Suzuki RV125 Motorcycle Manuals

Suzuki RV125 Motorcycle Manuals

Manuals and User Guides for Suzuki RV125 Motorcycle. We have 3 Suzuki RV125 Motorcycle manuals available for free PDF download: Service Manual

Suzuki RV125 Service Manual

Suzuki RV125 Service Manual (251 pages)

Brand: Suzuki | Category: Motorcycle | Size: 13 MB

Table of Contents

Foreword Group Index

2
- Table of Contents
  2
- General Information
  6
  - Suzuki Rv125K3 ('03-Model)
    8
  - Serial Number Location
    8
  - Fuel and Oil Recommendation
    8
    
    Fuel
    8
    
    Engine Oil
    9
    
    Brake Fluid
    9
    
    Front Fork Oil
    9
  - BREAK-Ln PROCEDURES
    9
  - Information Labels
    10
  - Specifications
    11
    
    Dimensions and Dry Mass
    11
    
    Engine
    11
    
    Drive Train
    11
    
    Chassis
    12
    
    Electrical
    12
    
    Capacities
    12
  - Country and Area Codes
    13
- General Precautions
  6
- Warning/Caution/Note
  6
Periodic Maintenance

14
- Periodic Maintenance Schedule
  15
  - Periodic Maintenance Chart
    15
  - Lubrication Points
    16
- Maintenance and Tune-Up Procedures
  17
  - Air Cleaner
    17
    
    Engine
    17
  - Valve Clearance
    18
  - Spark Plug
    20
  - Throttle Cable Play
    21
  - Engine Idle Speed
    21
  - Fuel Hose
    22
  - Clutch
    22
  - Engine Oil and Oil Filter
    23
  - Drive Chain
    24
  - Brakes
    26
  - Steering
    30
  - Tire and Wheel
    31
  - Exhaust Pipe Bolts and Muffler Mounting Bolts
    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
Engine

37
- Engine Components Removable with Engine in Place
  38
- Engine Removal and Installation
  39
  - Engine Removal
    39
  - Engine Installation
    44
- Engine Disassembly
  47
- Engine Components Inspection and Service
  57
  - Cylinder Head Cover
    57
  - Cylinder Head
    59
  - Camshaft
    68
  - Cylinder
    69
  - Cam Chain Tension Adjuster
    70
  - Cam Chain Guide
    70
  - Piston and Piston Pin
    70
  - Crankshaft and Conrod
    73
  - Starter Clutch and Starter Driven Gear Bearing
    75
  - Generator Stator and Pick-Up Coil
    76
  - Transmission
    77
  - Primary Driven Gear
    79
  - Clutch
    80
  - Oil Filter
    81
  - Oil Sump Filter
    81
  - Crankcase Bearings
    82
  - Generator Cover Bearing
    84
  - Clutch Release Camshaft
    85
- Engine Reassembly
  86
- Pair (Air Supply) System
  101
  - Pair Hose
    101
  - Pair Control Valve
    101
Fuel and Lubrication System

