Table of Contents
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FOREWORD
This motorcycle has been designed and produced utilizing Suzuki's most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this motorcycle.
Please review this set-up manual carefully before performing any work. Take spe-
cial care to properly perform the required assembly and servicing marked by either
a Warning or a Caution. Failure to follow the directions in either of these two (2) cat-
egories could lead to serious problems.
and
areas are
denoted to emphasize certain areas and carry the following meanings:
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in motorcycle damage.
This set-up manual is based on a motorcycle of standard specification. Some minor
differences from this manual may be found in other specifications.
K7
99505-01107-01E
February '07 Printed in Japan (TK) 19
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Table of Contents
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Summary of Contents for Suzuki fl125sdwk7
- Page 1 FOREWORD This motorcycle has been designed and produced utilizing Suzuki’s most modern technology. The finest product, however, cannot perform properly unless it is cor- rectly assembled and serviced. This set-up manual has been produced to aid you in properly assembling and servicing this motorcycle.
- Page 2 PREPARATION WORKSHOP The workshop where the machine is assembled should be clean, spacious, and have a level floor. A: Packed motorcycle B: Working space SELF PROTECTION The technician should wear protective clothing such as leather gloves, a long sleeve shirt, eye protection and safety shoes as shown in the illustration when handling metal crates.
- Page 3 Remove the nut to take off the handlebar holding bracket and stay. NOTE: The brackets, stay and nuts are no longer needed and these may be discarded. Remove the protection cover after taking out the motorcycle. A: Nut B: Bracket C: Stay D: Protection cover Remove the bolts A used to mount the steel frame on...
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Page 4: Location Of Parts
LOCATION OF PARTS Check all the components which have been removed from the crate. Item Part Name Q’ty Remarks Item Part Name Q’ty Remarks Front fender front Speedometer drive gearbox Stepped screw 6 × 16 mm Front wheel assembly Screw 6 ×... - Page 5 The photograph shown indicates the parts dismounted from the motorcycle in addition to the items shown in the preceding page. A: Speedometer cable Before assembling the motorcycle, thoroughly understand the “Safety Check Out” described on page 26. After completion of assembly, carefully check the motorcycle referring to the “Safety Check Out”, then deliver the motorcycle to the customer.
- Page 6 ASSEMBLY Loosen the rear axle nut. Remove the bolt. Remove the motorcycle supporting bracket. NOTE: The bracket and bolt are no longer needed and may be discarded. A: Bracket B: Bolt C: Rear axle nut Make sure that the washer is placed on the rear axle. Tighten the axle nut to the specified torque.
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Page 7: Front Fender
Remove the crate axle bracket from the crate base. NOTE: The bracket and bolts are no longer needed and these may be discarded. A: Crate axle bracket B: Bolt 1. Lift the front of motorcycle by using a hoist. 2. Raise the rear of motorcycle. 3. -
Page 8: Brake Disc
Install the front fender front to the front fork lower bracket. A: Front fender front B: 6 × 16 mm stepped screw C: 6 × 16 mm screw D: Stepped washer OD:16.0 mm ID:6.5 mm T:5.0 mm Reinstall the front brake hose guide. A: Bolt B: Front brake hose guide BRAKE DISC... - Page 9 Mount the front wheel assembly properly. A: Right fork leg B: Left fork leg C: Front axle D: Front axle nut E: Front wheel spacer F: Speedometer drive gear box Remove the supporter from the brake pad of the front brake caliper.
- Page 10 Insert the front axle from the right side of fork leg. Fix the front wheel assembly to the front fork. Never use force to install the front axle. If it cannot be installed by hand, it is not cor- rectly aligned. A: Front axle Align the edge slit of the meter cable with the blade in the gearbox.
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Page 11: Rear View Mirror
Place the motorcycle on the center-stand, then remove the hoist hook. Remove the protection cover from the motorcycle. A: Protection cover REAR VIEW MIRROR Remove the lock bolt. NOTE: Part D of the rear view mirror stay is opposite threaded. A: Lock bolt B: Rear view mirror stay C: Lock nut... - Page 12 OWNER’S MANUAL Push down and turn the key clockwise to release the seat lock. Open the seat. A: Key B: Seat Store the owner’s manual in place. A: Trunk B: Owner’s manual...
- Page 13 SERVICING BATTERY The battery is located under the seat. Open the seat. Remove the screws to take off the battery box lid. Remove the battery from the motorcycle. A: Battery box lid B: Screw Filling electrolyte Remove the aluminium tape sealing the battery elec- trolyte filler holes.
