Suzuki FL125S Service Manual Download Page 279

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FL125SDW 8-4

WIRE COLOR

: Black

: Orange

: Blue

: Pink

: Dark green

: Red

: Green

: White

: Gray

: Yellow

: Light green

B/G

: Black with Green tracer

B/Lg

: Black with Light green tracer

B/Lbl

: Black with Light blue tracer

B/W

: Black with White tracer

Bl/W

: Blue with White tracer

Br/B

: Blue with Black tracer

G/B

: Green with Black tracer

G/Bl

: Green with Blue tracer

O/B

: Orange with Black tracer

O/Bl

: Orange with Blue tracer

O/R

: Orange with Red tracer

R/B

: Red with Black tracer

R/W

: Red with White tracer

W/B

: White with Black tracer

W/Bl

: White with Blue tracer

W/G

: White with Green tracer

W/R

: White with Red tracer

W/Y

: White with Yellow tracer

Y/B

: Yellow with Black tracer

Y/Bl

: Yellow with Blue tracer

Y/G

: Yellow with Green tracer

Y/R

: Yellow with Red tracer

Y/W

: Yellow with White tracer

Summary of Contents for FL125S

Page 1: ...9 9 5 0 0 3 1 3 7 1 0 1 E...

Page 2: ...d that could result in motorcycle damage NOTE Indicates special information to make maintenance easier or instructions clearer Please note however that the warnings and cautions contained in this manu...

Page 3: ...MOTOR CORPORATION 2007 This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have been made since then differences may exist between the...

Page 4: ...help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit is its exploded view Work instructions and other service information such as the tig...

Page 5: ...l unless other wise specified Measure in voltage range Apply molybdenum oil solution Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 1 Measure in current range Apply SUZUKI SUPER GREASE A...

Page 6: ...FUEL AND OIL RECOMMENDATION 1 4 FUEL 1 4 ENGINE OIL 1 4 BRAKE FLUID 1 4 FRONT FORK OIL 1 4 BREAK IN PROCEDURES 1 4 SPECIFICATIONS 1 5 COUNTRY AND AREA CODES The following codes stand for the applicabl...

Page 7: ...ive cable first and then the positive cable When reconnecting the battery connect the positive cable first and then the negative cable and replace the terminal cover on the positive terminal When perf...

Page 8: ...er 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 es...

Page 9: ...it is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exer...

Page 10: ...5 mm Stroke 55 2 mm Displacement 124 cm Compression ratio 9 6 1 Carburetor MIKUNI VM18 Air cleaner Paper filter Starter system Kick FL125S Electric and kick FL125SD Lubrication system Wet sump Idle s...

Page 11: ...ng 10 B T D C at 1 400 r min Spark plug NGK C6HSA or DENSO U20FS U Battery 12 V 9 0 kC 2 5 Ah 10 HR FL125S 12V 12 6 kC 3 5 Ah 10HR FL125SD Generator Single phase A C generator Fuse 10 A Headlight 12 V...

Page 12: ...RK PLUG 2 9 FUEL LINE 2 10 ENGINE OIL AND OIL FILTER 2 11 THROTTLE CABLE PLAY 2 13 IDLE SPEED 2 13 PAIR AIR SUPPLY SYSTEM 2 13 DRIVE CHAIN 2 14 BRAKES 2 16 TIRES 2 19 STEERING 2 21 FRONT FORK 2 21 REA...

Page 13: ...NCE CHART NOTE I Inspect and adjust clean lubricate or replace as necessary R Replace T Tighten Interval Item km 1 000 4 000 8 000 months 5 20 40 Air cleaner I I Replace every 12 000 km Exhaust pipe n...

Page 14: ...ng each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray whenever the motorcycle has been opera...

Page 15: ...l the cleaned or new air cleaner element in the reverse order of removal Inspect every 4 000 km 20 months and replace every 12 000 km Always apply compressed air to the inside of the air cleaner eleme...

Page 16: ...PIPE NUT AND MUFFLER MOUNTING BOLT Tighten the exhaust pipe nuts 1 muffler mounting bolts 2 and muffler connecting bolt 3 Exhaust pipe nut 23 N m 2 3 kgf m Muffler mounting bolt 23 N m 2 3 kgf m Muffl...

Page 17: ...t 5 6 Disconnect the spark plug cap 1 and remove the spark plug 2 Remove the valve inspection caps 3 Remove the valve timing inspection plug 4 and generator cover plug 5 Remove the camshaft sprocket c...

Page 18: ...TE The piston must be at TDC on the compression stroke in order to check the valve clearance or to adjust the valve clearance The valve clearance specification is for COLD state To turn the generator...

Page 19: ...Standard IN 0 03 0 08 mm EX 0 08 0 13 mm 09900 20803 Thickness gauge 09917 14910 Valve clearance adjusting driver Valve clearance adjuster lock nut 10 N m 1 0 kgf m After finishing the valve clearance...

Page 20: ...is correct If not adjust it to the following gap Spark plug gap Standard 0 6 0 7 mm 09900 20803 Thickness gauge ELECTRODE S CONDITION Check the condition of the electrode If it is extremely worn or bu...

Page 21: ...plug wrench set FUEL LINE Remove the rear center leg shield 5 6 Remove the frame cover 5 7 Check the fuel hoses for damage and fuel leakage If any defects are found replace the fuel hose with a new o...

Page 22: ...at has a viscosity rating of 10W 40 Engine oil drain plug 17 5 N m 1 75 kgf m Make sure that the engine is cooled Place the motorcycle on level ground and hold it vertically Install the oil filler cap...

Page 23: ...alling the new oil filter and oil filter cap make sure that the spring 3 and new O ring 4 are installed correctly Add new engine oil and check the oil level as described in the engine oil replacement...

Page 24: ...ine idle speed Connect an electric tachometer Start up the engine and set its speed at anywhere between 1 300 and 1 500 r min by turning the throttle stop screw Engine idle speed 1 400 100 r min 09900...

Page 25: ...When replacing the drive chain replace the drive chain and sprockets as a set CHECKING AND ADJUSTING Remove the chain case by loosening four bolts 1 and screw 2 Loosen the rear axle nut 3 Tense the d...

Page 26: ...ine and rear sprockets as shown The reference marks 2 must be at the same position on the scale to ensure that the front and rear wheels are correctly aligned Drive chain slack Standard 15 25 mm After...

Page 27: ...e opposite to the direction of travel Direction of travel BRAKE Inspect initially at 1 000 km 5 months and every 4 000 km 20 months thereafter BRAKE HOSE AND BRAKE FLUID Inspect every 4 000 km 20 mont...

Page 28: ...andard 20 30 mm REAR BRAKE SHOE WEAR This motorcycle is equipped with the brake lining wear limit indi cator on the rear brake To check wear of the brake lining perform the following steps First check...

Page 29: ...the reservoir cap to prevent dirt from enter ing Attach a hose to the air bleeder valve 1 and insert the free end of the hose into a receptacle Squeeze and release the brake lever several times in ra...

Page 30: ...gh 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...

Page 31: ...is usually due to worn or loose wheel bearings and can be corrected by replacing the bearings If bearing replacement fails to reduce the runout replace the wheel Wheel runout Service Limit 2 0 mm SPO...

Page 32: ...es near the axle and pull forward If play is found readjust the steering 5 37 FRONT FORK Inspect the front forks for oil leakage scoring or scratches on the outer surface of the inner tubes Replace an...

Page 33: ...otrest bracket lower bolt 55 5 5 2 Footrest mounting bolt 14 5 1 45 3 Front fork clamp bolt 32 5 3 25 4 Handlebar clamp nut 60 6 0 5 Steering stem nut 80 8 0 6 Front axle nut 42 4 2 7 Brake disc bolt...

Page 34: ...2 23 PERIODIC MAINTENANCE...

Page 35: ...ck the engine for conditions listed above COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head nuts are tightened to the specified torque...

Page 36: ...osity is too high Clogged oil passage Combination of the above items OIL PRESSURE TEST PROCEDURE Connect a tachometer to the high tension cord Remove the main oil gallery plug 1 Install the oil pressu...

Page 37: ...g temperature Connect an electric tachometer to the high tension cord Seated on the motorcycle with the motorcycle on level ground increase the engine RPM slowly and note the RPM at which the motorcyc...

Page 38: ...ION 3 37 CAM CHAIN TENSION ADJUSTER 3 37 CAM CHAIN GUIDE 3 37 PISTON 3 38 CONROD AND CRANKSHAFT 3 41 CRANK BALANCER 3 43 OIL PUMP 3 43 TRANSMISSION 3 44 GEARSHIFT CAM 3 46 GEARSHIFT FORKS 3 46 PRIMARY...

