Suzuki FL125S Service Manual
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Suzuki FL125S Service Manual

Suzuki FL125S Service Manual

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Do you have a question about the FL125S and is the answer not in the manual?

Questions and answers

Gerhard Herden
February 22, 2025

Sitzbank laesst sich **** hochklappen,entsperren

0
gerhard
March 18, 2025

elektrischer Starter funktioniert ****.warum?

-2
1 comments:
Mr. Anderson
May 14, 2025

The electric starter on the Suzuki FL125S may not be working due to one of the following reasons:

1. If no click sound is heard from the starter relay when the starter button is pushed:
- Faulty starter button
- Faulty ignition switch
- Poor contact of couplers
- Open circuit in the wire harness

2. If a click sound is heard:
- If the starter motor runs when directly connected to the battery:
- Faulty starter relay
- Loose or disconnected starter motor lead wire
- Loose or disconnected wire between starter relay and battery
- If the starter motor does not run:
- Faulty starter motor

These checks should be done after ensuring the battery is fully charged.

This answer is automatically generated

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Summary of Contents for Suzuki FL125S

  • Page 1 9 9 5 0 0 - 3 1 3 7 1 - 0 1 E...
  • Page 2 NOTICE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. Indicates a potential hazard that could result in death or injury. Indicates a potential hazard that could result in motorcycle damage.

  • Page 3: General Information

    FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI FL125S/SD/SDW and procedures for its inspection/service and overhaul of its main com- GENERAL INFORMATION ponents. Other information considered as generally known is not included. PERIODIC MAINTENANCE Read the GENERAL INFORMATION section to familiarize yourself with the motorcycle and its main- tenance.

  • Page 4: How To Use This Manual

    HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
  • Page 5 Apply oil. Use engine oil unless other- Measure in voltage range. wise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI Measure in current range. MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. Measure in resistance range.

  • Page 6: Table Of Contents

    GENERAL INFORMATION GENERAL INFORMATION CONTENTS GENERAL PRECAUTIONS ................. 1- 2 SUZUKI FL125SK7/SDK7 (’07-MODEL)............. 1- 3 SERIAL NUMBER LOCATION ..............1- 3 FUEL AND OIL RECOMMENDATION ............1- 4 FUEL...................... 1- 4 ENGINE OIL ..................1- 4 BRAKE FLUID..................1- 4 FRONT FORK OIL.................

  • Page 7: General Precautions

    After servicing the fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for leaks. * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lents. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

  • Page 8: Suzuki Fl125Sk7/Sdk7 ('07-Model)

    GENERAL INFORMATION SUZUKI FL125SK7/SDK7 (’07-MODEL) RIGHT SIDE (FL125SD) LEFT SIDE (FL125SD) SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the left side of the steer- ing head pipe. The engine serial number 2 is located on the left side of the crankcase. These numbers are...

  • Page 9: Fuel And Oil Recommendation

    Always select good quality engine oil. Use oil with API classification of SF/SG or SH/SJ with JASO classification MA. SUZUKI recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative. accord- ing to the right chart.

  • Page 10: Specifications

    Displacement ................124 cm³ Compression ratio..............9.6 : 1 Carburetor................MIKUNI VM18 Air cleaner................Paper filter Starter system................. Kick ....... FL125S Electric and kick ..FL125SD Lubrication system ..............Wet sump Idle speed ................1 400 ± 100 r/min DRIVE TRAIN Clutch..................
  • Page 11 Ignition type................Electronic ignition (CDI) Ignition timing ................10° B.T.D.C at 1 400 r/min Spark plug ................NGK C6HSA or DENSO U20FS-U Battery..................12 V 9.0 kC (2.5 Ah)/10 HR ..FL125S 12V 12.6 kC (3.5 Ah)/10HR ..FL125SD Generator ................Single-phase A.C. generator Fuse ..................

  • Page 12: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ............2- 2 PERIODIC MAINTENANCE CHART ............ 2- 2 LUBRICATION POINTS ............... 2- 3 MAINTENANCE AND TUNE-UP PROCEDURES ......... 2- 4 AIR CLEANER ..................2- 4 EXHAUST PIPE NUT AND MUFFLER MOUNTING BOLT ....2- 5 VALVE CLEARANCE ................

  • Page 13: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometer and time for your convenience. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.

  • Page 14: Lubrication Points

    PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Speedometer Speedometer Side-stand pivot Center stand pivot gearbox cable and spring hook and spring hook Throttle cable Front brake lever holder...

  • Page 15: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item of the Periodic Maintenance requirements. AIR CLEANER Inspect every 4 000 km (20 months) and replace every 12 000 km. If the air cleaner element is clogged with dust, intake resistance will be increased, with a resultant decrease in power output and increase in fuel consumption.

  • Page 16: Exhaust Pipe Nut And Muffler Mounting Bolt

    PERIODIC MAINTENANCE • Remove the drain plug 2 from the air cleaner box to allow any water to drain out. EXHAUST PIPE NUT AND MUFFLER MOUNTING BOLT Tighten initially at 1 000 km (5 months) and every 8 000 km (40 months) thereafter. •...

  • Page 17: Valve Clearance

    PERIODIC MAINTENANCE VALVE CLEARANCE Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter. REMOVAL • Remove the leg shields, left and right. ($5-6) • Disconnect the spark plug cap 1 and remove the spark plug •...
  • Page 18 PERIODIC MAINTENANCE INSPECTION AND ADJUSTMENT The valve clearance specification is same for both valves. The valve clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshaft is removed for servicing. NOTE: * The piston must be at TDC on the compression stroke in order to check the valve clearance or to adjust the valve clearance.
  • Page 19 PERIODIC MAINTENANCE • Insert a thickness gauge between the valve stem end and the Adjusting screw adjusting screw on the rocker arm. If the clearance is out of specification, bring it into the speci- fied value. % Valve clearance (when cold): Lock-nut Standard: IN.: 0.03 –...

  • Page 20: Spark Plug

    PERIODIC MAINTENANCE SPARK PLUG Inspect at 4 000 km (20 months). Replace every 8 000 km (40 months). REMOVAL • Disconnect the spark plug cap 1 and remove the spark plug & 09930-10121: Spark plug socket wrench set Standard C6HSA DENSO U20FS-U CARBON DEPOSIT...

  • Page 21: Fuel Line

    PERIODIC MAINTENANCE 2-10 INSTALLATION Before using a spark plug wrench, carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage to the aluminum threads. • Install the spark plug to the cylinder head by finger tight, and then tighten it to the specified torque.

  • Page 22: Engine Oil And Oil Filter

    2-11 PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER ENGINE OIL REPLACEMENT (ENGINE OIL) Replace initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter. (OIL FILTER) Replace initially at 1 000 km (5 months) and every 8 000 km (40 months) thereafter.
  • Page 23 PERIODIC MAINTENANCE 2-12 OIL FILTER REPLACEMENT • Drain engine oil as described in the engine oil replacement procedure. • Remove the oil filter cap 1 and oil filter 2. • Replace the oil filter with a new one. • Install the spring 3 correctly. •...

  • Page 24: Throttle Cable Play

    2-13 PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter. Adjust the throttle cable play A with the following procedures. • Loosen the lock-nut 1 of the throttle cable. •...

  • Page 25: Drive Chain

    If any defects are found, the drive chain must be replaced. NOTE: When replacing the drive chain, replace the drive chain and sprockets as a set. The standard drive chain is D.I.D 428. SUZUKI recom- mends to use this standard drive chain as a replace- ment. CHECKING AND ADJUSTING •...

  • Page 26: Drive Chain Slack

    2-15 PERIODIC MAINTENANCE • Count out 21 pins (20-pitch) on the chain and measure the distance between the two points. If the distance exceeds the service limit, the drive chain must be replaced. % Drive chain 20-pitch length: Service limit: 259.0 mm NOTE: When replacing the drive chain, replace the drive chain and sprockets as a set.

  • Page 27: Brakes

    PERIODIC MAINTENANCE 2-16 The drive chain joint clip should be attached in the Direction of travel way that the slit end will face opposite to the direction of travel. BRAKES (BRAKE) Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter.
  • Page 28 2-17 PERIODIC MAINTENANCE FRONT BRAKE PADS The extent of brake pad wear can be checked by observing the grooved limit line A on the brake pad. When the wear exceeds the grooved limit line, replace the pads with new ones. ($5-16) Replace the brake pads as a set, otherwise braking performance will be adversely affected.
  • Page 29 PERIODIC MAINTENANCE 2-18 REAR BRAKE LIGHT SWITCH Adjust the rear brake light switch so that the brake light will come on just before pressure is felt when the brake pedal is depressed. AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper.

  • Page 30: Tires

    2-19 PERIODIC MAINTENANCE TIRES Inspect every 4 000 km (20 months). TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specifica- tion.
  • Page 31 PERIODIC MAINTENANCE 2-20 WHEEL Make sure that the wheel runout (axial and radial) does not exceed the service limit when checked as shown. An excessive amount of runout is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings. If bearing replacement fails to reduce the runout, replace the wheel.

  • Page 32: Steering

    2-21 PERIODIC MAINTENANCE STEERING Inspect initially at 1 000 km (5 months) and every 8 000 km (40 months) thereafter. The steering should be adjusted properly for smooth turning of handlebars and safe operation. Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability.

  • Page 33: Chassis Bolts And Nuts

    PERIODIC MAINTENANCE 2-22 CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-23 for the loca- tions of the following bolts and nuts on the motorcycle.) ITEM N·m...
  • Page 34 2-23 PERIODIC MAINTENANCE...

  • Page 35: Compression Pressure Check

    • Keep the throttle grip in the fully opened position. • Press the starter button (for FL125SD) or kick the kick starter lever (for FL125S) and crank the engine for a few seconds. Record the maximum gauge reading as the cylinder compres- sion.

  • Page 36: Oil Pressure Check

    2-25 PERIODIC MAINTENANCE OIL PRESSURE CHECK Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECIFICATION 8 – 22 kPa (0.08 – 0.22 kgf/cm²) at 3 000 r/min. If the oil pressure is lower or higher than specification, the following causes may be considered. LOW OIL PRESSURE * Clogged oil filter * Oil leakage from the oil passage...

  • Page 37: Automatic Clutch Inspection

    PERIODIC MAINTENANCE 2-26 AUTOMATIC CLUTCH INSPECTION This motorcycle is equipped with an automatic clutch. The engagement of the clutch is governed by engine RPMs and cen- trifugal mechanism located in the clutch. To insure proper performance and longer lifetime of the clutch assembly it is essential that the clutch engages smoothly and gradually.
  • Page 38 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE......................3- 2 ENGINE REMOVAL AND INSTALLATION ..........3- 3 ENGINE REMOVAL................3- 3 ENGINE INSTALLATION ..............3- 7 ENGINE DISASSEMBLY ................3-10 ENGINE COMPONENTS INSPECTION AND SERVICE......3-25 CYLINDER HEAD .................. 3-25 CYLINDER DISTORTION..............

  • Page 39: Engine Components Removable With The Engine In Place

    ENGINE 3-2 ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to page listed in each section for removal and reinstallation instructions. ENGINE CENTER PARTS REMOVAL INSTALLATION...

  • Page 40: Engine Removal And Installation

    ENGINE ENGINE REMOVAL AND INSTALLATION ENGINE REMOVAL Before taking the engine out of the frame, wash the engine using a steam cleaner. The procedure of engine removal is sequentially explained in the following steps. • Open the seat and disconnect the battery - lead wire. ($6-9) •...
  • Page 41 ENGINE 3-4 • Disconnect the crankcase breather hose 6 and ground lead wire 7. • Disconnect the gear position switch coupler 8. • Disconnect the generator lead wire coupler 9 and pick-up coil lead wire coupler 0. • Remove the engine guard. •...
  • Page 42 ENGINE • Remove the gearshift pedal. • Remove the muffler mounting bolts A and muffler connecting bolt B. • Remove the muffler C. • Remove the exhaust pipe D. • Remove the engine sprocket cover E. • Remove the drive chain covers F.
  • Page 43 ENGINE 3-6 • Remove the engine sprocket G with the drive chain H. • Remove the pillion footrest lower bolt I and spacers J, left and right. • Remove the engine from the frame.

  • Page 44: Engine Installation

    ENGINE ENGINE INSTALLATION Reinstall the engine in the reverse order of engine removal. • Install the engine mounting bolts and nuts as shown in the following illustration. • Tighten the engine mounting nuts to the specified torque. NOTE: The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use.
  • Page 45 ENGINE 3-8 • Tighten the engine sprocket bolts 1 to the specified torque. " Drive chain sprocket bolt: 10 N·m (1.0 kgf-m) • Install the exhaust pipe gasket 2. The removed gasket must be replaced with a new gas- ket to prevent exhaust gas leakage. •...
  • Page 46 ENGINE • Tighten the muffler mounting bolts to the specified torque. " Muffler mounting bolt: 23 N·m (2.3 kgf-m) • Tighten the muffler connecting bolt to the specified torque. " Muffler connecting bolt: 23 N·m (2.3 kgf-m) • Tighten the footrest mounting bolts to the specified torque. "...

