Suzuki VL125 Manuals

Manuals and User Guides for Suzuki VL125. We have 1 Suzuki VL125 manual available for free PDF download: Service Manual

Suzuki VL125 Service Manual

Suzuki VL125 Service Manual (242 pages)

Brand: Suzuki | Category: Motorcycle | Size: 16.89 MB

Table of Contents

General Information 1

5
- Electrical System
  2
- Fuel and Lubrication System
  2
- Servicing Information
  2
  - How to Use this Manual
    3
  - Table of Contents
    5
- General Information
  2
  - Periodic Maintenance
    2
- Warning/Caution/Note
  6
- General Precautions
  6
- Suzuki Vl125Y (2000-Model)
  8
- Serial Number Location
  8
- Fuel and Oil Recommendation
  9
  - Fuel
    9
  - Engine Oil
    9
  - Brake Fluid
    9
  - Front Fork Oil
    9
- Break-In Procedures
  9
- Cylinder Identification
  10
- Information Labels
  10
- Specifications
  11
  - Dimensions and Dry Mass
    11
- Country and Area Codes
  13
Periodic Maintenance

14
- Periodic Maintenance Schedule
  
  15
  - Periodic Maintenance Chart
    15
  - Lubrication Points
    16
- Maintenance and Tune-Up Procedures
  
  17
  - Valve Clearance
    17
  - Spark Plug
    19
  - Exhaust Pipe Bolt and Muffler Bolt
    20
  - Air Cleaner
    20
  - Carburetor
    22
    
    Idling Adjustment
    22
    
    Throttle Cable Play
    22
  - Fuel Hose
    23
  - Clutch
    23
  - Engine Oil and Oil Filter
    24
  - Drive Chain
    26
    
    Adjusting
    27
    
    Cleaning and Lubricating
    27
  - Brake System
    28
  - Steering
    32
  - Front Fork
    32
  - Rear Suspension
    32
  - Tire
    33
  - Chassis Bolts and Nuts
    33
- Compression Pressure Check
  
  34
- Oil Pressure Check
  
  35
Engine

36
- Engine Components Removable with Engine in Place
  37
- Engine Removal and Reinstallation
  38
  - Engine Removal
    38
  - Engine Reinstallation
    43
- Engine Disassembly
  46
- Engine Component Inspection and Service
  55
  - Cylinder Head Cover
    55
  - Camshaft
    57
  - Cam Chain Tension Adjuster
    58
  - Cam Chain Tensioner
    58
  - Cylinder Head
    59
  - Cylinder
    68
  - Piston
    69
    
    Piston Ring End Gap
    70
    
    Piston Ring Groove Width
    70
    
    Piston Ring Thickness
    70
  - Conrod and Crankshaft
    72
  - Generator Cover
    73
  - Starter Clutch
    74
  - Starter Driven Gear
    75
  - Clutch Cover
    76
  - Clutch
    77
  - Primary Driven Gear
    78
  - Oil Pump
    78
  - Transmission
    79
  - Crankcase
    81
- Engine Reassembly
  84
  - Primary Drive Gear
    92
  - Starter Idle Gear
    96
  - Piston Ring
    97
  - Cam Chain Guide
    98
  - Speed Sensor
    104
  - Starter Motor
    105
Fuel and Lubrication System

107
- Fuel System
  108
  - Fuel Pump
    108
- Fuel Tank/Fuel Cock
  109
  - Removal
    109
  - Inspection
    110
  - Reassembly
    111
- Fuel Pump
  111
- Carburetor
  112
  - Specifications
    112
  - Air Controle Valve
    113
  - Slow System
    114
  - Main System
    115
  - Accelerator Pump System
    116
  - Removal
    117
  - Disassembly
    117
  - Inspection
    120
  - Carburetor Cleaning
    120
  - Inspection
    121
  - Fuel Level Adjustment
    122
  - Float Height Adjustment
    123
  - Reassembly and Reinstallation
    124
- Lubrication System
  127
Chassis

128
- Exterior Parts Removal and Remounting
  129
  - Front Fender
    129
  - Front Seat
    129
  - Rear Seat
    129
  - Luggage Box
    129
  - Frame Cover
    130
  - Rear Fender
    132
- Front Wheel
  134
  - Removal
    134
  - Inspection and Disassembly
    135
  - Reassembly
    137
  - Remounting
    139
- Front Brake
  140
  - Brake Fluid Replacement
    140
  - Brake Pad Replacement
    140
  - Caliper Removal and Disassembly
    140
  - Caliper Inspection
    141
  - Caliper Reassembly
    141
  - Caliper Remounting
    142
  - Brake Disc Inspection
    143
  - Master Cylinder Removal and Disassembly
    144
  - Master Cylinder Inspection
    145
  - Master Cylinder Reassembly and Remounting
    145
- Handlebars
  147
  - Removal
    147
  - Remounting
    148
- Front Fork
  149
  - Removal and Disassembly
    149
  - Inspection
    152
  - Reassembly and Remounting
    153
  - Front Fork Oil
    155
- Steering
  157
  - Removal and Disassembly
    157
  - Inspection
    158
  - Reassembly and Remounting
    159
- Rear Wheel
  162
  - Removal
    163
  - Inspection and Disassembly
    164
  - Reassembly and Remounting
    166
- Rear Brake
  169
  - Removal and Disassembly
    169
  - Inspection
    170
  - Reassembly and Remounting
    170
- Rear Shock Absorber
  172
  - Removal
    173
  - Inspection and Disassembly
    174
  - Reassembly and Remounting
    175
Electrical System

177
- Cautions in Servicing
  178
- Location of Electrical Components
  180
- Charging System
  182
  - Description
    182
  - Troubleshooting
    183
  - Inspection
    184
- Starter System and Side-Stand/Ignition Interlock System
  186
  - Starter System Description
    186
  - Side-Stand/Ignition Interlock System Description
    186
  - Troubleshooting
    187
  - Starter Motor Removal and Disassembly
    188
  - Starter Motor Inspection
    188
  - Starter Motor Reassembly
    189
  - Starter Relay Inspection
    190
  - Side-Stand/Ignition Interlock System Part Inspection
    191
- Ignition System
  193
  - Description
    193
  - Troubleshooting
    194
  - Inspection
    195
- Speedometer
  199
  - Removal and Disassembly
    199
  - Speed Sensor Inspection
    200
- Lamps
  201
  - Headlight and Position Light
    201
  - Brake Light/Taillight
    202
  - Turn Signal Light
    202
- Switches
  203
  - Ignition Switch Removal
    203
- Battery
  205
  - Specifications
    205
  - Initial Charging
    205
  - Servicing
    206
  - Recharging Operation
    207
Servicing Information

208
- Troubleshooting
  209
  - Engine
    209
  - Carburetor
    212
  - Shaft Drive
    212
  - Chassis
    213
  - Brakes
    214
  - Electrical
    215
  - Battery
    216
- Wiring Diagram (for E-02, 19 / for E-03, 28, 33 / for E-24)
  217
- Wire Harness, Cable and Hose Routing
  220
  - Wire Harness Routing
    220
  - Cable Routing
    223
  - Fuel Hose Routing
    224
  - Cooling Hose Routing
    225
  - Front Brake Hose Routing
    226
  - Battery Protector
    227
  - Speed Sensor Lead Wire Routing
    227
- Special Tools
  228
- Tightening Torque
  231
  - Engine
    231
  - Secondary and Final
    232
  - Chassis
    233
  - Tightening Torque Chart
    234
- Service Data
  235

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