Page 1: General Information
FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI UY125/S and procedures for its inspec- tion/service and overhaul of its main components. GENERAL INFORMATION Other information considered as generally known is not included. Read the GENERAL INFORMATION section to...
Page 2 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 3 Apply oil. Use engine oil unless other- Use fork oil. wise specified. 99000-99044-10G Apply molybdenum oil solution. (Mixture of engine oil and SUZUKI Apply or use brake fluid. MOLY PASTE in a ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. Measure in voltage range.
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Page 5: Table Of Contents
GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE................ 1- 2 GENERAL PRECAUTIONS ................. 1- 2 SUZUKI UY125K6/SK6 (’06-MODEL) ............1- 4 SERIAL NUMBER LOCATION ..............1- 4 FUEL AND OIL RECOMMENDATION ............1- 5 FUEL...................... 1- 5 ENGINE OIL ..................1- 5 REDUCTION GEAR OIL ...............
Page 6: Warning/Caution/Note
GENERAL INFORMATION WARNING/CAUTION/NOTE 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 mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
Page 7 GENERAL INFORMATION " * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * 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 Uy125K6/Sk6 ('06-Model)
GENERAL INFORMATION SUZUKI UY125K6/SK6 (’06-MODEL) RIGHT SIDE (UY125S) LEFT SIDE (UY125) 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 required especially for registering the machine and ordering spare parts.
Page 9: Fuel And Oil Recommendation
Always select good quality engine oil. Use of SF/SG or SH/SJ in API with MA in JASO. 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
Steering angle................. 45° (right and left) Caster ..................25.6° Trail ..................100 mm Turning radius ................. 1.9 m Front brake................Drum brake ..UY125 Disc brake .... UY125S Rear brake ................Drum brake Front tire size ................70/90-14 M/C (34 P), tube type Rear tire size................
Page 11 GENERAL INFORMATION ELECTRICAL Ignition type................Electronic ignition (CDI) Ignition timing ................10° B.T.D.C.at 1 600 rpm Spark plug ................NGK CR6HSA or DENSO U20FSR-U Battery ..................12 V 12.6 kC (3.5 Ah)/10 HR Generator ................Single-phase A.C. generator Fuse ..................10 A Headlight .................
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Page 13: 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 BOLT AND MUFFLER MOUNTING NUT ....2- 5 COOLING FAN FILTER ...............
Page 14: 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 15: 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. Rear brake lever holder Footrest pivot Speedometer Side-stand pivot cable and spring hook Throttle cable Front brake lever holder...
Page 16: 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 thereafter. • Place the motorcycle on the side stand. •...
Page 17: Exhaust Pipe Bolt And Muffler Mounting Nut
PERIODIC MAINTENANCE • Remove the drain plug from the air cleaner box to allow any water to drain out. EXHAUST PIPE BOLT AND MUFFLER MOUNTING NUT Tighten initially at 1 000 km (5 months) and every 8 000 km (40 months) thereafter. •...
Page 18: 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 frame front cover. (!5-8) • Remove the spark plug. (!2-7) • Disconnect the breather hoses 1 and remove the head cover INSPECTION The valve clearance specification is same for both valves.
Page 19: Spark Plug
PERIODIC MAINTENANCE • After finishing the valve clearance adjustment, reinstall the fol- lowing items. * Cylinder head cover (!3-11) * Spark plug and plug cap (!2-7) * Frame front cover (!5-8) SPARK PLUG Inspect at 4 000 km (20 months) and replace every 8 000 km (40 months) thereafter.
Page 20: Fuel Line
PERIODIC MAINTENANCE INSTALLATION " Before using a spark plug wrench, carefully turn the spark plug by finger into the threads of the cylinder head to prevent damage the aluminum threads. • Install the spark plug to the cylinder head by finger tight, and then tighten it to the specified torque.
Page 21 PERIODIC MAINTENANCE • Turn off the engine and wait minute, then check the oil level by removing the filler cap 2. If the level is below mark “L”, add oil to “F” level. (off the center stand, do not screw the filler cap.) If the level is above mark “F”, drain oil to “F”...
Page 22: Engine Idle Speed
2-10 PERIODIC MAINTENANCE ENGINE IDLE SPEED Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter. NOTE: Make this adjustment when the engine is hot. • Connect an electric tachometer. • Start up the engine and set its speed at anywhere between 1 500 and 1 700 rpm by turning throttle stop screw.
Page 23: Drive Belt
PERIODIC MAINTENANCE 2-11 DRIVE BELT Inspect every 4 000 km (20 months) thereafter. • Keep the motorcycle upright. • Remove the clutch cover. (!3-10) • Check the contact surface for crack or other damage. If crack or other damage exists, replace the belt with a new one. "...
Page 24: Brake
2-12 PERIODIC MAINTENANCE BRAKE Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter. BRAKE LEVER PLAY • Adjust the brake lever play by turning the adjusting nut 1 so that the play A is 15 – 25 mm as shown. # Brake lever play A: 15 –...
Page 25: Brake Hose And Brake Fluid (Uy125S)
PERIODIC MAINTENANCE 2-13 BRAKE HOSE AND BRAKE FLUID (UY125S) Inspect every 4 000 km (20 months). Replace hoses every 4 years. Replace fluid every 2 years. BRAKE HOSE Check the brake hose for leakage, cracks, wear and damage. If any damages are found, replace the brake hose with a new one. BRAKE FLUID LEVEL CHECK •...
Page 26 2-14 PERIODIC MAINTENANCE FRONT BRAKE FLUID REPLACEMENT • Remove the handlebar cover. (!5-5) • Place the motorcycle on a level surface and keep the handle- bar straight. • Remove the front master cylinder reservoir cap and dia- phragm. • Suck up the old brake fluid as much as possible. •...
Page 27: Tire And Wheels
PERIODIC MAINTENANCE 2-15 • Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it. Loosen the bleeder valve by turning it a quarter of a turn so that the brake fluid runs into the receptacle; this will remove the tension of the brake lever causing it to touch the handle- bar grip.
Page 28 2-16 PERIODIC MAINTENANCE TIRE PRESSURE If the tire pressure is too high or too low, steering will be adversely affected and tire wear will increase. Therefore, main- tain the correct tire pressure for good roadability and a longer tire life. Cold inflation tire pressure is as follows. COLD INFLATION kgf/cm TIRE PRESSURE...
Page 29: Steering
PERIODIC MAINTENANCE 2-17 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 30: Chassis Bolts And Nuts
A Air breeder valve (UY125S) 0.75 B Front brake master cylinder bolt (UY125S) C Rear shock absorber mounting nut (Upper & Lower) D Front brake cam lever nut (UY125) E Rear brake cam lever nut F Spoke nipple 0.45 http://mototh.com...
Page 31 PERIODIC MAINTENANCE 2-19 http://mototh.com...
Page 32: Compression Pressure Check
2-20 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. COMPRESSION PRESSURE SPECIFICATION Standard Limit...
Page 33: Oil Pressure Check
PERIODIC MAINTENANCE 2-21 OIL PRESSURE CHECK Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. OIL PRESSURE SPECISFICATION 18 – 40 kPa (0.18 – 0.40 kgf/cm²) at 3 000 rpm, Oil temp. at 60 °C. If the oil pressure is lower or higher than specification, the following causes may be considered.
Page 34: Automatic Clutch Inspection
2-22 PERIODIC MAINTENANCE AUTOMATIC CLUTCH INSPECTION This motorcycle is equipped with an automatic clutch and vari- able ratio belt drive transmission. The engagement of the clutch is governed by engine RPMs and centrifugal 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 35 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH THE ENGINE IN PLACE .. 3- 2 ENGINE REMOVAL AND INSTALLATION ..........3- 4 ENGINE REMOVAL................3- 4 ENGINE REMOUNTING ................ 3- 8 ENGINE DISASSEMBLY ................3-10 ENGINE COMPONENT INSPECTION AND SERVICE ....... 3-20 CYLINDER HEAD COVER ..............
