Suzuki UH125 2008 Manuals

Manuals and User Guides for Suzuki UH125 2008. We have 1 Suzuki UH125 2008 manual available for free PDF download: Service Manual

Suzuki UH125 2008 Service Manual

Suzuki UH125 2008 Service Manual (357 pages)

Brand: Suzuki | Category: Scooter | Size: 34.94 MB

Table of Contents

Foreword Group Index

2
- Table of Contents
  2
- Glossary
  5
General Information 1

7
- Country and Area Code
  7
- General Precautions
  8
- Warning/Caution/Note
  8
- Product View
  10
- Serial Number Location
  10
- Suzuki Uh125K7 ('07-Model)
  10
- Fuel, Oil and Engine Coolant Recommendation
  11
  - Fuel
    11
  - Engine Oil and Final Gear Oil
    11
  - Brake Fluid
    11
  - Front Fork Oil
    11
  - Engine Coolant
    12
- Break-In Procedures
  13
- Specifications
  14
  - Dimensions and Dry Mass
    14
  - Engine
    14
  - Drive Train
    14
  - Chassis
    14
  - Electrical
    15
  - Capacities
    15
Periodic Maintenance

16
- Periodic Maintenance Schedule
  17
  - Periodic Maintenance Chart
    17
  - Lubrication Points
    18
- Maintenance and Tune-Up Procedures
  19
  - Air Cleaner
    19
  - Cooling Fan Filter
    20
  - Exhaust Pipe Nuts and Muffler Bolts
    21
  - Valve Clearance
    21
  - Spark Plug
    22
  - Fuel Line
    23
  - Engine Oil and Oil Filter
    24
  - Final Gear Box Oil
    25
  - Throttle Cable Play
    26
  - Cooling System
    27
  - Drive V-Belt
    29
  - Brake System
    30
  - Tire
    34
  - Tire Tread Depth
    34
  - Steering
    35
  - Front Fork
    35
  - Rear Suspension
    35
  - Chassis Bolt and Nut
    36
- Compression Pressure Check
  38
  - Compression Test Procedure
    38
- Oil Pressure Check
  39
  - Oil Pressure Test Procedure
    39
- Automatic Clutch Inspection
  40
  - Initial Engagement Inspection
    40
  - Clutch "Lock-Up" Inspection
    40
- Sds Check
  41
Engine

45
- Engine Components Removable with the Engine in Place
  46
- Engine Removal and Remounting
  47
  - Removal
    47
  - Remounting
    51
- Engine Disassembly
  54
- Engine Component Inspection and Service
  64
  - Rocker Arm and Shaft
    64
  - Cylinder Head
    65
  - Cylinder Head Distortion
    66
  - Camshaft
    72
  - Cam Chain Tension Adjuster
    74
  - Cam Chain Tensioner
    74
  - Cam Chain Guide
    74
  - Cylinder
    75
  - Piston
    75
  - Conrod and Crankshaft
    77
  - Oil Pump
    79
  - Oil Sump Filter
    79
  - Movable Drive Face Assembly
    80
  - Clutch Shoe/Movable Driven Face
    82
  - Starter Clutch
    88
  - Generator Cover
    90
  - Final Gear Box Cover
    92
  - Final Gear
    94
  - Crankcase
    94
- Engine Reassembly
  100
Fi System Diagnosis

116
- Precautions in Servicing
  118
  - Electrical Parts
    118
  - Fuse
    119
  - Switch
    119
  - Ecm/Various Sensors
    119
  - Electrical Circuit Inspection Procedure
    121
  - Using the Multi-Circuit Tester
    124
- Fi System Technical Features
  125
  - Injection Time (Injection Volume)
    125
  - Compensation of Injection Time (Volume)
    126
  - Injection Stop Control
    126
  - Fi System Parts Location
    127
  - Fi System Wiring Diagram
    129
- Ecm Terminal
  130
- Self-Diagnosis Function
  131
  - User Mode
    131
  - Dealer Mode
    132
- Fail-Safe Function
  133
- Fi System Troubleshooting
  134
- Sensors
  178
  - Ckp Sensor Inspection
    178
  - Ckp Sensor Removal and Installation
    178
  - Iap Sensor Inspection
    178
  - Iap Sensor Removal and Installation
    178
  - Tp Sensor Inspection
    178
  - Tp Sensor Removal and Installation
    178
  - Ect Sensor Inspection
    178
  - Ect Sensor Removal and Installation
    178
  - To Sensor Inspection
    179
  - To Sensor Removal and Installation
    179
  - Ho2 Sensor Inspection
    179
  - Ho2 Sensor Removal and Installation
    179
Fuel System and Throttle Body

180
- Fuel System and Throttle
  180
- Fuel System
  181
  - Construction
    181
  - Removal and Disassembly
    182
  - Fuel Tank Reassembly and Installation
    184
  - Fuel Pressure Inspection
    185
  - Fuel Pump Inspection
    186
  - Fuel Discharge Amount Inspection
    186
  - Fuel Mesh Filter Inspection and Cleaning
    187
- Throttle Body
  188
  - Construction
    188
  - Removal and Disassembly
    189
  - Inspection
    191
  - Reassembly and Installation
    192
- Exhaust System
  193
Cooling and Lubrication System

196
- Cooling and Lubrication
  196
  - Engine Coolant
    197
  - Radiator and Radiator Hose
    198
    