Page 39: ...ountershaft assembly 3 23 3 60 Driveshaft drive gear assembly 3 23 3 60 ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION Oil sump filter 3 14 3 73 Oil filter 3 14 3 74 Starter idle gear 3 15 3 72 Drive cha...

Page 40: ...eps Open the seat and disconnect the battery lead wire 6 9 Remove the front center leg shield 5 5 Remove the front frame covers left and right 5 7 Remove the rear center leg shield 5 6 Remove the leg...

Page 41: ...he crankcase breather hose 6 and ground lead wire 7 Disconnect the gear position switch coupler 8 Disconnect the generator lead wire coupler 9 and pick up coil lead wire coupler 0 Remove the engine gu...

Page 42: ...E Remove the gearshift pedal Remove the muffler mounting bolts A and muffler connecting bolt B Remove the muffler C Remove the exhaust pipe D Remove the engine sprocket cover E Remove the drive chain...

Page 43: ...ENGINE 3 6 Remove the engine sprocket G with the drive chain H Remove the pillion footrest lower bolt I and spacers J left and right Remove the engine from the frame...

Page 44: ...ustration Tighten the engine mounting nuts to the specified torque NOTE The engine mounting nuts are self locking Once the nuts have been removed they are no longer of any use Install the drive chain...

Page 45: ...kgf m Install a new exhaust gas sealer 3 into the exhaust pipe lip NOTE Exhaust gas sealer should be applied to both of the inside and outside of the connector EXHAUST GAS SEALER PERMATEX 1372 Commerc...

Page 46: ...otrest mounting bolts to the specified torque Footrest mounting bolt 14 5 N m 1 45 kgf m After installing the engine properly route the wire harness cables and hoses Refer to the wire and cable routin...

Page 47: ...R VALVE Remove the PAIR valve assembly 1 CRANKCASE BREATHER HOSE Remove the crankcase breather hose 2 SPARK PLUG Remove the spark plug Identify the position of each removed part Organize the parts in...

Page 48: ...move the camshaft sprocket cover 3 and gasket Turn the generator rotor with a box wrench to set the piston at TDC on the compression stroke Turn the generator rotor until the line A on the generator r...

Page 49: ...SION ADJUSTER Remove the cam chain tension adjuster 1 Remove the gasket 2 Remove the decomp cam assembly 3 and camshaft sprocket 4 Remove the locating pin 5 and angle pin 6 CYLINDER HEAD Remove the cy...

Page 50: ...LINDER Remove the dowel pins 1 cylinder head gasket 2 and cam chain guide 3 Remove the cylinder 4 NOTE If the cylinder does not come off easily lightly tap it with a plastic mallet Remove the dowel pi...

Page 51: ...lter cap 1 Remove the oil filter 2 Remove the O ring 3 and spring 4 OIL SUMP FILTER Remove the oil sump filter cap 1 and oil sump filter 2 Remove the gasket 3 GENERATOR COVER Remove the generator cove...

Page 52: ...gear 2 and shaft 3 GENERATOR ROTOR Hold the conrod with the special tool 09930 44530 Rotor holder Remove the generator rotor nut 1 Remove the generator rotor 2 with the special tool 09930 34951 Rotor...

Page 53: ...emove the gear position switch 1 Remove the gear position switch pin 2 and spring 3 CLUTCH COVER Remove the clutch cover 1 Remove the dowel pins 2 and gasket 3 GEARSHIFT LINK Remove the washer 1 sprin...

Page 54: ...2 6 Remove the gearshift shaft assembly 7 and roller 8 FIRST CLUTCH Remove the clutch bearing 1 and clutch push piece 2 Hold the conrod with the special tool 09910 20116 Conrod holder Remove the firs...

Page 55: ...ive gear spacer 9 and primary drive gear 0 GEARSHIFT CLUTCH Hold the clutch sleeve hub with the special tool 09930 40113 Rotor holder Remove the release plate 1 Remove the clutch springs 2 Hold the cl...

Page 56: ...wave washer 4 washer 5 gearshift clutch assembly 6 and primary driven gear 7 Remove the spacer 8 GEARSHIFT SHAFT Remove the gearshift cam drive plate 1 Remove the gearshift arm 2 Remove the gearshift...

Page 57: ...PUMP Remove the oil pump 1 Remove the dowel pins 2 CRANK BALANCER DRIVE DRIVEN GEAR Hold the crank balancer driven gear with the special tool 09930 44570 Crank balancer holder Remove the crank balanc...

Page 58: ...Remove the spacer 5 and key 6 Remove the crank balancer drive gear 7 Remove the pin 8 GEARSHIFT CAM Remove the gearshift cam plate 1 Remove the gearshift cam stopper bolt 2 gearshift cam stopper 3 wa...

Page 59: ...ith the special tool 09920 13120 Crankcase and shaft remover NOTE Fit the crankcase separating tool so that the tool arms are in parallel with the side of crankcase The crankshaft component should rem...

Page 60: ...by turning the shaft TRANSMISSION Remove the gearshift fork shafts 1 and 2 Remove the gearshift cam 3 Remove the gearshift fork No 1 4 and No 2 5 Remove the washer 6 Remove the driveshaft drive gear a...

Page 61: ...3 24 CRANKSHAFT Remove the crankshaft with the special tool 09920 13120 Crankcase and shaft remover CRANK BALANCER Remove the crank balancer GEARSHIFT STOPPER PIN BOLT Remove the gearshift stopper pi...

Page 62: ...the valve clearance inspection caps 2 Remove the camshaft retainer 3 Pull out the intake and exhaust rocker arm shafts 4 by using an 8 mm thread bolt Identify the position of each removed part Organiz...

Page 63: ...aft 7 Compress the valve spring with the special tools Remove the two cotter halves 8 from the valve stem 09916 14510 Valve spring compressor 09916 14521 Attachment 09916 84511 Tweezers Remove the val...

Page 64: ...camshaft contacting surface should be checked Rocker arm I D IN EX Standard 10 003 10 018 mm 09900 20605 Dial calipers CYLINDER HEAD DISTORTION Decarbonize the combustion chamber Inspect the gasketed...

Page 65: ...L RUNOUT Place the dial gauge at right angles to the valve head and mea sure the valve head radial runout If it measures more than limit replace the valve Valve head radial runout IN EX Service Limit...

Page 66: ...ting related parts carry out the steps shown in valve guide servicing VALVE GUIDE SERVICING Using the valve guide remover drive the valve guide out toward the intake or exhaust camshaft side 09916 443...

Page 67: ...mm 09916 34542 Reamer handle NOTE Be sure to cool down the cylinder head to ambient air tempera ture Insert the reamer from the combustion chamber and always turn the reamer handle clockwise VALVE SE...

Page 68: ...alve components Fill the intake and exhaust ports with gasoline to check for leaks If any leaks occur inspect the valve seat and face for burrs or other things that could prevent the valve from sealin...

Page 69: ...spect the valve spring for proper strength by measuring its free length and also by the force required to compress it If the spring length is less than the service limit or if the force required to co...

Page 70: ...f there is any thing unusual CAMSHAFT BEARING REPLACEMENT Remove the camshaft bearing with the special tool 09913 60910 Bearing gear puller Remove the bearing with the special tool 09921 20210 Bearing...

Page 71: ...nd replace the cam chain tensioner with a new one REASSEMBLY Install the valve spring seat 1 Apply a small quantity of engine oil to the valve stem seal 2 and press fit it into position Insert the val...

Page 72: ...cotter 4 to wedge in between retainer and stem Be sure that the rounded lip B of the cotter fits snugly into the groove C in the stem end 09916 14510 Valve spring compressor 09916 14521 Attachment 099...

Page 73: ...VALVE CLEARANCE INSPECTION CAP Install the valve clearance inspection cap gasket 1 Apply SUZUKI SUPER GREASE A to the valve clearance inspection cap gasket 99000 25010 SUZUKI SUPER GREASE A Tighten th...

Page 74: ...ceeds the limit replace the cylinder Cylinder distortion Service Limit 0 05 mm 09900 20803 Thickness gauge CYLINDER BORE Inspect the cylinder wall for any scratches nicks or other dam age Measure the...

Page 75: ...s less than the limit replace the piston Piston diameter Service Limit 53 335 mm 09900 20203 Micrometer 50 75 mm PISTON TO CYLINDER CLEARANCE Subtract the piston diameter from the cylinder bore diamet...

Page 76: ...rometer 0 25 mm 09900 20803 Thickness gauge NOTE Using a soft metal scraper decarbon the crown of the piston Clean the ring grooves similarly PISTON RING FREE END GAP AND PISTON RING END GAP Measure t...

Page 77: ...the piston Piston pin bore I D Service Limit 14 030 mm 09900 20602 Dial gauge 1 1000 mm 09900 22401 Small bore gauge 10 18 mm Measure the piston pin outside diameter at three positions using the micr...