  • Page 47: Engine Disassembly

    ENGINE 3-10 ENGINE DISASSEMBLY Identify the position of each removed part. Organize the parts in their respective groups so that they can be reinstalled in their original positions. KICK STARTER LEVER • Remove the kick starter lever. PAIR VALVE • Remove the PAIR valve assembly 1. CRANKCASE BREATHER HOSE •...
  • Page 48 3-11 ENGINE STARTER MOTOR • Remove the starter motor. CAMSHAFT SPROCKET/AUTOMATIC DECOMP. • Remove the valve timing inspection plug 1 and generator cover plug 2. • Remove the camshaft sprocket cover 3 and gasket. • Turn the generator rotor with a box wrench to set the piston at TDC on the compression stroke.
  • Page 49 ENGINE 3-12 CAM CHAIN TENSION ADJUSTER • Remove the cam chain tension adjuster 1. • Remove the gasket 2. • Remove the decomp. cam assembly 3 and camshaft sprocket 4. • Remove the locating pin 5 and angle pin 6. CYLINDER HEAD •...
  • Page 50 3-13 ENGINE • Remove the cylinder head nuts 2 in diagonally. • Remove the cylinder head nut gaskets 3. • Remove the cylinder head assembly 4. NOTE: If the cylinder head does not come off easily, lightly tap it with a plastic mallet.
  • Page 51 ENGINE 3-14 OIL FILTER • Remove the oil filter cap 1. • Remove the oil filter 2. • Remove the O-ring 3 and spring 4. OIL SUMP FILTER • Remove the oil sump filter cap 1 and oil sump filter 2. •...
  • Page 52 3-15 ENGINE STARTER IDLE GEAR • Remove the starter idle gear spacer 1, starter idle gear 2 and shaft 3. GENERATOR ROTOR • Hold the conrod with the special tool. & 09930-44530: Rotor holder • Remove the generator rotor nut 1. •...
  • Page 53 ENGINE 3-16 GEAR POSITION SWITCH • Remove the gear position switch 1. • Remove the gear position switch pin 2 and spring 3. CLUTCH COVER • Remove the clutch cover 1. • Remove the dowel pins 2 and gasket 3. GEARSHIFT LINK •...
  • Page 54 3-17 ENGINE • Remove the release ball 4, washer 5 and gearshift link arm No. 2 6. • Remove the gearshift shaft assembly 7 and roller 8. FIRST CLUTCH • Remove the clutch bearing 1 and clutch push piece 2. •...
  • Page 55 ENGINE 3-18 • Remove the first clutch housing 7 by removing the primary drive gear ring 8. • Remove the primary drive gear spacer 9 and primary drive gear 0. GEARSHIFT CLUTCH • Hold the clutch sleeve hub with the special tool. &...
  • Page 56 3-19 ENGINE • Remove the wave washer 4, washer 5, gearshift clutch assembly 6 and primary driven gear 7. • Remove the spacer 8. GEARSHIFT SHAFT • Remove the gearshift cam drive plate 1. • Remove the gearshift arm 2. •...
  • Page 57 ENGINE 3-20 • Remove the washer 5 and oil pump drive gear 6. OIL PUMP • Remove the oil pump 1. • Remove the dowel pins 2. CRANK BALANCER DRIVE/DRIVEN GEAR • Hold the crank balancer driven gear with the special tool. &...
  • Page 58 3-21 ENGINE • Remove the wave washer 3 and plate 4. • Remove the spacer 5 and key 6. • Remove the crank balancer drive gear 7. • Remove the pin 8. GEARSHIFT CAM • Remove the gearshift cam plate 1. •...
  • Page 59 ENGINE 3-22 CRANKCASE • Remove the left crankcase bolts. • Remove the right crankcase bolt. • Separate the crankcase with the special tool. & 09920-13120: Crankcase and shaft remover NOTE: * Fit the crankcase separating tool, so that the tool arms are in parallel with the side of crankcase.
  • Page 60 3-23 ENGINE • Remove the kick starter shaft 3 by turning the shaft. TRANSMISSION • Remove the gearshift fork shafts 1 and 2. • Remove the gearshift cam 3. • Remove the gearshift fork No. 1 4 and No. 2 5. •...
  • Page 61 ENGINE 3-24 CRANKSHAFT • Remove the crankshaft with the special tool. & 09920-13120: Crankcase and shaft remover CRANK BALANCER • Remove the crank balancer. GEARSHIFT STOPPER PIN BOLT • Remove the gearshift stopper pin bolt.

  • Page 62: Engine Components Inspection And Service

    3-25 ENGINE ENGINE COMPONENTS INSPECTION AND SERVICE Identify the position of each removed part. Organize the parts in their respective groups (i.e., intake or exhaust) so that they can be installed in their original locations. CYLINDER HEAD DISASSEMBLY • Remove the cam chain tensioner 1. •...
  • Page 63 ENGINE 3-26 • Remove the intake and exhaust rocker arms 5 and wave washers 6. • Remove the camshaft 7. • Compress the valve spring with the special tools. • Remove the two cotter halves 8 from the valve stem. &...
  • Page 64 3-27 ENGINE • Remove the valve stem seal B and valve spring seat C. ROCKER ARM SHAFT O.D. Measure the diameter of rocker arm shaft. % Rocker arm shaft O.D. (IN. & EX.): Standard: 9.981 – 9.990 mm & 09900-20205: Micrometer (0 – 25 mm) ROCKER ARM I.D.
  • Page 65 ENGINE 3-28 VALVE FACE WEAR The thickness of the valve face decreases as the face wears. Visually inspect each valve face for wear and replace any valve with an abnormally worn face. Measure the valve face thickness T. If it is out of specification, replace the valve with a new one. % Valve head thickness (IN.
  • Page 66 3-29 ENGINE VALVE STEM WEAR If the valve stem is worn down to the limit, as measured with a micrometer, replace the valve. If the stem is within the limit, then replace the guide. After replacing valve or guide, be sure to recheck the deflection. % Valve stem O.D.: Standard (IN.) : 4.975 –...
  • Page 67 ENGINE 3-30 • Cool down the new valve guides in a freezer for about one hour and heat the cylinder head to 100 – 150 °C with a hot plate. • Apply engine oil to the valve guide hole. • Drive the valve guide into the hole with the special tool. &...
  • Page 68 3-31 ENGINE • If the seat width W measured exceeds the standard value or seat width is not uniform, reface the seat using the seat cutter. % Valve seat width W: Standard: 0.9 – 1.1 mm If the valve seat is out of specification, correct the seat by servic- ing it as follows: VALVE SEAT SERVICING •...
  • Page 69 ENGINE 3-32 VALVE STEM END CONDITION Inspect the valve stem end face for pitting and wear. If pitting or wear is present, resurface the valve stem end. Make sure that the length A is not less than 2.2 mm. If this length becomes less than 2.2 mm, replace the valve.
  • Page 70 3-33 ENGINE CAMSHAFT BEARING INSPECTION Rotate the camshaft bearing outer race by finger to check for abnormal play, noise and smooth rotation. Replace the bearings in the following procedure if there is any- thing unusual. CAMSHAFT BEARING REPLACEMENT • Remove the camshaft bearing with the special tool. &...
  • Page 71 ENGINE 3-34 • Install the camshaft bearing to the cylinder head with the spe- cial tool. & 09913-70210: Bearing installer set The removed bearing must be replaced with a new one. CAM SPROCKET INSPECTION Check the cam sprocket teeth for wear or damage. If any defects are found, replace the cam sprocket and cam chain as a set.
  • Page 72 3-35 ENGINE • Install the valve spring with the small-pitch portion A facing cylinder head. B Large-pitch portion C UPWARD D Paint E Cylinder head • Put on the valve spring retainer 3, and using the valve lifter, press down the spring, fit the cotter halves to the stem end, and release the valve lifter to allow the valve cotter 4 to wedge in between retainer and stem.
  • Page 73 VALVE CLEARANCE INSPECTION CAP • Install the valve clearance inspection cap gasket 1. The removed gasket must be replaced with a new one. • Apply SUZUKI SUPER GREASE “A” to the valve clearance inspection cap gasket. * 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 74: Cylinder Distortion

    3-37 ENGINE CAM CHAIN TENSIONER • Install the cam chain tensioner 1 and washer 2. • Tighten the cam chain tensioner bolt 3 to the specified torque. " Cam chain tensioner bolt: 10 N·m (1.0 kgf-m) CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated.

  • Page 75: Piston

    ENGINE 3-38 PISTON PISTON DIAMETER Using a micrometer, measure the piston outside diameter at the place 10 mm from the piston skirt end as shown. If the measure- ment is less than the limit, replace the piston. % Piston diameter: Service Limit: 53.335 mm 10 mm &...

  • Page 76: Piston Ring Thickness

    3-39 ENGINE PISTON RING-TO-GROOVE CLEARANCE • Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge. • If any of the clearances exceeds the limit, replace both the piston and piston rings. % Piston ring-to-groove clearance: Service Limit (1st) : 0.180 mm (2nd): 0.150 mm % Piston ring groove width:...
  • Page 77 ENGINE 3-40 PISTON PIN AND PIN BORE • Measure the piston pin bore diameter using the small bore gauge. • If the measurement is out of specification, replace the piston. % Piston pin bore I.D.: Service Limit: 14.030 mm & 09900-20602: Dial gauge (1/1000 mm) 09900-22401: Small bore gauge (10 –...

  • Page 78: Conrod And Crankshaft

    3-41 ENGINE CONROD AND CRANKSHAFT 1 Primary drive gear 4 Crankshaft, LH 7 Crank pin 2 Crank balancer drive gear 5 Conrod 3 Crankshaft, RH 6 Bearing CONROD SMALL END I.D. Using a caliper gauge, measure the conrod small end inside diameter.

  • Page 79: Crankshaft Runout

    ENGINE 3-42 CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the small end of the conrod. This method can also check the extent of wear on the parts of the conrod’s big end.

  • Page 80: Crank Balancer

    3-43 ENGINE CRANK BALANCER CRANK BALANCER INSPECTION Inspect the crank balancer for wear or damage. If any defects are found, replace the crank balancer with a new one. BALANCER DRIVE/DRIVEN GEAR INSPECTION Inspect the balancer driven gear 1 and drive gear 2 for wear or damage.

  • Page 81: Transmission

    ENGINE 3-44 TRANSMISSION DISASSEMBLY • Disassemble the transmission gears as shown in the illustration. NOTE: When removing the 2nd drive gear, use a gear puller and a proper attachment. 1 1st driven gear 4 Rotary stop plate 7 4th drive gear 2 4th driven gear 5 Driveshaft 8 3rd drive gear...
  • Page 82 3-45 ENGINE • When installing a new snap ring, pay attention to the direction of the snap ring. Fit the snap ring to the side where the thrust Thrust is as shown in the illustration. The rounded side should be against the gear surface.

  • Page 83: Gearshift Cam

    ENGINE 3-46 GEARSHIFT CAM Inspect the gearshift cam wear or damage. If any defects are found, replace the gearshift cam with a new one. GEARSHIFT FORKS GEARSHIFT FORK-TO-GROOVE CLEARANCE Measure the gearshift fork clearance in the groove of its respec- tive gear using the thickness gauge.

  • Page 84: Primary Driven Gear

    3-47 ENGINE PRIMARY DRIVEN GEAR If the internal damper wears, play is generated between gear and housing, causing abnormal noise. If the play is extreme, replace the primary driven gear assembly with a new one. 1 Primary driven gear 2 Damper 3 Clutch housing GEARSHIFT CLUTCH CLUTCH DRIVE PLATES...

  • Page 85: First Clutch

    ENGINE 3-48 FIRST CLUTCH CLUTCH SHOES INSPECTION Inspect the clutch shoes for chips, cracks, uneven wear and burning. Check the thickness of the shoes using vernier calipers. If any damages are found or if the thickness is less than the ser- vice limit, replace the clutch shoe assembly.

  • Page 86: Starter Clutch

    3-49 ENGINE STARTER CLUTCH INSPECTION OF STARTER CLUTCH OPERATION Turn the starter driven gear by hand in the direction of arrow as shown and check that rotation is smooth. Also check that the gear is locked when attempted to turn in the other direction. If a large resistance is felt or noise occurs when turning the gear, check the starter driven gear sliding surface for wear or damage.

  • Page 87: Generator Cover

    • Install the oil seal 1 with the special tool. & 09913-70210: Bearing installer set The removed O-ring must be replaced with a new one to prevent oil leakage. • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. * 99000-25010: SUZUKI SUPER GREASE “A”...

  • Page 88: Clutch Cover

    3-51 ENGINE • When installing the generator coil set screws 2 and pick-up coil set screws 3, tighten them to the specified torque. " Generator coil set screw: 4.7 N·m (0.47 kgf-m) Pick-up coil set screw: 8.3 N·m (0.83 kgf-m) NOTE: Be sure to install the gromment 4 to the generator cover.

  • Page 89: Kick Starter

    The removed oil seal must be replaced with a new one to prevent oil leakage. • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal. * 99000-25010: SUZUKI SUPER GREASE “A” • Install the O-ring 4 to the release arm 5.

  • Page 90: Crankcase

    3-53 ENGINE • Remove the kick starter shaft 3 by turning the shaft. CRANKCASE BEARING INSPECTION • Inspect the play of the crankcase bearings by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. •...
  • Page 91 ENGINE 3-54 LEFT CRANKCASE BEARING REMOVAL • Remove the left crankcase bearings with the special tools. & 09913-70210: Bearing installer set 09921-20240: Bearing remover set Bearing 1: (52 Attachment Bearing 2: (10 Attachment Bearing 3: (20 Attachment Bearing 4: (10 Attachment LEFT CRANKCASE OIL SEAL REMOVAL •...
  • Page 92 3-55 ENGINE RIGHT CRANKCASE BEARING INSTALLATION • Install the right crankcase bearings with the special tool. & 09913-70210: Bearing installer set Bearing 1: (47 Attachment Bearing 2: (62 Attachment Bearing 3: (30 Attachment Bearing 4: (40 Attachment Bearing 5: (15 Attachment Bearing 6: (30 Attachment NOTE: When installing bearing, stamped mark on bearing must face...
  • Page 93 LEFT CRANKCASE OIL SEAL INSTALLATION • Install the left crankcase oil seal 1 to the left crankcase with the special tool. • Apply SUZUKI SUPER GREASE “A” to the oil seal lip. * 99000-25010: SUZUKI SUPER GREASE “A” & 09913-70210: Bearing installer set The removed oil seal must be replaced with a new one to prevent oil leakage.

  • Page 94: Crankshaft Shim Selection

    3-57 ENGINE CRANKSHAFT SHIM SELECTION • Degrease the right crankshaft web, shim and inner race of the right crankshaft bearing. • Place the removed shim 1 on the right crankshaft. • Put the plasti-gauge (special tool) 2 cut out about 10 mm on the shim as shown.

  • Page 95: Engine Reassembly

    ENGINE 3-58 ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reas- sembling. GEARSHIFT STOPPER PIN BOLT •...