Page 36: Engine Components Removable With The Engine In Place
ENGINE 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 !3-10...
Page 37 ENGINE ENGINE RIGHT SIDE PARTS REMOVAL INSTALLATION !3-5 !3-9 Muffler !3-11 !3-71 Fan cowling cover !3-13 !3-65 Cooling fan !3-15 !3-63 Starter idle gear !3-14 !3-63 Magneto cover !3-15 !3-62 Magnetorotor !3-16 !3-61 Oil pump !3-11 !3-71 Cylinder cowling right cover http://mototh.com...
Page 38: 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. Engine removal is sequentially explained in the following steps. Reinstall the engine by reversing the removal procedure. • Remove the front frame cover. (!5-8) •...
Page 39 ENGINE • Remove the air cleaner box. • Disconnect the magneto lead wire coupler 4 and pick-up coil lead wire coupler 5. • Remove the engine ground bolt. • Disconnect the spark plug cap 6. • Remove the exhaust pipe bolts. http://mototh.com...
Page 40 ENGINE • Remove the muffler mounting bolts and then remove the muf- fler 7. • Remove the rear brake cable clamp bracket 8. • Remove the rear brake cable adjuster nut 9, spring 0 and pin A. • Remove the rear brake cable clamp. •...
Page 41 ENGINE • Support the engine using a jack. • Remove the rear shock absorber lower mounting bolt. • Remove the engine mounting bolt and nut. NOTE: Never remove the crankcase bracket D from the frame. • Remove the engine from the frame. http://mototh.com...
Page 42: Engine Remounting
ENGINE ENGINE REMOUNTING Remount the engine in the reverse order of removal. Pay atten- tion to the following points: • Install the crankcase bracket 1 to the frame and insert the crankcase bracket mounting shaft. • Push up on the rear part of the crankcase bracket 1 and have the damper B touch the stopper A.
Page 43 ENGINE • Install the muffler. Replace the gasket with new one. • After installing the engine, properly route the wire harness, cables, and hoses. Refer to the wire and cable routing sec- tions. (!7-12 to -19) • Refer to the following sections to adjust the respective items to specification.
Page 44: Engine Disassembly
3-10 ENGINE 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. CLUTCH COVER • Remove the kick starter lever. • Remove the clutch cover assembly 1. CRANKCASE TUBE GROMMET •...
Page 45 ENGINE 3-11 PAIR CUT VALVE • Disconnect the PAIR hose 1 and vacuum hose 2. • Remove the PAIR cut valve 3. FAN COWLING COVER/CYLINDER COWLING/INTAKE PIPE • Remove the fan cowling cover 1 and cylinder cowling right cover 2. •...
Page 46 3-12 ENGINE • Turn the crankshaft clockwise with a box wrench and align the “Top” mark A on the cooling fan with the index mark B on the magneto cover. NOTE: The piston must be at TDC on the compression stroke. CAM CHAIN TENSION ADJUSTER •...
Page 47 ENGINE 3-13 • Remove the dowel pins 4 and gasket 5. PISTON • Remove the piston pin circlip. • Remove the piston by driving out the piston pin. NOTE: Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase.
Page 48 3-14 ENGINE REAR WHEEL/REAR BRAKE • Remove the rear wheel. • Remove the brake shoes. CENTER STAND • Remove the center stand spring 1. • Remove the cotter pin 2, washer 3, shaft 4 and center stand 5. MAGNETO COVER •...
Page 49 ENGINE 3-15 • Remove the dowel pins 2 and gasket 3. STARTER IDLE GEAR • Remove the starter idle gear 1 and shaft 2. MAGNETOROTOR • Hold the fixed drive face with the special tool. $ 09930-40113: Rotor holder • Remove the magnetorotor nut. •...
Page 50 3-16 ENGINE • Remove the key 3. OIL PUMP • Remove the oil pump cover 1. • Turn the oil pump sprocket and align the oil pump sprocket hole on the oil pump mounting screw 2. • Remove the oil pump screw 2. •...
Page 51 ENGINE 3-17 FIXED DRIVE FACE • Remove the fixed drive face nut with the special tool. $ 09930-40113: Rotor holder • Remove the washer 1, kick starter 2 and fixed drive face 3. MOVABLE DRIVEN FACE/CLUTCH HOUSING • Remove the clutch housing nut with the special tool. $ 09930-40113: Rotor holder •...
Page 52 3-18 ENGINE REDUCTION GEAR • Drain the reduction gear oil. (!2-11) • Remove the reduction gear cover 1. • Remove the gasket 2 and dowel pins 3. • Remove the washer 4, idle driven gear 5 and rear axle shaft OIL FILTER •...
Page 53 ENGINE 3-19 OIL SUMP FILTER • Remove the oil sump filter cap 1 and oil sump filter 2. BRAKE CAM LEVER • Remove the rear brake cam lever 1, brake lining wear indica- tor 2 and brake cam 3. CRANKCASE •...
Page 54: Engine Component Inspection And Service
3-20 ENGINE ENGINE COMPONENT INSPECTION AND SERVICE CYLINDER HEAD COVER DISASSEMBLY • Remove the PAIR reed valve cover 1 and PAIR reed valve • Remove the breather cover 3, oil separator 4 and gasket 5. INSPECTION REED VALVE • Inspect the reed valve for the carbon deposit. •...
Page 55: Cylinder Head
ENGINE 3-21 REASSEMBLY • Reassembly the cylinder head cover in the reverse order of disassembly. Pay attention to the following points: • Install the breather cover gasket 1. Replace the removed breather gasket with a new one. • Tighten the breather cover bolts to the specified torque. "...
Page 56 3-22 ENGINE • Pull out the intake and exhaust rocker arm shafts 3 by using an 8-mm thread bolt. • Remove the intake and exhaust rocker arms 4. • Remove the camshaft 5. • Compress the valve spring with the valve spring compressor. •...
Page 57: Cylinder Head Distortion
ENGINE 3-23 • Remove the valve stem seal 9 and valve spring seat 0. 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 58 3-24 ENGINE 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. &...
Page 59 ENGINE 3-25 VALVE STEM WEAR If the valve stem is worn down to the limit, when measured with a micrometer, and the clearance is found to be in excess of the limit indicated previously, replace the valve, if the stem is within the limit, then replace the guide.
Page 60 3-26 ENGINE • After fitting the valve guides, re-finish their guiding bores with the handle and reamer. Be sure to clean and oil the guides after reaming. $ 09916-34542: Handle 09916-34570: Valve guide reamer (5.0 mm) VALVE SEAT WIDTH INSPECTION Visually check for valve seat width on each valve face.
Page 61 ENGINE 3-27 VALVE SEAT SERVICE The valve seats 1 for both the intake and exhaust valves are machined to four different angles. The seat contact surface is cut at 45°. INTAKE SIDE EXHAUST SIDE 45° N-122 N-122 15° N-121 For intake 30°...
Page 62 3-28 ENGINE • Seat the pilot snugly. Install the 45° cutter 3, attachment and T-handle 4. INITIAL SEAT CUT • Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. • Measure the valve seat width W after every cut. 45˚...
Page 63 ENGINE 3-29 FINAL SEAT CUT • If the contact area W is too low or too narrow, use the 45° cut- ter to raise and widen the contact area. NOTE: After cutting the 15° and 30° angles, it is possible that the valve seat (45°) is too narrow.
Page 64 3-30 ENGINE VALVE SPRING INSPECTION The force of the coil spring keeps the valve seat tight. A weak- ened spring results in reduced engine power output and often accounts for the chattering noise coming from the valve mecha- nism. Check the valve springs for proper strength by measuring their free length and also by the force required to compress them.
Page 65 ENGINE 3-31 • Remove the bearings and cam sprocket flange with a bearing puller. $ 09913-60910: Bearing & gear puller NOTE: Avoid removing the cam sprocket flange and bearing from the camshaft unless it is really necessary to do so, for example, removing the damaged bearing.
Page 66 3-32 ENGINE • Install the valve spring, making sure that the close-pitch end A of each spring goes in first to rest on the head. The coil pitch of spring vary: the pitch decreases from top to bottom, Towards as shown in the illustration. Head •...
Page 67: Cylinder
ENGINE 3-33 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 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 68: Piston
