage this part INCORRECT RV125K7 07 MODEL 15 When disconnecting and connecting the ECM make sure to turn OFF the ignition switch 1 or electronic parts may get damaged Battery connection in reverse polarity is strictly prohibited Such a wrong connection will damage the components of the FI system instantly when reverse power is applied Removing any battery terminal of a running engine is strictly prohibited The moment such removal is made damaging counter elec tromotive force will be applied to the ECM which may result in serious damage Before measuring voltage at each terminal check to make sure that battery voltage is 11 V or higher Terminal voltage check with a low voltage battery will lead to erroneous diagno sis Never connect any tester voltmeter ohmmeter or whatever to the ECM when its coupler is disconnected Otherwise damage to ECM may result Never connect an ohmmeter to the ECM with its coupler con nected If attempted damage to ECM or sensors may result Be sure to use a specified voltmeter ohmmeter O
22. 25 5 EX 22 5 Valve clearance when cold IN 0 03 0 08 EX 0 13 0 18 Valve guide to valve stem clearance IN 0 010 0 037 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 EX 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 1 7 Valve seat width IN amp EX 0 9 1 1 Valve head radial runout IN amp EX 0 03 Valve spring free length INNER 31 3 IN amp EX OUTER 33 6 Valve spring tension IN amp EX INNER 38 1 43 9 N 3 9 4 4 kgf at length 26 78 mm OUTER 89 6 103 N 9 1 10 5 kgf at length 29 78 mm ITEM STANDARD LIMIT Cam height IN 33 720 33 760 33 420 EX 33 310 33 357 33 010 Camshaft journal oil clearance IN amp EX 0 032 0 066 0 150 Camshaft journal holder I D IN amp EX 22 012 22 025 Camshaft journal O D IN amp EX 21 959 21 980 Camshaft runout IN amp EX 0 10 Rocker arm I D IN amp EX 12 000 12 018 Rocker arm shaft O D IN amp EX 11 977 11 995 Cylinder head distortion 0 05 Cylinder head cover distortion 0 05 RV125K7 07 MODEL 99 CYLINDER PISTON PISTON RING Unit mm CONROD
23. 3 6 Battery Type designation YTX7L BS Capacity 12 V 21 6 kC 6 Ah 10 HR Fuse size 20 A ITEM STANDARD SPECIFICATION E 02 E 19 Headlight HI 60 LO 55 Position light 5 4 Brake light Taillight 21 5 Turn signal light 21 Speedometer light 1 7 Turn signal indicator light 3 4 High beam indicator light 1 7 Neutral indicator light 3 4 FI indicator light 3 Fuel level indicator light 3 4 RV125K7 07 MODEL 103 BRAKE WHEEL Unit mm SUSPENSION Unit mm TIRE PRESSURE ITEM STANDARD SPECIFICATION LIMIT Rear brake pedal free travel 20 30 Rear brake pedal height 5 15 Brake drum I D Rear 110 7 Brake disc thickness Front 4 0 0 2 3 5 Brake disc runout Front 0 30 Master cylinder bore Front 12 700 12 743 Master cylinder piston diam Front 12 657 12 684 Brake caliper cylinder bore Front 30 230 30 306 Brake caliper piston diam Front 30 150 30 200 Brake fluid type DOT 4 Wheel rim runout Axial 2 0 Radial 2 0 Wheel axle runout Front 0 25 Rear 0 25 Wheel rim size Front 18 M C MT 2 50 Rear 14 M C MT 4 50 Tire size Front 130 80 18 M C 66P Rear 180 80 14 M C 78P Tire tread depth Front 4 0 Rear 4 0 ITEM STANDARD SPECIFICATION LIMIT Front fork stroke 110 Front fork spring free length 382 9 375
24. 6 If OK then measure the voltage at the R wire and B Br wire TP sensor input voltage 4 5 5 5 V R Ground R B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK Step 1 When indicating P0120 H 1 Turn the ignition switch OFF 2 Check the TP sensor coupler 1 for loose or poor contacts If OK then check the TP sensor lead wire continuity 3 Disconnect the TP sensor coupler 4 Check the continuity between P wire and R wire If the sound is not heard from the tester the circuit condition is OK YES Go to Step 2 NO Loose or poor contacts on the ECM coupler terminal 9 or 4 Open or short circuit in the R wire or B Br wire V 1 1 1 54 RV125K7 07 MODEL 5 Disconnect the ECM coupler 6 Check the continuity between P wire A and terminal M 7 Also check the continuity between B Br wire C and terminal 4 TP sensor lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 8 After repairing the trouble clear the DTC using SDS tool Page 40 Step 1 When indicating P0120 L 1 Turn the ignition switch OFF 2 Check the TP sensor coupler 1 for loose or poor contacts If OK then check the TP sensor lead wire continuity 3 Disconnect the TP sensor coup
25. 7 MODEL REMOVAL AND DISASSEMBLY Remove the seat RV125K3 5 3 Remove the frame covers RV125K3 5 3 Disconnect the ISC valve coupler 1 Fuel injector coupler 2 and IAP TP IAT sensor coupler 3 Place a rag under the hose joint and disconnect the fuel hose 4 Disconnect the fuel hose 5 Disconnect the throttle cables 6 from their drum Remove the air cleaner bolts Drain out fuel before removing the throttle body Do not drain fuel while engine is hot The throttle body is assembled precisely in factory Do not disassemble it other than shown in this man ual Gasoline is highly flammable and explosive Keep heat spark and flame away RV125K7 07 MODEL 89 Loosen the air cleaner outlet tube clamp screw Remove the intake pipe nuts Move the air cleaner box backward and remove the throttle body Remove the insulator 7 Remove the O rings 8 and 9 Remove the fuel injector 0 Do not snap the throttle valve from full open to full close after disconnecting the throttle cables It may cause damage to the throttle valve and throttle body Ensure that the fuel injector is not exposed to dust etc Be careful not to expose the fuel injector to exces sive shock 90 RV125K7 07 MODEL Remove the return pipe A bracket B and upper cushion C Remove the O ring D and cushion seal E Remove the ISC valve
26. 9 9 5 0 1 3 1 1 5 0 0 1 E 4 mm Printed in Japan K7 USE THIS MANUAL WITH RV125 SERVICE MANUAL 99500 31233 01E RV125 DIC120 No 3900 RV125K7_01E SUPPLY 99500 31150 01E 2006 8 28 Cover_14 PS Printing 4 mm 2 1 K7 RV125K7 07 MODEL 1 CONTENTS RV125K7 07 MODEL COPYRIGHT SUZUKI MOTOR CORPORATION 2006 This manual describes service data service specifications troubleshooting for FI system and servicing procedures which differ from those of the K6 06 model NOTE Any differences between the K6 06 model and K7 07 model in specifications and service data are indicated with an asterisk mark Please refer to the K6 06 model service manual and service information for details which are not given in this manual ABBREVIATIONS USED IN THIS MANUAL 3 SPECIFICATIONS RV125K7 4 ENGINE 4 DRIVE TRAIN 4 CHASSIS 5 ELECTRICAL 5 CAPACITIES
27. Bl O R O B O W B R B Bl Y G B B W B B O B Y B B W Y B B W B Br O B B R W W Bl Y R B O B W B W R P G B Dg B Br Y B Y G R Bl B Br B B B Bl B Bl G O O B Br Lbl O Lg Lbl B W Y O B W Y B O Lg Lbl B W Y Y B B W B Y Bl Bl Bl G Bl B B B B O B Br W G W W Gr B W Lg B W B B W B B W Br B W Br B W Lg B W Y B W W IGNITION COIL IGNITION SWITCH SIDE STAND SWITCH REAR BRAKE SWITCH REGULATOR RECTIFIER ECM REAR TURN SIGNAL LIGHT R REAR TURN SIGNAL LIGHT L BRAKE LIGHT TAILLIGHT HANDLEBAR SWITCH L DIMMER SWITCH HORN HORN BUTTON HAZARD SWITCH TURN SIGNAL SWITCH CLUTCH LEVER POSITION SWITCH FRONT TURN SIGNAL LIGHT R FRONT TURN SIGNAL LIGHT L HEADLIGHT POSITION LIGHT TO SENSOR HO2 SENSOR ET SENSOR CKP SENSOR FUEL INJECTOR ISC VALVE TP IAP IAT SENSOR 94 RV125K7 07 MODEL CABLE AND HOSE ROUTING CABLE ROUTING 1 Throttle cable No 1 1 Pass the throttle cables in front of the brake hose 4 Set the clamp as shown 2 Throttle cable No 2 5 Clamp the harness only 3 Wiring harness 2 Pass the throttle cables above the wiring harness 6 Set the upper end of clutch cable protector to the lower end of cla
28. CRANKSHAFT Unit mm OIL PUMP CLUTCH Unit mm ITEM STANDARD LIMIT Compression pressure 1 100 1 500 kPa 11 15 kgf cm2 800 kPa 8 0 kgf cm2 Piston to cylinder clearance 0 040 0 050 0 120 Cylinder bore 57 000 57 015 57 090 Piston diam 56 955 56 970 Measure at 8 mm from the skirt end 56 880 Cylinder distortion 0 05 Piston ring free end gap 1st R Approx 7 2 5 8 2nd R Approx 5 0 4 0 Piston ring end gap 1st 0 20 0 32 0 7 2nd 0 20 0 32 0 7 Piston ring to groove clearance 1st 0 18 2nd 0 15 Piston ring groove width 1st 1 01 1 03 2nd 1 01 1 03 Oil 2 01 2 03 Piston ring thickness 1st 0 970 0 990 2nd 0 970 0 990 Piston pin bore 14 002 14 008 14 030 Piston pin O D 13 992 14 000 13 980 ITEM STANDARD LIMIT Conrod small end I D 14 006 14 014 14 040 Conrod deflection 3 0 Conrod big end side clearance 0 10 0 45 1 0 Conrod big end width 15 95 16 00 Crank web to web width 53 0 0 1 Crankshaft runout 0 08 ITEM STANDARD LIMIT Oil pressure at 60 C Above 15 kPa 0 15 kgf cm2 Below 35 kPa 0 35 kgf cm2 at 3 000 r min ITEM STANDARD LIMIT Clutch lever play 10 15 Drive plate thickness 2 95 3 15 2 65 Drive plate claw width 11 8 12 0 11 5 Driven plate distortion 0 10 Clutch spring free length 32 6 31 0 100 RV125K7 07