  • Page 96: Kick

    3-59 ENGINE KICK 1 Kick starter lever 3 Kick starter shaft 5 Kick starter return spring 2 Kick starter drive gear 4 Kick starter • Align the punched mark A of the kick starter drive gear with the groove B of the kick starter shaft.
  • Page 97 ENGINE 3-60 • Install the kick starter return spring 1, kick starter shaft 2 and kick starter spring hook end 3 onto the clutch cover boss TRANSMISSION • Install the countershaft assembly 1 and driveshaft assembly • Install the gearshift forks. 3: Gearshift fork No.
  • Page 98 • Install the dowel pins 1 into the left half of the crankcase. • Apply engine oil to the conrod big end and transmission gears. • Apply SUZUKI BOND “1207B” to the mating surface of the right crankcase as shown. , 99104-31140: SUZUKI BOND “1207B”...
  • Page 99 ENGINE 3-62 NOTE: * After the crankcase bolts have been tightened, make sure that the crankshaft, countershaft and driveshaft rotate smoothly. * If these shafts do not rotate smoothly, try to free it by tapping with a plastic mallet. GEARSHIFT CAM •...
  • Page 100 3-63 ENGINE • Install the crank balancer driven gear 6. NOTE: Align the matching marks A as shown. • Holding the crank balancer driven gear with the special tool, tighten the crank balancer driven gear nut 7 to the specified torque.
  • Page 101 ENGINE 3-64 GEARSHIFT SHAFT • Install the gearshift shaft 1 and washer 2. • Install the gearshift arm 3. • Install the gearshift cam drive plate 4.
  • Page 102 3-65 ENGINE CLUTCH 1 Push piece 0 First clutch shoe 2 Release plate A Primary drive gear spacer 3 Clutch sleeve hub B First clutch housing " 4 Clutch drive plate C Primary drive gear 5 Clutch driven plate A Release plate bolt ITEM N·m kgf-m...
  • Page 103 ENGINE 3-66 GEARSHIFT CLUTCH • Install the spacer 1. NOTE: Apply engine oil to the both surfaces of the spacer. • Install the primary driven gear 2. NOTE: When engaging the primary drive and driven gears, rotate the primary driven gear counterclockwise. •...
  • Page 104 3-67 ENGINE • Install the clutch springs 9. • Install the release plate 0 and release plate bolts A. • Hold the clutch sleeve hub 5 with the special tool and tighten the release plate bolts A to the specified torque. &...
  • Page 105 ENGINE 3-68 • Install the first clutch shoe 3, washer 4 and wave washer 5. • Hold the conrod with the special tool. & 09910-20116: Conrod holder • Install the first clutch nut 6 and tighten it to the specified torque.
  • Page 106 3-69 ENGINE GEAR SHIFT 1 Gearshift link arm No. 2 8 Gear position switch 2 Gearshift cam drive plate 9 Gearshift stopper " 3 Gearshift arm 0 Gearshift fork No. 1 4 Gearshift link arm No. 1 A Gearshift fork No. 2 ITEM N·m kgf-m...
  • Page 107 ENGINE 3-70 GEARSHIFT LINK • Install the gearshift shaft assembly 1 and roller 2. • Install the spring 3, gearshift link arm No. 2 4, washer 5 and release ball 6. NOTE: Face the lug A of the release ball 6 to the outside. •...
  • Page 108 3-71 ENGINE CLUTCH ADJUSTMENT • Loosen the clutch adjustment lock-nut 1. • First, turn the adjusting bolt clockwise by one turn and turn it counterclockwise until resistance is felt, then turn it clockwise by 1/8 turn. • Tighten the clutch adjustment lock-nut to the specified torque. "...
  • Page 109 ENGINE 3-72 • Install the starter driven gear 2 and key 3. • Degrease the tapered portion of the generator rotor and also the crankshaft. Use nonflammable cleaning solvent to wipe off oily or greasy matter to make these surface completely dry. •...
  • Page 110 3-73 ENGINE OIL SUMP FILTER • Clean the oil sump filter with compressed air. • Apply engine oil lightly to the gasket 1. • Install the gasket 1 to the oil sump filter cap 2. • Install the oil sump filter 3. The removed gasket must be replaced with a new one to prevent oil leakage.
  • Page 111 ENGINE 3-74 OIL FILTER • Install the oil filter 1. • Apply engine oil lightly to the gasket 2 of oil filter before installation. Install the oil filter so that the valve A comes outside. • Apply engine oil lightly to the O-ring 2. •...
  • Page 112 3-75 ENGINE • The 1st and 2nd piston rings should be installed with their marks facing up. • Position the gaps of the three rings as shown. • 2nd ring • Upper side rail • Lower side rail NOTE: Before inserting piston into the cylinder, check that the gaps are so located.
  • Page 113 CYLINDER • Thoroughly wipe off oil from the fitting surface of the crank- case. • Apply SUZUKI BOND “1207B” to the crankcase as shown. , 99104-31140: SUZUKI BOND “1207B” Be careful about oil leakage. • Apply MOLYBDENUM OIL SOLUTION to the sliding surface of the piston and piston rings.
  • Page 114 3-77 ENGINE • Install the cylinder head assembly 3. • Install the cylinder head nut gaskets 4. The removed nut gaskets must be replaced with new ones to prevent oil leakage. • Tighten the cylinder head nut diagonally to the specified torque.
  • Page 115 ENGINE 3-78 • Install the camshaft sprocket 3. • Engage the cam chain onto the camshaft sprocket with the mark C at just top position. • Align the mark C of the cam sprocket with the concave line D of the cylinder head. •...
  • Page 116 (some turns), and recheck the positions of the camshaft sprocket. Be sure to check the valve clearance. ($2-6) • Apply SUZUKI SUPER GREASE “A” to the O-ring 1. • Install the O-ring 1 to the camshaft sprocket cover. * 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 117 " Camshaft sprocket cover bolt: 10 N·m (1.0 kgf-m) • Install the spark plug. ($2-9) VALVE TIMING INSPECTION PLUG/GENERATOR COVER • Apply SUZUKI SUPER GREASE “A” to the generator cover plug O-ring 1. • Tighten the generator cover plug 2 and valve timing inspec- tion plug 3 to the specified torque.
  • Page 118 " PAIR pipe nut: 10 N·m (1.0 kgf-m) KICK STARTER LEVER • Apply SUZUKI SUPER GREASE “A” to the kick starter lever. * 99000-25010: SUZUKI SUPER GREASE “A” • Install the kick starter lever and its bolt. • Tighten the kick starter lever bolt to the specified torque.

  • Page 119: Pair (Air Supply) System

    ENGINE 3-82 PAIR (AIR SUPPLY) SYSTEM PAIR HOSES INSPECTION • Remove the leg shields, left and right. ($5-6) • Check the PAIR hoses for wear or damage. • Check the PAIR hoses are securely connected. DISASSEMBLY • Remove the PAIR valve. ($3-10) •...

  • Page 120: Pair Valve Inspection

    3-83 ENGINE PAIR VALVE INSPECTION • Remove the PAIR valve. ($3-10) • Check that air flows through the PAIR valve air inlet port to the air outlet port. If air does not flow out, replace the PAIR valve with a new one. •...
  • Page 121 FUEL AND LUBRICATION SYSTEM 4-1 FUEL AND LUBRICATION SYSTEM CONTENTS FUEL TANK AND FUEL TAP ................ 4- 2 REMOVAL ..................... 4- 2 INSPECTION ..................4- 3 REMOUNTING ..................4- 3 FUEL LEVEL GAUGE ..................4- 4 REMOVAL ..................... 4- 4 INSPECTION ..................

  • Page 122: Fuel Tank And Fuel Tap

    FUEL AND LUBRICATION SYSTEM FUEL TANK AND FUEL TAP REMOVAL • Remove the front frame cover. ($5-5) • Remove the frame covers, left and right. ($5-7) • Drain the gasoline. • Disconnect the fuel hose 1. Gasoline is highly flammable and explosive. Keep heat, spark and flame away.

  • Page 123: Inspection

    FUEL AND LUBRICATION SYSTEM • Remove the fuel hose 7 and fuel tap vacuum hose 8. • Remove the fuel tap 9. INSPECTION FUEL FILTER If the fuel filter is dirty with sediment or rust, fuel will not flow smoothly and loss in engine power may result. Clean the fuel fil- ter with compressed air.

  • Page 124: Fuel Level Gauge

    FUEL AND LUBRICATION SYSTEM FUEL LEVEL GAUGE REMOVAL • Open the seat. ($5-5) • Disconnect the fuel level gauge coupler 1. • Remove the fuel gauge retainer 2. Gasoline is highly flammable and explosive. Keep heat, spark and flame away. •...

  • Page 125: Inspection

    FUEL AND LUBRICATION SYSTEM INSPECTION Measure the resistance between the terminals when the float is at the position listed below. & 09900-25008: Multi-circuit tester Float position Resistance 4 – 10 Ω Full 37.9 mm 95 – 110 Ω Empty 100.4 mm If the resistance is incorrect, replace the fuel level gauge assem- bly with a new one.

  • Page 126: Installation

    FUEL AND LUBRICATION SYSTEM INSTALLATION • Install the rubber cushion 1. • Install the fuel level gauge 2. The removed rubber cushion must be replaced with a new one. • Install the fuel gauge retainer 3. • Install the fuel level gauge coupler 4.

  • Page 127: Carburetor

    FUEL AND LUBRICATION SYSTEM CARBURETOR CONSTRUCTION 1 Top cap 0 Starter plunger I Main jet 2 Gasket A Coasting valve cover J Pilot jet 3 Spring B Coasting valve K Needle valve 4 Jet needle locker C Spring L Pin 5 Jet needle D Pilot air screw M Float...

  • Page 128: Specifications

    FUEL AND LUBRICATION SYSTEM SPECIFICATIONS ITEM SPECIFICATION I.D. NO, LOCATION The carburetor has I.D. Number A Carburetor type MIKUNI MV18SH ( 17 mm Bore size stamped on the carburetor body. I.D. No. 16H0 Idle r/min 1 400 ± 100 r/min Float height 16 mm Main jet...

  • Page 129: Disassembly

    FUEL AND LUBRICATION SYSTEM • Loosen the clamp screw 6. • Disconnect the starter cable 7. • Remove the throttle cable assembly 8. • Remove the carburetor 9 with intake pipe. DISASSEMBLY • Remove the intake pipe 1 and insulator 2. •...
  • Page 130 4-10 FUEL AND LUBRICATION SYSTEM • Remove the float assembly 8 by removing the pin 9. • Remove the following parts. 0 Main jet A Needle jet holder B Needle jet C Pilot jet Do not use a wire for cleaning passage. •...
  • Page 131 FUEL AND LUBRICATION SYSTEM 4-11 • Remove the following parts. L Coasting valve cover M Spring N Coasting valve • Remove the throttle cable A. • Disconnect the throttle position switch lead wire coupler B. • Remove the top cap L, gasket M, spring N and throttle valve •...
  • Page 132 4-12 FUEL AND LUBRICATION SYSTEM • Remove the throttle position switch T from the top cap L.

  • Page 133: Carburetor Cleaning

    FUEL AND LUBRICATION SYSTEM 4-13 CARBURETOR CLEANING Some carburetor cleaning chemicals, especially dip- type soaking solutions, are very corrosive and must be handled carefully. Always follow the chemical man- ufacturer’s instructions on proper use, handling and storage. • Clean all jets with a spray-type carburetor cleaner and dry them using compressed air.

  • Page 134: Needle Valve Inspection

    4-14 FUEL AND LUBRICATION SYSTEM NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the nee- dle valve, the gasoline will continue flowing and cause it to over- flow. If the valve seat and needle valve are worn beyond the permissible limits, similar trouble will occur.
  • Page 135 FUEL AND LUBRICATION SYSTEM 4-15 • Install the pilot air screw 1 and throttle valve adjuster 2. NOTE: Turn in the pilot air screw 1 until it lightly seats, then back it out the counted number of turns. ( $ 4-8) The removed O-rings must be replaced with new ones to prevent fuel leakage.
  • Page 136 4-16 FUEL AND LUBRICATION SYSTEM • Install the O-rings 0 to the intake pipe. The removed O-rings must be replaced with new ones to prevent fuel leakage. • Install the O-ring A to the carburetor body. The removed O-ring must be replaced with a new one to prevent fuel leakage.

  • Page 137: Lubrication System

    FUEL AND LUBRICATION SYSTEM 4-17 LUBRICATION SYSTEM OIL PRESSURE $2-25 OIL FILTER $2-11 OIL SUMP FILTER $3-73 OIL PUMP $3-43 ENGINE LUBRICATION SYSTEM CHART CYLINDER CAMSHAFT CAM FACE HEAD INTAKE EXHAUST CYLINDER ROCKER ROCKER CAM CHAIN CYLINDER WALL LEFT CRANKCASE RIGHT CRANKCASE DRIVESHAFT OIL JET...
  • Page 138 5-1 CHASSIS CHASSIS CONTENTS EXTERIOR PARTS ..................5- 3 FASTENER REMOVAL AND INSTALLATION........5- 3 REMOVAL ..................... 5- 4 FRONT WHEEL ................... 5- 9 CONSTRUCTION .................. 5- 9 REMOVAL ..................... 5- 9 INSPECTION AND DISASSEMBLY ............. 5-10 REASSEMBLY AND INSTALLATION ..........5-12 FRONT BRAKE....................
  • Page 139 CHASSIS CHASSIS CONTENTS REAR WHEEL....................5-42 CONSTRUCTION .................. 5-42 REMOVAL ..................... 5-43 DISASSEMBLY AND INSPECTION ............. 5-44 INSPECTION ..................5-46 REASSEMBLY AND INSTALLATION ..........5-47 REAR BRAKE....................5-50 REMOVAL AND DISASSEMBLY ............5-50 INSPECTION ..................5-51 REASSEMBLY AND REMOUNTING............ 5-52 REAR SUSPENSION ...................

  • Page 140: Exterior Parts

    CHASSIS EXTERIOR PARTS FASTENER REMOVAL AND INSTALLATION Removal • Turn the head of fastener center screw 1 counterclockwise. • Pull out the fastener. Installation • Pull out the fastener center screw toward the head so that the pawls 2 close. •...