3-34 ENGINE PISTON PISTON DIAMETER Using a micrometer, measure the piston outside diameter at the place 10 mm from the skirt end as shown. If the measurement is less than the limit, replace the piston. & Piston diameter Service Limit: 53.380 mm 10 mm $ 09900-20203: Micrometer (50 –...
Page 69 ENGINE 3-35 PISTON RING END GAP • Measure the piston ring end gap using the vernier calipers. • Next, fit the piston ring squarely into the cylinder and measure the piston ring end gap using the thickness gauge. • If any of the measurements exceeds the service limit, replace the piston ring with a new one.
Page 70: Crankshaft
3-36 ENGINE CRANKSHAFT CONROD SMALL END I.D. Using a caliper gauge, measure the conrod small end inside diameter. & Conrod small end I.D. Service Limit: 14.064 mm $ 09900-20605: Dial calipers If the conrod small end bore inside diameter exceeds the limit, replace the conrod.
Page 71: Oil Pump
ENGINE 3-37 REASSEMBLY • When rebuilding the crankshaft, the width between the weds A should be within the standard range. & Crank wed to wed width A: 48.9 – 49.1 mm OIL PUMP DISASSEMBLY • Remove the circlip 1, washer 2, oil pump driven gear 3 and pin 4.
Page 72 3-38 ENGINE MOVABLE DRIVE FACE INSPECTION Check the drive face for any abnormal condition such as stepped wear or discoloration caused by burning. If any defects are found, replace the movable drive face with a new one. • Remove the movable drive face plate 1. •...
Page 73: Clutch Shoe/Movable Driven Face
ENGINE 3-39 CLUTCH SHOE/MOVABLE DRIVEN FACE DISASSEMBLY • Loosen the clutch shoe nut with the special tool. $ 09930-40113: Rotor holder 09930-40120: Rotor holder attachment (A) Do not remove the clutch shoe nut at this time. • Lock the clutch shoe assembly with the special tool handle turned in.
Page 74 3-40 ENGINE • Remove the pins 5, movable driven face 6, and fixed driven face 7. • Remove the bearing with the special tool. $ 09921-20240: Bearing remover set The removed bearing should be replaced with a new one. • Remove the snap ring. •...
Page 75 ENGINE 3-41 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. $ 09900-20101: Vernier calipers &...
Page 76 • Install the bearing 2 in the fixed driven face 1 with the spe- cial tool. $ 09943-88211: Bearing installer • Apply SUZUKI SUPER GREASE “A” to the bearing 2. * 99000-25010: SUZUKI SUPER GREASE “A” • Securely install the snap ring.
Page 77 ENGINE 3-43 • Install the pins 3 at three places on the drive face hub. • Apply as small amount of SUZUKI SUPER GREASE “A” to the cam where the pins are placed. * 99000-25010: SUZUKI SUPER GREASE “A” • Install the new O-rings 4.
Page 78: Drive Belt
3-44 ENGINE DRIVE BELT Remove the drive belt and check for cracks, wear and separa- tion and measure the drive belt width with vernier calipers. If any damages are found or if the width of the drive belt is less than the service limit, replace the drive belt with a new one.
Page 79: Starter Clutch
• Install the plate after aligning the cooling belt cover holes A with the plate pins B. • Apply grease to the new O-ring and install the duct 1. * 99000-25010: SUZUKI SUPER GREASE “A” Use the new O-ring to prevent oil leakage. STARTER CLUTCH...
Page 80: Magneto Cover
3-46 ENGINE • Remove the roller 3, spring 4 and push pieces 5. INSPECTION Inspect the rollers 1 and push pieces 2 for damage and exces- sive wear. If any defects are found, replace the new one. REASSEMBLY • Reassemble the starter clutch in the reverse order of disas- sembly.
Page 81: Kick Starter
Pay attention to the following points: • Install the oil seal with the special tool. $ 09913-70210: Bearing installer set (35 mm) • Apply a small quantity of SUZUKI SUPER GREASE “A” to the lip of the oil seal. * 99000-25010: SUZUKI SUPER GREASE “A”...
Page 82 • Apply SUZUKI SUPER GREASE “A” onto the inside of the kick starter shaft spacer. * 99000-25010: SUZUKI SUPER GREASE “A” • Apply a light coat of SUZUKI SUPER GREASE “A” onto the end of the kick starter shaft. * 99000-25010: SUZUKI SUPER GREASE “A”...
Page 83: Reduction Gear
ENGINE 3-49 • Apply SUZUKI SUPER GREASE “A” onto the shaft and gear of the kick starter drive gear. * 99000-25010: SUZUKI SUPER GREASE “A” • Install the kick starter driven gear 4. • Apply SUZUKI SUPER GREASE “A” to the oil seal lip.
Page 84 3-50 ENGINE BEARING INSPECTION Play Wash the bearing with a cleaning solvent and lubricate it with motor oil before inspection. Rotate the inner race and check to see that it turns smoothly. If it does not turn quietly and Play smoothly, or if there are signs of any abnormalities, the bearing is defective and must be replaced with a new one.
Page 85: Bearing Inspection
ENGINE 3-51 BEARING INSPECTION Play Wash the bearing with a cleaning solvent and lubricate it with motor oil before inspection. Rotate the inner race and check to see that it turns smoothly. If it does not turn quietly and Play smoothly, or if there are signs of any abnormalities, the bearing is defective and must be replaced with a new one.
Page 86: Left Crankcase
3-52 ENGINE • Install the engine mounting bushing using two steel tubes of the appropriate size and a vise. Press the mounting bushing into the crankcase holes. (!7-23) LEFT CRANKCASE BEARING/OIL SEAL REMOVAL • Remove the bearing retainer 1. • Remove the rear axle shaft bearing with the special tool. $ 09921-20240: Bearing remover set (20 mm) Replace the removed bearing with a new one.
Page 87 ENGINE 3-53 • Remove the crankshaft oil seal with the special tool. $ 09913-50121: Oil seal remover Replace the removed oil seal with a new one. • Remove the crankshaft bearing with the special tool. $ 09913-70210: Bearing installer set (35 mm) Replace the removed bearing with a new one.
Page 88: Engine Mounting Bushings
3-54 ENGINE • Install the crankshaft bearing with the special tool. $ 09913-70210: Bearing installer set (52 mm) • Install the crankshaft oil seal with the special tool. $ 09913-70210: Bearing installer set (42 mm) • Install the bearing retainer. NOTE: When installing the bearing retainers, apply THREAD LOCK to the screws.
Page 89: Crankshaft Shim Selection
ENGINE 3-55 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) cut out about 10 mm on the shim as shown.
Page 90: Engine Reassembly
3-56 ENGINE ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. Pay attention to the following points: NOTE: Apply engine oil to each running and sliding part before reas- sembling. * Make sure to coat the rotating and sliding sections with engine oil.
Page 91 ENGINE 3-57 • Apply sealant to the right crankcase. , 99000-31110: SUZUKI BOND “1215” * Coat the sealant evenly without break. * Application of sealant must be performed within a short period of time. * Take extreme care not to let sealant enter into the oil hole or bearing.
Page 92 3-58 ENGINE * The lip A of the oil sump filter should be positioned downward. * The thinner side B of the oil sump filter should be positioned inside. • Install the oil sump filter cap 3. • Tighten the oil sump filter cap bolts to the specified torque. "...
Page 93 ENGINE 3-59 REDUCTION GEAR • Install the driveshaft 1 to the case. • Install the rear axle shaft 2. • Install the idle driven gear 3 and washer 4. Apply engine oil to each gear and shaft. • Install the dowel pins 5 and new gasket 6. •...
Page 94 3-60 ENGINE MOVABLE DRIVEN FACE • Check that no roller inside the movable drive face is out of position from the slot. • Install the movable drive face 1 and spacer 2. The assembly work should be carefully performed so as not to allow the roller to dislocate.
Page 95 ENGINE 3-61 • Install the fixed drive face 7. • Install the kick starter 8. • Install the washer 9 and nut 0. Check that the fixed drive face is not fouled with grease or other substance and if found, clean and degrease completely.
Page 96 3-62 ENGINE • With the other side of the chain engaged with the crankshaft gear, install the oil pump assembly after applying THREAD LOCK to the screw. + 99000-32110: THREAD LOCK SUPER “1322” • Tighten the oil pump mounting screws to the specified torque. "...