29. DS 4 4 0 0 4 0 sec 1 0 sec FI RV125K7 07 MODEL 39 USE OF SDS DIAGNOSTIC PROCEDURES NOTE Do not disconnect the coupler from ECM battery cable from battery ECM ground wire from engine or main fuse before confirming the DTC Diagnostic Trouble Code stored in mem ory Such disconnection will erase the memorized information in ECM memory DTC stored in ECM memory can be checked by SDS Be sure to read PRECAUTIONS IN SERVICING Page 13 before inspection and observe what is written there Remove the right frame cover RV125K3 5 3 Set up the SDS tool Refer to the SDS operation manual for further details Read the DTC Diagnostic Trouble Code and show data when trouble displaying data at the time of DTC according to instructions displayed on SDS SDS is not only used for detecting DTC but also for reproduc ing and checking on screen the failure condition as described by customers using the trigger How to use trigger Refer to the SDS operation manual for further details 09904 41010 SDS set tool 99565 01010 009 CD ROM Ver 9 40 RV125K7 07 MODEL USE OF SDS DIAGNOSIS RESET PROCEDURE After repairing the trouble turn OFF the ignition switch and turn ON again Click the DTC inspection button 1 Check the DTC The previous malfunction history code Past DTC still remains stored in the ECM Therefore erase the history code memorized in th
30. F Never remove the IAP TP IAT sensor G from the throt tle body Never remove the throttle valve H from the throttle body Never use carburetor cleaning chemicals to the throttle body assembly Never use compressed air to the passage ways RV125K7 07 MODEL 91 INSPECTION Check following items for any damage or clogging O ring Throttle valve Injector cushion seal ISC valve Remove the O ring Visually inspect the ISC valve for wear damage or carbon deposit replace it with a new one if necessary NOTE The ISC valve can be checked without removing it Page 91 If the resistance is not within the standard range replace the ISC valve with a new one REASSEMBLY AND INTSTALLATION Reassembly and installation is in the reverse order of removal and disassembly Pay attention to the following points Install the ISC valve 1 ISC valve screw 2 N m 0 2 kgf m Apply thin coat of engine oil to the cushion seal and O ring Avoid removing the adjustetr I and throttle stop screw J Replace the O ring with a new one Replace the cushion seal and O ring with new ones 92 RV125K7 07 MODEL Install the injector as shown Install the O rings 2 and 3 Install the insulator NOTE Set the insulator so the O ring faces to the engine side and tab A upward Install the throttle body Connect the throttle pu
31. Front fork oil level 171 Front fork oil type SUZUKI FORK OIL 10 or an equivalent fork oil Front fork oil capacity each leg 230 ml Rear wheel travel 136 Swingarm pivot shaft runout 0 6 COLD INFLATION TIRE PRESSURE SOLO AND DUAL RIDING kPa kgf cm2 FRONT 125 1 25 REAR 125 1 25 104 RV125K7 07 MODEL FUEL OIL ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 91 octane or higher An unleaded gasoline type is recom mended Fuel tank capacity 6 5 L Engine oil type SAE 10W 40 API SF SG or SH SJ with JASO MA Engine oil capacity Change 850 ml Filter change 950 ml Overhaul 1 200 ml Prepared by September 2006 Part No 99501 31150 01E Printed in Japan 104 9 9 5 0 1 3 1 1 5 0 0 1 E 4 mm Printed in Japan K7 USE THIS MANUAL WITH RV125 SERVICE MANUAL 99500 31233 01E RV125 DIC120 No 3900 RV125K7_01E SUPPLY 99500 31150 01E 2006 8 28 Cover_14 PS Printing 4 mm 2 1 K7
32. PROCEDURES NOTE Do not disconnect the coupler from ECM battery cable from battery ECM ground wire from engine or main fuse before confirming the DTC Diagnostic Trouble Code stored in mem ory Such disconnection will erase the memorized information in ECM memory DTC stored in ECM memory can be checked by the special tool Before checking DTC read SELF DIAGNOSIS FUNCTION USER MODE and DEALER MODE Page 30 and 31 carefully to have good understanding as to what functions are available and how to use it Be sure to read PRECAUTIONS IN SERVICING Page 13 before inspection and observe what is written there Remove the right frame cover RV125K3 5 3 Connect the special tool to the dealer mode coupler at the wir ing harness Turn the special tool s switch ON and check the malfunction code to determine the malfunction part 09930 82720 Mode select switch 36 RV125K7 07 MODEL UNDERSTANDING THE DTC Diagnostic Trouble Code A two digit DTC is shown through the flashing pattern of the FI indicator light The DTCs are displayed from a smaller number to a larger number in that order When all the applicable DTCs have been displayed the displaying of the DTCs repeat from the first one again If no DTC is recorded the FI indicator light will not turned on 0 3 0 3 0 3 0 3 1 0 3 0 0 3 0 3 0 3 0 3 0 3 0 3 0 3 0 3 1 0 3 0 1 0 0 3 0 3 0 3 0 3 1 2 2 3 1
33. R INSPECTION The intake air pressure sensor throttle position sensor intake air temperature sensor are combined into one and installed in the throttle body Page 47 52 and 61 ET SENSOR INSPECTION The engine temperature sensor is installed in the cylinder Page 57 Remove the ET sensor Page 80 Check the ET sensor by testing it at the bench as shown in the figure Connect the ET sensor 1 to a circuit tester and place it in the oil 2 contained in a pan which is placed on a stove Heat the oil to raise its temperature slowly and read the col umn thermometer 3 and the ohmmeter Do not attempt to remove the IAP TP IAT sensor from the throttle body It is available only as a throttle body assembly 80 RV125K7 07 MODEL If the ET sensor ohmic value does not change in the propor tion indicated replace it with a new one Engine temperature sensor specification ET SENSOR REMOVAL AND INSTALLATION Remove the clamp 1 Disconnect the coupler 2 Remove the ET sensor 3 Install the ET sensor in the reverse order of removal ET sensor 9 N m 0 9 kgf m TO SENSOR INSPECTION The tip over sensor is located between the tool box and rear fender Page 65 Temperature Resistance 20 C Approx 13 0 k 40 C Approx 6 2 k 80 C Approx 1 7 k 100 C Approx 1 0 k Take special care when handling the ET sensor It may cause damage if it gets
34. a sharp impact Do not contact the ET sensor and the column ther mometer with a pan RV125K7 07 MODEL 81 TO SENSOR REMOVAL AND INSTALLATION Remove the right frame cover RV125K3 5 3 Remove the rear fender bolts Remove the TO sensor Install the TO sensor in the reverse order of removal NOTE When installing the TO sensor the arrow mark A must be pointed upward HO2 SENSOR INSPECTION The heated oxygen sensor is installed in the exhaust pipe Page 75 HO2 SENSOR REMOVAL AND INSTALLATION Remove the seat RV125K3 5 3 Remove the right frame cover RV125K3 5 3 Disconnect the coupler 1 82 RV125K7 07 MODEL Remove the HO2 sensor 2 Installation is in the reverse order of removal Tighten the HO2 sensor to the specified torque HO2 sensor 25 N m 2 5 kgf m Do not remove the HO2 sensor while it is hot Be careful not to expose the HO2 sensor to exces sive shock Do not use an impact wrench while removing or installing the HO2 sensor Be careful not to twist or damage the HO2 sensor lead wires Do not apply oil or other materials to the HO2 sensor air holes RV125K7 07 MODEL 83 FUEL SYSTEM FUEL TANK REMOVAL Remove the seat RV125K3 5 3 Place a rag under the hose joint and disconnect the fuel hose 1 Disconnect the fuel level switch lead wire coupler 2 Remove the f
