Suzuki FL125SD Manuals

Manuals and User Guides for Suzuki FL125SD. We have 1 Suzuki FL125SD manual available for free PDF download: Service Manual

Suzuki FL125SD Service Manual

Suzuki FL125SD Service Manual (399 pages)

Brand: Suzuki | Category: Motorcycle | Size: 23 MB

Table of Contents

General Information

6
- General Information
  3
- Periodic Maintenance
  3
- Servicing Information
  3
- How to Use this Manual
  4
- Table of Contents
  6
- General Precautions
  7
- Suzuki Fl125Sk7/Sdk7 ('07-Model)
  8
- Serial Number Location
  8
- Fuel and Oil Recommendation
  9
  - Fuel
    9
  - Engine Oil
    9
  - Brake Fluid
    9
  - Front Fork Oil
    9
- Break-In Procedures
  9
- Specifications
  10
Periodic Maintenance

12
- Periodic Maintenance Schedule
  13
  - Periodic Maintenance Chart
    13
  - Lubrication Points
    14
- Maintenance and Tune-Up Procedures
  15
  - Air Cleaner
    15
  - Exhaust Pipe Nut and Muffler Mounting Bolt
    16
  - Valve Clearance
    17
  - Spark Plug
    20
  - Fuel Line
    21
  - Engine Oil and Oil Filter
    22
  - Throttle Cable Play
    24
  - Idle Speed
    24
  - Pair (Air Supply) System
    24
  - Drive Chain
    25
  - Drive Chain Slack
    26
  - Brakes
    27
  - Tires
    30
  - Steering
    32
  - Front Fork
    32
  - Rear Suspension
    32
  - Chassis Bolts and Nuts
    33
- Compression Pressure Check
  35
  - Compression Test Procedure
    35
- Oil Pressure Check
  36
  - Oil Pressure Test Procedure
    36
- Automatic Clutch Inspection
  37
  - Initial Engagement Inspection
    37
  - Clutch "Lock-Up" Inspection
    37
Engine

38
- Engine Components Removable with the Engine in Place
  39
- Engine Removal and Installation
  40
  - Engine Removal
    40
  - Engine Installation
    44
- Engine Disassembly
  47
- Engine Components Inspection and Service
  62
  - Cylinder Head
    62
  - Cylinder Distortion
    74
  - Cam Chain Tension Adjuster
    74
  - Cam Chain Guide
    74
  - Piston
    75
    
    Piston Diameter
    75
    
    Piston Ring Thickness
    76
  - Conrod and Crankshaft
    78
  - Crankshaft Runout
    79
  - Crank Balancer
    80
  - Oil Pump
    80
  - Transmission
    81
  - Gearshift Cam
    83
  - Gearshift Forks
    83
  - Primary Driven Gear
    84
  - Gearshift Clutch
    84
  - First Clutch
    85
  - Starter Clutch
    86
  - Generator Cover
    87
  - Clutch Cover
    88
  - Kick Starter
    89
  - Crankcase
    90
  - Crankshaft Shim Selection
    94
  - Engine Reassembly
    95
  - Kick
    96
- Pair (Air Supply) System
  119
  - Pair Valve Inspection
    120
Fuel and Lubrication System

121
- Fuel Tank and Fuel Tap
  122
  - Removal
    122
  - Inspection
    123
  - Remounting
    123
- Fuel Level Gauge
  124
  - Removal
    124
  - Inspection
    125
  - Installation
    126
- Carburetor
  127
  - Construction
    127
  - Specifications
    128
  - I.D. No, Location
    128
  - Removal
    128
  - Disassembly
    129
  - Carburetor Cleaning
    133
  - Carburetor Inspection
    133
  - Needle Valve Inspection
    134
  - Float Height Adjustment
    134
  - Throttle Position Switch Inspection
    134
  - Reassembly and Remounting
    134
- Lubrication System
  137
  - Oil Pressure
    137
  - Oil Filter
    137
  - Oil Sump Filter
    137
  - Oil Pump
    137
  - Engine Lubrication System Chart
    137
Chassis

138
- Exterior Parts
  140
  - Fastener Removal and Installation
    140
  - Removal
    141
- Front Wheel
  146
  - Construction
    146
  - Removal
    146
  - Inspection and Disassembly
    147
  - Reassembly and Installation
    149
- Front Brake
  152
  - Construction
    152
  - Brake Fluid Replacement
    153
  - Brake Pad Replacement
    154
  - Caliper Removal
    154
  - Caliper Disassembly
    155
  - Caliper Inspection
    156
  - Caliper Reassembly
    157
  - Caliper Installation
    158
  - Brake Disc Inspection
    159
  - Master Cylinder Removal and Disassembly
    159
  - Master Cylinder Inspection
    161
  - Master Cylinder Reassembly and Installation
    162
- Front Fork
  164
  - Construction
    164
  - Removal and Disassembly
    164
  - Inspection
    166
  - Reassembly
    167
  - Installation
    170
- Handlebars
  171
  - Construction
    171
  - Removal
    171
  - Inspection
    172
  - Installation
    172
- Steering
  174
  - Construction
    174
  - Removal
    174
  - Inspection and Disassembly
    175
  - Reassembly
    177
  - Installation
    177
- Rear Wheel
  179
  - Construction
    179
  - Removal
    180
  - Disassembly and Inspection
    181
  - Inspection
    183
  - Reassembly and Installation
    184
- Rear Brake
  187
  - Removal and Disassembly
    187
  - Inspection
    188
  - Reassembly and Remounting
    189
- Rear Suspension
  193
  - Construction
    193
  - Removal and Disassembly
    193
  - Inspection
    194
  - Reassembly and Remounting
    194
- Swingarm
  195
  - Construction
    195
  - Removal and Disassembly
    195
  - Inspection
    197
  - Reassembly and Remounting
    199
  - Final Inspection and Adjustment
    200
Electrical System