Page 97 • Apply SUZUKI SUPER GREASE “A” to the center stand spring and shaft. (!7-26) * 99000-25010: SUZUKI SUPER GREASE “A” BRAKE CAM • Apply SUZUKI SUPER GREASE “A” to the brake cam, and then install the brake cam into the crankcase. * 99000-25010: SUZUKI SUPER GREASE “A” http://mototh.com...
Page 98 3-64 ENGINE • Position the brake cam so that the punch mark A faces the rear axle shaft. (!7-27) • Align the tang 1 on the brake lining wear indicator plate 2 with the cutaway 3 on the brake cam. Then, slide the brake lining wear indicator plate 2 onto the brake cam.
Page 99 ENGINE 3-65 • Install the washer 2. • Tighten the cooling fan holder nut to the specified torque with the special tool. " Cooling fan holder nut: 33 N·m (3.3 kgf-m) $ 09930-40113: Rotor holder • Align the boss C of the cooling fan to the groove D of the cooling fan holder.
Page 100 3-66 ENGINE When installing the spacer, be careful not to allow its INCORRECT two ends to overlap in the groove. CORRECT • Top ring and 2nd ring differ in the shape of ring face, and the face of top ring is chrome-plated whereas that of 2nd ring is not.
Page 101 ENGINE 3-67 • After the piston pin 1 has been inserted through the conrod, install the circlip 2. * Replace the circlip with a new one. * Place a piece of rag under the piston when installing the circlip to prevent it from falling into the crank- case.
Page 102 3-68 ENGINE • Install the cylinder head and the oil separator plate 4 and washer 5. • Tighten the cylinder head nuts to the specified torque diago- nally. " Cylinder head nut: 25 N·m (2.5 kgf-m) • Tighten the cylinder head side nuts to the specified torque. "...
Page 103 ENGINE 3-69 • Install the spring 6 and plastic washer 7 to the decompres- sion cam. • Hook the part E of the spring onto the cam and fit the part F to the washer’s slit and hole of cam sprocket 8. •...
Page 104 • Fit a new gasket 1 to the cylinder head cover. • Apply sealant to cam end cap. - 99104-31140: SUZUKI BOND “1207B” Make sure to replace the gasket with a new one. • Place the cylinder head cover on the cylinder head.
Page 105 PAIR CONTROL VALVE • Install the PAIR control valve 1. (!7-18) STARTER MOTOR • Fit the O-ring 1 to the starter motor. • Apply a small amount of grease to the O-ring 1. * 99000-25010: SUZUKI SUPER GREASE “A” http://mototh.com...
Page 106 3-72 ENGINE • Mount the starter motor 2 on the engine. • Tighten the starter motor bolts to the specified torque. " Starter motor mounting bolt: 10 N·m (1.0 kgf-m) CRANKCASE TUBE GROMMET • Install the crankcase tube grommet No.1 1 and No.2 2. NOTE: The boss A of the crankcase tube grommet faces front side.
Page 107: Pair (Air Supply) System
ENGINE 3-73 PAIR (AIR SUPPLY) SYSTEM PAIR HOSES INSPECTION • Remove the frame front cover. (!5-8) • Inspect the PAIR hoses for wear or damage. • Inspect the PAIR hoses are securely connected. PAIR REED VALVE INSPECTION • Remove the PAIR reed valve cover. (!3-20) •...
Page 108 White Page http://mototh.com...
Page 109: Fuel And Lubrication System
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- 4 FUEL LEVEL GAUGE ................. 4- 5 REMOVAL ................... 4- 5 INSPECTION ................
Page 110: Fuel Tank And Fuel Tap
FUEL AND LUBRICATION SYSTEM FUEL TANK AND FUEL TAP REMOVAL • Remove the frame front cover. (!5-8) • Remove the luggage box. (!5-9) • Remove the E-ring 1 and pin 2. • Disconnect the fuel hose 3 and vacuum hose 4. "...
Page 111: Inspection
FUEL AND LUBRICATION SYSTEM • Remove the fuel tank 7. • Remove the fuel tap 8. INSPECTION FUEL FILTER If the 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 112: Remounting
FUEL AND LUBRICATION SYSTEM FUEL TAP Connect the vacuum pump gauge to the vacuum port of the fuel tap. Apply negative pressure to the fuel tap and breathe the fuel outlet port. If air A does not flow out, replace the fuel tap with a new one.
Page 113: Fuel Level Gauge
FUEL AND LUBRICATION SYSTEM FUEL LEVEL GAUGE REMOVAL • Open the seat. (!5-8) • Remove the retainer 1. • Disconnect the fuel level gauge coupler 2. • Remove the rubber cushion 3. • Remove the fuel level gauge 4. http://mototh.com...
Page 114: Inspection
FUEL AND LUBRICATION SYSTEM INSPECTION Measure resistance between the terminals when the float is at the position listed below. $ 09900-25008: Multi-circuit tester Float position Resistance between terminals 4 – 10 Ω Full Approx. 38 Ω 90 – 100 Ω Empty If the resistance measured is out of the specification, replace the gauge assembly with a new one.
Page 115: Carburetor
FUEL AND LUBRICATION SYSTEM CARBURETOR CONSTRUCTION 1 Top cap 6 Starter body A Needle valve 2 Spring 7 Pilot screw B Float 3 Holder 8 Air vent hose C Pilot jet 4 Jet needle 9 Needle jet holder D Float chamber 5 Piston valve assembly 0 Main jet E Throttle stop screw...
Page 116: Specifications
FUEL AND LUBRICATION SYSTEM SPECIFICATIONS ITEM SPECIFICATION I.D. LOCATION The carburetor has I.D. Number A Carburetor type MIKUNI BS26 & 26 mm Bore size stamped on the carburetor body. I.D. No. 46G0 Idle rpm 1 600 ± 100 rpm Float height XX.X ±...
Page 117: Disassembly
FUEL AND LUBRICATION SYSTEM • Disconnect the starter cable 3. • Disconnect the throttle cable 4. • Remove the carburetor. DISASSEMBLY • Disconnect the fuel hose 1, air vent hose 2, fuel drain hose 3 and vacuum hose 4. • Remove the throttle stop screw 5. •...
Page 118 4-10 FUEL AND LUBRICATION SYSTEM • Remove the spring 7 and diaphragm 8. • Remove the holder 9 by turning it counterclockwise with a screwdriver. • Remove the following parts. 0 Holder A Spring B Washers C Jet needle • Remove the float chamber body D. •...
Page 119 FUEL AND LUBRICATION SYSTEM 4-11 • Remove the following parts. H Main jet I Pilot jet J Needle jet holder K Needle jet Do not use a wire for cleaning of passage and jets. • Remve the starter body L. •...
Page 120: Carburetor Cleaning
4-12 FUEL AND LUBRICATION SYSTEM 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 121: Needle Valve Inspection
Reassemble and remount the carburetor in the reverse order of disassembly and removal. Pay attention to the following points: • Apply SUZUKI SUPER GREASE “A” to thread part of the throttle stop screw, then install the throttle stop screw to the carburetor.
Page 122 4-14 FUEL AND LUBRICATION SYSTEM • Install the pilot screw 1. NOTE: Turn in the pilot screw 1 until it lightly seats, then back it out the counted number of turns. (!4-11) Replace the removed O-ring with a new one. •...
Page 123: Lubrication System
FUEL AND LUBRICATION SYSTEM 4-15 • Position the diaphragm to the carburetor body properly. • Align the lug on the carburetor with the intake pipe cutout A. • Adjust the following items to the specification. * Idling adjustment........... !2-10 * Throttle cable play..........!2-10 LUBRICATION SYSTEM OIL PRESSURE !2-21...
Page 124: Engine Lubrication System Chart
4-16 FUEL AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART CYLINDER CAMSHAFT HEAD PISTON CONROD CYLINDER ROCKER SMALL ROCKER PISTON WALL CHAIN CYLINDER SHAFT CRANK PIN ORIFICE MAIN GALLERY CRANK BEARING (L) CONROD BIG END OIL FILTER BY-PASS OIL PUMP OIL SUMP FILTER http://mototh.com...
Page 125 CONTENTS EXTERIOR PARTS ..................5- 2 FASTENER REMOVAL AND INSTALLATION........5- 2 REMOVAL ..................... 5- 3 FRONT WHEEL AND FRONT BRAKE (UY125) ......... 5-10 REMOVAL ..................... 5-10 INSPECTION AND DISASSEMBLY ............. 5-12 REASSEMBLY AND INSTALLATION ..........5-15 FRONT WHEEL (UY125S)................5-18 REMOVAL .....................
Page 126: Exterior Parts
CHASSIS EXTERIOR PARTS FASTENER REMOVAL AND INSTALLATION REMOVAL • Turn the head of fastener center piece 1. • Pull out the fastener. INSTALLATION • Let the center piece stick out toward the head so that the pawls 2 close. • Insert the fastener into the installation hole. NOTE: To prevent the pawl 2 from damage, insert the fastener all the way into the installation hole.
Page 127: 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 remove the rear handlebar cover 5. • Disconnect the speedometer coupler 6 and right and left handlebar switch couplers 7.