35. al and ground ISC valve continuity Infinity Terminal Ground 09900 25008 Multi circuit tester set Tester knob indication Resistance Are the resistance and continuity OK 6 After repairing the trouble clear the DTC using SDS tool Page 40 Step 2 1 Turn the ignition switch ON 2 Measure the ISC valve voltage between B O wire and ground ISC valve voltage Battery voltage B O Ground 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool Page 40 YES Go to Step 2 NO Replace the ISC valve with a new one Page 88 1 2 V YES B O or Y R wire open or shorted to ground or poor 2 connection If wire and connection is OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Open circuit in the B O wire When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend 2 ECM coupler Harness side RV125K7 07 MODEL 73 ACTIVE CONTROL INSPECTION ISC RPM CONTROL Check 1 1 Set up the SDS tool Refer to the SDS operation manual for further details 2 Check that t
36. arm up 10 RV125K7 07 MODEL Data at 3 000 r min under no load Data at the time of racing RV125K7 07 MODEL 11 Data of intake negative pressure during idling 90 C Data of manifold absolute pressure operation at the time of starting 12 RV125K7 07 MODEL Example of trouble Three data value 1 current data 1 value 2 past data 2 and value 3 past data 3 can be made in compar ison by showing them in the graph Read the change of value by comparing the current data to the past data that have been saved under the same condition then you may determine how changes have occurred with the pass of time and identify what problem is currently occurring With DTC not output if the value of engine temperature is found to be higher than the data saved previously the possible cause may probably lie in a sensor circuit opened or ground circuit opened or influence of inter nal resistance value changes etc Abnormal value of engine temperature No DTC output Unstable idling speed RV125K7 07 MODEL 13 FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system observe the following points for the safety of the system ELECTRICAL PARTS Connector Coupler When connecting a connector be sure to push it in until a click is felt With a lock type coupler be sure to release the lock when dis connecting and push in fully to engage the lock when con necti
37. ater voltage between W wire harness side and ground 4 If the tester voltage indicates the battery voltage it is good condition Heater voltage Battery voltage W Ground NOTE Battery voltage can be detected only before starting the engine 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool Page 40 YES B O or W wire open or shorted to ground or poor 6 connection Recheck each terminal and wire harness for open circuit and poor connection If wire and connection are OK intermittent trou ble or faulty ECM Replace the ECM with a known good one and inspect it again NO Open or short circuit in the W wire or B O wire Loose or poor contacts on the ECM coupler terminal 6 or HO2 sensor coupler When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend 2 V 2 ECM coupler Harness side RV125K7 07 MODEL 79 SENSORS CKP SENSOR INSPECTION The crankshaft position sensor is installed in the generator cover Page 44 CKP SENSOR REMOVAL AND INSTALLATION Remove the generator cover RV125K3 3 14 Install the generator cover in the reverse order of removal IAP TP IAT SENSO
38. cial tool s coupler to connect to the dealer mode coupler The memorized malfunction code is displayed by the flashing pattern of FI indicator light Malfunction means that the ECM does not receive normal signal from the devices These affected devices are indicated in the code form 09930 82720 Mode select switch The DTC is indicated from small code to large code FI Before checking DTC Diagnostic Trouble Code do not disconnect the ECM lead wire coupler If the coupler from the ECM is disconnected the DTC memory is erased and can not be checked MALFUNCTION FI INDICATOR LIGHT INDICATION NO OFF YES ON and blinks 32 RV125K7 07 MODEL FAIL SAFE FUNCTION FI system is provided with fail safe function to allow the engine to start and the motorcycle to run in a mini mum performance necessary even under malfunction condition The engine can start and can run even if the above signal is not received from each sensor But the engine running condition is not complete providing only emergency help by fail safe circuit In this case it is nec essary to bring the motorcycle to the workshop for complete repair ITEM FAIL SAFE MODE STARTING ABILITY RUNNING ABILITY IAP sensor Intake air pressure is fixed to 101 kPa 760 mmHg YES YES TP sensor The throttle opening is fixed to full open position Ignition timing is also fixed YES YES IAT sensor Intake air temperat
39. continuity between A and B If there is no continuity replace the fuel level indicator check relay with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity test Gasoline is very explosive Extreme care must be taken The gaskets 1 and 2 must be replaced with new ones to prevent fuel leakage 86 RV125K7 07 MODEL FUEL FILTER REMOVAL Remove the right frame cover RV125K3 5 3 Remove the screws Place a rag under the hose joint and disconnect the fuel hoses Remove the fuel filter 1 INSPECTION When gosoline is poured lightly to the fuel filter from the port 1 the gasoline should flow out through the port 3 smoothly Also check for clogging from the port 2 to 3 If any defects are found replace the fuel filter with a new one INSTALLATION Installation is in the reverse order of removal Pay attention to the following point Rout the fuel hoses properly Page 95 Drain out fuel before removing the fuel filter Do not drain fuel while engine is hot Gasoline is highly flammable and explosive Keep heat spark and flame away Always use extreme caution when handling gasoline RV125K7 07 MODEL 87 THROTTLE BODY CONSTRUCTION 1 Return pipe 5 Cushion seal 2 Upper cushion 6 ISC valve ITEM N m kgf m 3 O ring 7 Throttle body A 2 0 2 4 Fuel injector A ISC valve screw 88 RV125K7 0
40. coupler 1 for loose or poor contacts If OK then measure the fuel injector resistance 3 Disconnect the fuel injector coupler 4 Measure the fuel injector resistance Fuel injector resistance Approx 1 9 at 20 C Terminal Terminal DETECTED CONDITION POSSIBLE CAUSE When the fuel injector current in each detection is low for consecutive10 times or more Fuel injector circuit open or short Fuel injector malfunction ECM malfunction Fuel injector Fuel injector R W Fuel injector ECM W Bl 1 1 70 RV125K7 07 MODEL 5 If OK then check the continuity between each terminal and ground Fuel injector continuity Infinity Terminal Ground 09900 25008 Multi circuit tester set Tester knob indication Resistance Are the resistance and continuity OK 6 After repairing the trouble clear the DTC using the SDS tool Page 40 Step 2 1 Turn the ignition switch ON 2 Measure the fuel injector voltage between R W wire and ground Fuel injector voltage Battery voltage 1 0 V and more R W Ground NOTE Ex It is possible that 11 5 V measured when the battery volt age is 12 5 V 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool Page 40 YES Go to Step 2 NO Replace the fuel injecto
41. d 0 V Also if measured values are as listed below a resistance abnormality exists which causes the voltage drop in the circuit between terminals A and B Voltage Between C and body ground Approx 5 V B and body ground Approx 5 V 2 V voltage drop A and body ground 3 V 5 V 0 V 5 V 5 V 18 RV125K7 07 MODEL Short circuit check wire harness to ground Disconnect the negative cable from the battery Disconnect the connectors couplers at both ends of the circuit to be checked NOTE If the circuit to be checked branches to other parts as shown disconnect all connectors couplers of those parts Otherwise diagnosis will be misled Measure resistance between terminal at one end of circuit A terminal in figure and body ground If continuity is indicated there is a short circuit to ground between terminals A and C 1 Other parts 1 To other parts Disconnect the connector coupler included in circuit coupler B and measure resistance between terminal A and body ground If continuity is indicated the circuit is shorted to the ground between terminals A and B 1 ECM 1 To other parts 1 5 V 1 RV125K7 07 MODEL 19 USING THE MULTI CIRCUIT TESTER Use the Suzuki multi circuit tester set 09900 25008 Use well charged batteries in the tester Be sure to set the tester to the correct testing range Using the tester Incorrectly connecting the and probes ma