102
- Fuel and Lubrication
  102
  - Fuel Tank/Fuel Valve
    103
    
    Removal
    103
    
    Inspection
    103
    
    Remounting
    104
  - Carburetor
    105
    
    Construction
    105
    
    Specifications
    106
    
    I.D. No. Location
    106
    
    Removal
    106
    
    Disassembly
    107
    
    Cleaning
    110
    
    Inspection
    110
    
    Float Height Adjustment
    111
    
    Fuel Level Adjustment
    111
    
    Carburetor Heater Inspection
    112
    
    Carburetor Thermo-Switch Inspection
    112
    
    Throttle Position Sensor Inspection
    112
    
    Reassembly and Remounting
    113
  - Engine Lubrication System
    115
    
    Engine Lubrication System Chart
    115
    
    Oil Pressure
    116
    
    Oil Filter
    116
    
    Oil Sump Filter
    116
Chassis

117
- Exterior Parts
  119
  - Removal and Installation
    119
- Front Wheel
  120
  - Removal and Disassembly
    120
  - Inspection and Disassembly
    121
  - Remounting
    122
- Front Brake
  125
  - Brake Fluid Replacement
    126
  - Brake Pad Replacement
    127
  - Brake Caliper Removal and Disassembly
    127
  - Caliper Inspection
    129
  - Caliper Reassembly
    129
  - Caliper Remounting
    130
  - Brake Disc Inspection
    130
  - Master Cylinder Removal and Disassembly
    131
  - Master Cylinder Inspection
    132
  - Master Cylinder Reassembly and Remounting
    132
- Handlebars
  134
  - Removal
    134
  - Remounting
    135
- Front Fork
  136
  - Removal and Disassembly
    136
  - Inspection
    139
  - Reassembly and Remounting
    140
- Steering
  144
  - Removal and Disassembly
    144
  - Inspection
    147
  - Reassembly and Remounting
    148
- Rear Wheel
  150
  - Removal
    150
  - Inspection and Disassembly
    151
  - Reassembly and Remouning
    152
- Rear Brake
  154
  - Removal and Disassembly
    154
  - Inspection
    155
  - Reassembly
    155
  - Rear Brake Pedal Removal
    156
  - Rear Brake Pedal Installation
    157
- Rear Shock Absorber
  158
  - Removal
    158
  - Inspection
    159
  - Reassembly and Remounting
    160
  - Rear Shock Absorber Disposal
    161
- Swingarm
  162
  - Removal
    162
  - Inspection and Replacement
    163
  - Swingarm Pivot Shaft Installation
    165
  - Remounting
    165
  - Final Inspection and Adjustment
    165
- Tire and Wheel
  166
  - Tire Removal
    166
  - Inspection
    166
  - Tire Installation
    167
Electrical System

169
- Cautions in Servicing
  170
  - Connector
    170
  - Coupler
    170
  - Clamp
    170
  - Fuse
    170
  - Semi-Conductor Equipped Part
    170
  - Battery
    171
  - Connecting the Battery
    171
  - Wiring Procedure
    171
  - Using the Multi Circuit Tester
    171
- Location of Electrical Components
  172
- Charging System
  174
  - Troubleshooting
    175
  - Inspection
    176
- Starter System and Side-Stand/Ignition Interlock System
  179
  - Trouble Shooting
    180
  - Starter Motor Removal and Disassembly
    181
  - Starter Motor Inspection
    181
  - Starter Motor Reassembly
    182
  - Starter Relay Inspection
    183
  - Side-Stand/Ignition Interlock System Parts Inspection
    184
- Ignition System
  186
  - Troubleshooting
    187
  - Inspection
    188
- Speedometer
  191
- Lamps
  192
  - Headlight
    192
  - Brake Light/Taillight
    192
  - Turn Signal Light
    193
- Relays
  194
  - Turn Signal/Side-Stand Relay
    194
  - Starter Relay
    194
- Throttle Position Sensor
  194
- Switches
  195
  - Ignition Switch Removal
    195
- Battery
  197
  - Specifications
    197
  - Initial Charging
    197
  - Servicing
    199
  - Recharging Operation
    199
Servicing Information

200
- Troubleshooting
  201
  - Engine
    201
  - Carburetor
    204
  - Chassis
    205
  - Brakes
    206
  - Electrical
    207
  - Battery
    208
- Wiring Diagram
  209
- Wire Routing
  210
- Engine Electrical Parts Wire Routing
  211
- Cable Routing
  212
- Front Brake Hose Routing
  213
- Pair (Air Supply) System Hose Routing
  214
- Side-Stand Installation
  215
- Speedometer Cable Routing
  215
- Fuel Tank Installation
  216
- Rear Brake Pedal Installtaion
  216
- Drive Chain Guide Roller Installation
  217
- Handlebar Balancer Installation
  217
- Exhaust Pipe and Muffler Installation
  218
- Carburetor and Air Cleaner Installation
  219
- Special Tools
  220
- Tightening Torque
  223
  - Engine
    223
  - Chassis
    224
  - Tightening Torque Chart
    225
- Service Data
  226
- Rv125K4/K5 ('04, '05-Models)
  232
  - Specifications
    233
  - Service Data
    234
  - Wire Routing
    240
  - Rear Fender Installation
    241
- Rv125K6 ('06-Models)
  242