Page 128 CHASSIS FRONT LEG SHIELD • Remove the front leg shield mounting screws. !: Hooked part • Disconnect the front turn signal couplers 1. • Remove the front leg shield 2. FRONT LEG LOWER SHIELD • Remove the front leg shield. ("Abobe) •...
Page 129 CHASSIS LEG LOWER SHIELD • Remove the leg lower shield. LEG SHIELD COVER • Remove the frame front cover. ("5-8) • Remove the luggage box. ("5-9) • Remove the pillion rider handle. ("5-9) • Remove the frame cover assembly. ("5-10) •...
Page 130 CHASSIS FRAME FRONT COVER • Open the seat 1 using the ignition key. • Remove the frame front cover 2. LEG REAR SHIELD • Remove the frame front cover. ("5-8) • Remove the luggage box. ("5-9) • Remove the pillion rider handle. ("5-9) •...
Page 131 CHASSIS LUGGAGE BOX • Open the seat. ("5-8) • Remove the luggage box mounting screws. • Remove the fuse box 1 from luggage box 2. • Remove the luggage box 2. PILLION RIDER HANDLE • Remove the pillion rider handle 1. http://mototh.com...
Page 132 CHASSIS FRAME COVER (R&L) • Remove the frame front cover. ("5-8) • Remove the luggage box. ("5-9) • Remove the pillion rider handle. ("5-9) • Remove the frame cover assembly mounting screws. !: Hooked part http://mototh.com...
Page 133 CHASSIS • Disconnect the seat lock cable 1. • Disconnect the rear combination light coupler 2. • Remove the frame cover assembly. • Remove the right frame cover 3 and left frame cover 4. • Pull the ignition key stopper plate 5. •...
Page 134: Front Wheel And Front Brake (Uy125)
5-10 CHASSIS FRONT WHEEL AND FRONT BRAKE (UY125) 1 Collar 2 Dust seal 3 Bearing 4 Front wheel spacer 5 Front wheel 6 Bearing 7 Front brake shoe 8 Dust seal Speedometer drive gear 0 Front brake camshaft A Front brake panel...
Page 135 CHASSIS 5-11 • Remove the front brake panel 1. • Remove the brake shoes. • Remove the dust seal with the special tool. $ 09913-50121: Oil seal remover • Remove the speedometer drive gear 2. • Remove the brake cam lever 3. http://mototh.com...
Page 136: Inspection And Disassembly
5-12 CHASSIS • Replace the indicator plate 4, dust seal 5, spring 6 and brake camshaft 7. • Pull out the pinion outer bush 8. • Remove the washer 9 and pinion gear 0. INSPECTION AND DISASSEMBLY DUST SEAL • Remove the spacer 1. •...
Page 137 CHASSIS 5-13 Remove the wheel bearings as follows: • Insert the bearing remover attachment 1 into the wheel bear- ing. • Insert the wedge bar 2 from the opposite side and lock it into the slit of the bearing remover attachment. •...
Page 138 5-14 CHASSIS SPOKE NIPPLE Make sure that all nipples are tight. If necessary tighten them with a spoke nipple wrench. # S poke nipple: 4.5 N·m (0.45 kgf-m) $ 09940-60113: Spoke nipple wrench TIRE................"2-15 BRAKE SHOE Inspect the brake shoes wear or damage. If any wear or dam- ages are found, replace the brake shoes as a set.
Page 139: Reassembly And Installation
Pay attension to the following points: WHEEL BEARING • Apply SUZUKI SUPER GREASE “A” to the wheel bearings. ' 99000-25010: SUZUKI SUPER GREASE “A” • Install the wheel bearings using the special tool. $09924-84521: Bearing installer set * First, install the left wheel bearing, and then install the right wheel bearing.
Page 140 5-16 CHASSIS • Install the pinion gear 1, washer 2 and pinion outer bush 3. • Apply SUZUKI SUPER GREASE “A” to the gear and the inside of gear box. ' 99000-25010: SUZUKI SUPER GREASE “A” Pinion outer bush Pinion gear Washer •...
Page 141 CHASSIS 5-17 • Apply SUZUKI SUPER GREASE “A” to the inside and outside of drive gear. ' 99000-25010: SUZUKI SUPER GREASE “A” • Install the new dust seal 7. • Apply SUZUKI SUPER GREASE “A” to the camshaft, pin and lip of dust seal before installing the brake shoes.
Page 142: Front Wheel (Uy125S)
5-18 CHASSIS FRONT WHEEL (UY125S) 1 Spacer 2 Bearing 3 Front axle spacer 4 Bearing 5 Brake disc 6 Speedometer gearbox 7 Front axle A Front axle nut B Brake disc bolt ITEM N·m kgf-m REMOVAL • Disconnect the speedometer cable 1. •...
Page 143: Inspection And Disassembly
CHASSIS 5-19 • Remove the brake disc by removing its bolts. INSPECTION AND DISASSEMBLY WHEEL BEARING............"5-14 FRONT AXLE ............. "5-15 WHEEL ............... "5-15 TIRE ................"2-15 SPEEDOMETER GEARBOX Turn the speedometer gear and check to see that the gear turns smoothly together with the speedometer pinion.
Page 144: 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. ("5-17) ' 99000-25010: SUZUKI SUPER GREASE “A” • Install the wheel bearings using the special tool.
Page 145 CHASSIS 5-21 SPEEDOMETER GEARBOX • Apply SUZUKI SUPER GREASE “A” to the speedometer gearbox. ' 99000-25010: SUZUKI SUPER GREASE “A” • Align the lugs 1 on the speedometer gearbox with the recesses 2 on the front wheel. FRONT WHEEL • Make sure that the stopper 3 on the front fork and the speed- ometer gearbox protrusion 4 are installed as shown.
Page 146: Front Brake (Uy125S)
5-22 CHASSIS FRONT BRAKE (UY125S) 1 Reservoir cap 2 Diaphragm 3 Master cylinder 4 Piston set 5 Dust seal boot 6 Brake hose 7 Caliper holder 8 Caliper holder pin 9 Caliper holder pin 0 Rubber parts A Pad set B Piston and dust seal C Piston D Caliper...
Page 147: Brake Fluid Replacement
CHASSIS 5-23 BRAKE FLUID REPLACEMENT • Remove the front handlebar cover. ("5-5) • Place the motorcycle on a level surface and keep the handle- bars straight. • Remove the master cylinder reservoir cap and diaphragm. • Suck up the old brake fluid as much as possible. •...
Page 148: Caliper Removal
5-24 CHASSIS • Remove the brake pad mounting pin 2 and brake pads 4 . * Do not operate the brake lever after brake pad removal. * Replace the brake pad as a set, otherwise braking performance will be adversely affected. •...
Page 149: Caliper Inspection
CHASSIS 5-25 • 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. Do not use high pressure air to prevent piston dam- age.
Page 150: Caliper Reassembly
* Specification and classification: DOT 4 PISTON SEAL • Install the piston seal and dust seal as shown. BRAKE CALIPER HOLDER • Apply SUZUKI SILICON GREASE to the brake caliper holder pin. + 99000-25100: SUZUKI SILICONE GREASE http://mototh.com...
Page 151: Caliper Installation
CHASSIS 5-27 • Install the brake pad 1. • Temporary tighten the brake pad mounting pin 2. CALIPER INSTALLATION Install the caliper in the reverse order of removal. Pay attention to the following points: • Tighten the brake caliper mounting bolts and brake pad mounting pin.
Page 152: Master Cylinder Removal And Disassembly
5-28 CHASSIS MASTER CYLINDER REMOVAL AND DISAS- SEMBLY • Remove the front and rear handlebar covers. ("5-5) • Place a rag underneath the brake hose union bolt 1 on the master cylinder to catch any spilt brake fluid. ("5-25) Immediately wipe off any brake fluid contacting any part of the motorcycle.
Page 153: Master Cylinder Inspection
CHASSIS 5-29 • Pull out the dust seal boot 9 and remove the snap ring 0. • Remove the plate A, piston B and spring C. MASTER CYLINDER INSPECTION CYLINDER Inspect the master cylinder bore for any scratches or damage. PISTON AND CUP SET Inspect the piston surface for any scratches or other damage.
Page 154 Boot • When installing the brake light switch, align the projection on the switch with the hole in the master cylinder. • Apply SUZUKI SUPER GREASE “A” to the piston and brake lever pivot. ' 99000-25010: SUZUKI SUPER GREASE “A”...
Page 155 CHASSIS 5-31 • Install the brake hose union as shown and tighten the union bolt to the specified torque. # Brake hose union bolt: 23 N·m (2.3 kgf-m) • Fill the master cylinder with brake fluid and bleed air. ("2-14) http://mototh.com...
Page 156: Front Fork
REMOVAL AND DISASSEMBLY • Remove the front leg shield. ("5-6) • Remove the front wheel. ("UY125: 5-12)("UY125S: 5-20) • Remove the front fender 1. • Remove the front brake hose guide and front brake caliper. (UY125S)("5-25) • Loosen the front fork top cap 2.
Page 157 CHASSIS 5-33 • Remove the front fork cap bolt 2 and spring 4. • Invert the fork and stroke it several times to drain out the fork oil. NOTE: Hold the fork inverted for a few minutes to drain the oil. •...
Page 158: Inspection