  • Page 141: Removal

    CHASSIS REMOVAL HANDLEBAR COVERS • Remove the rear view mirrors 1. • Remove the front handlebar cover 2. • Disconnect the headlight coupler 3. • Disconnect the speedometer cable 4 and speedometer indi- cator lights couplers 5 and 6. • Remove the rear handlebar cover 7. •...
  • Page 142 CHASSIS FRONT CENTER LEG SHIELD • Remove the front center leg shield. FRONT FRAME COVER • Open the seat 1 using the ignition key, to push in and turn the ignition key clockwise. • Remove the front frame cover 2. LUGGAGE BOX •...
  • Page 143 CHASSIS REAR CENTER LEG SHIELD • Remove the front center leg shield. ($5-5) • Remove the front frame cover. ($5-5) • Remove the rear center leg shield. LEG SHIELD • Remove the rear center leg shield. ($Above) • Remove the leg shield. FRAME HEAD COVER •...
  • Page 144 CHASSIS PILLION RIDER HANDLE • Remove the pillion rider handle 1. FRAME COVER • Remove the rear center leg shield. ($5-6) • Remove the pillion rider handle. ($Above) • Remove the frame cover. .: Hooked part...
  • Page 145 CHASSIS • Disconnect the rear turn signal light coupler 1 and rear com- bination light coupler 2.

  • Page 146: Front Wheel

    CHASSIS FRONT WHEEL CONSTRUCTION 1 Front axle bolt 2 Brake disc 3 Spacer Front wheel bearing (Right) 5 Spoke nipple 6 Front wheel 7 Front axle spacer Front wheel bearing (Left) 9 Speedometer gearbox A Front axle nut B Brake disc bolt "...

  • Page 147: Inspection And Disassembly

    CHASSIS 5-10 INSPECTION AND DISASSEMBLY WHEEL BEARING Inspect the wheel bearing play by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. Replace the bearing in the following procedure if there is any- thing unusual.
  • Page 148 5-11 CHASSIS SPEEDOMETER GEARBOX Turn the speedometer gear and check to see that the gear turns smoothly together with the speedometer pinion. If any defects are found, replace the speedometer gearbox with a new one. WHEEL RIM ..............$2-19 SPOKE NIPPLE ............$2-19 TIRE................

  • Page 149: Reassembly And Installation

    Reassemble and install the front wheel in the reverse order of removal and disassembly. Pay attention to the following points: WHEEL BEARING • Apply SUZUKI SUPER GREASE “A” to the wheel bearings. * 99000-25010: SUZUKI SUPER GREASE “A” • Install the front wheel bearings with the special tool.
  • Page 150 5-13 CHASSIS SPEEDOMETER GEARBOX • Apply SUZUKI SUPER GREASE “A” to the speedometer gearbox. * 99000-25010: SUZUKI SUPER GREASE “A” • Align the lugs A on the speedometer gearbox with the recesses B on the front wheel. • Align the speedometer gearbox case 1 with the concave por- tion of the front fork 2 as shown.
  • Page 151 CHASSIS 5-14 • Tighten the front axle nut 4 to the specified torque. " Front axle nut: 42 N·m (4.2 kgf-m) • Connect the speedometer cable 5. • Install the brake caliper 6. ($5-17) When installing the front wheel, position the brake disc between the brake pads.

  • Page 152: Front Brake

    5-15 CHASSIS FRONT BRAKE CONSTRUCTION 1 Reservoir cap A Dust seal 2 Diaphragm B Piston seal 3 Master cylinder C Piston " 4 Piston set D Brake caliper 5 Dust boot E Pad spring ITEM N·m kgf-m 6 Brake hose A Master cylinder mounting bolt 7 Caliper holder B Brake hose union bolt...

  • Page 153: Brake Fluid Replacement

    CHASSIS 5-16 * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid. Do not use or mix different types of fluid such as silicone-based or petroleum-based. * Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left over from the last servicing or stored for a long periods.

  • Page 154: Brake Pad Replacement

    5-17 CHASSIS BRAKE PAD REPLACEMENT • Loosen the brake pad mounting pin bolts 1. • Remove the brake caliper 2 by removing the brake caliper mounting bolts. • Remove the brake pad mounting pin bolts 1 and brake pads * Do not operate the brake lever after brake pad removal.

  • Page 155: Caliper Disassembly

    CHASSIS 5-18 CALIPER DISASSEMBLY • Remove the brake pads. ($5-17) • Remove the caliper holder 1. • Remove the pad spring 2. • Remove the rubber parts 3. • Place a rag over the pistons to prevent them from popping out and then force out the pistons using compressed air.

  • Page 156: Caliper Inspection

    5-19 CHASSIS CALIPER INSPECTION CALIPER AND PISTON Inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages. If any abnormal condition are found, replace the caliper or cali- per piston with a new one. PAD SPRING Inspect the brake pad spring for damage or excessive bend.

  • Page 157: Caliper Reassembly

    / 99000-25100: SUZUKI SILICONE GREASE • Install the piston seals and dust seals as shown. Never reuse the piston seals to prevent brake fluid leakage. • Apply SUZUKI SILICON GREASE to the brake caliper holder pins. / 99000-25100: SUZUKI SILICONE GREASE...

  • Page 158: Caliper Installation

    5-21 CHASSIS • Install the pad spring 1. • Install the brake pads 2. • Temporarily tighten the brake pad mounting pin bolts 3. CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: •...

  • Page 159: Brake Disc Inspection

    CHASSIS 5-22 BRAKE DISC INSPECTION Check the brake disc for cracks or damage. Measure the thickness with the micrometer. Replace the disc if the thickness is less than the service limit, or if damage is found. % Brake disc thickness: Service Limit: 3.5 mm &...
  • Page 160 5-23 CHASSIS • Remove the brake lever 5 and front brake switch 6. • Remove the reservoir cap 7, diaphragm plate 8 and dia- phragm 9. • Pull out the dust seal boot 0 and remove the snap ring A. •...

  • Page 161: Master Cylinder Inspection

    CHASSIS 5-24 MASTER CYLINDER INSPECTION MASTER CYLINDER Inspect the master cylinder bore for any scratches or damage. If any defects are found, replace the master cylinder with a new one. PISTON AND CUP SET Inspect the piston 1 surface for any scratches or other damage. Inspect the primary cup 2, secondary cup 3 and dust seal 4 for wear or damage.

  • Page 162: Master Cylinder Reassembly And Installation

    • When installing the front brake switch 1, align the projection A on the front brake switch 1 with the hole B in the master cylinder. • Apply SUZUKI SUPER GREASE “A” to the piston 2 and brake lever pivot 3. * 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 163 CHASSIS 5-26 • Tighten the brake lever nut 4 and front brake switch screw " Brake lever nut: 6 N·m (0.6 kgf-m) Front brake switch screw: 1 N·m (0.1 kgf-m) • When installing the master cylinder onto the handlebars, align Master cylinder the master cylinder holder’s mating surface C with the Handlebars...

  • Page 164: Front Fork

    5-27 CHASSIS FRONT FORK CONSTRUCTION 1 Stopper ring 2 Front fork cap 3 O-ring 4 Front fork spring 5 Damper rod ring 6 Damper rod 7 Rebound spring 8 Inner tube 9 Dust seal 0 Oil seal stopper ring A Oil seal B Outer tube A Damper rod bolt "...
  • Page 165 CHASSIS 5-28 • Remove the front fork clamp bolts 4. NOTE: Hold the front fork by hand to prevent sliding out of the steering stem. • Remove the front fork 5. • Remove the front fork cap 6, stopper ring 7 and front fork spring 8.

  • Page 166: Inspection

    5-29 CHASSIS • Pull out the inner tube B from the outer tube. • Remove the oil seal stopper ring C. • Remove the oil seal D with the special tool. & 09913-50121: Oil seal remover INSPECTION INNER AND OUTER TUBE Inspect the inner tube sliding surface and outer tube sliding sur- face for any scuffing or damage.

  • Page 167: Reassembly

    CHASSIS 5-30 FRONT FORK SPRING Measure the front fork spring free length. If the front fork spring free length is shorter than the service limit, replace the front fork spring with a new one. % Front fork spring free length: Service Limit: 290 mm DAMPER ROD RING Inspect the damper rod ring for wear or damage.
  • Page 168 • Install the inner tube 1 into the outer tube 2. • Apply fork oil to the lip of oil seal 3 lightly. 0 99000-99001-SS8: SUZUKI FORK OIL SS-08 or equivalent fork oil • Insert the oil seal 3 to the inner tube.
  • Page 169 • Pour specified fork oil into the outer tube. % Front fork oil capacity (each leg): 51 ml 0 99000-99001-SS8: SUZUKI FORK OIL SS-08 or equivalent fork oil • Hold the front fork leg in a vertical position and adjust the fork oil level with the special tool.

  • Page 170: Installation

    5-33 CHASSIS INSTALLATION • Install the front fork to the steering stem. • Tighten the front fork clamp bolts 1 to the specified torque. " Front fork clamp bolt: 32.5 N·m (3.25 kgf-m) • Install the front fender No. 2 2 and front fender No. 1 3. •...

  • Page 171: Handlebars

    CHASSIS 5-34 HANDLEBARS CONSTRUCTION 1 Handlebars 2 Left handlebar grip 3 Starter lever 4 Front brake lever 5 Front brake switch 6 Throttle grip case 7 Right handlebar grip A Handlebar clamp nut B Brake lever nut " ITEM N·m kgf-m REMOVAL •...

  • Page 172: Inspection

    • When installing the throttle grip case, engage the stopper A of upper throttle case with the hole B of handlebar 1. • Apply SUZUKI SUPER GREASE “A” to the throttle cable end and cable drum. * 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 173 CHASSIS 5-36 HANDLEBAR LEFT SIDE PARTS • Apply handle grip bond onto the handlebars before installing the handlebar grip. Handlebars • Install the starter lever 1. After installing the steering, the following adjustments are required before driving. • Cable routing. ($7-16) •...

  • Page 174: Steering

    5-37 CHASSIS STEERING CONSTRUCTION 1 Steering stem nut 2 Washer 3 Dust cover Upper bearing inner race 5 Steel ball Upper bearing outer race Lower bearing outer race 8 Steering stem Lower bearing inner race A Steering stem nut " ITEM N·m kgf-m...

  • Page 175: Inspection And Disassembly

    CHASSIS 5-38 • Remove the washer 2. • Remove the steering stem nut 3 with the special tool. NOTE: Hold the steering stem by hand to prevent it from falling. & 99000-60611: Universal clamp wrench • Remove the dust cover 4. •...
  • Page 176 5-39 CHASSIS • Remove the lower bearing inner race with a chisel. The removed lower bearing inner race must be replaced with a new one. • Drive out the upper and lower bearing outer races. The removed bearing outer races must be replaced with new ones.

  • Page 177: Reassembly

    • Press fit the lower bearing inner race 1 with the special tools. & 09913-70210: Bearing installer set 09940-51710: Bearing installer • Apply SUZUKI SUPER GREASE “A” to the upper and lower bearing outer races. • Install the steel balls.
  • Page 178 5-41 CHASSIS • Turn the steering stem about five or six times to the left and right so that the steel balls will be seated properly. 1/4 – 1/2 turn • Loosen the stem nut by 1/4 – 1/2 turn. NOTE: This adjustment will vary from motorcycle to motorcycle.

  • Page 179: Rear Wheel

    CHASSIS 5-42 REAR WHEEL CONSTRUCTION 1 Rear axle shaft 2 Lock washer 3 Rear sprocket 4 Sprocket drum spacer 5 Oil seal 6 Sprocket drum bearing 7 Sprocket drum 8 Sprocket drum retainer 9 Rear sprocket damper Rear wheel outer bearing (Left) Rear wheel inner bearing (Left)

  • Page 180: Removal

    5-43 CHASSIS REMOVAL • Support the motorcycle with the center stand. • Remove the drive chain covers 1 by removing the bolts and screw. • Remove the rear brake adjuster nut 2. • Remove the cotter pin and torque link nut 3. •...

  • Page 181: Disassembly And Inspection

    CHASSIS 5-44 DISASSEMBLY AND INSPECTION REAR AXLE SHAFT ........... $5-10 REAR WHEEL ............$2-19 SPOKE NIPPLES............$2-19 TIRE ................$2-19 • Remove the rear brake panel 1. • Remove the sprocket drum 2. • Remove the rear sprocket damper 3 out of the wheel hub. WHEEL BEARINGS •...
  • Page 182 5-45 CHASSIS • Remove the rear wheel bearings left 4 and right 5 with the special tool. & 09941-50111: Wheel bearing remover The removed rear wheel bearings must be replaced with new ones. REAR SPROCKET DRUM • Remove the sprocket drum spacer 1 and sprocket drum retainer 2.

  • Page 183: Inspection

    CHASSIS 5-46 REAR SPROCKET DRUM • Inspect the play of the rear sprocket drum bearing by finger while they are in the wheel. Rotate the inner race by finger to inspect for abnormal noise and smooth rotation. • Replace the bearing in the following procedure if there is any- thing unusual.

  • Page 184: Reassembly And Installation

    Pay attention to the following points: REAR WHEEL BEARINGS • Apply SUZUKI SUPER GREASE “A” to the rear wheel bear- ings before installing. * 99000-25010: SUZUKI SUPER GREASE “A” • First, install the right wheel bearing 1, then spacer 2, left inner bearing 3, and left outer bearing 4 with a suitable size box wrench, and the special tool.
  • Page 185 • Install the oil seal 2 with the special tool. & 09913-70210: Bearing installer set • Apply SUZUKI SUPER GREASE “A” to the oil seal lip. * 99000-25010: SUZUKI SUPER GREASE “A” The removed oil seal must be replaced with a new one.
  • Page 186 5-49 CHASSIS • Adjust the drive chain slack after installing the rear wheel. ($2-12) • Tighten the rear axle nut 3 and torque link nut 4 to the spec- ified torque. " Rear axle nut: 42 N·m (4.2 kgf-m) Torque link nut: 13 N·m (1.3 kgf-m) •...

  • Page 187: Rear Brake

    CHASSIS 5-50 REAR BRAKE 1 Brake shoe 2 Rear brake panel 3 Brake camshaft 4 Dust seal Brake lining wear indi- cator plate 6 Rear axle spacer 7 Brake cam lever bolt 8 Brake cam lever Rear brake adjuster 0 Pin A Spring A Brake cam lever nut B Rear axle nut...

  • Page 188: Inspection

    5-51 CHASSIS • Remove the brake cam lever nut 3 and bolt. • Remove the brake cam lever 4. • Remove the brake lining wear indicator plate 5. • Remove the brake camshaft 6 and dust seal 7. INSPECTION BRAKE DRUM Inspect the brake drum and measure the brake drum I.D.