Page 78: ...od small end inside diameter Conrod small end I D Service Limit 14 040 mm 09900 20605 Dial calipers If the conrod small end bore inside diameter exceeds the limit replace the conrod 1 Primary drive ge...

Page 79: ...eplace crankshaft assembly or bring the deflection and side clearance into specifi cation by replacing the worn parts e g conrod big end bearing and crank pin Conrod big end side clearance Service Lim...

Page 80: ...r damage If any defects are found replace them with new ones OIL PUMP DISASSEMBLY Remove the circlip 1 washer 2 oil pump driven gear 3 and pin 4 INSPECTION Rotate the oil pump shaft by finger and chec...

Page 81: ...to the bearing and inner surface of the each gear 1 1st driven gear 4 Rotary stop plate 7 4th drive gear 2 4th driven gear 5 Driveshaft 8 3rd drive gear 3 3rd driven gear 6 Countershaft 9 2nd drive g...

Page 82: ...talling a new snap ring pay attention to the direction of the snap ring Fit the snap ring to the side where the thrust is as shown in the illustration The rounded side should be against the gear surfa...

Page 83: ...of the shifting action If the clearance exceeds the specification replace the fork its respective gear or both Gearshift fork to groove clearance Service Limit No 1 0 5 mm No 2 0 55 mm 09900 20803 Th...

Page 84: ...e thickness Service Limit 2 6 mm 09900 20101 Vernier calipers Clutch drive plate claw width Service Limit 11 0 mm 09900 20101 Vernier calipers CLUTCH DRIVEN PLATES Measure each clutch driven plate for...

Page 85: ...T CLUTCH HOUSING INSPECTION Inspect the first clutch housing surface for scrolling cracks or uneven wear and measure the inside diameter of the clutch housing with inside calipers Measure the diameter...

Page 86: ...amage If any abnormal condition is found replace the starter clutch with a new one DISASSEMBLY Remove the starter driven gear Holding the generator rotor with the special tool and remove the starter c...

Page 87: ...t 10 N m 1 0 kgf m 99000 32030 THREAD LOCK SUPER 1322 09930 34951 Rotor holder GENERATOR COVER DISASSEMBLY Remove the generator coil 1 pick up coil 2 and gromment 3 Remove the oil seal 4 REASSEMBLY Re...

Page 88: ...adjustment lock nut 1 and remove the release arm 2 Remove the oil seal 3 Remove the snap ring 4 Remove the bearing 5 with the special tool 09921 20240 Bearing remover set NOTE If there is no abnormal...

Page 89: ...5 Install the release arm 5 to the clutch cover Tighten the clutch adjustment lock nut 6 to the specified torque Clutch adjustment lock nut 13 N m 1 3 kgf m KICK STARTER DISASSEMBLY Remove the washer...

Page 90: ...aring in the following procedure if there is any thing unusual RIGHT CRANKCASE BEARING REMOVAL NOTE If there is no abnormal condition the bearing removal is not nec essary Remove the bearing retainer...

Page 91: ...ller set 09921 20240 Bearing remover set Bearing 1 52 Attachment Bearing 2 10 Attachment Bearing 3 20 Attachment Bearing 4 10 Attachment LEFT CRANKCASE OIL SEAL REMOVAL Remove the oil seal retainer 1...

Page 92: ...ly a small quantity of THREAD LOCK 1322 to the bear ing retainer screw 99000 32050 THREAD LOCK 1322 Install the bearing retainer 7 and tighten its screw securely LEFT CRANKCASE BEARING INSTALLATION In...

Page 93: ...left crankcase with the special tool Apply SUZUKI SUPER GREASE A to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A 09913 70210 Bearing installer set Install the oil seal retainer 2 and tighten it...

Page 94: ...of compressed plasti gauge with the enve lope scale Crankshaft thrust clearance From 0 02 to 0 07 mm If the thrust clearance is not within specification select the proper size of shim The shim size i...

Page 95: ...torque Gearshift stopper pin bolt 23 N m 2 3 kgf m CRANK BALANCER Install the crank balancer 1 and crankshaft 2 to the left crankcase CRANKSHAFT When installing the crankshaft into the left crankcase...

Page 96: ...CK Align the punched mark A of the kick starter drive gear with the groove B of the kick starter shaft 1 Kick starter lever 3 Kick starter shaft 5 Kick starter return spring 2 Kick starter drive gear...

Page 97: ...kick starter spring hook end 3 onto the clutch cover boss 3 TRANSMISSION Install the countershaft assembly 1 and driveshaft assembly 2 Install the gearshift forks 3 Gearshift fork No 1 4 Gearshift fo...

Page 98: ...own 99104 31140 SUZUKI BOND 1207B NOTE Use of SUZUKI BOND 1207B is as follows Make surfaces free from moisture oil dust and other foreign materials Spread on surfaces thinly to form an even layer and...

Page 99: ...e return spring 1 washer 2 gearshift cam stopper 3 gearshift cam stopper bolt 4 and gear shift cam pins 5 Tighten the gearshift cam stopper bolt to the specified torque Gearshift cam stopper bolt 10 N...

Page 100: ...gear nut 7 to the specified torque 09930 44570 Crank balancer holder Crank balancer driven gear nut 40 N m 4 0 kgf m OIL PUMP Install the dowel pins 1 Install the oil pump 2 and tighten the oil pump...

Page 101: ...ENGINE 3 64 GEARSHIFT SHAFT Install the gearshift shaft 1 and washer 2 Install the gearshift arm 3 Install the gearshift cam drive plate 4...

Page 102: ...hub B First clutch housing 4 Clutch drive plate C Primary drive gear 5 Clutch driven plate A Release plate bolt ITEM N m kgf m 6 Clutch pressure disc B Clutch sleeve hub nut A 10 1 0 7 Spacer C Clutc...

Page 103: ...clutch pressure disc 3 to the clutch sleeve hub 4 while aligning the marks A on the clutch pressure disc 3 with the marks B on the clutch sleeve hub 4 Install the gearshift clutch assembly 5 washer 6...

Page 104: ...he release plate bolts A to the specified torque 09930 40113 Rotor holder Release plate bolt 10 N m 1 0 kgf m Install the clutch bearing B and clutch push piece C Install the primary drive gear D and...

Page 105: ...the first clutch shoe 3 washer 4 and wave washer 5 Hold the conrod with the special tool 09910 20116 Conrod holder Install the first clutch nut 6 and tighten it to the specified torque First clutch n...

Page 106: ...ve plate 9 Gearshift stopper 3 Gearshift arm 0 Gearshift fork No 1 4 Gearshift link arm No 1 A Gearshift fork No 2 ITEM N m kgf m 5 Gearshift shaft A Gearshift stopper pin bolt A 23 2 3 6 Gearshift ca...

Page 107: ...6 NOTE Face the lug A of the release ball 6 to the outside Install the release ball outer guide 7 spring 8 and washer 9 CLUTCH COVER Install the dowel pins 1 and gasket 2 Install the clutch cover and...

Page 108: ...kwise by 1 8 turn Tighten the clutch adjustment lock nut to the specified torque Clutch adjustment lock nut 13 N m 1 3 kgf m GEAR POSITION SWITCH Install the spring 1 and gear position switch pin 2 In...

Page 109: ...nut 5 to the specified torque 09930 44530 Rotor holder Generator rotor nut 80 N m 8 0 kgf m STARTER IDLE GEAR Install the starter idle gear 1 and spacer 2 onto the starter idle gear shaft 3 NOTE Appl...

Page 110: ...ll the oil sump filter 3 Install the oil sump filter cap 3 Tighten the oil sump filter cap bolts to the specified torque Oil sump filter cap bolt 10 N m 1 0 kgf m The removed gasket must be replaced w...

Page 111: ...e of the spacer The spacer and side rails do not have a specific top or bottom when they are new When reassembling used parts install them in their original place and direction The 1st ring and 2nd ri...

Page 112: ...con rod Install the piston with the punched mark A on the piston head facing towards the exhaust side MOLYBDENUM OIL SOLUTION Place a clean rag over the cylinder base to prevent the piston pin circlip...

Page 113: ...itioned correctly and put it into the cylinder Make sure that the piston rings are caught by the cylinder skirt NOTE When mounting the cylinder after attaching the camshaft drive chain keep the cam ch...

Page 114: ...head base bolt 10 N m 1 0 kgf m CAMSHAFT SPROCKET AUTOMATIC DECOMP Turn the generator rotor until the line A on the generator rotor is aligned with the center of the hole in the generator cover Insta...

Page 115: ...t E of the spring onto the decomp cam and fit the part F to the slit of plastic washer and hole of the cam sprocket 7 Turn the decomp cam 6 counterclockwise and install the decomp cam stopper 8 Tighte...