42. e ECM E2 TOS R B Br VCC TO sensor Br W 1 YES Go to Step 2 NO Replace the TO sensor with a new one 1 66 RV125K7 07 MODEL Step 1 When indicating P1651 H 1 Turn the ignition switch OFF 2 Remove the right frame cover 3 Check the TO sensor coupler 1 for loose or poor contacts If OK then check the TO sensor lead wire continuity 4 Disconnect the TO sensor coupler 5 Check the continuity between R wire A and Br W wire B If the sound is not heard from the tester the circuit condition is OK 6 Disconnect the ECM coupler 7 Check the continuity between Br W wire B and terminal A 8 Also check the continuity between B Br wire C and terminal 4 TO sensor lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 9 After repairing the trouble clear the DTC using SDS tool Page 40 1 1 When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend YES Go to Step 2 NO Br W wire shorted to VCC or B Br wire open ECM coupler Harness side 1 RV125K7 07 MODEL 67 Step 1 When indicating P1651 L 1 Turn the ignition switch OFF 2 Remove the right frame cover 3 Check the TO sensor coupler 1 for lo
43. e ECM using SDS tool NOTE The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when a wire coupler has been disconnected at the time of diagnosis erase the stored malfunction history code using SDS Click Clear 2 to delete history code Past DTC Follow the displayed instructions Check that both Current DTC 3 and Past DTC 4 are deleted NIL RV125K7 07 MODEL 41 SHOW DATA WHEN TROUBLE DISPLAING DATA AT THE TIME OF DTC ECM stores the engine and driving conditions in the form of data as shown in the figure at the moment of the detection of a malfunction in its memory This data is called Show data when trouble Therefore it is possible to know engine and driving conditions e g whether the engine was warm or not where the motorcycle was running or stopped when a malfunction was detected by checking the show data when trouble This show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM Also ECM has a function to store each show data when trouble for two different malfunctions in the order as the malfunction is detected Utilizing this function it is possible to know the order of malfunctions that have been detected Its use is helpful when rechecking or diagnosing a trouble Click Show data when trouble 1 to display the data By clicking the drop down button 2 either Failu
44. e higher the signal voltage becomes TP sensor TP Throttle Position sensor is a sort of variable resistor and detects the throttle valve opening The sensor voltage is translated to throttle opening voltage and sent to ECM The base fuel injection time volume in high load is determined in accordance with this electrical signal output signal The wider the throttle opening the higher the signal voltage becomes IAT sensor IAT Intake Air Temperature sensor senses the intake air tem perature as ohmic value of thermistor and sends it to ECM When the intake air temperature is low the injection volume is increased The thermistor ohmic value increases with the intake air temper ature low and decreases with the temperature high 65 65 28 RV125K7 07 MODEL CKP SENSOR CKP Crank position sensor generates the reference ignition signal and sends it to ECM ECM calculates and determines the injection and ignition tim ings on the basis of this signal HO2 SENSOR HO2 Heated Oxygen sensor is made of zirconia element plat inum plated which changes output voltage depending on the oxygen concentration difference between its internal and exter nal surfaces The terminal voltage change is dependent on the oxygen con centration in the exhaust gas This detected voltage value there fore represents the oxygen concentration The terminal voltage decreases when the oxygen concentration is high and increases when it is low
45. e ignition switch OFF 2 Remove the seat 3 Check the HO2 sensor 1 for loose or poor contacts If OK then measure the HO2 sensor resistance 4 Disconnect the HO2 sensor coupler and measure the resis tance between terminals NOTE Temperature of the sensor affects resistance value largely Make sure that the sensor heater is at correct temperature HO2 heater resistance 6 5 8 9 at 23 C W W 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool Page 40 YES W G wire or B Br wire open or shorted to ground or poor C or 4 connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Replace the HO2 sensor with a new one When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend 2 ECM coupler Harness side 1 YES Go to Step 2 NO Replace the HO2 sensor with a new one 1 78 RV125K7 07 MODEL Step 2 When indicating 44 P0135 1 Connect the HO2 sensor coupler 2 Insert the needle pointed probes to the HO2 sensor coupler 3 Turn the ignition switch ON and measure the he
46. e or poor contacts If OK then measure the CKP sensor resistance 4 Disconnect the CKP sensor coupler and measure the resis tance CKP sensor resistance 172 288 G Bl DETECTED CONDITION POSSIBLE CAUSE The CKP sensor signal does not reach ECM for 4 sec or more after receiving the IAP sensor signal Metal particles or foreign material being stuck on the CKP sensor and rotor tip CKP sensor circuit open or short CKP sensor malfunction ECM malfunction Generator ECM CKP sensor To regulator rectifier CKP G Bl Bl E2 B Br 1 1 RV125K7 07 MODEL 45 5 If OK then check the continuity between each terminal and ground CKP sensor continuity Infinity G Ground Bl Ground 09900 25008 Multi circuit tester set Tester knob indication Resistance Are the resistance and continuity OK 6 After repairing the trouble clear the DTC using SDS tool Page 40 Step 2 1 Crank the engine a few seconds with the starter motor and measure the CKP sensor peak voltage at the coupler 2 Repeat the above test procedure a few times and measure the highest peak voltage CKP sensor peak voltage 2 0 V and more G Bl 1 Peak volt adaptor 09900 25008 Multi circuit tester set Tester knob indication Voltage YES Go to step 2 NO Replace the CKP sensor with a new one 1 2 V 46 RV125K7 07
47. ecified value ECM IAT sensor B Br R E2 VCC IAT Dg 1 62 RV125K7 07 MODEL 4 Measure the voltage between Dg wire terminal and ground 5 Also measure the voltage between Dg wire terminal and B Br wire terminal IAT sensor input voltage 4 5 5 5 V R Ground R B Br 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK Step 1 When indicating P0110 H 1 Turn the ignition switch OFF 2 Check the IAT sensor coupler for loose or poor contacts If OK then check the IAT sensor lead wire continuity 3 Disconnect the IAT sensor coupler and ECM coupler 4 Check the continuity between Dg wire A and terminal L 5 Also check the continuity between B Br wire B and terminal 4 IAT sensor lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 6 After repairing the trouble clear the DTC using SDS tool Page 40 YES Go to Step 2 NO Loose or poor contacts on the ECM coupler Terminal L or 4 Open or short circuit in the Dg wire or B Br wire 1 V 1 When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or termina
48. el indicator light 12 V 3 4 W CAPACITIES Fuel tank including reserve 6 5 L Engine oil oil change 850 ml filter change 950 ml overhaul 1 200 ml These specifications are subject to change without notice 6 RV125K7 07 MODEL 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 kilometers and time for your convenience NOTE More frequent servicing may be performed on motorcycles that are used under severe conditions PERIODIC MAINTENANCE CHART NOTE I Inspect and clean adjust replace or lubricate as necessary R Replace T Tighten Interval Item km 1 000 4 000 8 000 months 5 20 40 Air cleaner element I I Exhaust pipe bolts and muffler mounting bolts T T T Valve clearance I I I Spark plug I R Fuel line I I I Replace every 4 years Engine oil R R R Engine oil filter R R Throttle cable play I I I Clutch I I I Drive chain I I I Clean and lubricate every 1 000 km Brakes I I I Brake hose I I Replace every 4 years Brake fluid I I Replace every 2 years Wheels and tires