  • Page 189: Reassembly And Remounting

    Reassemble and remount the rear brake in the reverse order of removal and disassembly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the brake camshaft and pin, and install the brake shoes. * 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 190 5-53 CHASSIS • Install the dust seal 1. The removed dust seal must be replaced with a new one. • Install the camshaft 2. • When installing the brake lining wear indicator plate 3, align the tongue 4 on the brake lining wear indicator plate 3 with the cutaway 5 on the brake camshaft.
  • Page 191 CHASSIS 5-54 • Install the brake shoes 0. • Install the rear wheel. ($5-47) REAR BRAKE PEDAL • Remove the muffler. ($3-5) • Remove the rear brake adjuster nut 1. • Remove the rear brake switch spring 2. • Remove the rear brake pedal return spring 3.
  • Page 192 INSTALLATION Install the rear brake pedal in the reverse order of removal. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the rear brake pedal shaft. * 99000-25010: SUZUKI SUPER GREASE “A” • Install the right pillion footrest bracket 1.

  • Page 193: Rear Suspension

    CHASSIS 5-56 REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber Rear shock absorber mounting bolt (Upper) Rear shock absorber mounting bolt (Lower) " ITEM N·m kgf-m 28.5 2.85 28.5 2.85 REMOVAL AND DISASSEMBLY • Remove the frame covers, left and right. ($5-7) •...

  • Page 194: Inspection

    5-57 CHASSIS INSPECTION SHOCK ABSORBER Inspect the rear shock absorber for damage and oil leakage. If any defects are found, replace the rear shock absorber with a new one. Do not attempt to disassemble the rear shock absorber unit. It is unserviceable. SPACER AND BUSH Inspect the spacers and bushes for wear and damage.

  • Page 195: Swingarm

    CHASSIS 5-58 SWINGARM CONSTRUCTION 1 Swingarm 2 Chain buffer 3 Swingarm pivot shaft 4 Torque link 5 Pillion footrest bracket A Swingarm pivot nut B Torque link nut Pillion footrest bracket lower bolt " ITEM N·m kgf-m REMOVAL AND DISASSEMBLY •...
  • Page 196 5-59 CHASSIS • Remove the swingarm pivot nut 5, washer 6 and shaft 7. • Remove the pillion footrest brackets 8, left and right. • Remove the swingarm 9. SWINGARM • Remove the chain buffer 1 and washer 2. • Remove the cotter pin 3, torque link nut 4, washer 5 and torque link 6.

  • Page 197: Inspection

    CHASSIS 5-60 • Remove the pin 4, washer 5 and pillion footrest 6. INSPECTION SWINGARM Inspect the swingarm for damage. If any defects are found, replace the swingarm with a new one.
  • Page 198 5-61 CHASSIS SWINGARM PIVOT SHAFT Measure the swingarm pivot shaft runout using the dial gauge. If the runout exceeds the service limit, replace the swingarm pivot shaft with a new one. % Swingarm pivot shaft runout Service limit: 0.6 mm &...

  • Page 199: Reassembly And Remounting

    CHASSIS 5-62 TORQUE LINK Inspect the torque link for bend or damage. If any defects are found, replace the torque link with a new one. REASSEMBLY AND REMOUNTING Reassemble and remount the swingarm and pillion footrest in the reverse order of removal and disassembly. Pay attention to the following points: PILLION FOOTREST •...

  • Page 200: Final Inspection And Adjustment

    5-63 CHASSIS • Install the rear shock absorber. ($5-57) • Install the rear wheel. ($5-47) FINAL INSPECTION AND ADJUSTMENT After installing the rear brake, rear sprocket drum and wheel, the following adjustments are required before driving. * Drive chain ($2-14) * Rear brake ($2-19)
  • Page 201 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................. 6- 2 CONNECTOR ..................6- 2 COUPLER....................6- 2 CLAMP ....................6- 2 FUSE...................... 6- 2 SEMI-CONDUCTOR EQUIPPED PART ..........6- 3 BATTERY ....................6- 3 CONNECTING THE BATTERY............. 6- 3 WIRING PROCEDURE................

  • Page 202: Cautions In Servicing

    ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. Click • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER Click • With a lock type coupler, be sure to release the lock when dis- connecting, and push in fully to engage the lock when con- necting.

  • Page 203: Semi-Conductor Equipped Part

    ELECTRICAL SYSTEM 6-3 SEMI-CONDUCTOR EQUIPPED PART • Be careful not to drop the part which has a semi-conductor INCORRECT built in such as a CDI unit and regulator/rectifier. • When inspecting these parts, follow the instructions carefully. Failure to follow the proper procedure can cause damage to these parts.

  • Page 204: Using The Multi-Circuit Tester

    ELECTRICAL SYSTEM USING THE MULTI-CIRCUIT TESTER • Properly use the multi-circuit tester + and - probes. Improper use can cause damage to the motorcycle and tester. • If the voltage and current values are not known, begin mea- suring in the highest range. •...

  • Page 205: Location Of Electrical Components

    ELECTRICAL SYSTEM 6-5 LOCATION OF ELECTRICAL COMPONENTS 1 Regulator/rectifier 5 Fuse 2 Turn signal relay 6 Ignition coil 3 Horn 7 Generator 4 Battery...
  • Page 206 ELECTRICAL SYSTEM 1 CDI unit 3 Starter motor (For FL125SD) 2 Starter relay (For FL125SD)

  • Page 207: Charging And Lighting System

    ELECTRICAL SYSTEM 6-7 CHARGING AND LIGHTING SYSTEM Starter relay Starter button Ignition Starter Front brake Main switch motor switch fuse Rear brake switch Gear position switch Battery Brake light Bl W/Y R/B G/Bl Y/Bl Bl W/Y R/B G/Bl Y/Bl and taillight Bl W/Y R/B G/Bl Y/Bl Bl W/Y R/B G/Bl Y/Bl CDI unit...
  • Page 208 ELECTRICAL SYSTEM Step 2 1) Check the battery for current leaks. ($6-9) Is the battery OK? Go to Step 3. • Shorted circuit of wire harness. • Faulty electrical equipment. Step 3 1) Measure the charging output between the battery terminals. ($6-9) Is the charging output OK? •...

  • Page 209: Inspection

    ELECTRICAL SYSTEM 6-9 INSPECTION BATTERY CURRENT LEAKAGE • Turn the ignition switch to the OFF position. • Open the seat. ($5-5) • Remove the battery box lid 1. • Disconnect the battery - lead wire. • Measure current between the - battery terminal and - bat- tery lead wire using the multi-circuit tester.
  • Page 210 6-10 ELECTRICAL SYSTEM GENERATOR COIL RESISTANCE • Remove the front frame cover. ($5-5) • Remove the rear center leg shield. ($5-6) • Disconnect the generator coupler. Measure the resistance between generator lead wires using the multi-circuit tester. If the resistance is not within the specified value, replace the generator with a new one.
  • Page 211 ELECTRICAL SYSTEM 6-11 REGULATOR/RECTIFIER • Remove the frame head cover. ($5-6) • Disconnect the regulator/rectifier coupler 1. • Remove the regulator/rectifier 2. Measure the voltage between the terminals using the multi-cir- cuit tester, as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.

  • Page 212: Starter System (For Fl125Sd)

    6-12 ELECTRICAL SYSTEM STARTER SYSTEM (For FL125SD) Starter relay Starter Ignition Starter button switch motor Main fuse Battery TROUBLESHOOTING (For FL125SD) NOTE: * Make sure that the fuse is not blown and the battery is fully-charged before diagnosing. Starter motor will not run. Step 1 1) Disconnect the starter motor lead wire.

  • Page 213: Starter Motor Removal (For Fl125Sd)

    ELECTRICAL SYSTEM 6-13 Step 3 1) Measure the starter relay voltage at the starter relay couplers (between Y/G + and B/W -) when the starter button is pushed. Is the voltage OK? Go to Step 4. • Faulty starter button. •...

  • Page 214: Starter Motor Disassembly (For Fl125Sd)

    6-14 ELECTRICAL SYSTEM STARTER MOTOR DISASSEMBLY (For FL125SD) • Disassemble the starter motor as shown in the illustration. " 1 Housing end (outside) 5 O-ring 2 Starter motor case A Starter motor lead wire nut ITEM N·m kgf-m 3 Armature B Starter motor mounting bolt 4 Housing end (inside) •...
  • Page 215 ELECTRICAL SYSTEM 6-15 • Remove the armature 6. • Remove the thrust washer 7 (t: 0.8), thrust washer 8 (t: 0.2) and brush holder 9. • Remove the insulators 0. • Remove the nut A, washer B, slip washer No. 1 C, slip washers No.

  • Page 216: Starter Motor Inspection (For Fl125Sd)

    6-16 ELECTRICAL SYSTEM STARTER MOTOR INSPECTION (For FL125SD) CARBON BRUSH Inspect the brushes for abnormal wear, cracks, or smoothness in the brush holder. If any defects are found, replace the brush assembly with a new one. Make sure that the length A is not less than 3.5 mm, If this length becomes less than 3.5 mm, replace the brush.

  • Page 217: Starter Motor Reassembly And Installation (For Fl125Sd)

    INSTALLATION (For FL125SD) Reassemble and install the starter motor in the reverse order of disassembly. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to the lip of the oil seal and bearing. * 99000-25010: SUZUKI SUPER GREASE “A”...
  • Page 218 ELECTRICAL SYSTEM • Install the O-ring. The removed O-ring must be replaced with a new one. • Apply SUZUKI SUPER GREASE “A” to the O-ring. * 99000-25010: SUZUKI SUPER GREASE “A” STARTER MOTOR INSTALLATION • Tighten the starter motor mounting bolts 1 to the specified torque.

  • Page 219: Starter Relay Inspection (For Fl125Sd)

    ELECTRICAL SYSTEM 6-19 STARTER RELAY INSPECTION (For FL125SD) • Remove the front frame cover. ($5-5) • Disconnect the battery - lead wire from the battery. • Disconnect the starter relay coupler 1. • Remove the starter relay 2. • Apply 12 V to A and B terminals and check for continuity between the positive C and negative D terminals using the multi-circuit tester.

  • Page 220: Ignition System

    6-20 ELECTRICAL SYSTEM IGNITION SYSTEM Ignition Main fuse switch Regulator/ Rectifier Battery Ignition coil CDI unit B/W B/W W/Bl BI/Y Spark plug Pick-up coil Generator TROUBLESHOOTING NOTE: * Make sure that the fuse is not blown and the battery is fully-charged before diagnosing. No spark or poor spark Step 1 1) Check the ignition system couplers for poor connections.
  • Page 221 ELECTRICAL SYSTEM 6-21 Step 3 1) Measure the ignition coil primary peak voltage and ignition coil resistance. ($6-23) NOTE: This inspection method is applicable only with the multi-circuit tester and the peak volt adaptor. Are the primary peak voltage and resistance OK? Go to Step 4.

  • Page 222: Inspection

    6-22 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the leg shield. ($5-6) • Disconnect the spark plug cap 1. • Connect a new spark plug 2 to the spark plug cap and ground it to the cylinder head cover. NOTE: Make sure that the spark plug cap and spark plug are connected properly.
  • Page 223 ELECTRICAL SYSTEM 6-23 IGNITION COIL RESISTANCE • Remove the rear center leg shield. ($5-6) • Disconnect the ignition coil lead wire 1 and remove the igni- tion coil 2. • Remove the spark plug cap. ($6-22) Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi-circuit tester.
  • Page 224 6-24 ELECTRICAL SYSTEM If the peak voltage measured on the CDI unit coupler is lower than the specified value, measure the peak voltage on the pick-up coil coupler as follows. • Remove the rear center leg shield. ($5-6) • Disconnect the pick-up coil coupler 1. •...

  • Page 225: Speedometer

    ELECTRICAL SYSTEM 6-25 SPEEDOMETER REMOVAL AND DISASSEMBLY • Remove the rear view mirrors. ($5-4) • Remove the rear handlebar covers. ($5-4) • Remove the speedometer 1. • Disassemble the speedometer as shown.

  • Page 226: Inspection

    6-26 ELECTRICAL SYSTEM INSPECTION Check the continuity between the lead wires using the multi-circuit tester. If there is no continuity replace the respective parts. & 09900-25008: Multi-circuit tester set 7 Tester knob indication: Continuity test (8) High beam indicator light Gear position indicator light Turn signal indicator light (R) Turn signal indicator light (L)

  • Page 227: Fuel Meter And Fuel Level Gauge

    ELECTRICAL SYSTEM 6-27 FUEL METER AND FUEL LEVEL GAUGE FUEL METER INSPECTION To test the fuel meter, perform the following tests. Test 1 This test will determine if the fuel meter is operating. • Open the seat. ($5-5) • Disconnect the fuel level gauge coupler. ($4-2) •...

  • Page 228: Relays

    6-28 ELECTRICAL SYSTEM RELAYS TURN SIGNAL RELAY INSPECTION • Remove the frame head cover. ($5-4) 1: Turn signal relay Before removing the turn signal relay, check the operation of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.

  • Page 229: Lamps

    ELECTRICAL SYSTEM 6-29 LAMPS HEADLIGHT 1: Headlight bulb: 12 V 25/25 W HEADLIGHT BULB REPLACEMENT • Remove the handlebar cover. ($5-4) • Remove the headlight bulbs 1. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.

  • Page 230: Front Turn Signal Light

    6-30 ELECTRICAL SYSTEM FRONT TURN SIGNAL LIGHT 1: Front turn signal light bulb: 12 V 10 W FRONT TURN SIGNAL LIGHT BULB REPLACEMENT • Remove the frame head cover. ($5-6) • Remove the front turn signal light bulbs 1, left and right. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.

  • Page 231: Brake Light/Taillight And Rear Turn Signal Light

    ELECTRICAL SYSTEM 6-31 BRAKE LIGHT/TAILLIGHT AND REAR TURN SIGNAL LIGHT 1: Brake light/Taillight: LED 2: Rear turn signal light bulb: 12V 10 W REAR TURN SIGNAL LIGHT BULB REPLACEMENT • Remove the frame covers, left and right. ($5-7) • Remove the rear turn signal light bulbs, left and right. If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
  • Page 232 6-32 ELECTRICAL SYSTEM • Remove the rear combination light bracket 2. • Remove the rear combination light lens 3. • Remove the brake light/taillight assembly 4.