Page 116: ...ap 3 After installing the cam chain tension adjuster rotate the crankshaft some turns and recheck the positions of the camshaft sprocket Apply SUZUKI SUPER GREASE A to the O ring 1 Install the O ring...

Page 117: ...99000 25030 SUZUKI SUPER GREASE A Generator cover plug 5 5 N m 0 55 kgf m Valve timing inspection plug 20 5 N m 2 05 kgf m STARTER MOTOR Install the O ring 1 to the starter motor Apply SUZUKI SUPER GR...

Page 118: ...tighten them to the specified torque PAIR pipe nut 10 N m 1 0 kgf m KICK STARTER LEVER Apply SUZUKI SUPER GREASE A to the kick starter lever 99000 25010 SUZUKI SUPER GREASE A Install the kick starter...

Page 119: ...hoses for wear or damage Check the PAIR hoses are securely connected DISASSEMBLY Remove the PAIR valve 3 10 Remove the PAIR valve cover 1 Remove the PAIR reed valve 2 PAIR REED VALVE INSPECTION Inspec...

Page 120: ...valve as shown in the photograph Apply negative pressure slowly to the valve and inspect the air flow If air does not flow out the valve is in normal condi tion If the valve does not function replace...

Page 121: ...ARBURETOR 4 7 CONSTRUCTION 4 7 SPECIFICATIONS 4 8 I D NO LOCATION 4 8 REMOVAL 4 8 DISASSEMBLY 4 9 CARBURETOR CLEANING 4 13 CARBURETOR INSPECTION 4 13 NEEDLE VALVE INSPECTION 4 14 FLOAT HEIGHT ADJUSTME...

Page 122: ...Remove the frame covers left and right 5 7 Drain the gasoline Disconnect the fuel hose 1 Remove the rubber cover 2 Disconnect the fuel level gauge coupler 3 Remove the fuel tank 4 Remove the fuel hos...

Page 123: ...compressed air Also check the fuel filter for cracks 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...

Page 124: ...L GAUGE REMOVAL Open the seat 5 5 Disconnect the fuel level gauge coupler 1 Remove the fuel gauge retainer 2 Remove the fuel level gauge 3 Remove the rubber cushion 4 Gasoline is highly flammable and...

Page 125: ...een the terminals when the float is at the position listed below 09900 25008 Multi circuit tester If the resistance is incorrect replace the fuel level gauge assem bly with a new one Float position Re...

Page 126: ...CATION SYSTEM INSTALLATION Install the rubber cushion 1 Install the fuel level gauge 2 Install the fuel gauge retainer 3 Install the fuel level gauge coupler 4 The removed rubber cushion must be repla...

Page 127: ...over J Pilot jet 3 Spring B Coasting valve K Needle valve 4 Jet needle locker C Spring L Pin 5 Jet needle D Pilot air screw M Float 6 Throttle valve E Throttle valve adjuster N Gasket 7 Throttle posit...

Page 128: ...ION I D NO LOCATION The carburetor has I D Number A stamped on the carburetor body Carburetor type MIKUNI MV18SH Bore size 17 mm I D No 16H0 Idle r min 1 400 100 r min Float height 16 mm Main jet M J...

Page 129: ...ect the starter cable 7 Remove the throttle cable assembly 8 Remove the carburetor 9 with intake pipe DISASSEMBLY Remove the intake pipe 1 and insulator 2 Remove the O rings 3 and 4 Disconnect the bre...

Page 130: ...w H Throttle valve adjuster E Spring I Spring F Washer J Washer G O ring K O ring NOTE Before removing the pilot air screw D determine the setting by slowly turning it clockwise and count the number o...

Page 131: ...ing N Coasting valve Remove the throttle cable A Disconnect the throttle position switch lead wire coupler B Remove the top cap L gasket M spring N and throttle valve O Remove the following parts from...

Page 132: ...4 12 FUEL AND LUBRICATION SYSTEM Remove the throttle position switch T from the top cap L...

Page 133: ...air screw Needle jet holder Throttle valve adjuster Needle jet Throttle valve Starter plunger Jet needle locker Needle jets air bleeding hole Jet needle Pilot outlet and bypass parts Some carburetor c...

Page 134: ...float height invert the carburetor body with the float arm kept free measure the height A while the float arm is just in contact with needle valve by using vernier calipers Bend the tongue 1 as neces...

Page 135: ...op cap 4 Install the gasket 5 to the float chamber body 6 Reassemble the clip 7 ring 8 and washer 9 to the jet nee dle When installing the casting valve make sure the tab of the casting valve is align...

Page 136: ...h the part D of the throttle position rod When installing the carburetor align the hole E of the top cap with the part F of the throttle position rod Adjust the following items to the specification Id...

Page 137: ...T OIL ORIFICE OIL FILTER OIL JET CYLINDER HEAD CYLINDER WALL DRIVESHAFT GEAR COUNTER SHAFT GEAR CONROD BIG END BEARING PRIMARY DRIVE GEAR FIRST CLUTCH GEAR SHIFT CLUCH CYLINDER OIL PUMP OIL SUMP FILTE...

Page 138: ...Y 5 18 CALIPER INSPECTION 5 19 CALIPER REASSEMBLY 5 20 CALIPER INSTALLATION 5 21 BRAKE DISC INSPECTION 5 22 MASTER CYLINDER REMOVAL AND DISASSEMBLY 5 22 MASTER CYLINDER INSPECTION 5 24 MASTER CYLINDER...

Page 139: ...47 REAR BRAKE 5 50 REMOVAL AND DISASSEMBLY 5 50 INSPECTION 5 51 REASSEMBLY AND REMOUNTING 5 52 REAR SUSPENSION 5 56 CONSTRUCTION 5 56 REMOVAL AND DISASSEMBLY 5 56 INSPECTION 5 57 REASSEMBLY AND REMOU...

Page 140: ...fastener Installation Pull out the fastener center screw toward the head so that the pawls 2 close Insert the fastener into the installation hole NOTE To prevent the pawls 2 from damage insert the fas...

Page 141: ...over 2 Disconnect the headlight coupler 3 Disconnect the speedometer cable 4 and speedometer indi cator lights couplers 5 and 6 Remove the rear handlebar cover 7 Disconnect the following couplers Turn...

Page 142: ...eg shield FRONT FRAME COVER Open the seat 1 using the ignition key to push in and turn the ignition key clockwise Remove the front frame cover 2 LUGGAGE BOX Open the seat Above Remove the battery 6 37...

Page 143: ...ove the front frame cover 5 5 Remove the rear center leg shield LEG SHIELD Remove the rear center leg shield Above Remove the leg shield FRAME HEAD COVER Remove the leg shields left and right Above Re...

Page 144: ...5 7 CHASSIS PILLION RIDER HANDLE Remove the pillion rider handle 1 FRAME COVER Remove the rear center leg shield 5 6 Remove the pillion rider handle Above Remove the frame cover Hooked part...

Page 145: ...CHASSIS 5 8 Disconnect the rear turn signal light coupler 1 and rear com bination light coupler 2...

Page 146: ...r wooden block Remove the front axle shaft and front wheel Remove the brake disc by removing its bolts 1 Front axle bolt 2 Brake disc 3 Spacer 4 Front wheel bearing Right 5 Spoke nipple 6 Front wheel...

Page 147: ...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 Drive out the wheel bearing by striking...

Page 148: ...RBOX Turn the speedometer gear and check to see that the gear turns smoothly together with the speedometer pinion If any defects are found replace the speedometer gearbox with a new one WHEEL RIM 2 19...

Page 149: ...gs 99000 25010 SUZUKI SUPER GREASE A Install the front wheel bearings with the special tool 09924 84521 Bearing installer set BRAKE DISC Tighten the brake disc bolts to the specified torque Brake disc...

Page 150: ...gearbox 99000 25010 SUZUKI SUPER GREASE A Align the lugs A on the speedometer gearbox with the recesses B on the front wheel Align the speedometer gearbox case 1 with the concave por tion of the front...

Page 151: ...ter cable 5 Install the brake caliper 6 5 17 When installing the front wheel position the brake disc between the brake pads Be careful not to dam age the brake pads Move the front fork up and down fou...

Page 152: ...caliper 5 Dust boot E Pad spring ITEM N m kgf m 6 Brake hose A Master cylinder mounting bolt A 10 1 0 7 Caliper holder B Brake hose union bolt B 22 5 2 25 8 Caliper holder pin C Brake caliper mountin...

Page 153: ...sed DOT 4 brake fluid Do not use or mix different types of fluid such as silicone based or petroleum based Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid...

Page 154: ...After replacing the brake pads pump the brake lever a few times to check for proper brake operation and then check the brake fluid level CALIPER REMOVAL Loosen the brake pad mounting pin bolts Above...