5-34 CHASSIS • Pull the inner tube out of the outer tube. • Remove the oil seal by using the special tool. $ 09913-50121: Oil seal remover The removed oil seal must be replaced with a new one. INSPECTION INNER AND OUTER TUBE Inspect the inner tube sliding surface and outer tube sliding sur- face for any scuffing or damage.
Page 159: Reassembly And Installation
• Insert the oil seal 1 to the outer tube. NOTE: Apply fork oil to the oil seal 1 lip lightly before installing it. , 99000-99044-10G: SUZUKI FORK OIL G10 or equivalent fork oil OIL SEAL • Install the oil seal 1 into the outer tube using the front fork oil seal installer.
Page 160 • Pour the specified fork oil into the inner tube. & Front fork oil capacity (each leg): 55 ml , 99000-99044-10G: SUZUKI FORK OIL G10 or equivalent fork oil • Hold the front fork leg in a vertical position and adjust the fork oil level by using the special tool.
Page 161 • Fit the O-ring to the front fork cap bolt and apply fork oil. Use a new O-ring to prevent oil leakage. , 99000-99044-10G: SUZUKI FORK OIL G10 or equivalent fork oil • Temporarily install the front fork to the motorcycle.
Page 162: Handlebars
5-38 CHASSIS HANDLEBARS 1 Handlebars A Handlebar clamp nut ITEM N·m kgf-m REMOVAL • Remove the front leg shield. ("5-6) • Remove the front and rear handlebar covers. ("5-5) • Remove the cable clamp. HANDLEBAR LEFT SIDE PARTS • Disconnect the rear brake cable 1 and brake switch 2. •...
Page 163: Installation
• Remove the throttle grip 2. • Disconnect the front brake cable 3 and brake switch 4. (UY125) • Remove the front brake lever holder 5. (UY125) • Disconnect the brake light switch lead wires, and remove the front brake master cylinder. (UY125S)("5-30) •...
Page 164 5-40 CHASSIS • Apply SUZUKI SUPER GREASE “A” to the cable end and brake lever pivot. ' 99000-25010: SUZUKI SUPER GREASE “A” • Apply SUZUKI SUPER GREASE “A” onto the handlebars before installing the throttle grip. ' 99000-25010: SUZUKI SUPER GREASE “A”...
Page 165 CHASSIS 5-41 • Apply SUZUKI SUPER GREASE “A” to the cable end and brake lever pivot. ' 99000-25010: SUZUKI SUPER GREASE “A” • After installing the handlebar, route the wire harness properly. ("7-12) • Adjust the throttle operation and cable play ("2-10)
Page 166: Steering
REMOVAL AND DISASSEMBLY • Remove the handlebars. ("5-40) • Remove the front wheel. ("UY125: 5-12)("UY125S: 5-20) • Remove the front fender and front forks. ("5-34) • Remove the cable guide 1. • Remove the steering stem lock-nut with the special tool.
Page 167 CHASSIS 5-43 • Remove the washer 2. • Loosen the steering stem nut 3 with the special tool. $ 99000-60611: Universal clamp wrench • Remove the steering stem nut 3 and dust cover 4. NOTE: Hold the steering stem bracket to prevent it from falling. •...
Page 168: Inspection
5-44 CHASSIS • Drive out the upper and lower races. INSPECTION Inspect the steering stem for any damage. Inspect the steel balls and race for corrosion, wear or other dam- age. http://mototh.com...
Page 169: Reassembly And Installation
• Press in the outer lower race 2 with the special tools. $ 09913-70210: Bearing installer set 3 09940-51710: Bearing installer 4 • Apply SUZUKI SUPER GREASE “A” to the upper and lower races. • Install the steel balls. ' 99000-25010: SUZUKI SUPER GREASE “A”...
Page 170 Therefore after tightening the lock-nut, check the steering movement again and adjust if necessary. • Install the front forks and front fender. ("5-39) • Install the front wheel. ("UY125: 5-19)("UY125S: 5-23) • Install the handlebars. ("5-41) • Perform the steering inspection after assembly has been completed.
Page 171: Rear Wheel And Rear Brake
CHASSIS 5-47 REAR WHEEL AND REAR BRAKE CONSTRUCTION 1 Rear wheel 2 Washer 3 Brake shoe 4 Spring 5 Brake camshaft 6 Brake cam lever 7 Brake cam lever bolt Brake lining wear indi- cator A Rear axle nut Rear brake cam lever ITEM N·m kgf-m...
Page 172: Inspection
5-48 CHASSIS • Remove the brake cable plate 2. • Remove the brake adjuster 3. • Remove the brake cam lever nut and bolt 4. • Remove the brake cam lever 5, brake lining wear indicator 6 and brake camshaft 7. INSPECTION BRAKE DRUM Measure the brake drum I.D.
Page 173: Reassembly And Remounting
Reassemble and remount the rear wheel and rear brake in the reverse order of removal and disassembly. Pay attention to the following points: • When installing the camshaft, apply SUZUKI SUPER GREASE “A” to the camshaft. ' 99000-25010: SUZUKI SUPER GREASE “A”...
Page 174 • Tighten the brake cam lever nut to the specified torque. # Brake cam lever nut: 11 N·m (1.1 kgf·m) • Apply SUZUKI SUPER GREASE “A” to the camface and pin. ' 99000-25010: SUZUKI SUPER GREASE “A” • Install the brake shoes with spring hooks faced inside.
Page 175: Rear Suspension
CHASSIS 5-51 REAR SUSPENSION CONSTRUCTION 1 Rear shock absorber 2 Washer Rear shock absorber mounting nut (Upper) Rear shock absorber mounting bolt (Lower) ITEM N·m kgf-m REMOVAL • Remove the luggage box. ("5-9) • Remove the clutch upper cover 1. •...
Page 176: Inspection And Disassembly
5-52 CHASSIS INSPECTION AND DISASSEMBLY • Remove the spacer 3 and bushing 4. REAR 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. SPACER AND BUSHING Inspect the spacer and bushing for wear and damage.
Page 177 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................. 6- 3 CONNECTOR ..................6- 3 COUPLER....................6- 3 CLAMP ....................6- 3 FUSE...................... 6- 3 SEMI-CONDUCTOR EQUIPPED PART ..........6- 4 BATTERY ....................6- 4 CONNECTING THE BATTERY............. 6- 4 WIRING PROCEDURE................
Page 178 ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS LAMPS ......................6-30 HEADLIGHT ..................6-30 FRONT TURN SIGNAL LIGHT ............. 6-31 BRAKE LIGHT/TAILLIGHT AND REAR TURN SIGNAL LIGHT ..6-32 SWITCHES ....................6-34 BATTERY ....................6-35 SPECIFICATIONS ................. 6-35 INITIAL CHARGING ................6-35 SERVICING ................... 6-37 RECHARGING OPERATION ..............
Page 179: 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 180: Semi-Conductor Equipped Part
ELECTRICAL SYSTEM 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 AC/DC rectifier. • When inspecting these parts, follow the instructions carefully. Failure to follow the proper procedure can cause damage to these parts.
Page 181: 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 182: Location Of Electrical Components
ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Horn 2 Turn signal relay 3 Regulator/rectifier 4 Magneto 5 Battery 6 Fuse 7 CDI unit http://mototh.com...
Page 183 ELECTRICAL SYSTEM 8 Ignition coil 9 Starter relay 0 Starter motor http://mototh.com...
Page 184: Charging And Lighting System
ELECTRICAL SYSTEM CHARGING AND LIGHTING SYSTEM Magneto switch AC/DC Rectifire Ignition CDI unit coil Fuse Load Battery M/L T/L CDI unit TROUBLESHOOTING Battery runs down quickly. Step 1 1) Check accessories which use excessive amounts of electricity. Are accessories being installed? Remove accessories.
Page 185 ELECTRICAL SYSTEM Step 3 1) Measure the charging output between the battery terminals. (!6-10) Is the charging output OK? • Faulty battery • Abnormal driving condition Go to Step 4. Step 4 1) Measure the resistance of the stator coil. (!6-11) Is the resistance of stator coil OK? Go to Step 5.
Page 186: Inspection
6-10 ELECTRICAL SYSTEM INSPECTION BATTERY CURRENT LEAKAGE • Turn the ignition switch to the OFF position. • Open the seat. (!5-8) • Remove the battery box lid 1. • Disconnect the battery - lead wire. • Measure the current between - battery terminal and the - battery lead wire using the multi-circuit tester.
Page 187 ELECTRICAL SYSTEM 6-11 STATOR COIL RESISTANCE • Remove the frame front cover. (!5-8) • Disconnect the stator coupler. Measure the resistance between the lead wires using the multi-circuit tester. If the resistance is not within the specified value, replace the stator coil with a new one. "...