201
- Cautions in Servicing
  202
  - Connector
    202
  - Coupler
    202
  - Clamp
    202
  - Fuse
    202
  - Semi-Conductor Equipped Part
    203
  - Battery
    203
  - Connecting the Battery
    203
  - Wiring Procedure
    203
  - Using the Multi-Circuit Tester
    204
- Location of Electrical Components
  205
- Charging and Lighting System
  207
  - Troubleshooting
    207
  - Inspection
    209
- STARTER SYSTEM (for FL125SD)
  212
- Ignition System
  220
  - Troubleshooting
    220
  - Inspection
    222
- Speedometer
  225
  - Removal and Disassembly
    225
  - Inspection
    226
- Fuel Meter and Fuel Level Gauge
  227
  - Fuel Meter Inspection
    227
  - Fuel Level Gauge Inspection
    227
- Relays
  228
  - Turn Signal Relay Inspection
    228
  - Starter Relay Inspection
    228
- Lamps
  229
  - Headlight
    229
  - Front Turn Signal Light
    230
  - Brake Light/Taillight and Rear Turn Signal Light
    231
  - License Plate Light
    233
- Switches
  234
- Battery
  235
  - Specifications
    235
  - Initial Charging
    235
  - Servicing
    237
  - Recharging Operation
    237
  - Removal
    237
  - Remounting
    237
Servicing Information

238
- Troubleshooting
  239
  - Engine
    239
  - Clutch
    242
  - Carburetor
    243
  - Chassis
    244
  - Brakes
    245
  - Electrical
    246
  - Battery
    247
- Wiring Diagram
  248
- Wiring Harness, Cable and Hose Routing
  250
  - Wiring Harness Routing
    250
  - Cable Routing
    253
  - Seat Lock Cable Routing
    254
  - Front Brake Hose Routing
    255
  - Fuel Hose Routing
    256
  - Hose Routing
    257
  - Pair (Air Supply) System Hose Routing
    258
  - Exterior Parts Construction
    259
  - Prop Stand Installation
    261
  - Center Stand Installation
    261
  - Brake Pedal
    262
  - Pillion Footrest
    263
- Special Tools
  264
- Tightening Torque
  267
  - Engine
    267
  - Chassis
    268
  - Tightening Torque Chart
    269
- Service Data
  270
Fl125Sdw

276
- Abbreviations Used in this Manual
  278
  - Wire Color
    279
- Specifications (Fl125Sdw)
  280
  - Engine
    280
  - Drive Train
    280
Chassis

281
- Capacities
  281
- Electrical
  281
- Periodic Maintenance Schedule
  282
  - Periodic Maintenance Chart
    282
- Maintenance and Tune-Up Procedures
  283
  - Fuel Line
    283
  - Throttle Cable Play
    283
- Sds Check
  284
  - Data at the Time of Racing
    285
- Fi System Diagnosis
  287
  - Precautions in Servicing
    287
  - Fi System Technical Features
    294
  - Ecm Terminal
    303
  - Self-Diagnosis Function
    304
  - Fail-Safe Function
    306
  - Fi System Troubleshooting
    307
- Chassis
  
  345
  - Front Brake
    345
- Electrical
  
  345
  - Battery
    345
  - Fuse
    345
  - Sensors
    353
    
    Ckp Sensor Inspection
    353
    
    Ckp Sensor Removal and Installation
    353
    
    Iap/Tp/Iat Sensor Inspection
    353
    
    Et Sensor Inspection
    353
    
    Et Sensor Removal and Installation
    354
    
    To Sensor Inspection
    354
    
    To Sensor Removal and Installation
    355
    
    Ho2 Sensor Inspection
    355
    
    Ho2 Sensor Removal and Installation
    355
  - Fuel System
    356
    
    Fuel Filter
    356
    
    Throttle Body
    357
    
    Fuel Injector
    361
  - Electrical System
    363
    
    Charging System
    363
    
    Starter System and Side-Stand/Ignition Interlock System
    367
    
    Ignition System
    371
    
    Speedometer
    375
    
    Relays
    376
    
    Diodes
    377
    
    Lamps
    378
    
    Position/Parking Light
    378
  - Wiring Diagram
    381
  - Wiring Harness, Cable and Hose Routing
    382
    
    Wiring Harness Routing
    382
    
    Cable Routing
    385
    
    Fuel Hose Routing
    386
  - Exterior Parts Construction
    387
  - Throttle Body and Fuel Injector Installation
    389
  - Special Tools
    390
  - Tightening Torque
    390
  - Service Data
    391
  - Brake Light/Taillight
    396
  - License Plate Light
    396
  - Speedometer Light
    396
  - High Beam Indicator Light
    396
  - Turn Signal Indicator Light
    396
  - Gear Position Indicator Light
    396
  - Neutral Indicator Light
    396
  - FI Indicator Light
    396
    
    Brake Disc
    396
- Capacities
  
  397
  - Fuel Tank
    397
  - Overhaul
    397

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