Page 155: ...rubber parts 3 Place a rag over the pistons to prevent them from popping out and then force out the pistons using compressed air Remove the dust seals 4 and piston seals 5 Do not use high pressure air...

Page 156: ...place the caliper or cali per piston with a new one PAD SPRING Inspect the brake pad spring for damage or excessive bend If any defects are found replace it with a new one RUBBER PARTS Inspect the boo...

Page 157: ...s shown Apply SUZUKI SILICON GREASE to the brake caliper holder pins 99000 25100 SUZUKI SILICONE GREASE Clean the caliper components with fresh brake fluid before reassembly Never use cleaning solvent...

Page 158: ...N m 2 55 kgf m Tighten the brake pad mounting pin bolts 2 to the specified torque Brake pad mounting pin bolt 17 5 N m 1 75 kgf m Install the brake hose union bolt 3 with the front brake hose washers...

Page 159: ...e 1 100 mm 09900 20701 Magnetic stand MASTER CYLINDER REMOVAL AND DISAS SEMBLY Remove the front handlebar cover 5 4 Place the motorcycle on a level surface and keep the handle bars straight Remove the...

Page 160: ...ASSIS Remove the brake lever 5 and front brake switch 6 Remove the reservoir cap 7 diaphragm plate 8 and dia phragm 9 Pull out the dust seal boot 0 and remove the snap ring A Remove the piston B and s...

Page 161: ...cratches or damage If any defects are found replace the master cylinder with a new one PISTON AND CUP SET Inspect the piston 1 surface for any scratches or other damage Inspect the primary cup 2 secon...

Page 162: ...I SUPER GREASE A to the piston 2 and brake lever pivot 3 99000 25010 SUZUKI SUPER GREASE A Clean the master cylinder components with new brake fluid before reassembly Never reuse cleaning solvents or...

Page 163: ...rst as shown Master cylinder mounting bolt 10 N m 1 0 kgf m Connect the front brake switch lead wires Install the front brake hose union bolt 4 with the front brake hose washers 5 Tighten the front br...

Page 164: ...and front brake caliper Remove the front fender No 1 2 Remove the front fender No 2 3 Hooked parts 1 Stopper ring 2 Front fork cap 3 O ring 4 Front fork spring 5 Damper rod ring 6 Damper rod 7 Reboun...

Page 165: ...e steering stem Remove the front fork 5 Remove the front fork cap 6 stopper ring 7 and front fork spring 8 Invert the front fork and stroke it several times to drain out the fork oil NOTE Hold the for...

Page 166: ...er ring C Remove the oil seal D with the special tool 09913 50121 Oil seal remover INSPECTION INNER AND OUTER TUBE Inspect the inner tube sliding surface and outer tube sliding sur face for any scuffi...

Page 167: ...t the damper rod ring for wear or damage If it is worn or damaged replace the damper rod ring with a new one REASSEMBLY Reassemble and install the front fork in the reverse order of removal and disass...

Page 168: ...Install the oil seal stopper ring 4 and dust seal 5 The removed oil seal must be replaced with a new one to prevent oil leakage When installing the oil seal to the outer tube be care ful not to damage...

Page 169: ...he fork spring and com press the inner tube fully Front fork oil level without spring 107 mm 09943 74111 Fork oil level gauge Fit the O ring 1 to the front fork cap and apply front fork oil 0 99000 99...

Page 170: ...32 5 N m 3 25 kgf m Install the front fender No 2 2 and front fender No 1 3 Install the front brake holder guide 4 Install the front brake caliper 5 21 Install the front wheel 5 13 Move the front fork...

Page 171: ...the left handlebar grip 2 Remove the starter lever 3 HANDLEBAR RIGHT SIDE PARTS Remove the handle balancer 1 Remove the throttle cable by removing the throttle grip case 2 Remove the right throttle gr...

Page 172: ...w one INSTALLATION Install the handlebars in the reverse order of removal Pay attention to the following points Tighten the handlebar clamp nut to the specified torque Handlebar clamp nut 60 N m 6 0 k...

Page 173: ...p bond onto the handlebars before installing the handlebar grip Install the starter lever 1 After installing the steering the following adjustments are required before driving Cable routing 7 16 Check...

Page 174: ...k nut 1 with the special tool 09910 60611 Universal clamp wrench 1 Steering stem nut 2 Washer 3 Dust cover 4 Upper bearing inner race 5 Steel ball 6 Upper bearing outer race 7 Lower bearing outer race...

Page 175: ...ench Remove the dust cover 4 Remove the upper bearing inner race 5 Remove the upper and lower steel balls Upper 22 pcs Lower 27 pcs INSPECTION AND DISASSEMBLY Inspect the removed parts for the followi...

Page 176: ...e lower bearing inner race with a chisel Drive out the upper and lower bearing outer races The removed lower bearing inner race must be replaced with a new one The removed bearing outer races must be...

Page 177: ...bearing inner race 1 with the special tools 09913 70210 Bearing installer set 09940 51710 Bearing installer Apply SUZUKI SUPER GREASE A to the upper and lower bearing outer races Install the steel ba...

Page 178: ...ove of steering stem Tighten the steering stem lock nut to the special tool 09910 60611 Universal clamp wrench NOTE Tightening the steering stem lock nut can affect the steering stem nut adjustment Th...

Page 179: ...et drum retainer 9 Rear sprocket damper 0 Rear wheel outer bearing Left A Rear wheel inner bearing Left B Spoke nipple C Rear wheel D Rear wheel spacer E Rear wheel bearing Right F Brake shoe G Rear b...

Page 180: ...g the bolts and screw Remove the rear brake adjuster nut 2 Remove the cotter pin and torque link nut 3 Loosen the rear axle nut 4 Loosen the drive chain adjusters 5 left and right Remove the rear axle...

Page 181: ...1 Remove the sprocket drum 2 Remove the rear sprocket damper 3 out of the wheel hub WHEEL BEARINGS Inspect the play of the wheel bearings by finger while they are in the wheel Rotate the inner race by...

Page 182: ...RUM Remove the sprocket drum spacer 1 and sprocket drum retainer 2 Remove the rear sprocket 3 When removing the rear sprocket nuts A flatten the lock washer tongues B Remove the oil seal 4 09913 50121...

Page 183: ...0240 Bearing remover set INSPECTION REAR SPROCKET Inspect the rear sprocket teeth for wear If they are worn as shown replace the sprocket and drive chain as a set REAR SPROCKET DAMPER Inspect the rear...

Page 184: ...KI SUPER GREASE A to the rear wheel bear ings before installing 99000 25010 SUZUKI SUPER GREASE A First install the right wheel bearing 1 then spacer 2 left inner bearing 3 and left outer bearing 4 wi...

Page 185: ...tall the oil seal 2 with the special tool 09913 70210 Bearing installer set Apply SUZUKI SUPER GREASE A to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A REAR SPROCKET Tighten the rear sprocket nu...

Page 186: ...rear axle nut 3 and torque link nut 4 to the spec ified torque Rear axle nut 42 N m 4 2 kgf m Torque link nut 13 N m 1 3 kgf m Install the cotter pin 5 Tighten both chain adjusters securely Adjust th...

Page 187: ...brake shoes 2 from the rear brake panel 1 1 Brake shoe 2 Rear brake panel 3 Brake camshaft 4 Dust seal 5 Brake lining wear indi cator plate 6 Rear axle spacer 7 Brake cam lever bolt 8 Brake cam lever...

Page 188: ...rake camshaft 6 and dust seal 7 INSPECTION BRAKE DRUM Inspect the brake drum and measure the brake drum I D to determine the extent of wear If the measurement exceeds the service limit replace the bra...

Page 189: ...Inspect the rear brake panel for wear or damage If any defects are found replace the rear brake with a new one REASSEMBLY AND REMOUNTING Reassemble and remount the rear brake in the reverse order of r...

Page 190: ...ng wear indicator plate 3 with the cutaway 5 on the brake camshaft When installing the brake cam lever 6 align the punched mark 7 on the brake camshaft with the punched mark 8 on the brake cam lever 6...

Page 191: ...Install the brake shoes 0 Install the rear wheel 5 47 REAR BRAKE PEDAL Remove the muffler 3 5 Remove the rear brake adjuster nut 1 Remove the rear brake switch spring 2 Remove the rear brake pedal ret...

Page 192: ...the rear brake pedal shaft 99000 25010 SUZUKI SUPER GREASE A Install the right pillion footrest bracket 1 Install the washer 2 swingarm pivot nut 3 spacer 4 and right pillion footrest bracket lower b...

Page 193: ...move the rear shock absorber upper mounting bolts 1 Remove the rear shock absorber lower mounting bolts 2 Remove the rear shock absorbers 3 Remove the spacers 1 and bushes 2 upper and lower 1 Rear sho...