  • Page 233: License Plate Light

    ELECTRICAL SYSTEM 6-33 LICENSE PLATE LIGHT 1: License plate light bulb: 12 V 5 W Do not overtighten the lens fitting screws. LICENSE PLATE LIGHT BULB REPLACEMENT • Remove the license plate light case 1. • Remove the license plate light bulb.

  • Page 234: Switches

    6-34 ELECTRICAL SYSTEM SWITCHES Measure each switch for continuity using the multi-circuit tester. If there is no continuity, replace the respec- tive switch with a new one. IGNITION SWITCH FRONT BRAKE SWITCH Color Color Position Position TURN SIGNAL SWITCH REAR BRAKE SWITCH Color Color B/Lbl...

  • Page 235: Battery

    ELECTRICAL SYSTEM 6-35 BATTERY SPECIFICATIONS FL125S FL125SD Type designation YTZ3 FTZ5S 12 V, 8.0 kC 12 V, 12.6 kC Capacity (2.5 Ah)/10 HR (3.5 Ah)/10 HR 1 Upper cover breather 5 Terminal 2 Cathode plates 6 Safety valve 3 Stopper...
  • Page 236 6-36 ELECTRICAL SYSTEM • Make sure air bubbles 5 are coming up in each electrolyte container, and leave in this position for about more than 20 minutes. NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times.

  • Page 237: Servicing

    ELECTRICAL SYSTEM 6-37 SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, clean the battery terminals with sandpaper.
  • Page 238 SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING.................. 7- 2 ENGINE ....................7- 2 CLUTCH ....................7- 5 CARBURETOR ..................7- 6 CHASSIS ....................7- 7 BRAKES....................7- 8 ELECTRICAL ..................7- 9 BATTERY ....................7-10 WIRING DIAGRAM..................7-11 WIRING HARNESS, CABLE AND HOSE ROUTING........7-13 WIRING HARNESS ROUTING ..............

  • Page 239: Troubleshooting

    SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low start, or is hard to 1. Valve clearance out of adjustment. Adjust. start. 2. Worn valve guides or poor seating of valves. Repair or replace. 3.
  • Page 240 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Noisy engine. Noise seems to come from timing chain 1. Stretched chain. Replace. 2. Worn sprocket. Replace. 3. Not working tension adjuster. Repair or replace. Noise seems to come from clutch 1. Worn splines of countershaft or hub. Replace.
  • Page 241 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Transmission will 1. Broken gearshift cam. Replace. not shift. 2. Distorted gearshift forks. Replace. 3. Worn gearshift pawl. Replace. Transmission 1. Worn shifting gears on driveshaft or countershaft. Replace. jumps out of gear. 2.

  • Page 242: Clutch

    SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine lacks power. 1. Loss of valve clearance. Adjust. 2. Weakened valve spring. Replace. 3. Valve timing out of adjustment. Adjust. 4. Worn piston rings or cylinder. Replace. 5. Poor seating of valves. Repair.

  • Page 243: Carburetor

    SERVICING INFORMATION CARBURETOR Complaint Symptom and possible causes Remedy Starting difficulty. 1. Clogged starter plunger. Clean. 2. Clogged starter plunger passage. Clean. 3. Air leaking from joint between starter lever and Tighten, adjust, or replace carburetor. the gasket. 4. Air leaking from carburetor joint or vacuum hose Tighten or replace defec- joint.

  • Page 244: Chassis

    SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Heavy steering. 1. Overtightened steering stem nut. Adjust. 2. Broken bearing in steering stem. Replace. 3. Distorted steering stem. Replace. 4. Not enough pressure in tires. Adjust. Wobbly handlebars. 1. Loss of balance between right and left front forks. Replace.

  • Page 245: Brakes

    SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Remedy Insufficient front 1. Leakage of brake fluid from hydraulic system. Repair or replace. brake power. 2. Worn pads or disc. Replace. 3. Oil adhesion on friction surface of pads. Clean disc and pads. 4.

  • Page 246: Electrical

    SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil or CDI unit. Replace. sparking. 2. Defective spark plug. Replace. 3. Defective pick-up coil or generator coil. Replace. 4. Open-circuited wiring connections. Check and repair. Spark plug soon 1.

  • Page 247: Battery

    SERVICING INFORMATION 7-10 BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Cracked battery case. Replace the battery. white powdery sub- 2. Battery has been left in a run-down condition for Replace the battery. stance or spots on a long time. surface of cell plates.

  • Page 248: Wiring Diagram

    7-11 SERVICING INFORMATION WIRING DIAGRAM FL125S...
  • Page 249 SERVICING INFORMATION 7-12 FL125SD...

  • Page 250: Wiring Harness, Cable And Hose Routing

    7-13 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Pass though the wiring harness to the frame bracket. Battery Battery terminal Clamp Wiring harness Battery Horn lead wire Seat lock Front turn signal Regulator/Rectifier cable light (R) coupler Rear combination License plate light coupler...
  • Page 251 SERVICING INFORMATION 7-14 Front fork upper bracket Wiring harness Speedometer cable Front brake hose Starter cable Speedometer Throttle cable Horn button Front brake switch Dimmer switch Headlight coupler Turn signal switch Fuel level gauge lead wire Starter motor relay Relay bracket Fuel Rear combination tank...
  • Page 252 7-15 SERVICING INFORMATION Gear position lead wire Engine sprocket cover Generator rotor Clamp Gear position switch Crank case (L) Clamp...

  • Page 253: Cable Routing

    SERVICING INFORMATION 7-16 CABLE ROUTING Frame Harness Starter cable Speedometer cable Front brake hose Throttle cable Starter cable Starter lever Starter cable holder Throttle cable Starter cable Pass through the throttle cable and speedometer inside of the starter cable. Front brake hose Speedometer cable Starter cable Starter cable...

  • Page 254: Seat Lock Cable Routing

    7-17 SERVICING INFORMATION SEAT LOCK CABLE ROUTING Pass through the seat lock cable inside of the air cleaner box mount. Seat lock cable Seat lock cable Clamp Clamp Clamp Pass through the seat lock cable inside cable guide. Clamp Wiring harness Seat lock cable Clamp Wiring harness...

  • Page 255: Front Brake Hose Routing

    SERVICING INFORMATION 7-18 FRONT BRAKE HOSE ROUTING 90˚ Pass through the brake hose inside the guide. Pass through the brake hose inside the guide. Set the brake hose into clamp firmly. 28˚...

  • Page 256: Fuel Hose Routing

    7-19 SERVICING INFORMATION FUEL HOSE ROUTING Pass through the vacuum of the wiring harness Vacuum hose Clamp Fuel hose guide Fuel filter Fuel tank hose Fuel tank Fuel tap vacuum hose Fuel hose clamp Fuel hose guide...

  • Page 257: Hose Routing

    SERVICING INFORMATION 7-20 HOSE ROUTING Air vent carburetor hose Fuel hose Crank case breather hose Clamp Breather hose Fuel tap vacuum hose Pass the breather hose through the guide. PAIR valve vacuum hose...

  • Page 258: Pair (Air Supply) System Hose Routing

    7-21 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING Matching mark (White) Pass the second air cleaner hose the through the downward of the high tension cord. Intake pipe Direct the grip section of the clamp downward PAIR valve vacuum hose Air cleaner box PAIR valve PAIR valve pipe...

  • Page 259: Exterior Parts Construction

    SERVICING INFORMATION 7-22 EXTERIOR PARTS CONSTRUCTION Front right Frame head cover leg shield Rear right leg shield Front left leg shield Rear left leg shield Front center leg shield Frame Rear center leg shield...
  • Page 260 7-23 SERVICING INFORMATION Front frame cover Right lower frame cover Rear Right frame cover combination lamp Frame center cover Battery box lid Rear fender Left frame cover Helmet holder Luggage box Luggage mud guard Left lower frame cover Frame...

  • Page 261: Prop Stand Installation

    SERVICING INFORMATION 7-24 PROP STAND INSTALLATION 40 N . m (4.0 kgf-m) Outside Assembling direction of return spring. CENTER STAND INSTALLATION Assembling direction of return spring.

  • Page 262: Brake Pedal

    7-25 SERVICING INFORMATION BRAKE PEDAL...

  • Page 263: Pillion Footrest

    SERVICING INFORMATION 7-26 PILLION FOOTREST...

  • Page 264: Special Tools

    7-27 SERVICING INFORMATION SPECIAL TOOLS 09900-20101 09900-20202 09900-20203 09900-20205 09900-20530 09900-20102 Micrometer Micrometer Micrometer Cylinder gauge set Vernier calipers (25 – 50 mm) (1/100 mm, 50 – 75 mm) (1/1 000 mm, 0 – 25 mm) (1/100 mm, 40 – 80 mm) 09900-20602 09900-20605 09900-20607...
  • Page 265 SERVICING INFORMATION 7-28 09915-63311 09915-64512 09915-74533 Compression gauge Compression gauge 09915-72410 09915-74511 Oil pressure gauge adaptor Adaptor Oil pressure gauge adaptor 09916-14522 09916-34542 09916-34570 09916-10911 09916-14510 Valve lifter Valve guide reamer Valve guide reamer Valve lapper set Valve lifter attachment handle (5.0 mm) 09916-34580...
  • Page 266 7-29 SERVICING INFORMATION 09930-44570 09940-52861 09940-60113 09941-34513 Crank barancer 09940-51710 Front fork oil seal Spoke nipple Steering outer race holder Bearing installer installer set wrench installer 09941-50111 09943-74111 09951-16080 Bearing remover Fork oil level gauge Bearing installer NOTE: Before placing order for the special tool, please check for availability.

  • Page 267: Tightening Torque

    SERVICING INFORMATION 7-30 TIGHTENING TORQUE ENGINE ITEM N·m kgf-m Exhaust pipe nut Muffler mounting bolt Muffler connecting bolt Valve clearance adjuster lock-nut Spark plug Engine oil drain plug 17.5 1.75 Oil filter cap bolt Main oil gallery plug Engine mounting nut Drive chain sprocket bolt Valve clearance inspection cap bolt Starter clutch bolt...

  • Page 268: Chassis

    7-31 SERVICING INFORMATION CHASSIS ITEM N·m kgf-m Rear axle nut Air bleeder valve 0.55 Spoke nipple 2.75 0.275 Pillion footrest bracket lower bolt Footrest mounting bolt 14.5 1.45 Front fork clamp bolt 32.5 3.25 Handlebar clamp nut Steering stem nut Front axle nut Brake disc bolt Brake caliper mounting bolt...

  • Page 269: Tightening Torque Chart

    SERVICING INFORMATION 7-32 TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter A Conventional or “4” marked bolt “7” marked bolt (mm) N·m kgf-m N·m kgf-m 0.15 0.23 0.45 0.55 13.5 10.5...

  • Page 270: Service Data

    7-33 SERVICING INFORMATION SERVICE DATA VALVE + GUIDE Unit: mm ITEM STANDARD LIMIT Valve diam. — — Valve clearance (when cold) 0.03 – 0.08 — 0.08 – 0.13 — Valve guide-to-valve stem 0.010 – 0.037 — clearance 0.030 – 0.057 —...
  • Page 271 SERVICING INFORMATION 7-34 CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Compression pressure 750 kPa 1 200 – 1 700 kPa (12 – 17 kgf/cm²) (7.5 kgf/cm²) Piston-to-cylinder clearance 0.04 – 0.05 0.120 Cylinder bore 53.500 – 53.515 53.635 Piston diam.
  • Page 272 7-35 SERVICING INFORMATION GEAR SHIFT CLUTCH Unit: mm ITEM STANDARD LIMIT Clutch release screw 1/8 turn back — Drive plate thickness 2.9 – 3.1 Drive plate claw width 11.80 – 12.00 11.0 Driven plate distortion — 0.10 Clutch spring free length 32.0 30.4 TRANSMISSION + DRIVE CHAIN...
  • Page 273 40 V or more at 5 000 r/min -: Ground Starter motor brush length Regulated voltage 13.5 – 15.2 V at 5 000 r/min 9 – 11 Ω Starter relay resistance Battery FL125S YTZ3 Type des- ignation FL125SD YTZ5S 12 V 8.0 kC (2.5 Ah)/ FL125S...
  • Page 274 Front fork spring free length 296.6 Front fork oil level (without spring, — inner tube fully compressed) Front fork oil type SUZUKI FORK OIL SS-08 or equivalent fork oil — Front fork oil capacity (each leg) 51 ml — ( 26 Front fork inner tube diam.
  • Page 275 SERVICING INFORMATION 7-38 TIRE ITEM STANDARD LIMIT Cold inflation tire pressure 175 kPa Front — (Solo riding) (1.75 kgf/cm²) 225 kPa Rear — (2.25 kgf/cm²) Cold inflation tire pressure 175 kPa Front (1.75 kgf/cm²) (Dual riding) 280 kPa Rear (2.80 kgf/cm²) Tire size Front 60/100-17 M/C 33P...

  • Page 276: Fl125Sdw

    FL125S/SD. NOTE: • Any differences between the FL125S/SD and FL125SDW in specifications and service data are indicated with an asterisk mark (*). • Please refer to the chapters 1 tbrough 7 for details which are not given in this chapter.
  • Page 277 FL125SDW FL125SDW CONTENTS FUEL SYSTEM ....................8-81 FUEL FILTER ..................8-81 THROTTLE BODY................. 8-82 FUEL INJECTOR................... 8-86 ELECTRICAL SYSTEM .................. 8-88 CHARGING SYSTEM ................8-88 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM ....................8-92 IGNITION SYSTEM ................8-96 SPEEDOMETER.................. 8-100 RELAYS....................8-101 DIODES ....................

  • Page 278: Abbreviations Used In This Manual

    : Read Only Memory : Fuel Injection, Fuel Injector (Dis- charge pump; DCP) : Society of Automotive Engineers : Fuel Pump : Suzuki Diagnosis System : Fuel Pressure Regulator FP Relay : Fuel Pump Relay TO Sensor : Tip Over Sensor (TOS)

  • Page 279: Wire Color

    FL125SDW WIRE COLOR : Black : Orange : Blue : Pink : Dark green : Red : Green : White : Gray : Yellow : Light green : Black with Green tracer B/Lg : Black with Light green tracer B/Lbl : Black with Light blue tracer : Black with White tracer Bl/W...