Page 188 6-12 ELECTRICAL SYSTEM AC/DC RECTIFIER • Remove the frame cover assembly. (!5-11) • Disconnect the AC/DC rectifier coupler. • Remove the AC/DC rectifier 1. Measure the voltage between the terminals using the multi-cir- cuit tester, as indicated in the table below. If voltage is not within the specified value, replace the AC/DC rectifier with a new one.
Page 189: Starter System
ELECTRICAL SYSTEM 6-13 STARTER SYSTEM Starter relay Starter motor Front brake light switch Ignition switch Fuse Starter button Rear brake Battery CDI unit light switch TROUBLESHOOTING Make sure that the fuse is not blown and the battery is fully-charged before diagnosing. Starter motor will not run.
Page 190: Starter Motor Removal
6-14 ELECTRICAL SYSTEM Step 4 1) Check the starter relay. (!6-20) Is the starter relay OK? Poor contact of the starter relay Faulty starter relay Starter motor runs but does not crank the engine. Step 1 1) Check the starter clutch. Is the starter clutch OK? Faulty starter motor Faulty starter clutch...
Page 191: Starter Motor Disassembly
ELECTRICAL SYSTEM 6-15 STARTER MOTOR DISASSEMBLY • Disassemble the starter motor as shown in the illustration. 1 O-ring 4 Armature 2 Housing end (inside) 5 Housing end (outside) 3 Starter motor case • Remove the housing end (inside) 1. • Remove the slip washer 2, thrust washer 3 (t: 0.2), thrust washer 4 (t: 0.5) and starter motor case 5.
Page 192 6-16 ELECTRICAL SYSTEM • 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.2 D, O-ring E, brush F and terminating holder •...
Page 193: Starter Motor Inspection
ELECTRICAL SYSTEM 6-17 STARTER MOTOR INSPECTION 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 194: Starter Motor Reassembly
STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order of disassem- bly. 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 195 ELECTRICAL SYSTEM 6-19 • Apply SUZUKI SUPER GREASE to the O-ring. . 99000-25010: SUZUKI SUPER GREASE “A” • Install the crankcase grommet No.1 and No.2. (!3-72) • Install the cooling fan duct. (!3-45) http://mototh.com...
Page 196: Starter Relay Inspection
6-20 ELECTRICAL SYSTEM STARTER RELAY INSPECTION • Remove the luggage box. (!5-9) • Disconnect the battery - lead wire from the battery. • Disconnect the starter motor lead wire 1, battery lead wire 2 and starter relay coupler 3. • Remove the starter relay 4. •...
Page 197: Ignition System
ELECTRICAL SYSTEM 6-21 IGNITION SYSTEM Fuse CDI unit Regulator/ rectifier Battery Ignition coil W/Bl BI/Y Spark plug 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 198 6-22 ELECTRICAL SYSTEM Step 3 1) Measure the ignition coil primary peak voltage. (!6-23) NOTE: This inspection method is applicable only with the multi-circuit tester and the peak volt adaptor. Is the peak voltage and its resistance OK? Go to Step 4. Go to Step 5.
Page 199: Inspection
ELECTRICAL SYSTEM 6-23 INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Remove the leg rear shield. (!5-8) • Remove the spark plug cap. • Connect a new spark plug 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 200 6-24 ELECTRICAL SYSTEM IGNITION COIL RESISTANCE • Remove the leg rear shield. (!5-8) • Disconnect the ignition coil lead wires and spark plug cap. • Remove the ignition coil. Measure the ignition coil resistance in both the primary and sec- ondary windings using the multi-circuit tester.
Page 201 ELECTRICAL SYSTEM 6-25 If the peak voltage measured on the CDI unit coupler is lower than the standard value, measure the peak voltage on the pickup coil coupler as follows. • Remove the frame front cover. (!5-8) • Disconnect the pickup coil coupler. •...
Page 202: Speedometer
6-26 ELECTRICAL SYSTEM SPEEDOMETER REMOVAL AND DISASSEMBLY • Remove the handlebar covers. (!5-5) • Remove the speedometer. • Disassemble the speedometer, as shown. http://mototh.com...
Page 203: Inspection
ELECTRICAL SYSTEM 6-27 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 (-) Speedometer Fuel meter High beam indicator light Turn signal indicator light WIRE COLOR : Black...
Page 204: Fuel Meter And Fuel Level Gauge
6-28 ELECTRICAL SYSTEM 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. (!5-8) • Disconnect the fuel level gauge coupler. (!4-2) •...
Page 205: Relays
ELECTRICAL SYSTEM 6-29 RELAYS TURN SIGNAL RELAY The turn signal relay is located behind the front leg shield. INSPECTION 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 206: Lamps
6-30 ELECTRICAL SYSTEM LAMPS HEADLIGHT Headlight bulb: 12 V 30/30 W HEADLIGHT BULB REPLACEMENT • Remove the front handlebar cover. (!5-5) • Remove the headlight bulb. 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 207: Front Turn Signal Light
ELECTRICAL SYSTEM 6-31 FRONT TURN SIGNAL LIGHT Turn signal light: 12 V 10 W FRONT TURN SIGNAL LIGHT BULB REPLACEMENT • Remove the front leg shield. (!5-6) • Remove the front turn signal light bulb. 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 208: Brake Light/Taillight And Rear Turn Signal Light
6-32 ELECTRICAL SYSTEM BRAKE LIGHT/TAILLIGHT AND REAR TURN SIGNAL LIGHT Brake light/taillight: 12 V 18/5 W Turn signal light: 12V 10 W BRAKE LIGHT/TAILLIGHT BULB REPLACEMENT • Remove the rear combination light lens 1 and brake light/tail- light lens 2. http://mototh.com...
Page 209 ELECTRICAL SYSTEM 6-33 • Remove the brake light/taillight bulb 3. 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. REAR TURN SIGNAL LIGHT BULB REPLACEMENT •...
Page 210: 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 HORN BUTTON Color Color Position Position PUSH TURN SIGNAL LIGHT SWITCH FRONT BRAKE LIGHT SWITCH Color Color...
Page 211: Battery
ELECTRICAL SYSTEM 6-35 BATTERY SPECIFICATIONS Type designation FTZ5S Capacity 12 V, 12.6 kC (3.5 Ah)/10 HR 1 Upper cover breather 5 Terminal 2 Cathode plates 6 Safety valve 3 Stopper 7 Anode plates 4 Filter 8 Separator (Fiberglass plate) INITIAL CHARGING Filling electrolyte •...
Page 212 6-36 ELECTRICAL SYSTEM NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery.
Page 213: 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 214 White Page http://mototh.com...
Page 215: Servicing Information
PROP STAND INSTALLATION ............. 7-26 CENTER STAND INSTALLATION ............7-26 REAR BRAKE CAM LEVER INSTALLATION ........7-27 BATTERY INSTALLATION..............7-28 SEAT HINGE INSTALLATION............... 7-29 FRONT WHEEL (UY125) ............... 7-30 FRONT WHEEL (UY125S)..............7-31 REAR WHEEL..................7-32 SPECIAL TOOLS ..................7-33 TIGHTENING TORQUE ................7-36 ENGINE ....................
Page 216: Troubleshooting
SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not Compression too low start, or is hard to 1. Out of adjustment valve clearance. Adjust. start. 2. Worn valve guides or poor seating of valves. Repair or replace. 3.
Page 217 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 or slipping drive belt. Replace.
Page 218 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine runs poorly 1. Weakened valve spring. Replace. in high speed range. 2. Worn camshaft. Replace. 3. Valve timing out of adjustment. Adjust. 4. Too narrow spark plug gap. Adjust. 5. Ignition not advanced sufficiently due to poorly Replace CDI unit.
Page 219: Carburetor
SERVICING INFORMATION CARBURETOR Complaint Symptom and possible causes Remedy Starting difficulty. 1. Clogged starter jet. Clean. 2. Clogged starter jet passage. Clean. 3. Air leaking from joint between starter body and Tighten, adjust, or replace carburetor. gasket. 4. Air leaking from carburetor joint or vacuum hose Tighten or replace defective joint.
Page 220: 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 221 Complaint Symptom and possible causes Remedy Insufficient brake 1. Worn shoes or drum. Replace. power. (UY125) 2. Too much brake lever play Adjust. 3. Excessive brake lever play. Adjust. 4. Friction surfaces of shoes are dirty with oil or Replace.
Page 222: 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 startor coil. Replace. 4. Open-circuited wiring connections. Check and repair. Spark plug soon 1.
Page 223: Battery
SERVICING INFORMATION 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 224: Wiring Diagram