Page 194: ...with a new one REASSEMBLY AND REMOUNTING Reassemble and remount the rear shock absorber in the reverse order of removal and disassembly Pay attention to the following points Tighten the rear shock abs...

Page 195: ...orber lower mounting bolts 1 Remove the drive chain adjusters 2 Remove the pillion footrest bracket lower bolt 3 and spacer 4 1 Swingarm 2 Chain buffer 3 Swingarm pivot shaft 4 Torque link 5 Pillion f...

Page 196: ...llion footrest brackets 8 left and right Remove the swingarm 9 SWINGARM Remove the chain buffer 1 and washer 2 Remove the cotter pin 3 torque link nut 4 washer 5 and torque link 6 PILLION FOOTREST BRA...

Page 197: ...CHASSIS 5 60 Remove the pin 4 washer 5 and pillion footrest 6 INSPECTION SWINGARM Inspect the swingarm for damage If any defects are found replace the swingarm with a new one...

Page 198: ...swingarm pivot bush for wear or damage If any defects are found replace swingarm pivot bush with a new one DRIVE CHAIN BUFFER Inspect the chain buffer for wear or damage If any defects are found repl...

Page 199: ...ion footrest 1 and washer 2 Install the pin 3 Install the cotter pin 4 SWINGARM Install the torque link 1 to the swingarm Tighten the torque link nut 2 to the specified torque Torque link nut 13 N m 1...

Page 200: ...shock absorber 5 57 Install the rear wheel 5 47 FINAL INSPECTION AND ADJUSTMENT After installing the rear brake rear sprocket drum and wheel the following adjustments are required before driving Driv...

Page 201: ...ARTER MOTOR INSPECTION For FL125SD 6 16 STARTER MOTOR REASSEMBLY AND INSTALLATION For FL125SD 6 17 STARTER RELAY INSPECTION For FL125SD 6 19 IGNITION SYSTEM 6 20 TROUBLESHOOTING 6 20 INSPECTION 6 22 S...

Page 202: ...ct each terminal for corrosion and contamination Push in the coupler straightly An angled or skewed insertion may cause the terminal to be deformed possibly resulting in poor electrical contact CLAMP...

Page 203: ...rby when charging the battery Be sure to recharge the battery in a well ventilated and open area Note that the charging system for the MF battery is different from that of a conventional battery Do no...

Page 204: ...voltage and current values are not known begin mea suring in the highest range When measuring the resistance make sure that no voltage is applied If voltage is applied the tester will be damaged After...

Page 205: ...ELECTRICAL SYSTEM 6 5 LOCATION OF ELECTRICAL COMPONENTS 1 Regulator rectifier 2 Turn signal relay 3 Horn 4 Battery 5 Fuse 6 Ignition coil 7 Generator...

Page 206: ...6 6 ELECTRICAL SYSTEM 1 CDI unit 2 Starter relay For FL125SD 3 Starter motor For FL125SD...

Page 207: ...B W R W R Y G B W B W Regulator Gear position switch Brake light and taillight License plate light Head light Low beam Head light High beam R Low High L Turn signal light R Turn signal light L Turn s...

Page 208: ...ct the regulator rectifier 6 11 Is the regulator rectifier OK Step 7 1 Inspect wire harness Is the wire harness OK Battery overcharges Faulty regulator rectifier Faulty battery Poor contact of generat...

Page 209: ...e the battery cover Above Start the engine and keep it running at 5 000 r min with the dimmer switch turned to the HI position Measure DC voltage between the and battery terminals using the multi circ...

Page 210: ...ow White Ground Charge side 0 6 1 2 White Red Ground GENERATOR NO LOAD PERFORMANCE Remove the front frame cover 5 5 Remove the rear center leg shield 5 6 Disconnect the generator coupler Start the eng...

Page 211: ...If the voltage is not within the specified value replace the regulator rectifier with a new one 09900 25008 Multi circuit tester set 4 Tester knob indication Diode test 5 Unit V 61 4 V or more tester...

Page 212: ...n the starter button is pushed Is a click sound heard Step 2 1 Check if the starter motor runs when its terminal is connected to the battery terminal Do not use thin wire because a large amount of cur...

Page 213: ...does not crank the engine Step 1 1 Check the starter clutch Is the starter clutch OK STARTER MOTOR REMOVAL For FL125SD Disconnect the battery lead wire Disconnect the starter motor lead wire 1 Remove...

Page 214: ...stration 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 1 Housing end outside 5 O ring 2 Starter motor case A Starter mot...

Page 215: ...ove 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 and brush...

Page 216: ...new one If the commutator surface is discolored polish it with 400 sand paper and wipe it using a clean dry cloth If there is no undercut scrape out the insulator with a saw blade 1 Insulator 2 Segme...

Page 217: ...e order of disassembly Pay attention to the following points Apply SUZUKI SUPER GREASE A to the lip of the oil seal and bearing 99000 25010 SUZUKI SUPER GREASE A Apply a small quantity of SUZUKI MOLY...

Page 218: ...GREASE A STARTER MOTOR INSTALLATION Tighten the starter motor mounting bolts 1 to the specified torque Starter motor mounting bolt 10 N m 1 0 kgf m Tighten the starter motor lead wire nut 2 to the spe...

Page 219: ...rter relay clicks and continuity are found the relay is OK 09900 25008 Multi circuit tester set 7 Tester knob indication Continuity test 8 Measure the relay coil resistance between the terminals using...

Page 220: ...1 Measure the battery voltage between input lead wires O and B W at the CDI unit with the ignition switch in the ON position Is the voltage OK YES Go to Step 2 NO Poor connection of couplers YES Go t...

Page 221: ...Is the ignition coil OK Step 6 1 Measure the pick up coil peak voltage and pick up coil resistance 6 23 NOTE The pick up coil peak voltage inspection is applicable only with the multi circuit tester a...

Page 222: ...ion coil lead wires 09900 25008 Multi circuit tester set Turn the ignition switch to the ON position Press the starter button and allow the engine to crank for a few seconds and then measure the ignit...

Page 223: ...nd right 5 7 NOTE Make sure that all of the couplers are connected properly and the battery is fully charged Disconnect the CDI unit coupler 1 Measure the pick up coil peak voltage in the following pr...

Page 224: ...l peak voltage 2 0 V or more If the peak voltage on the pick up coil coupler is within specifica tion but that on the CDI unit coupler is not within specification replace the wire harness with a new o...

Page 225: ...ELECTRICAL SYSTEM 6 25 SPEEDOMETER REMOVAL AND DISASSEMBLY Remove the rear view mirrors 5 4 Remove the rear handlebar covers 5 4 Remove the speedometer 1 Disassemble the speedometer as shown...

Page 226: ...Y B Fuel gauge Fuel meter High beam indicator light WIRE COLOR B Gr Lg O Y B W G Bl R B W Y Y B Y Bl Black Gray Light green Orange Yellow Black White Green Blue Red Black White Yellow Yellow Black Ye...

Page 227: ...ition The fuel meter should indicate F full Test 2 This test will determine the accuracy of the fuel meter in the E empty and F full positions Connect a 95 resistor between the Y B and B W lead wires...

Page 228: ...on of the turn signal light If the turn signal light does not illuminate inspect the bulb turn signal switch and circuit connection If the bulb turn signal switch and circuit connection are OK the tur...

Page 229: ...ar cover 5 4 Remove the headlight bulbs 1 HEADLIGHT BEAM ADJUSTMENT Loosen the screw A Moving the headlight assembly adjust the headlight vertical beam A Vertical adjuster If you touch the bulb with y...

Page 230: ...V 10 W FRONT TURN SIGNAL LIGHT BULB REPLACEMENT Remove the frame head cover 5 6 Remove the front turn signal light bulbs 1 left and right If you touch the bulb with your bare hands clean the bulb with...

Page 231: ...ACEMENT Remove the frame covers left and right 5 7 Remove the rear turn signal light bulbs left and right BRAKE LIGHT TAILLIGHT ASSEMBLY REPLACEMENT Remove the frame covers left and right 5 7 Remove t...

Page 232: ...6 32 ELECTRICAL SYSTEM Remove the rear combination light bracket 2 Remove the rear combination light lens 3 Remove the brake light taillight assembly 4...

Page 233: ...M 6 33 LICENSE PLATE LIGHT 1 License plate light bulb 12 V 5 W LICENSE PLATE LIGHT BULB REPLACEMENT Remove the license plate light case 1 Remove the license plate light bulb Do not overtighten the len...

Page 234: ...tracer B W Black with White tracer W B White with Black tracer W Y White with Yellow tracer Y G Yellow with Green tracer Y Bl Yellow with Blue tracer Y W Yellow with White tracer R B Red with Black t...