49. en or shorted to ground or poor L or 4 connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Replace the throttle body assembly with a new one 2 ECM coupler Harness side RV125K7 07 MODEL 65 23 P1651 H L TO SENSOR CIRCUIT MALFUNCTION INSPECTION Step 1 When indicating 23 1 Turn the ignition switch OFF 2 Remove the right frame cover RV125K3 5 3 3 Check the TO sensor coupler 1 for loose or poor contacts If OK then measure the TO sensor resistance 4 Disconnect the TO sensor coupler 5 Measure the resistance between terminal A and terminal C TO sensor resistance 16 5 22 3 k Terminal A Terminal C 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK DETECTED CONDITION POSSIBLE CAUSE 23 The sensor voltage should be the follow ing for 2 sec and more after ignition switch is turned ON 0 2 V Sensor voltage lt 4 6 V TO sensor circuit open or short TO sensor malfunction ECM malfunction P1651 H Sensor voltage is higher than specified value TO sensor circuit shorted to VCC or ground circuit open TO sensor circuit open or shorted to ground or VCC circuit open L Sensor voltage is lower than specified valu
50. f any defects are found replace the fuel hose with a new one Inspect initially at 1 000 km 5 months and every 4 000 km 20 months thereafter Replace every 4 years RV125K7 07 MODEL 9 SDS CHECK Using SDS sample the data at the time of new and periodic vehicle inspections After saving the sampled data in the computer file them by model and by user The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time For example when a vehicle is brought in for service but the troubleshooting of a failure is not easy compar ing the current data value to the past filed data value at time of normal condition can allow the specific engine failure to be determined Also in the case of a customer vehicle which is not periodically brought in for service with no past data value having been saved if the data value of a good vehicle condition have been already saved as a master STD comparison between the same models helps facilitate the troubleshooting Remove the right frame cover RV125K3 5 3 Set up the SDS tools Page 39 09904 41010 SDS set tool 99565 01010 009 CD ROM Ver 9 NOTE Before taking the sample of data check and clear the Past DTC Page 40 A number of different data under a fixed condition as shown below should be saved and filed as sample SAMPLE Data sampled from cold starting through w
51. he engine is running 3 Make sure that the engine temperature on data monitor is indicated 80 C or more 4 Click the Active control 5 Click the ISC rpm control 1 6 Check that the Spec 2 is idle speed 1 500 100 rpm 7 Check that the Desired idle speed 3 is within the specified idle rpm Check 2 1 Click the button 1 and decrease the Spec 2 to 1 000 rpm slowly 2 Check that the Desired idle speed 3 is nearly equal to the Spec 2 At the same time check that the air volume of the ISC duty decreases 3 Click the button 4 and increase the Spec 2 slowly 4 Check that the Desired idle speed 3 is nearly equal to the Spec 2 Also check that the air volume 5 of the ISC duty increases 74 RV125K7 07 MODEL Check 3 1 Click the button 1 and increase the Spec 2 to 1 300 rpm slowly 2 Check that the Desired idle speed 3 is nearly equal to the Spec 2 Also check that the air volume 4 of the ISC duty increases Check 4 1 Increase the Spec 1 to 1 900 rpm 2 Check that the Desired idle speed 2 is approx 1 900 rpm 3 Check that the Engine speed 3 is close to 1 900 rpm NOTE Be careful not to increase the Spec to more than 3 000 rpm or the Engine speed may reach the upper limit If the ISC valve does not function properly replace the ISC valve Page 88 or inspect the ISC valve Page 91 42 P01650
52. ial which could impede proper terminal contact 1 Check contact tension by insert ing and removing 2 Check each terminal for bend and proper alignment Using continuity inspect or voltage check procedure as described below inspect the wire harness terminals for open circuit and poor connection Locate abnormality if any A Looseness of crimping B Open C Thin wire a few strands left 1 1 2 RV125K7 07 MODEL 17 Continuity check Measure resistance across coupler B between A and C in the figure If no continuity is indicated infinity or over limit the circuit is open between terminals A and C 1 ECM Disconnect the coupler B and measure resistance between couplers A and B If no continuity is indicated the circuit is open between cou plers A and B If continuity is indicated there is an open cir cuit between couplers B and C or an abnormality in coupler B or coupler C 1 ECM Voltage check If voltage is supplied to the circuit being checked voltage check can be used as circuit check With all connectors couplers connected and voltage applied to the circuit being checked measure voltage between each terminal and body ground If measurements were taken as shown in the figure at the right and results are as listed below it means that the circuit is open between terminals A and B Voltage Between C and body ground Approx 5 V B and body ground Approx 5 V A and body groun
53. l bend 1 ECM coupler Harness side YES Go to Step 2 NO Dg wire or B Br wire open RV125K7 07 MODEL 63 Step 1 When indicating P0110 L 1 Turn the ignition switch OFF 2 Check the IAT sensor coupler for loose or poor contacts If OK then check the IAT sensor lead wire continuity 3 Disconnect the IAT sensor coupler 4 Check the continuity between Dg wire and ground If the sound is not heard from the tester the circuit condition is OK Tester knob indication Continuity test 5 Connect the IAT sensor coupler and turn the ignition switch ON 6 Measure the voltage between Dg wire A and ground IAT sensor output voltage Approx 2 5 V at 23 C Approx 1 8 V at 40 C Dg Ground 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Are the continuity and voltage OK 7 After repairing the trouble clear the DTC using SDS tool Page 40 1 1 YES Go to Step 2 NO Dg wire shorted to ground If wire is OK go to Step 2 1 V 64 RV125K7 07 MODEL Step 2 1 Turn the ignition switch OFF 2 Measure the IAT sensor resistance IAT sensor resistance Approx 2 56 k at 20 C Approx 1 20 k at 40 C Terminal Terminal 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the resistance OK 2 YES Dg or B Br wire op
54. l to the ECM Then this signal cuts OFF current sup plied to the fuel injector and ignition coil OVER REV LIMITER SIGNAL The fuel injector stops operation when engine rpm reaches rev limit rpm 22 RV125K7 07 MODEL FI SYSTEM PARTS LOCATION A ECM D Ignition coil IG coil B Tip over sensor TOS E Speedometer C Heated oxygen sensor HO2S RV125K7 07 MODEL 23 A ECM H Engine temperature sensor ETS F Fuel injector I Crankshaft position sensor CKPS G ISC valve J Intake air pressure sensor Throttle position sensor Intake air temperature sensor IAPS TPS IATS 24 RV125K7 07 MODEL FI SYSTEM WIRING DIAGRAM Crankshaft position sensor CKPS Throttle position sensor TPS Intake air pressure sensor IAPS Intake air temperature sensor IATS Tip over sensor TOS HO2 sensor HO2S Neutral switch Engine temperature sensor Fuel injector HO2 sensor heater Ignition coil ISC valve FI indicator light Side stand switch Engine stop switch Ignition switch Regulator rectifier Magneto 20 A Battery M Starter relay Clutch switch Starter button Side stand relay RV125K7 07 MODEL 25 FUEL INJECTOR The system employs fuel injector Discharge pump DCP that causes injection fuel to be pressurized within the pump The fuel injector pressurizes gravity fed fuel with its plunger and injects the pressurized fuel into the intake pipe With the pressure
55. ler 4 Check the continuity between P wire and ground 5 Also check the continuity between P wire and B Br wire If the sound is not heard from the tester the circuit condition is OK When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend YES Go to Step 2 NO P wire shorted to VCC or B Br wire open 1 ECM coupler Harness side 1 1 RV125K7 07 MODEL 55 6 Disconnect the ECM coupler 7 Check the continuity between P wire A and terminal M 8 Also check the continuity between R wire B and terminal 9 TP sensor lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 9 After repairing the trouble clear the DTC using SDS tool Page 40 When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend YES Go to Step 1 Page 52 and go to Step 2 NO R wire or P wire open or P wire shorted to ground 1 ECM coupler Harness side 56 RV125K7 07 MODEL Step 2 1 Connect the TP sensor coupler 2 Turn the ignition switch ON 3 Measure the TP sensor output voltage between P and B Br by turning the throttle gri