  • Page 280: Specifications (Fl125Sdw)

    FL125SDW SPECIFICATIONS (FL125SDW) DIMENSIONS AND DRY MASS Overall length................1 885 mm Overall width ................715 mm Overall height................1 075 mm Wheelbase ................1 220 mm Ground clearance ..............135 mm Seat height................770 mm Dry mass................. 104 kg ENGINE Type ..................

  • Page 281: Chassis

    FL125SDW CHASSIS Front suspension..............Telescopic, coil spring, oil damped Rear suspension ..............Swingarm type, coil spring, oil damped Front fork stroke ..............90 mm Rear wheel travel ..............77 mm Caster..................27° Trail ..................70 mm Steering angle ................. 45° (right and left) Turning radius .................

  • Page 282: Periodic Maintenance Schedule

    FL125SDW PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometer and time for your convenience. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.

  • Page 283: Maintenance And Tune-Up Procedures

    PROCEDURES This section describes the servicing procedures for each Peri- odic Maintenance item which differ from those of the FL125S/ For details other than the following items, refer to the FL125S/ SD Service Manual. FUEL LINE Inspect every 4 000 km (20 months).

  • Page 284: Sds Check

    FL125SDW 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.

  • Page 285: Data At The Time Of Racing

    FL125SDW 8-10 Data at 3 000 r/min under no load 3 000 r/min Check the manifold absolute pressure. Approx. XXX kPa (XXX mmHg) Data at the time of racing Throttle: Throttle: Slowly open Quick wide open...
  • Page 286 8-11 FL125SDW Data of intake negative pressure during idling (90 °C) Check the engine temperature. Approx. 90 ˚ Check the manifold absolute pressure. Approx. XXX kPa (XXX mmHg) 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.

  • Page 287: Fi System Diagnosis

    FL125SDW 8-12 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.
  • Page 288 8-13 FL125SDW • 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.
  • Page 289 FL125SDW 8-14 • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, or electronic parts may get damaged. INCORRECT • 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.
  • Page 290 8-15 FL125SDW 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.
  • Page 291 FL125SDW 8-16 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.
  • Page 292 8-17 FL125SDW 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.
  • Page 293 FL125SDW 8-18 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 may cause the inside of the tester to burnout.

  • Page 294: Fi System Technical Features

    8-19 FL125SDW 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.
  • Page 295 FL125SDW 8-20 COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ENGINE TEMPERATURE SENSOR When engine temperature is low, injection time (volume) is SIGNAL increased.
  • Page 296 8-21 FL125SDW FI SYSTEM PARTS LOCATION A ECM E Intake air pressure sensor/Throttle position sensor/Intake air tem- B Tip-over sensor (TOS) perature sensor (IAPS/TPS/IATS) C Fuel injector F Engine temperature sensor (ETS) D ISC valve G Heated oxygen sensor (HO2S)
  • Page 297 FL125SDW 8-22 A ECM I Ignition coil (IG coil) H Speedometer J Crankshaft position sensor (CKPS)
  • Page 298 8-23 FL125SDW FI SYSTEM WIRING DIAGRAM Crankshaft position sensor (CKPS) Generator Fuel injector HO2 sensor heater Ignition coil Throttle position sensor (TPS) ISC valve Intake air pressure sensor (IAPS) Intake air temperature sensor (IATS) FI indicator light Ignition switch Tip-over sensor (TOS) Regulator/ rectifier Load cut off relay...
  • Page 299 FL125SDW 8-24 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.
  • Page 300 8-25 FL125SDW 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 fuel injector.
  • Page 301 FL125SDW 8-26 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).
  • Page 302 8-27 FL125SDW 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.

  • Page 303: Ecm Terminal

    FL125SDW 8-28 ECM TERMINAL ECM coupler TERMINAL TERMINAL CIRCUIT CIRCUIT Power ground (E0) Ignition coil ISC valve (ISC) FI indicator light Fuel injector - Control ground (E1) Sensor ground (E2) Mode select switch Fuel injector + Power source (+B) HO2 sensor heater (HO2H) —...

  • Page 304: Self-Diagnosis Function

    8-29 FL125SDW 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.
  • Page 305 FL125SDW 8-30 DEALER MODE The defective function is memorized in the ECM. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is indicated by the flashing pattern of FI indicator light. Mal- function means that the ECM does not receive normal signal from the devices. These affected devices are indicated in the code form.

  • Page 306: Fail-Safe Function

    8-31 FL125SDW 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. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to 101 “YES”...

  • Page 307: Fi System Troubleshooting

    FL125SDW 8-32 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.
  • Page 308 8-33 FL125SDW MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °C) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous ( Uphill Downhill) Tarmacadam...
  • Page 309 FL125SDW 8-34 SELF-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.
  • Page 310 8-35 FL125SDW UNDERSTANDING THE DTC (Diagnostic Trouble Code) A two-digit DTC is shown through the flashing pattern of the FI indicator light. The DTCs are indicated from a smaller number to a larger number in that order. When all the applicable DTCs have been indicated, the displaying of the DTCs repeat from the first one again.
  • Page 311 FL125SDW 8-36 DTC INDICATION CHART FLASHING PATTERN DTC No. MALFUNCTION PART REMARKS None CKP sensor (#8-43) Pick up coil signal IAP sensor (#8-46) TP sensor (#8-51) ET sensor (#8-56) IAT sensor (#8-60) TO sensor (#8-64) Ignition coil (#8-68) Fuel injector (#8-68) ISC valve (#8-70) Ignition switch (#8-73) HO2 sensor (#8-74)
  • Page 312 8-37 FL125SDW *40: 40 code has no first digit display. For this reason, the interval A between the displays as shown below is longer than the others. 4.0 sec. 1.0 sec. SELF-DIAGNOSIS RESET PROCEDURE • After repairing the trouble, turn OFF the ignition switch and turn ON again.
  • Page 313 FL125SDW 8-38 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.
  • Page 314 8-39 FL125SDW 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.
  • Page 315 FL125SDW 8-40 SHOW DATA WHEN TROUBLE (DISPLAYING 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.
  • Page 316 8-41 FL125SDW DTC TABLE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The CKP sensor signal does not reach CKP sensor wiring and mechan- ECM for 4 sec. or more, after receiving ical parts.
  • Page 317 FL125SDW 8-42 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 2 sec. or more, after ignition connection. switch is turned ON. 0.2 V sensor voltage < 4.6 V In other than the above value, 23 (P1651) is indicated.
  • Page 318 8-43 FL125SDW “12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The CKP sensor signal does not reach ECM for 4 • Metal particles or foreign material being stuck on sec. or more, after receiving the IAP sensor signal. the CKP sensor and rotor tip.
  • Page 319 FL125SDW 8-44 5) If OK, then check the continuity between each terminal and ground. ! CKP sensor continuity: ∞ Ω (Infinity) (Bl/Y – Ground) (G/W – Ground) $ 09900-25008: Multi-circuit tester set & Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to step 2.
  • Page 320 8-45 FL125SDW 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 or more (+ Bl/Y –...
  • Page 321 FL125SDW 8-46 “13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing value. and IAP sensor. 0.2 V Sensor voltage < 4.5 V • Air being drawn from vacuum passage between throttle body and IAP sensor.
  • Page 322 8-47 FL125SDW 4) Disconnect the IAP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the R wire A and ground. 7) If OK, then measure the voltage at the R wire A and Br/B wire B. ! IAP sensor input voltage: 4.5 –...
  • Page 323 FL125SDW 8-48 6) Disconnect the ECM coupler. 7) Check the continuity between G/B wire C and terminal N. 8) If OK, then check the continuity between Br/B 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 ())
  • Page 324 8-49 FL125SDW 7) Disconnect the ECM coupler. 8) Check the continuity between R wire A and terminal 9. ! IAP sensor lead wire continuity: Continuity ()) $ 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set * Tester knob indication: Continuity test ()) ECM coupler (Harness side) When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle...
  • Page 325 FL125SDW 8-50 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 Br/B wire B and G/B wire C). ! IAP sensor output voltage: 2.0 –...
  • Page 326 8-51 FL125SDW “14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor circuit open or short. value. • TP sensor malfunction. Difference between actual throttle open- • ECM malfunction. ing and opening calculated by ECM is larger than specified value.
  • Page 327 FL125SDW 8-52 4) Disconnect the TP sensor coupler. 5) Turn the ignition switch ON. 6) Measure the voltage at the R wire A and ground. 7) If OK, then measure the voltage at the R wire A and Br/B wire B. ! TP sensor input voltage: 4.5 –...
  • Page 328 8-53 FL125SDW 6) Disconnect the ECM coupler. 7) Check the continuity between Br/B wire B 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 ()) ECM coupler (Harness side) When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle...
  • Page 329 FL125SDW 8-54 7) Disconnect the ECM coupler. 8) Check the continuity between R wire A and terminal 9. 9) Also, check the continuity between P wire C and terminal M. ! TP sensor lead wire continuity: Continuity ()) $ 09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set * Tester knob indication: Continuity test ()) ECM coupler (Harness side)
  • Page 330 8-55 FL125SDW Step 2 1) Connect the TP 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 TP sensor output voltage (between + P wire C and - Br/B wire B) by turning the throttle grip.
  • Page 331 FL125SDW 8-56 “15” (P0115-H/L) ET SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ET sensor circuit open or short. value. • ET sensor malfunction. 0.1 V Sensor voltage < 4.7 V • ECM malfunction. P0115 Sensor voltage is higher than specified •...
  • Page 332 8-57 FL125SDW 4) Disconnect the ET sensor coupler and turn the ignition switch 5) Measure the voltage between O/B wire A and ground. 6) If OK, then measure the voltage between O/B wire A and Br/ B wire B. ! ET sensor voltage: 4.5 – 5.5 V (+ O/B –...
  • Page 333 FL125SDW 8-58 Step 1 (When indicating P0115-L:) 1) Turn the ignition switch OFF. 2) Remove the rear center leg shield. (#5-6) 3) Check the ET sensor coupler 1 for loose or poor contacts. If OK, then check the ET sensor lead wire continuity. 4) Disconnect the ET sensor coupler.
  • Page 334 8-59 FL125SDW 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. 13.0 kΩ at 20 °C Approx. 6.2 kΩ at 40 °C (B –...
  • Page 335 FL125SDW 8-60 “21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short. value. • IAT sensor malfunction. Sensor voltage 4.6 V • ECM malfunction. P0110 Sensor voltage is higher than specified •...
  • Page 336 8-61 FL125SDW Step 1 (When indicating P0110-H:) 1) Turn the ignition switch OFF. 2) Remove the right leg shield. (#5-6) 3) Check the IAT sensor coupler 1 for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler and ECM coupler.
  • Page 337 FL125SDW 8-62 Step 1 (When indicating P0110-L:) 1) Turn the ignition switch OFF. 2) Remove the right leg shield. (#5-6) 3) Check the IAT sensor coupler 1 for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 4) Disconnect the IAT sensor coupler.
  • Page 338 8-63 FL125SDW Step 2 1) Turn the ignition switch OFF. 2) Disconnect the IAT sensor coupler. 3) Measure the IAT sensor resistance. ! IAT sensor resistance: Approx. 2.56 kΩ at 20 °C Approx. 1.20 kΩ at 40 °C (Terminal A – Terminal B) $ 09900-25008: Multi-circuit tester set &...
  • Page 339 FL125SDW 8-64 “23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow- • TO sensor circuit open or short. ing for 2 sec. or more, after ignition • TO sensor malfunction. switch is turned ON. •...
  • Page 340 8-65 FL125SDW Step 1 (When indicating P1651-H:) 1) Turn the ignition switch OFF. 2) Remove the front frame cover. (#5-5) 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.
  • Page 341 FL125SDW 8-66 Step 1 (When indicating P1651-L:) 1) Turn the ignition switch OFF. 2) Remove the front frame cover. (#5-5) 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.
  • Page 342 8-67 FL125SDW 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 Bl/W wire B and Br/B wire C. ! TO sensor voltage (Normal): 0.4 –...
  • Page 343 FL125SDW 8-68 “32” (P0201) FUEL INJECTOR CIRCUIT MALFUNCTION NOTE: When the ignition switch is turned to ON position, the fuel injector starts to operate approx. 2 sec. as purge operation (initial operation) DETECTED CONDITION POSSIBLE CAUSE When the fuel injector current in each detection is •...
  • Page 344 8-69 FL125SDW 6) If OK, then check the continuity between each terminal and ground. ! Fuel injector continuity: ∞ Ω (Infinity) (Terminal – Ground) $ 09900-25008: Multi-circuit tester set & Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.

  • Page 345: Front Brake

    FL125SDW 8-70 “40” (P0505) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE When the ISC operation voltage • ISC valve circuit open or shorted to ground. remains at 1.0 V or lower continuously (P0505) • ISC valve malfunction. for 2 sec. or longer. •...
  • Page 346 8-71 FL125SDW 6) If OK, then check the continuity between each terminal and ground. ! ISC valve continuity: ∞ Ω (Infinity) (Terminal – Ground) $ 09900-25008: Multi-circuit tester set & Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.
  • Page 347 FL125SDW 8-72 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 the engine is running. 3) Make sure that the engine temperature on data monitor is indicated 80 °C or more.
  • Page 348 8-73 FL125SDW Check 3 1) Input 1 900 to the ISC rpm “Spec” field 1. 2) Check that the “Desired idle speed” 2 is equal or close to the “Spec” 1. 3) Check that the “Engine speed” 3 is close to 1 900. NOTE: Be careful not to increase the “Spec”...
  • Page 349 FL125SDW 8-74 “44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE HO2 sensor output voltage is not input • HO2 sensor circuit open or shorted to ground. (P0130) to ECM during engine operation and • Fuel system malfunction. running condition.
  • Page 350 8-75 FL125SDW 7) Disconnect the ECM coupler. 8) Check the continuity between W/G wire A and terminal C. 9) Also, check the continuity between Br/B wire B and terminal 4. 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.
  • Page 351 FL125SDW 8-76 Is the voltage OK? ECM coupler (Harness side) • W/G wire or Br/B wire open or shorted to ground, or poor C or 4 connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM. •...
  • Page 352 8-77 FL125SDW 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 heater voltage between W wire C (harness side) and ground. 4) If the tester voltage indicates the battery voltage, it is good condition.