Page 235: ...motorcycle and must be put on the level ground Remove the caps 2 NOTE After filling the electrolyte completely use the removed cap 2 as sealing caps of battery filler holes Do not remove or pierce th...

Page 236: ...nto the filler holes pressing in firmly so that the top of the caps does not protrude above the upper surface of the battery s top cover For initial charging use the charger specially designed for MF...

Page 237: ...charging wait for 30 minutes or more and check the battery voltage with a multi circuit tester If the battery voltage is 12 5 V or less recharge the battery again If battery voltage is still 12 5 V or...

Page 238: ...ING HARNESS ROUTING 7 13 CABLE ROUTING 7 16 SEAT LOCK CABLE ROUTING 7 17 FRONT BRAKE HOSE ROUTING 7 18 FUEL HOSE ROUTING 7 19 HOSE ROUTING 7 20 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 7 21 EXTERIOR PARTS...

Page 239: ...rburetor needle valve 4 Clogged fuel hose or fuel filter Adjust Repair or replace Adjust Replace Replace or rebore See electrical section Retighten Repair or replace Clean Clean and dry Replace Replac...

Page 240: ...rnt journal bearing Noise seems to come from transmission 1 Worn or rubbing gears 2 Worn splines 3 Worn or rubbing primary gears 4 Worn bearings Replace Replace Repair or replace Replace Replace Repla...

Page 241: ...t 4 Too narrow spark plug gap 5 Ignition not advanced sufficiently due to poorly working timing advance circuit 6 Defective ignition coil 7 Defective pick up coil or CDI unit 8 Too low float chamber f...

Page 242: ...Clean Replace Retighten or replace Drain out excess oil Replace Engine overheats 1 Heavy carbon deposit on piston crown 2 Not enough oil in the engine 3 Defective oil pump or clogged oil circuit 4 To...

Page 243: ...se pilot air screw 3 Air leaking from carburetor joint 4 Clogged pilot outlet port 5 Clogged bypass port 6 Starter cable not fully closed Clean or tighten Clean or tighten Tighten or replace defec tiv...

Page 244: ...Defective or incorrect tire 4 Loose axle 5 Incorrect front fork oil level 6 Incorrect front wheel weight balance Replace Replace Replace Retighten Adjust Adjust Front suspension too soft 1 Weakened sp...

Page 245: ...h sandpaper Insufficient rear brake power 1 Worn shoes or drum 2 Too much brake pedal play 3 Excessive brake pedal play 4 Friction surfaces of shoes are dirty with oil or dust 5 Excessively worn brake...

Page 246: ...nections 2 Short circuited grounded or open generator coils 3 Short circuited or punctured regulator rectifier Repair replace or retighten Replace Replace Battery does charge but charg ing rate is bel...

Page 247: ...ing 3 A short circuit condition exists within the battery 4 Too low battery voltage 5 Too old battery Check the generator regu lator rectifier and circuit connections and make nec essary adjustments t...

Page 248: ...k tracer White with Black tracer White with Blue tracer White with Red tracer White with Yellow tracer Yellow with Black tracer Yellow with Blue tracer Yellow with White tracer WIRE COLORS LICENSE PLA...

Page 249: ...White with Blue tracer White with Red tracer White with Yellow tracer Yellow with Black tracer Yellow with Blue tracer Yellow with Green tracer Yellow with White tracer WIRE COLORS LED BREAKE LIGHT TA...

Page 250: ...r position switch coupler Starter motor relay Gear position lead wire Front turn signal light L coupler Turn signal relay lead wire Regulator Rectifier Horn lead wire Front turn signal light R coupler...

Page 251: ...e Face the terminal of the ignition coil downward Battery spacer Battery Battery lead wire Battery terminal Fuel tank Frame Fuel level gauge lead wire Fuse box Fuse box Seat lock cable Battery box lid...

Page 252: ...7 15 SERVICING INFORMATION Gear position lead wire Generator rotor Clamp Clamp Crank case L Gear position switch Engine sprocket cover...

Page 253: ...rottle cable and speedometer inside of the starter cable Starter cable Starter cable Frame Front brake hose Speedometer cable Speedometer cable Throttle cable Throttle cable Pass through the throttle...

Page 254: ...leaner box mount Pass through the seat lock cable inside cable guide Pass through the seat lock cable inside the left frame cover plate Clamp Clamp Seat lock cable Clamp Clamp Clamp Clamp Clamp Seat l...

Page 255: ...SERVICING INFORMATION 7 18 FRONT BRAKE HOSE ROUTING Set the brake hose into clamp firmly Pass through the brake hose inside the guide Pass through the brake hose inside the guide 90 28...

Page 256: ...RVICING INFORMATION FUEL HOSE ROUTING Fuel filter Fuel tank hose Vacuum hose Fuel hose guide Fuel hose guide Fuel hose clamp Fuel tank Pass through the vacuum of the wiring harness Fuel tap vacuum hos...

Page 257: ...RVICING INFORMATION 7 20 HOSE ROUTING Crank case breather hose Fuel hose Fuel tap vacuum hose Pass the breather hose through the guide PAIR valve vacuum hose Air vent carburetor hose Breather hose Cla...

Page 258: ...STEM HOSE ROUTING Intake pipe Pass the second air cleaner hose the through the downward of the high tension cord PAIR valve PAIR valve pipe PAIR valve vacuum hose Air cleaner box Direct the grip secti...

Page 259: ...ING INFORMATION 7 22 EXTERIOR PARTS CONSTRUCTION Frame head cover Front right leg shield Front left leg shield Front center leg shield Rear center leg shield Rear left leg shield Frame Rear right leg...

Page 260: ...N Front frame cover Right lower frame cover Battery box lid Right frame cover Rear fender Luggage box Luggage box mud guard Helmet holder Frame Left lower frame cover Left frame cover Rear combination...

Page 261: ...SERVICING INFORMATION 7 24 PROP STAND INSTALLATION CENTER STAND INSTALLATION Assembling direction of return spring Outside 40 N m 4 0 kgf m Long Assembling direction of return spring Short...

Page 262: ...7 25 SERVICING INFORMATION BRAKE PEDAL L o n g 11 mm S h o r t...

Page 263: ...SERVICING INFORMATION 7 26 PILLION FOOTREST Cotter pin Bend the cotter pin and its ends should face upward...

Page 264: ...ge 1 100 mm 10 mm 09900 20701 Magnetic stand 09900 20803 Thickness gauge 09900 20805 Tire depth gauge 09900 21304 V block set 100 mm 09900 22302 Plasti gauge 09900 22401 Small bore gauge 10 18 mm 0990...

Page 265: ...34570 Valve guide reamer 5 0 mm 09916 34580 Valve guide reamer 10 8 mm 09916 44310 Valve guide remover installer 09916 84511 Tweezers 09917 14910 Valve clearance adjusting driver 09917 47011 Vacuum pu...

Page 266: ...r availability 09930 44570 Crank barancer holder 09940 51710 Bearing installer 09940 52861 Front fork oil seal installer set 09940 60113 Spoke nipple wrench 09941 34513 Steering outer race installer 0...

Page 267: ...hift stopper pin bolt 23 2 3 Crankcase bolt 10 1 0 Gearshift cam stopper bolt 10 1 0 Crank balancer driven gear nut 40 4 0 Oil pump mounting bolt 10 1 0 Clutch sleeve hub nut 50 5 0 Gearshift pin bolt...

Page 268: ...Steering stem nut 80 8 0 Front axle nut 42 4 2 Brake disc bolt 23 2 3 Brake caliper mounting bolt 25 5 2 55 Brake pad mounting pin bolt 17 5 1 75 Brake hose union bolt 22 5 2 25 Master cylinder mounti...

Page 269: ...er to this chart Bolt Diameter A mm Conventional or 4 marked bolt 7 marked bolt N m kgf m N m kgf m 4 1 5 0 15 2 3 0 23 5 3 0 3 4 5 0 45 6 5 5 0 55 10 1 0 8 13 1 3 23 2 3 10 29 2 9 50 5 0 12 45 4 5 85...

Page 270: ...N 4 975 4 990 EX 4 955 4 970 Valve stem deflection IN EX 0 35 Valve stem runout IN EX 0 05 Valve head thickness IN EX 0 5 Valve stem end length IN EX 2 2 Valve seat width IN EX 0 9 1 1 Valve head radi...

Page 271: ...ve clearance 1st 0 180 2nd 0 150 Piston ring groove width 1st 1 01 1 03 2nd 1 01 1 03 Oil 2 01 2 03 Piston ring thickness 1st 0 97 0 99 2nd 0 97 0 99 Piston pin bore I D 14 002 14 008 14 030 Piston pi...