7-10 SERVICING INFORMATION WIRING DIAGRAM UY125 http://mototh.com...
Page 225: Uy125S
SERVICING INFORMATION 7-11 UY125S http://mototh.com...
Page 226: Wiring Harness, Cable And Hose Routing
7-12 SERVICING INFORMATION WIRING HARNESS, CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Fuel gauge Guide Throttle cable Harness clamp Guide Harness Harness Clamp Frame Engine side IG coil Battery High tension cord Battery Relay Fuse http://mototh.com...
Page 227 Clamp cover bolt Magneto wire Harness Brake cable Clamp Starter cable Cushion Harness Throttle cable Speedometer Speedometer UY125 Rear brake switch coupler Handlebar Clamp Harness Front brake switch Starter cable Front brake cable Rear brake Head lamp coupler cable Throttle...
Page 228: Cable Routing (Uy125)
7-14 SERVICING INFORMATION CABLE ROUTING (UY125) Handlebar Clamp starter cable Harness firmly. Starter cable Rear brake cable Speedometer Front brake cable cable Throttle cable Pass through the guide. Starter cable Striker support bracket Clamp Vacuum hose Fuel hose Clamp Clamp...
Page 229: Cable Routing (Uy125S)
SERVICING INFORMATION 7-15 CABLE ROUTING (UY125S) Handlebar Clamp starter cable Harness firmly. Starter cable Rear brake cable Speedometer Front brake hose cable Throttle cable Pass through the guide. Starter cable Striker support bracket Clamp Vacuum hose Fuel hose Clamp Clamp Rear brake cable Clamp Seat lock...
Page 230: Engine Electric Parts Installation
7-16 SERVICING INFORMATION ENGINE ELECTRIC PARTS INSTALLATION 6.9 N . m (0.69 kgf-m) 30˚ Avoid twisting the lead wire when grommet installation. 120 N . m (12.0 kgf-m) 6 N . m (0.6 kgf-m) http://mototh.com...
Page 231: Front Brake Hose Routing (Uy125S)
SERVICING INFORMATION 7-17 FRONT BRAKE HOSE ROUTING (UY125S) Handlebar After brake hose touching to the stopper, tighten the union bolt. Set the brake hose firmly into the clamp. Front brake hose Brake hose Outside After brake hose touching to the stopper, tighten the union bolt.
Page 232: Pair (Air Supply) System Hose Routing
7-18 SERVICING INFORMATION PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING Breather hose Match mark Intake pipe Fuel tap vaccum hose Carburetor Air cleaner http://mototh.com...
Page 233: Fuel Hose Routing
SERVICING INFORMATION 7-19 FUEL HOSE ROUTING Vacuum hose Fuel tap Fuel hose Clip Fuel tap Fuel hose and vacuum hose must be wrap by clip at mark position. Vacuum hose Carburetor Clip http://mototh.com...
Page 234: Cluth/Transmission/Drive Belt Installation
7-20 SERVICING INFORMATION CLUTCH/TRANSMISSION/DRIVE BELT INSTALLATION * 1 Remove excess grease. http://mototh.com...
Page 235: Cooling Fan Installation
SERVICING INFORMATION 7-21 COOLING FAN INSTALLATION 33 N . m (3.3 kgf-m) 10 N . m (1.0 kgf-m) http://mototh.com...
Page 236: Fuel Tank Installation
7-22 SERVICING INFORMATION FUEL TANK INSTALLATION Fuel tap Clip Vacuum hose Fuel hose http://mototh.com...
Page 237: Crankcase Installation
7-23 CRANKCASE INSTALLATION 37 mm 2 mm + 0.4 Ê Ê 22.3 Ê ± 0.2 + 0.4 45˚ 2 mm 2 mm 37 mm Turn the projection with the assemble tube ahead. Apply SUZUKI BOND “1215” to the gasket. http://mototh.com...
Page 238: Exterior Parts Construction
7-24 SERVICING INFORMATION EXTERIOR PARTS CONSTRUCTION Leg shield cover Leg shield rack " Front leg shield Leg rear shield Front leg lower shield Leg lower shield http://mototh.com...
Page 239 SERVICING INFORMATION 7-25 Battery box lid Luggage box " Rear front fender Pillion rider handle Rear fender Frame cover (R) & Frame cover (L) Frame front cover http://mototh.com...
Page 240: Prop Stand Installation
7-26 SERVICING INFORMATION PROP STAND INSTALLATION 10 N . m (1.0 kgf-m) 40 N . m (4.0 kgf-m) OUTSIDE CENTER STAND INSTALLATION Long Short http://mototh.com...
Page 241: Rear Brake Cam Lever Installation
SERVICING INFORMATION 7-27 REAR BRAKE CAM LEVER INSTALLATION http://mototh.com...
Page 242: Battery Installation
7-28 SERVICING INFORMATION BATTERY INSTALLATION Battery Starter relay 18 mm 18 mm 5 mm Protector Front rear fender http://mototh.com...
Page 243: Seat Hinge Installation
SERVICING INFORMATION 7-29 SEAT HINGE INSTALLATION E-ring 96˚ Seat Assy. http://mototh.com...
Page 244: Front Wheel (Uy125)
7-30 SERVICING INFORMATION FRONT WHEEL (UY125) http://mototh.com...
Page 245: Front Wheel (Uy125S)
SERVICING INFORMATION 7-31 FRONT WHEEL (UY125S) Clearance 1 mm http://mototh.com...
Page 246: Rear Wheel
7-32 SERVICING INFORMATION REAR WHEEL http://mototh.com...
Page 247: Special Tools
SERVICING INFORMATION 7-33 SPECIAL TOOLS 09900-20101 09900-00410 09900-06107 09900-06108 09900-09004 09900-20102 Hexagon wrench set Snap ring pliers Snap ring pliers Impact driver set Vernier calipers 09900-20202 09900-20203 09900-20205 09900-20530 09900-20602 Micrometer Micrometer Micrometer Cylinder gauge set Dial gauge (25 – 50 mm) (1/100 mm, 50 –...
Page 248 7-34 SERVICING INFORMATION 09915-63311 09915-74531 09913-60910 09913-70210 Compression gauge 09915-64512 Oil pressure gauge Bearing puller Bearing installer set adaptor Compression gauge attachment 09916-14521 09916-20630 09915-74511 09916-10911 09916-14510 Valve lifter Valve seat cutter Oil pressure gauge Valve lapper set Valve lifter attachment (N-126) 09916-24311...
Page 249 SERVICING INFORMATION 7-35 09930-10121 09925-98221 Spark plug socket 09930-30104 09930-34980 09930-40113 Bearing installer wrench set Sliding shaft Rotor remover Rotor holder 09930-40120 09940-52861 Rotor holder 09940-34520 09940-34561 09940-51710 Front fork oil seal attachment (A) “T” handle Attachment (D) Bearing installer installer set 09940-60113 09941-34513...
Page 250: Tightening Torque
7-36 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N·m kgf-m Cylinder head cover bolt Initial Final Crank case bracket nut 10.2 Engine mounting nut Breather cover bolt Intake pipe mounting bolt Cylinder head nut Cylinder head side nut Spark plug Valve clearance adjuster locknut Magnetorotor nut 12.0 Clutch housing nut...
Page 251: Chassis
CHASSIS ITEM N·m kgf-m Front axle nut Steering stem lock-nut Handlebar clamp nut Brake cam lever nut Front (UY125) Rear Rear axle nut 12.0 Rear shock absorber mounting nut Front fork clamp bolt Front fork cap bolt Damper rod bolt...
Page 252: Tightening Torque Chart
7-38 SERVICING INFORMATION 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 253: Service Data
SERVICING INFORMATION 7-39 SERVICE DATA VALVE + GUIDE Unit: mm ITEM STANDARD LIMIT Valve diam. 25.0 — 22.0 — Valve clearance (when cold) 0.04 – 0.07 — 0.10 – 0.15 — Valve guide to valve stem 0.010 – 0.037 — clearance 0.030 –...
Page 254 7-40 SERVICING INFORMATION ITEM STANDARD LIMIT Piston ring groove width 1.01 – 1.03 — 1.01 – 1.03 — 2.01 – 2.03 — Piston ring thickness 0.97 – 0.99 — 0.97 – 0.99 — Piston pin bore I.D. 14.002 – 14.008 14.038 Piston pin O.D.
Page 255 SERVICING INFORMATION 7-41 CARBURETOR ITEM SPECIFICATION Carburetor type BS26 Bore size 26 mm I.D. No. 46G0 Idle rpm 1 600 ± 100 rpm Fuel level X.X ± X.X mm Float height XX.X ± X.X mm Main jet (M.J.) Main air jet (M.A.J.) Press-fitted Jet needle...
Page 256 291.7 285.8 Front fork oil level (without spring, — outer tube fully compressed) Front fork oil type SUZUKI FORK OIL G10 or an equivalent fork oil — Front fork oil capacity (each leg) 55 ml — ! 26 Front fork inner tube diam.
Page 257 SERVICING INFORMATION 7-43 TIRE ITEM STANDARD LIMIT Cold inflation tire pressure 175 kPa Front — (1.75 kgf/cm²) 225 kPa Rear — (2.25 kgf/cm²) Tire size Front 70/90-14 M/C (34P) — Rear 80/90-14 M/C (40P) — Tire type Front IRC: NF59 —...
Page 258 Prepared by THAI SUZUKI MOTOR CO., LTD. August, 2005 Part No. 99500-31310-01E Printed in Thailand http://mototh.com...

This manual is also suitable for:

Uy125s

Suzuki UY125 Service Manual

General Information 1

Periodic Maintenance

Engine

Fuel and Lubrication System

Fuel Tank and Fuel Tap

Fuel Level Gauge

Carburetor

Lubrication System

Chassis

Electrical System

Servicing Information

Quick Links

GENERAL INFORMATION

PERIODIC MAINTENANCE

ELECTRICAL SYSTEM

Chapters

Troubleshooting

Related Manuals for Suzuki UY125

Summary of Contents for Suzuki UY125