56. lling cable 4 and throttle returning cable 5 to the throttle cable drum Loosen each throttle cable lock nut Turn in each throttle cable adjuster fully and locate each outer cable so that the clearance is 0 mm Tighten each lock nut Adjust the throttle cable play Page 7 Rout the harness and fuel hoses properly Page 94 and 95 Never turn the injector while pushing it 22 5 22 5 Replace the O rings with new ones 0 mm 0 mm RV125K7 07 MODEL 93 WIRING DIAGRAM HANDLEBAR SWITCH R SPEEDOMETER DIODE FUEL GAUGE CHECK RELAY ENGINE STOP SWITCH STARTER BUTTON FRONT BRAKE SWITCH 1 FREE HI LO OFF ON L PUSH R PUSH PUSH ON OFF ON OFF FREE PUSH C ON LOCK P OFF RUN OFF BATTERY STARTER MOTOR GENERATOR NEUTRAL SWITCH STARTER RELAY 1 MAIN 20A TURN SIGNAL SIDE STAND RELAY Y B G B W O Y B Bl B Lg B B W B B W W B B W Y B O B B O O W B Y G R O O Y R B O Br O Bl G B W G B W O W B O W B B B B R B W Bl O Y G B P Dg O Bl Gr R W W R W Bl B G B W G Br W R Y B W B O B Br B W Y R B W R Br W B Br Br B W W B Lg B W B B W B B W Lg B W Gr B W W B B O W R B W Gr R O O Y BW Gr Br O W O
57. mp 4 Clutch cable 5 Harness 3 Set the thread part of throttle cables to lowest position 7 Cotter pin must face upper side 0 mm 0 mm 3 5 6 4 7 1 2 RV125K7 07 MODEL 95 HOSE ROUTING 1 Throttle body insulator 1 Assemble the hoses union and clamps in the proper direction as shown 2 Air cleaner outlet tube clamp 2 Yellow marking 3 Fuel hose 3 way union 3 White marking 4 Fuel filter 4 Red marking 5 Fuel injector 5 Fuel hose must be free from sag UPPER LH RH LH RH LH RH UPPER 45 45 22 5 30 35 2 3 1 1 1 1 1 4 5 5 4 4 96 RV125K7 07 MODEL FUEL TANK INSTALLATION 1 Frame 1 Align the recess of cushion with the positioning plate 2 Cushion 2 Cut the clamp so the end 10 mm remains 3 Fuel tank joint 4 4 N m 0 44 kgf m 2 1 RV125K7 07 MODEL 97 SPECIAL TOOLS NOTE When order the special tool please confirm whether it is available or not TIGHTENING TORQUE 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 09904 41010 SDS set tool 09930 82720 Mode select switch 99565 01010 009 CD ROM Ver 9 ITEM N m kgf m ET sensor 9 0 9 HO2 sensor 25 2 5 ISC valve screw 2 0 2 98 RV125K7 07 MODEL SERVICE DATA VALVE GUIDE Unit mm CAMSHAFT CYLINDER HEAD Unit mm ITEM STANDARD LIMIT Valve diam IN
58. n Fuel Injector Dis charge pump DCP FP Fuel Pump FPR Fuel Pressure Regulator FP Relay Fuel Pump Relay G GEN Generator GND Ground H HC Hydrocarbons HO2 Sensor Heated Oxygen Sensor HO2S I IAP Sensor Intake Air Pressure Sensor IAPS IAT Sensor Intake Air Temperature Sensor IATS IG Ignition ISC Valve Idle Speed control valve ISCV L LCD Liquid Crystal Display LED Light Emitting Diode Malfunction Indicator Lamp LH Left Hand M MAL Code Malfunction Code Diagnostic Code Max Maximum MIL Malfunction Indicator Lamp LED Min Minimum N NOx Nitrogen Oxides O OHC Over Head Camshaft P PCV Positive Crankcase Ventilation Crankcase Breather R RH Right Hand ROM Read Only Memory S SAE Society of Automotive Engineers SDS Suzuki Diagnosis System T TO Sensor Tip Over Sensor TOS TP Sensor Throttle Position Sensor TPS 4 RV125K7 07 MODEL SPECIFICATIONS RV125K7 DIMENSIONS AND DRY MASS Overall length 2 140 mm Overall width 860 mm Overall height 1 120 mm Wheelbase 1 385 mm Ground clearance 215 mm Seat height
59. ng When disconnecting the coupler be sure to hold the coupler body and do not pull the lead wires Inspect each terminal on the connector coupler for looseness or bending Inspect each terminal for corrosion and contamination The terminals must be clean and free of any foreign material which could impede proper terminal contact Inspect each lead wire circuit for poor connection by shaking it by hand lightly If any abnormal condition is found repair or replace When taking measurements at electrical connectors using a tester probe be sure to insert the probe from the wire harness side backside of the connector coupler 1 Coupler 2 Probe Click 14 RV125K7 07 MODEL When connecting meter probe from the terminal side of the coupler where connection from harness side not being possi ble use extra care not to force and cause the male terminal to bend or the female terminal to open Connect the probe as shown to avoid opening of female ter minal Never push in the probe where male terminal is supposed to fit Check the male connector for bend and female connector for excessive opening Also check the coupler for locking loose ness corrosion dust etc 1 Coupler 2 Probe 3 Where male terminal fits FUSE When a fuse blows always investigate the cause to correct it and then replace the fuse Do not use a fuse of a different capacity Do not use wire or any other substitute for
60. o check the continuity between B Br wire B and terminal 4 HO2 sensor lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 10 After repairing the trouble clear the DTC using SDS tool Page 40 Step 2 When indicating 44 P0130 1 Connect the ECM coupler and HO2 sensor coupler 2 Warm up the engine enough 3 Measure the HO2 sensor output voltage between W G wire and B Br wire when idling condition HO2 sensor output voltage at idle speed 0 3 1 0 V W G B Br 4 If OK measure the HO2 sensor output voltage while holding the engine speed at 5 000 r min HO2 sensor output voltage at 5 000 r min 0 6 V and more W G B Br 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend YES Go to Step 2 When indicating 44 P0130 NO W G wire shorted to ground or W G or B Br wire open 1 ECM coupler Harness side 2 V RV125K7 07 MODEL 77 Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool Page 40 Step 1 When indicating 44 P0135 1 Turn th
61. or voltage 4 5 5 5 V O Ground O B Br 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK DETECTED CONDITION POSSIBLE CAUSE 15 Output voltage is not within the following range 0 1 V Sensor voltage lt 4 7 V ET sensor circuit open or short ET sensor malfunction ECM malfunction P0115 H Sensor voltage is higher than specified value ET sensor circuit open or ground circuit open ET sensor circuit shorted to ground L Sensor voltage is lower than specified value ECM E2 ET B B O ET sensor B Br 1 YES Go to Step 2 NO Loose or poor contacts on the ECM coupler terminal K or 4 Open or short circuit in the O wire or B Br wire 1 V 58 RV125K7 07 MODEL Step 1 When indicating P0115 H 1 Turn the ignition switch OFF 2 Check the ET sensor coupler 1 for loose or poor contacts If OK then check the ET sensor lead wire continuity 3 Disconnect the ET sensor coupler and ECM coupler 4 Check the continuity between O wire A and terminal K 5 Also check the continuity between B Br wire B and terminal 4 ET sensor lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 6 After repairing the trouble clear the DTC using SDS tool
62. ose or poor contacts If OK then check the TO sensor lead wire continuity 4 Disconnect the TO sensor coupler 5 Check the continuity between Br W wire B and ground 6 Also check the continuity between Br W wire B and B Br wire C If the sound is not heard from the tester the circuit condition is OK 7 Disconnect the ECM coupler 8 Check the continuity between R wire A and terminal 9 9 Also then check the continuity between Br W wire B and ter minal A TO sensor lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 10 After repairing the trouble clear the DTC using SDS tool Page 40 1 1 When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend YES Go to Step 2 NO R or Br W wire open or Br W wire shorted to ground ECM coupler Harness side 1 68 RV125K7 07 MODEL Step 2 1 Connect the TO sensor coupler and ECM coupler 2 Insert the needle pointed probes to the lead wire coupler 3 Turn the ignition switch ON 4 Measure the voltage between Br W and B Br wires TO sensor voltage Normal 0 4 1 4 V Br W B Br Also measure the voltage as the motorcycle is leaned 5 Dismount the TO sensor from its b