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Suzuki RV125 Service Manual

Suzuki RV125 Service Manual (108 pages)

Brand: Suzuki | Category: Motorcycle | Size: 6 MB

Table of Contents

Table of Contents
2
Abbreviations Used in this Manual
4
Dimensions and Dry Mass
5
Specifications (Rv125K7)
5
- Engine
  5
- Drive Train
  5
- Chassis
  6
- Electrical
  6
- Capacities
  6
Periodic Maintenance Schedule
7
- Periodic Maintenance Chart
  7
- Spark Plug
  7
Maintenance and Tune-Up Procedures
8
- Throttle Cable Play
  8
- Fuel Line
  9
Data Sampled from Cold Starting through Warm-Up
10
Sds Check
10
Fi System Diagnosis
14
- Precautions in Servicing
  14
  - Electrical Parts
    14
  - Connector/Coupler
    14
- Fuse
  15
  - Switch
    15
  - Ecm/Various Sensors
    15
  - Electrical Circuit Inspection Procedure
    17
  - Open Circuit Check
    17
  - Continuity Check
    18
  - Voltage Check
    18
  - Short Circuit Check (Wire Harness to Ground)
    19
  - Using the Multi-Circuit Tester
    20
  - Using the Tester
    20
- Fi System Technical Features
  21
  - Injection Time (Injection Volume)
    21
  - Compensation of Injection Time (Volume)
    22
  - Fi System Parts Location
    23
  - Fi System Wiring Diagram
    25
  - Fuel Injector
    26
  - Operation
    26
  - Fuel Circulation
    27
  - Ecm
    27
  - Et Sensor
    27
  - To Sensor
    28
  - IAP Sensor
    28
  - TP Sensor
    28
  - IAT Sensor
    28
  - Ckp Sensor
    29
  - Ho2 Sensor
    29
  - ISC Valve
    29
- Ecm Terminal
  30
- Self-Diagnosis Function
  31
  - User Mode
    31
  - Dealer Mode
    32
- Fail-Safe Function
  33
- Fi System Troubleshooting
  34
- Ckp Sensor Inspection
  80
- Ckp Sensor Removal and Installation
  80
- Iap/Tp/Iat Sensor Inspection
  80
- Et Sensor Inspection
  80
Sensors
80
Fuel System
84
- Fuel Tank
  84
  - Inlet Tube Filter
    85
  - Fuel Level Switch
    85
- Fuel Level Indicator Check Relay
  86
- Fuel Filter
  87
- Throttle Body
  88
Wiring Diagram
94
Cable and Hose Routing
95
- Hose Routing
  96
- Fuel Tank Installation
  97
Special Tools
98
Tightening Torque
98
- Valve + Guide
  99
- Camshaft + Cylinder Head
  99
Service Data
99
- Clutch
  100
- Conrod + Crankshaft
  100
- Cylinder + Piston + Piston Ring
  100
- Oil Pump
  100
- Drive Train + Drive Chain
  101
- Fuel Injector + Isc Valve
  101
- Fi Sensors
  102
- Brake Light/Taillight
  103
- Electrical
  103
- FI Indicator Light
  103
- Headlight
  103
- High Beam Indicator Light
  103
- Neutral Indicator Light
  103
- Position Light
  103
- Speedometer Light
  103
- Turn Signal Light
  103
  - Wattage
    103
  - Brake + Wheel
    104
  - Suspension
    104
  - Tire Pressure
    104
- Filter Change
  105
- Fuel + Oil
  105
- Overhaul
  105

Suzuki RV125 Service Manual

Suzuki RV125 Service Manual (26 pages)

Brand: Suzuki | Category: Motorcycle | Size: 12 MB

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