- Page 14 With just enough force to break the nozzle seal of elec- trolyte container, push each nozzle of the electrolyte container into the battery’s electrolyte filler ports and hold the container firmly so that it does not fall. Take precaution not to allow any of the fluid to spill. A: Electrolyte containers Make sure air bubbles are coming up in each electro- lyte container, and leave in this position for about 20...
- Page 15 Charge the battery with a battery charger. For charging the battery, make sure to use the charger specially designed for MF battery. Otherwise, the battery may be overcharged resulting in shortened service life. Do not remove the cap during charging. Position the battery with the cap facing upward during charging.
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Page 16: Brake Fluid
BRAKE FLUID Keep the motorcycle upright and place the handlebars straight. LOWER LOWER Check the brake fluid level in the front master cylinder reservoirs. If the fluid level is below the “LOWER” level indicated in the figure, add the correct type of brake fluid as fol- lows. - Page 17 Remove the boss. A: Handlebar cover front B: Boss Disconnect the headlight lead wire coupler to take off the handlebar cover front. A: Handlebar cover front B: Coupler Remove the front brake master cylinder reservoir tank cap. Add the correct type of brake fluid. Refer to the chart below for the proper selection.
- Page 18 BRAKE AIR BLEEDING Any air which may have been trapped in the brake fluid circuit must be bled completely. If the brake lever feels spongy or weak, then most likely there is air in the hydraulic circuit. To bleed the air from the front brake, use the following procedure: 1.
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Page 19: Throttle Cable
THROTTLE CABLE This motorcycle has a twin throttle cable system. Cable A is for pulling cable and cable B is for return- ing. Check the throttle cable play at the throttle grip. 2.0–4.0 mm Throttle cable play: 2.0–4.0 mm If adjustment is necessary, carry out the procedure below: 1. - Page 20 REAR BRAKE PEDAL After the drive chain slack has been checked or adjusted, check the brake pedal free travel. Rear brake pedal free travel: 20–30 mm If adjustment is necessary, adjust the free travel by turning the brake rod adjuster nut A. TIRE PRESSURE Using an accurate air gauge, check the air pressure of the front and rear tires.
- Page 21 API: American Petroleum Institute JASO: Japanese Automobile Standards Organization SAE Engine Oil Viscosity ENGINE OIL VISCOSITY RATING SELECTION CHART Suzuki recommends the use of SAE 10W-40 engine oil. 20W - 50 If SAE 10W-40 engine oil is not available, select an 15W - 40 15W - 50 alternative according to the following chart.
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Page 22: Idle Speed Adjustment
Engine idle speed: 1 400–1 600 r/min NOTE: If the engine idle speed is not within the speci- fied range, ask your Suzuki dealer or a qualified mechanic to inspect and repair the motorcycle. Test ride the motorcycle checking all mechanical func- tions. -
Page 23: Tightening Torque
TIGHTENING TORQUE Item Part Name N·m kgf-m Item Part Name N·m kgf-m FRONT FORK AXLE Handlebar holder stopper bolt Front axle nut Front fork clamp bolt Rear axle nut BRAKE ABSORBER Front brake master cylinder mounting Rear shock absorber bolt (Upper) bolt Rear shock absorber bolt (Lower) Front brake caliper mounting bolt... -
Page 24: Harness Routing
HARNESS ROUTING Handlebar Speedometer assembly Clamp Starter switch lead wire Wiring harness Speedometer cable Front brake switch lead wire Front brake hose Pass the engine ground lead wire through Throttle cable (Returning) upside of the ignition coil. Throttle cable (Pulling) Seat-lock cable Handlebar switch lead wire (L) Engine ground lead wire... - Page 25 License plate light coupler Clamp Rear turn signal light (R) coupler Test switch coupler Battery + terminal Rear turn signal light (L) coupler Fuse FI control unit Battery Horn lead wire Rear combination light Pass the wiring harness Condenser coupler through over the frame bracket.
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Page 26: Cable Routing
CABLE ROUTING Handlebar Wiring harness Speedometer cable Front brake hose Throttle cable (Returning) Throttle cable (Pulling) Clamp Throttle cable (Pulling) Throttle cable (Returning) Clamp Clamp Throttle cable (Pulling) Throttle cable (Returning) Front brake hose Cable guide Clamp position is upside Wiring harness of the handlebar clamp bolt. -
Page 27: Safety Check-Out
SAFETY CHECK OUT ELECTRICALS ITEM CHECK FOR After completion of the setting-up the motorcy- Light Lighting/Adjust cle all the following items should be double- Headlight high/low beam Tail/Brake light checked to confirm that the operation and func- Turn signal light tion of the motorcycle are satisfactory.