    Inspection
    198
    
    Removal
    199
    
    Disassembly
    200
    
    Reassembly and Installation
    200
  - Cooling Fan
    202
    
    Inspection
    202
    
    Removal
    202
    
    Installation
    202
  - Cooling Fan Thermo-Switch
    203
    
    Removal
    203
    
    Inspection
    203
    
    Installation
    203
  - Engine Coolant Temperature Gauge
    204
    
    Removal
    204
    
    Inspection
    204
    
    Installation
    204
  - Ect Sensor
    205
    
    Removal
    205
    
    Inspection
    205
    
    Installation
    206
  - Thermostat
    206
    
    Removal
    206
    
    Inspection
    206
    
    Installation
    207
  - Water Pump
    208
    
    Removal and Disassembly
    208
    
    Inspection
    210
    
    Reassembly and Installation
    210
  - Lubrication System
    213
    
    Oil Pressure
    213
    
    Oil Filter
    213
    
    Oil Sump Filter
    213
    
    Oil Pump
    213
    
    Engine Lubrication System Chart
    214
Chassis

215
- Exterior Parts
  217
  - Fastener
    217
  - Handlebar Covers
    218
  - Front Cover
    218
  - Windscreen
    218
  - Lower Meter Panel
    219
  - Front Leg Shield
    220
  - Lower Leg Shield
    221
  - Side Leg Shield (Lh)
    221
  - Side Leg Shield (Rh)
    222
  - Rear Lower Leg Shield
    222
  - Front Frame Cover
    222
  - Seat
    223
  - Pillion Rider Handles
    223
  - Lower Frame Cover
    223
  - Frame Cover
    223
  - Trunk Box
    225
  - Footboard
    226
  - Front Box
    227
- Front Wheel
  228
  - Construction
    228
  - Removal
    229
  - Inspection and Disassembly
    229
  - Reassembly and Installation
    231
- Handlebars
  233
  - Construction
    233
  - Removal
    234
  - Installation
    234
- Front Fork
  236
  - Construction
    236
  - Removal and Disassembly
    237
  - Inspection
    239
  - Reassembly
    240
- Steering
  243
  - Construction
    243
  - Removal and Disassembly
    244
  - Inspection and Disassembly
    245
  - Reassembly
    246
- Rear Wheel
  249
  - Construction
    249
  - Removal
    250
  - Inspection
    250
  - Installation
    250
- Front Brake
  251
  - Construction
    251
  - Brake Fluid Replacement
    252
  - Brake Pad Replacement
    252
  - Front Brake Caliper Removal and Disassembly
    252
  - Front Brake Caliper Inspection
    254
  - Front Brake Caliper Reassembly
    254
  - Brake Disc Inspection
    256
  - Front Brake Master Cylinder Removal and Disassembly
    256
  - Front Brake Master Cylinder Inspection
    257
  - Front Brake Master Cylinder Reassembly and Installation
    258
- Rear Brake
  260
- Rear Suspension
  265
  - Construction
    265
  - Rear Swingarm Bearing Inspection
    266
  - Rear Swingarm Bearing Removal
    266
  - Rear Swingarm Bearing Installation
    266
  - Rear Shock Absorber Removal
    267
  - Rear Shock Absorber Inspection
    267
  - Rear Shock Absorber Installation
    267
- Tire and Wheel
  268
  - Tire Removal
    268
  - Inspection
    268
  - Valve Inspection
    269
  - Tire Installation
    270
Electrical System

272
- Cautions in Servicing
  274
  - Connector
    274
  - Coupler
    274
  - Clamp
    274
  - Fuse
    274
  - Switch
    274
  - Semi-Conductor Equipped Part
    275
  - Battery
    275
  - Connecting the Battery
    275
  - Wiring Procedure
    275
  - Using the Multi-Circuit Tester
    276
- Location of Electrical Components
  277
- Charging System
  279
  - Troubleshooting
    279
  - Inspection
    281
- Starter System
  284
  - Trouble Shooting
    284
  - Starter Motor Removal
    285
  - Starter Motor Disassembly
    286
  - Starter Motor Inspection
    287
  - Starter Motor Reassembly
    288
  - Starter Motor Installation
    289
  - Starter Relay Inspection
    290
  - Side-Stand/Ignition Interlock System Parts Inspection
    291
- Ignition System
  293
  - Troubleshooting
    293
  - Inspection
    295
- Combination Meter
  298
  - Removal and Disassembly
    298
  - Inspection
    299
- Lamps
  301
- Switches
  306
  - Ignition Switch Removal and Installation
    306
  - Inspection
    307
- Battery
  308
  - Specifications
    308
  - Initial Charging
    308
  - Servicing
    310
  - Recharging Operation
    310
Servicing Information

311
- Troubleshooting
  312
  - Fi System Malfunction Code and Defective Condition
    312
  - Engine
    314
  - Radiator (Cooling System)
    319
  - Chassis
    320
  - Brakes
    321
  - Electrical
    322
  - Battery
    323
- Wiring Diagram
  324
- Wiring Harness, Cable and Hose Routing
  325
  - Wiring Harness Routing
    325
  - Cable Routing
    327
  - Cooling System Hose Routing
    328
  - Brake Hose Routing
    329
  - Engine Electrical Parts Harness Routing
    330
  - Ho2 Sensor Harness Routing
    331
  - Speedometer Cable Routing
    332
  - Throttle Body Hose Routing
    333
  - Drain Hose Routing
    334
  - Seat Molding Installation
    335
  - Exterior Parts Set-Up
    336
  - Drive Belt Cooling Filter and Clutch Cover Gasket Installation
    339
  - Front Box Cushion Installation
    340
  - Side-Stand Installation
    341
  - Center Stand Installation
    341
  - Special Tools
    342
- Tightening Torque
  346
  - Engine
    346
  - Fi System and Intake Air System
    347
  - Cooling System
    347
  - Brake Disc
    347
  - Tightening Torque Chart
    348
- Service Data
  349

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