  • Page 353: Sensors

    FL125SDW 8-78 SENSORS CKP SENSOR INSPECTION The crankshaft position sensor is installed in the generator cover. (#8-43) CKP SENSOR REMOVAL AND INSTALLATION • Remove the generator cover. (#3-14) • Install the generator cover in the reverse order of removal. IAP/TP/IAT SENSOR INSPECTION The intake air pressure sensor/throttle position sensor/intake air temperature sensor are combined into one and installed in the throttle body.

  • Page 354: Et Sensor Removal And Installation

    8-79 FL125SDW • If the ET sensor ohmic value does not change in the propor- tion indicated, replace it with a new one. ! Engine temperature sensor specification Temperature Resistance 20 °C Approx. 13.0 kΩ 40 °C Approx. 6.2 kΩ 80 °C Approx.

  • Page 355: To Sensor Removal And Installation

    FL125SDW 8-80 TO SENSOR REMOVAL AND INSTALLATION • Remove the front frame cover. (#5-5) • 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.

  • Page 356: Fuel System

    8-81 FL125SDW FUEL SYSTEM FUEL FILTER REMOVAL * 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. • Remove the luggage box. (#5-5) •...

  • Page 357: Throttle Body

    FL125SDW 8-82 THROTTLE BODY CONSTRUCTION 1 Throttle body 8 Return pipe 2 ISC valve 9 Upper cushion seal 3 O-ring 0 Spacers 4 Intake pipe A Holder ITEM N·m kgf-m 5 Insulator A ISC valve screw 6 Lower cushion seal B Throttle body bolt 7 Fuel injector C Fuel injector bolt...
  • Page 358 8-83 FL125SDW REMOVAL AND DISASSEMBLY The throttle body is assembled precisely in factory. Do not disassemble it other than shown in this manual. • Remove the leg shields, left and right. (#5-6) • Remove the air cleaner box 1. • Disconnect the ISC valve coupler 2 and IAP/TP/IAT sensor coupler 3.
  • Page 359 FL125SDW 8-84 • Remove the O-ring 6. • Remove the ISC valve 7. Never remove the IAP/TP/IAT sensor 8 from the throt- tle body. * Never remove the throttle valve 9 from the throttle body. * Never use carburetor cleaning chemicals to the throttle body assembly.
  • Page 360 8-85 FL125SDW INSPECTION Throttle valve Visually inspect the throttle valve for any damage or clogging, replace it with a new one if necessary. ISC valve • Remove the O-ring 1. • Visually inspect the ISC valve for wear, damage or carbon deposit, replace it with a new one if necessary.

  • Page 361: Fuel Injector

    FL125SDW 8-86 • Connect the throttle pulling cable 4 and throttle returning cable 5 to the throttle cable drum. • Tighten each lock-nut. • Adjust the throttle cable play. (!8-8) • Route the harness and fuel hoses properly. (!8-107 and 111) FUEL INJECTOR REMOVAL "...
  • Page 362 8-87 FL125SDW • Remove the insulator 8. • Remove the return pipe 9, upper cushion seal 0, O-ring A and lower cushion seal B. INSTALLATION Installation is in the reverse order of removal. Pay attention to the following points: • Apply thin coat of engine oil to the O-ring 1, upper cushion seal 2 and lower cushion seal 3.

  • Page 363: Electrical System

    FL125SDW 8-88 ELECTRICAL SYSTEM BATTERY CUT OFF RELAY The battery cut off relay 1 cuts off the battery power from the charging circuit while kick-starting if the battery voltage is in lower condition or the battery terminal is disconnected. LOAD CUT OFF RELAY The load cut off relay 2 cuts off the battery power from the elec- tric load while kick-starting if the battery voltage is in lower con- dition or the battery terminal is disconnected.
  • Page 364 8-89 FL125SDW Step 3 1) Measure the regulated voltage between the battery terminals. (#6-9) Is the regulated voltage OK? • Faulty battery. • Abnormal driving condition. Go to Step 4. Step 4 1) Inspect the battery cut off relay. (#8-101) Is the battery cut off relay OK? Go to Step 5.
  • Page 365 FL125SDW 8-90 Step 2 1) Inspect wirings. Are the wirings OK? Faulty ECM. • Open circuit in wire harness. • Poor contact of couplers. Battery overcharges. • Faulty regulator/rectifier. • Faulty battery. • Poor contact of generator lead wire coupler. INSPECTION Generator coil resistance •...
  • Page 366 8-91 FL125SDW Regulator/rectifier • Remove the frame covers, left and right. (#5-7) • Disconnect the regulator/rectifier coupler. • Remove the regulator/rectifier. Measure the voltage between the terminals using the multi cir- cuit tester as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.

  • Page 367: Starter System And Side-Stand/Ignition Interlock System

    FL125SDW 8-92 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Starter Front brake Ignition button switch switch Starter motor Side-stand Side-stand Side-stand switch relay diode Battery cut off Fuse relay (15A) Battery Starter relay Gear position switch (N) Neutral diode To ECM TROUBLESHOOTING Make sure that the fuse are not blown and the battery is fully-charged before diagnosing.
  • Page 368 8-93 FL125SDW Step 3 1) Measure the starter relay voltage at the starter relay connectors (between Y/G + and Y/B -) when the starter button is pushed. Is a voltage OK? Go to Step 4. • Faulty front brake switch. •...
  • Page 369 FL125SDW 8-94 SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. Side-stand switch •...
  • Page 370 8-95 FL125SDW Side-stand relay • Remove the frame head cover. (#5-6) • Remove the side-stand relay. 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 continuity between A and B terminals.

  • Page 371: Ignition System

    FL125SDW 8-96 IGNITION SYSTEM Battery cut off Fuse Ignition relay Ignition coil switch (15A) Battery diodes ( x 5) Regulator /rectifier Battery Generator CKP sensor Gear position sensor switch NOTE: The fuel and ignition cut-off circuits are incorporated in this ECM in order to prevent over-running of engine. When engine speed reaches 9 700 r/min, this circuit cuts off fuel at the fuel injector and ignition primary cur- rent for spark plug.
  • Page 372 8-97 FL125SDW Step 3 1) Measure the ignition coil primary peak voltage. (#6-22) NOTE: This inspection method is applicable only with the multi-circuit tester and the peak volt adaptor. Is the peak voltage OK? Go to Step 4. Go to Step 5. Step 4 1) Inspect the spark plug.
  • Page 373 FL125SDW 8-98 INSPECTION Ignition coil resistance • Remove the rear center leg shield. (#5-6) • Disconnect the ignition coil lead wires 1 and 2. • Remove the ignition coil 3. • Remove the spark plug cap. Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi-circuit tester.
  • Page 374 8-99 FL125SDW If the peak voltage measured on the ECM coupler is lower than the specified value, measure the peak voltage on the CKP sen- sor coupler as follows. • Remove the rear center leg shield. (#5-8) • Disconnect the CKP sensor coupler 2. •...

  • Page 375: Speedometer

    FL125SDW 8-100 SPEEDOMETER INSPECTION Check the continuity between the lead wires using the multi-circuit tester. If there is no continuity replace the respective parts. $ 09900-25008: Multi-circuit tester set * Tester knob indication: Continuity test ()) Turn signal indicator light Gear position FI indicator light High beam indicator light...

  • Page 376: Relays

    8-101 FL125SDW RELAYS BATTERY CUT OFF RELAY AND LOAD CUT OFF RELAY Removal and installation • Remove the front frame cover. (#5-5) • Remove the battery cut off relay 1 and load cut off relay 2. • Install the battery cut off relay 1 and load cut off relay 2 in the reverse order of removal.

  • Page 377: Diodes

    FL125SDW 8-102 DIODES REMOVAL AND INSTALLATION Battery diodes • Remove the right frame cover. (#5-7) • Remove the battery diodes 1, 2, 3, 4 and 5. • Install the battery diodes in the reverse order of removal. NOTE: The battery diodes 1 , 2 , 3 , 4 and 5 are the same parts. Neutral diode •...

  • Page 378: Lamps

    8-103 FL125SDW LAMPS HEADLIGHT, POSITION/PARKING LIGHT 1: Headlight bulb: 12 V 35/35 W (HS1) 2: Position/Parking light bulb: 12 V 5 W If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure.
  • Page 379 FL125SDW 8-104 TURN SIGNAL LIGHT 1: Turn signal light bulb: 12 V 21 W * If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. * Do not overtighten the lens fitting screws.
  • Page 380 8-105 FL125SDW BRAKE LIGHT/TAILLIGHT 1: Brake light/Taillight: 12 V 21/5 W * If you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure. * Do not overtighten the lens fitting screws.

  • Page 381: Wiring Diagram

    FL125SDW 8-106 WIRING DIAGRAM...

  • Page 382: Wiring Harness, Cable And Hose Routing

    8-107 FL125SDW WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Wiring harness Front fork upper bracket Speedometer cable Clamp Front brake hose Speedometer The engine ground lead wire Throttle returning cable passes upside of the ignition coil. Throttle pulling cable Hron button lead wire Front brake Dimmer switch lead wire...
  • Page 383 FL125SDW 8-108 Battery License plate light coupler Dealer mode coupler Rear turn signal light (R) coupler Battery terminal Fuse Rear turn signal light (L) coupler FI control unit Pass through the main harness leftside of the frame tube and leg shield. Battery Horn lead wire...
  • Page 384 8-109 FL125SDW...

  • Page 385: Cable Routing

    FL125SDW 8-110 CABLE ROUTING Handlebar Harness Speedometer cable Front brake hose Throttle returning cable Throttle pulling cable Clamp Throttle pulling cable Throttle returning cable Clamp Clamp Throttle pulling cable Throttle returning cable Front brake hose Clamp the upside of the Speedometer Wiring handlebar clamp bolt.

  • Page 386: Fuel Hose Routing

    8-111 FL125SDW FUEL HOSE ROUTING Upper Marking (Red) Marking (White) Fuel injector Fuel filter Fuel hose 3-way union Marking (Red) Marking (Red) Fuel injector Marking (Yellow)

  • Page 387: Exterior Parts Construction

    FL125SDW 8-112 EXTERIOR PARTS CONSTRUCTION Front right Frame head cover leg shield Rear right leg shield Front left leg shield Rear left leg shield Front center leg shield Frame Rear center leg shield...
  • Page 388 8-113 FL125SDW Front frame cover Right frame lower cover Right frame cover Rear combination light Battery box lid Frame center cover Rear fender Left frame cover Luggage Left lower frame cover Frame...

  • Page 389: Throttle Body And Fuel Injector Installation

    FL125SDW 8-114 THROTTLE BODY AND FUEL INJECTOR INSTALLATION 1 – 2 mm 9 N·m (0.9 kgf-m) 9 N·m (0.9 kgf-m) 9 N·m (0.9 kgf-m) 1 Throttle body 5 Spacer 2 Intake pipe 6 Holder 3 Fuel injector 7 Return pipe 4 Insulator *1 Adjust the clearance between the fuel injector coupler and bolt to provide 1 to 2 mm.

  • Page 390: Special Tools

    8-115 FL125SDW SPECIAL TOOLS 09900-25008 09900-25009 Multi-circuit tester Needle pointed 09904-41010 09930-82720 99565-01010-011 probe set SDS set tool Mode select switch CD-ROM Ver. 11 NOTE: When order the special tool, please confirm whether it is available or not. TIGHTENING TORQUE ITEM N·m kgf-m...

  • Page 391: Service Data

    FL125SDW 8-116 SERVICE DATA VALVE + GUIDE Unit: mm ITEM STANDARD LIMIT Valve diam. 24.9 – 25.1 — 21.9 – 22.1 — Valve clearance (when cold) 0.03 – 0.08 — 0.08 – 0.13 — Valve guide-to-valve stem 0.010 – 0.037 —...
  • Page 392 8-117 FL125SDW CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Compression pressure 650 kPa 750 – 1 200 kPa (7.5 – 12 kgf/cm²) (6.5 kgf/cm²) Piston-to-cylinder clearance * 0.020 – 0.030 0.120 Cylinder bore * 53.500 – 53.515 53.635 Piston diam.
  • Page 393 FL125SDW 8-118 GEAR SHIFT CLUTCH Unit: mm ITEM STANDARD LIMIT Drive plate thickness 2.9 – 3.1 Drive plate claw width 11.80 – 12.00 11.0 Driven plate distortion — 0.10 Clutch spring free length — 32.0 TRANSMISSION + DRIVE CHAIN Unit: mm (in) (Except ratio) ITEM STANDARD LIMIT...
  • Page 394 8-119 FL125SDW * FI SENSORS ITEM SPECIFICATION NOTE 180 – 280 Ω CKP sensor resistance + Bl/Y – - G/W CKP sensor peak voltage 2.0 V (When cranking) or more IAP sensor input voltage 4.5 – 5.5 V + G/B – - Br/B IAP sensor output voltage Approx.
  • Page 395 FL125SDW 8-120 ELECTRICAL Unit: mm ITEM SPECIFICATION NOTE Spark plug * NGK: CR6HSA Type * DENSO: U20FSR-U 0.6 – 0.7 Spark performance 8.0 mm or more at 1 atm. + Terminal – Ignition coil resistance * 2 – 5 Ω Primary - Terminal Plug cap –...

  • Page 396: Brake Light/Taillight

    Front fork spring free length 296.6 Front fork oil level (without spring, — inner tube fully compressed) Front fork oil type SUZUKI FORK OIL SS-08 or equivalent fork oil — Front fork oil capacity (each leg) 51 ml — ! 26 Front fork inner tube diam.

  • Page 397: Fuel Tank

    FL125SDW 8-122 TIRE ITEM STANDARD LIMIT Cold inflation tire pressure 175 kPa Front — (Solo riding) (1.75 kgf/cm²) 200 kPa Rear — (2.00 kgf/cm²) Cold inflation tire pressure 175 kPa Front (1.75 kgf/cm²) (Dual riding) 280 kPa Rear (2.80 kgf/cm²) Tire size Front * 70/90-17 M/C 38P...
  • Page 398 Prepared by March, 2007 Part No. 99500-31371-01E Printed in Japan...
  • Page 399 Printed in Japan...

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