63. p TP sensor output voltage Throttle valve is closed Approx 0 7 V Throttle valve is opened Approx 3 9 V 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 4 After repairing the trouble clear the DTC using SDS tool Page 40 3 V YES P R or B Br wire open or shorted to ground or poor M 9 or 4 connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO If check result is not satisfactory replace the throt tle body assembly with a new one When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend 3 ECM coupler Harness side RV125K7 07 MODEL 57 15 P0115 H L ET SENSOR CIRCUIT MALFUNCTION INSPECTION Step 1 When indicating 15 1 Turn the ignition switch OFF 2 Check the ET sensor coupler 1 for loose or poor contacts If OK then measure the ET sensor voltage at the coupler 3 Disconnect the coupler and turn the ignition switch ON 4 Measure the voltage between O wire terminal A and ground 5 If OK then measure the voltage between O wire terminal A and B Br wire terminal B ET sens
64. plunger controlled by ECM necessary volume of fuel is injected at the best timing for the engine operating condition Operation When the plunger returns fuel in the pump chamber enters through IN check valve By the ECM signal the coil is energized causing the plunger to pressurize fuel This pressurization occurs after vapor inside the pump chamber has been bled through the pressure valve When the pressurization begins OUT check valve opens and the fuel pressure rises until the injection nozzle opens The volume of fuel injection is controlled by the length of time in which the plunger compresses fuel When the ignition switch is turned ON the discharge pump starts to operate for 2 seconds for purging ini tial operation Vapor Coil Pressure valve IN check valve OUT check valve Fuel Filter Orifice Injection Plunger 26 RV125K7 07 MODEL FUEL CIRCULATION From the fuel tank fuel enters into the fuel injector through the fuel filter Vapor generated here returns to the fuel tank ECM ECM Engine Control Module consists of CPU Central Pro cessing Unit memory ROM RAM and IN OUT section Sig nals from various sensors are sent to the input section and then to CPU On the basis of information received CPU performs cal culation of necessary amount of fuel injection by means of a map that is programmed for various engine conditions and sends operation signal from the output section to
65. prox 3 9 V IAT sensor input voltage 4 5 5 5 V IAT sensor output voltage Approx 2 5 V at 23 C 1 8 V at 40 C IAT sensor resistance Approx 2 56 k at 20 C 1 20 k at 40 C ET sensor input voltage 4 5 5 5 V ET sensor resistance Approx 5 13 k at 20 40 C TO sensor resistance 16 5 22 3 k TO sensor voltage Normal 0 4 1 4 V Br W B Br Leaning 65 3 7 4 4 V HO2 sensor output voltage 0 3 1 0 V at idle speed W G B Br 0 6 V and more at 5 000 r min HO2 sensor resistance 6 5 8 9 at 23 C W W ITEM SPECIFICATION I D No 13G0 Bore size 26 mm Fast idle r min 1 800 r min at 20 0 C 1 650 r min at 0 20 C 1 600 r min at 20 60 C Idle r min 1 500 100 r min Warmed engine Throttle cable play 2 0 4 0 mm 102 RV125K7 07 MODEL ELECTRICAL WATTAGE Unit W ITEM SPECIFICATION NOTE Spark plug Type DENSO U24ESR N NGK CR8E Gap 0 7 0 8 mm Spark performance Over 8 mm at 1 atm Ignition coil resistance Primary 1 6 2 7 tap tap Secondary 18 26 k Plug cap tap Generator coil resistance 0 4 0 8 Y Y Ground Y Ignition coil primary peak voltage More than 200 V B Ground Generator no load voltage when engine is cold More than 60 V AC at 5 000 r min Regulated voltage 14 0 15 5 V at 5 000 r min Starter relay resistance
66. r K or 4 connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Replace the ET sensor with a new one When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend Engine temperature Resistance 20 C Approx 13 0 k 40 C Approx 6 2 k 80 C Approx 1 7 k 100 C Approx 1 0 k 2 2 ECM coupler Harness side RV125K7 07 MODEL 61 21 P0110 H L IAT SENSOR CIRCUIT MALFUNCTION NOTE IAT sensor is incorporated in the IAP sensor TP sensor INSPECTION Step 1 When indicating 21 1 Turn the ignition switch OFF 2 Check the IAT sensor coupler 1 for loose or poor contacts If OK then measure the IAT sensor voltage at the wire side coupler 3 Disconnect the IAT sensor coupler and turn the ignition switch ON DETECTED CONDITION POSSIBLE CAUSE 21 P0110 Output voltage is not within the following range 0 1 Sensor voltage 4 6 V IAT sensor circuit open or short IAT sensor malfunction ECM malfunction P0110 H Sensor voltage is higher than specified value IAT sensor circuit open or ground circuit open IAT sensor circuit shorted to ground L Sensor voltage is lower than sp
67. r with a new one Page 88 YES R W or W Bl wire open or shorted to ground poor H or F connection If wire and connection is OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Open circuit in the R W wire or ECM malfunction When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend 1 V 2 2 ECM coupler Harness side RV125K7 07 MODEL 71 40 P0505 ISC VALVE CIRCUIT MALFUNCTION INSPECTION Step 1 1 Turn the ignition switch OFF 2 Check the ISC valve coupler 1 for loose or poor contacts If OK then check the ISC valve resistance 3 Disconnect the ISC valve coupler 4 Measure the ISC valve resistance ISC valve resistance Approx 35 Terminal Terminal DETECTED CONDITION POSSIBLE CAUSE 40 P0505 When the ISC operation voltage remains at 1 0 V or lower continuously for 2 sec or longer Idle speed is higher than the normal condition ISC valve circuit open or shorted to ground ISC valve malfunction ECM malfunction Ignition SW ECM B O To regulator rectifier ISC valve Battery 20 A ISC Y R 1 1 72 RV125K7 07 MODEL 5 If OK then check the continuity between each termin
68. racket and measure the voltage when it is leaned 65 left and right TO sensor voltage Leaning 3 7 4 4 V Br W B Br 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 6 After repairing the trouble clear the DTC using SDS tool Page 40 24 P0351 IGNITION SYSTEM MALFUNCTION Refer to the IGNITION SYSTEM for details RV125K3 6 18 2 V V 2 65 YES R Br W or B Br wire open or shorted to ground or poor 9 A or 4 connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO Loose or poor contacts on the ECM coupler Open or short circuit Replace the TO sensor with a new one When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend 3 ECM coupler Harness side RV125K7 07 MODEL 69 32 P0201 FUEL INJECTOR CIRCUIT MALFUNCTION NOTE When the ignition switch is turned to ON position the fuel injec tor starts to operate approx 2 sec as purge operation initial operation INSPECTION Step 1 1 Turn the ignition switch OFF 2 Check the fuel injector
69. re 1 or Failure 2 can be selected 42 RV125K7 07 MODEL DTC TABLE AND DEFECTIVE CONDITION DTC No DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR 00 NO FAULT 12 CKP sensor The CKP sensor signal does not reach ECM for 4 sec or more after receiving the IAP sensor signal CKP sensor wiring and mechan ical parts CKP sensor lead wire coupler connection P0335 13 IAP sensor The sensor should produce following voltage 0 2 V sensor voltage lt 4 5 V In other than the above range 13 P0105 is indicated IAP sensor lead wire coupler connection P0105 H Sensor voltage is higher than specified value IAP sensor circuit open or shorted to VCC or ground circuit open L Sensor voltage is lower than specified value IAP sensor circuit shorted to ground or VCC circuit open 14 TP sensor The sensor should produce following voltage 0 3 V sensor voltage lt 4 7 V In other than the above range 14 P0120 is indicated TP sensor lead wire coupler connection P0120 H Sensor voltage is higher than specified value TP sensor circuit shorted to VCC or ground circuit open L Sensor voltage is lower than specified value TP sensor circuit open or shorted to ground or VCC circuit open 15 ET sensor The sensor voltage should be the fol lowing 0 1 V sensor voltage lt 4 7 V In other than the above range
70. therwise accurate measurements may not be obtained and personal injury may result INCORRECT 16 RV125K7 07 MODEL ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter Open circuit check Possible causes for the open circuits are as follows As the cause can exist in the connector coupler or terminal they need to be checked carefully Loose connection of connector coupler Poor contact of terminal due to dirt corrosion or rust poor contact tension entry of foreign object etc Wire harness being open Poor terminal to wire connection Disconnect the negative cable from the battery Check each connector coupler at both ends of the circuit being checked for loose connection Also check for condition of the coupler lock if equipped 1 Sensor 2 ECM 1 Check for loose connection Using a test male terminal check the female terminals of the circuit being checked for contact tension Check each terminal visually for poor contact possibly caused by dirt corrosion rust entry of foreign object etc At the same time check to make sure that each terminal is fully inserted in the coupler and locked If contact tension is not enough rectify the contact to increase tension or replace The terminals must be clean and free of any foreign mater
71. tinuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 9 After repairing the trouble clear the DTC using SDS tool Page 40 When using the multi circuit tester do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend YES Go to Step 1 Page 47 and go to Step 2 NO R or G B wire open or G B wire shorted to ground 1 ECM coupler Harness side RV125K7 07 MODEL 51 Step 2 1 Connect the IAP sensor coupler and ECM coupler 2 Insert the needle pointed probes to the lead wire coupler 3 Start the engine at idle speed and measure the IAP sensor output voltage between G B and B Br wires IAP sensor output voltage 2 0 3 5 V at idle speed G B B Br 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK 4 After repairing the trouble clear the DTC using SDS tool Page 40 YES G B R or B Br wire open or shorted to ground or poor N 9 or 4 connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection Replace the ECM with a known good one and inspect it again NO
72. to read the code of the malfunction items USER MODE 1 When one of the signals is not received by ECM the fail safe circuit works and injection is not stopped In this case FI indica tor light is lighted and the motorcycle can run 2 The injection signal is stopped when the crankshaft position sensor signal tip over sensor signal ignition signal injector sig nal or ignition switch signal is not sent to ECM In this case FI indicator light is ON and blinks and the motorcycle can not run When the ignition switch is turned ON FI indicator light is lit for 2 seconds and thereafter remains unlit When the ignition switch is turned ON and the engine stop switch is turned OFF in this case the speedometer does not receive any signal from ECM and the speedometer does not light FI indicator light If FI indicator light is not lighted when turning the ignition switch to ON the FI indicator light does not indicate the trouble code It is necessary to check the wiring harness between ECM and speedometer couplers The possible cause of this indication is as follows Engine stop switch is in OFF position Fuse is burnt FI indicator bulb is burnt MALFUNCTION FI INDICATOR LIGHT INDICATION NO YES Engine can start FI indicator light turns ON 1 Engine can not start FI indicator light turns ON and blinks 2 FI RV125K7 07 MODEL 31 DEALER MODE The defective function is memorized in the ECM Use the spe
73. uel tank bolts Disconnect the fuel hose 3 Remove the fuel tank Drain out fuel before removing the fuel tank Do not drain fuel while engine is hot Gasoline is highly flammable and explosive Keep heat spark and flame away 84 RV125K7 07 MODEL Remove the inlet tube filter 4 Remove the fuel level switch 5 INSPECTION Inlet tube filter Inspect the inlet tube filter for clogging or any damage If necessary clean the inlet tube filter using compressed air Fuel level switch Connect a 12 V battery and bulb 12 V 3 4 W to the fuel level switch as shown It is possible that the bulb comes on in 20 30 sec after the connection Immerse the fuel level switch into kerosen 1 and make sure that the bulb goes off If not replace the fuel level switch with a new one B W B W Y B Y B Y B B W RV125K7 07 MODEL 85 INSTALLATION Installation is in the reverse order of removal Pay attention to the following point FUEL LEVEL INDICATOR CHECK RELAY REMOVAL AND INSTALLATION Fuel level indicator check relay is located behind the ECM Remove the right frame cover RV125K3 5 3 Remove the fuel level indicator check relay 1 Install the fuel level indicator check relay in the reverse order of removal INSPECTION First check the insulation between A and B terminals with tester Then apply 12 V to C and D terminals to C and to D and check the
74. ure value is fixed to 25 C YES YES ET sensor Engine temperature value is fixed to 80 C YES YES HO2 sensor Feedback compensation is inhibited Air fuel ratio is fixed to normal YES YES ISC valve ISC operation is stopped YES YES RV125K7 07 MODEL 33 FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem failure complaint and how it occurred as described by the customer For this purpose use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis EXAMPLE CUSTOMER PROBLEM INSPECTION FORM User name Model VIN Date of issue Date Reg Date of problem Mileage FI indicator light condition Always ON Sometimes ON Always OFF Good condition PROBLEM SYMPTOMS Difficult Starting Poor Driveability No cranking Hesitation on acceleration No initial combustion Back fire After fire No combustion Lack of power Poor starting at cold warm always Surging Abnormal knocking Other Engine rpm jumps briefly Other Poor Idling Engine Stall when Poor fast Idle Immediately after start Abnormal idling speed High Low r min Throttle valve is opened Throttle valve is closed Unstable Load is applied Hunting r min to r min Other Other OTHERS 34 RV125K7 07 MODEL NOTE The above form is a standard sample The form should be
75. wiring coupler con nection power supply from the battery P0351 32 Fuel injector CKP sensor pickup coil signal is pro duced but fuel injector signal is inter rupted 10 times or more continuously In this case the code 32 P0201 is indicated Primary fuel injector wiring cou pler connection power supply to the injector P0201 40 ISC valve When the ISC operation voltage remains at 1 0 V or lower continuously for 2 sec or longer Idle speed is higher than the normal condition ISC valve circuit open or shorted to ground Power source circuit open ISC valve is fixed to full open Disconnected ISC valve hose P0505 42 Ignition switch Ignition switch signal is not input to the ECM Ignition switch lead wire coupler etc P1650 44 HO2 sensor HO2 sensor output voltage is not input to ECM during engine operation and running condition Sensor voltage lt 0 60 V In other than the above value 44 P0130 is indicated HO2 sensor circuit open or shorted to ground P0130 44 The Heater can not operate so that heater operation voltage is not supply to the oxygen heater circuit 44 P0135 is indicated HO2 sensor lead wire coupler connection Battery voltage supply to the HO2 sensor P0135 44 RV125K7 07 MODEL 12 P0335 CKP SENSOR CIRCUIT MALFUNCTION INSPECTION Step 1 1 Turn the ignition switch OFF 2 Remove the seat RV125K3 5 3 3 Check the CKP sensor coupler 1 for loos
76. y cause the inside of the tester to burnout If the voltage and current are not known make measure ments using the highest range When measuring the resistance with the multi circuit tester 1 will be shown as 10 00 M and 1 flashes in the display Check that no voltage is applied before making the measure ment If voltage is applied the tester may be damaged After using the tester turn the power off 09900 25008 Multi circuit tester set NOTE When connecting the multi circuit tester use the needle pointed probe to the back side of the lead wire coupler and connect the probes of tester to them Use the needle pointed probe to prevent the rubber of the water proof coupler from damage 09900 25009 Needle pointed probe set 20 RV125K7 07 MODEL FI SYSTEM TECHNICAL FEATURES INJECTION TIME INJECTION VOLUME The factors to determine the injection time include the basic fuel injection time which is calculated on the basis of intake air pressure engine speed and throttle opening angle and various compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions Intake Air Pressure Sensor IAP Sensor Intake air pressure signal Engine speed signal Throttle opening angle signal Crankshaft Position Sensor CKP Sensor Throttle Position Sensor TP Sensor Various Sensors Various signals Injection

2 - Pour RV 125

Contents

Download Pdf Manuals

Related Search

Related Contents