Page 272: ...s Low 2 909 32 11 2nd 1 785 25 14 3rd 1 294 22 17 4th 1 052 20 19 Gearshift fork to groove clearance No 1 0 1 0 3 0 5 No 2 0 15 0 35 0 55 Gearshift fork groove width No 1 4 5 4 6 No 2 4 55 4 65 Gearsh...

Page 273: ...Plug cap Tap Ignition coil primary peak voltage 150 V or more B W W Bl Generator coil resistance Lamp 0 4 1 0 Y W Ground Charge 0 6 1 2 W R Ground Generator coil no load voltage when cold Lamp 50 V or...

Page 274: ...0 0 2 3 5 Front brake disc runout 0 30 Master cylinder bore 12 700 12 743 Master cylinder piston diam 12 657 12 684 Brake caliper cylinder bore 27 000 27 050 Brake caliper piston diam 26 918 26 968 Br...

Page 275: ...a 2 80 kgf cm Tire size Front 60 100 17 M C 33P Rear 70 90 17 M C 43P Tire type Front IRC NF63AD Rear IRC NR70 Tire tread depth Front 1 6 Rear 2 0 ITEM SPECIFICATION NOTE Fuel type Gasoline used shoul...

Page 276: ...5 CHASSIS 8 6 ELECTRICAL 8 6 CAPACITIES 8 6 PERIODIC MAINTENANCE SCHEDULE 8 7 PERIODIC MAINTENANCE CHART 8 7 MAINTENANCE AND TUNE UP PROCEDURES 8 8 FUEL LINE 8 8 THROTTLE CABLE PLAY 8 8 SDS CHECK 8 9...

Page 277: ...WIRING DIAGRAM 8 106 WIRING HARNESS CABLE AND HOSE ROUTING 8 107 WIRING HARNESS ROUTING 8 107 CABLE ROUTING 8 110 FUEL HOSE ROUTING 8 111 EXTERIOR PARTS CONSTRUCTION 8 112 THROTTLE BODY AND FUEL INJE...

Page 278: ...Water Temp Sensor WTS ET sensor Engine Temperature sensor F FI Fuel Injection Fuel Injector Dis charge pump DCP FP Fuel Pump FPR Fuel Pressure Regulator FP Relay Fuel Pump Relay G GEN Generator GND Gr...

Page 279: ...th Black tracer G B Green with Black tracer G Bl Green with Blue tracer O B Orange with Black tracer O Bl Orange with Blue tracer O R Orange with Red tracer R B Red with Black tracer R W Red with Whit...

Page 280: ...e 55 2 mm Displacement 124 cm Corrected compression ratio 9 6 1 Carburetor Fuel injection Air cleaner Paper filter Starter system Electric and kick Lubrication system Wet sump Idle speed 1 500 100 r m...

Page 281: ...B T D C at 1 500 r min Spark plug NGK CR6HSA or DENSO U20FSR U Battery 12V 16 2 kC 4 5 Ah 10HR Generator Three phase A C generator Fuse 15 A Headlight 12 V 35 35 W HS1 Position parking light 12 V 5 W...

Page 282: ...s PERIODIC MAINTENANCE CHART NOTE I Inspect and adjust clean lubricate or replace as necessary R Replace T Tighten Interval Item km 1 000 4 000 8 000 months 5 20 40 Air cleaner I I Replace every 12 00...

Page 283: ...TTLE CABLE PLAY Adjust the throttle cable play A as follows Loosen the lock nut 2 of the throttle pulling cable 1 Turn the adjuster 3 in or out until the throttle cable play A should be 2 0 4 0 mm at...

Page 284: ...icle which is not periodically brought in for service with no past data value having been saved if the data value of a good vehicle condition have been already saved as a master STD comparison between...

Page 285: ...FL125SDW 8 10 Data at 3 000 r min under no load Data at the time of racing 3 000 r min Check the manifold absolute pressure Approx XXX kPa XXX mmHg Throttle Quick wide open Throttle Slowly open...

Page 286: ...ccurred with the pass of time and identify what problem is currently occurring With DTC not output if the value of engine temperature is found to be lower than the data saved previously the possible c...

Page 287: ...wires Inspect each terminal on the connector coupler for looseness or bending Push in the coupler straightly An angled or skewed insertion may cause the terminal to be deformed possibly resulting in...

Page 288: ...e coupler for locking loose ness corrosion dust etc 1 Coupler 2 Probe 3 Where male terminal fits FUSE When a fuse blows always investigate the cause to correct it and then replace the fuse Do not use...

Page 289: ...e force will be applied to the ECM which may result in serious damage Before measuring voltage at each terminal check to make sure that battery voltage is 11 V or higher Terminal voltage check with a...

Page 290: ...ck for condition of the coupler lock if equipped 1 Sensor 2 ECM 1 Check for loose connection Using a test male terminal check the female terminals of the circuit being checked for contact tension Chec...

Page 291: ...it being checked voltage check can be used as circuit check With all connectors couplers connected and voltage applied to the circuit being checked measure voltage between each terminal and body groun...

Page 292: ...rts Otherwise diagnosis will be misled Measure resistance between terminal at one end of circuit A terminal in figure and body ground If continuity is indicated there is a short circuit to ground betw...

Page 293: ...asuring the resistance with the multi circuit tester 1 will be shown as 10 00 M and 1 flashes in the display Check that no voltage is applied before making the measure ment If voltage is applied the t...

Page 294: ...compensations These compensations are determined according to the signals from various sensors that detect the engine and driving conditions Intake Air Pressure Sensor IAP Sensor Intake air pressure...

Page 295: ...s rich ENGINE RPM SIGNAL At high speed the injection time volume is increased When starting engine additional fuel is injected during cranking engine STARTING SIGNAL When starting engine additional fu...

Page 296: ...TS LOCATION A ECM E Intake air pressure sensor Throttle position sensor Intake air tem perature sensor IAPS TPS IATS B Tip over sensor TOS C Fuel injector F Engine temperature sensor ETS D ISC valve G...

Page 297: ...FL125SDW 8 22 A ECM I Ignition coil IG coil H Speedometer J Crankshaft position sensor CKPS...

Page 298: ...re sensor IATS Tip over sensor TOS HO2 sensor HO2S Side stand switch Gear position switch Neutral Engine temperature sensor ETS Fuel injector HO2 sensor heater Ignition coil ISC valve FI indicator lig...

Page 299: ...mber enters through IN check valve By the ECM signal the coil is energized causing the plunger to pressurize fuel This pressurization occurs after vapor inside the pump chamber has been bled through t...

Page 300: ...the engine load is high the fuel injection time volume is determined on the basis of throttle valve opening and engine speed ET SENSOR ET Engine Temperature sensor sends the signal of engine temperat...

Page 301: ...e opening voltage and sent to ECM The base fuel injection time volume in high load is determined in accordance with this electrical signal output signal The wider the throttle opening the higher the s...

Page 302: ...l voltage decreases when the oxygen concentration is high and increases when it is low NOTE As the zirconia element is not conductive below 250 C HO2 sensor will not function properly until the engine...

Page 303: ...F Fuel injector 4 Sensor ground E2 G Mode select switch 5 Power source B H Fuel injector 6 HO2 sensor heater HO2H I 7 Load cut off relay J Neutral switch 8 Side stand switch K ET sensor ET 9 Power sou...

Page 304: ...torcycle can not run When the ignition switch is turned ON FI indicator light is lit for 2 seconds and thereafter remains unlit When the ignition switch is turned ON and the engine stop switch is turn...

Page 305: ...m the devices These affected devices are indicated in the code form 09930 82720 Mode select switch The DTC are indicated from small code to large code TPS ADJUSTMENT Before checking DTC Diagnostic Tro...

Page 306: ...safe circuit In this case it is nec essary to bring the motorcycle to the workshop for complete repair ITEM FAIL SAFE MODE STARTING ABILITY RUNNING ABILITY IAP sensor Intake air pressure is fixed to...

Page 307: ...eg Date of problem Mileage FI indicator light condition Always ON Sometimes ON Always OFF Good condition PROBLEM SYMPTOMS Difficult Starting Poor Driveability No cranking Hesitation on acceleration No...

Page 308: ...8 Broken fuse FI indicator light operation 8 29 Exhaust gas leakage and noise 2 5 Each coupler disconnection MOTORCYCLE ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair...

Page 309: ...ng DTC read SELF DIAGNOSIS FUNCTION USER MODE and DEALER MODE 8 29 and 30 care fully to have good understanding as to what functions are avail able and how to use it Be sure to read PRECAUTIONS IN SER...

Page 310: ...a smaller number to a larger number in that order When all the applicable DTCs have been indicated the displaying of the DTCs repeat from the first one again If no DTC is recorded the FI indicator lig...

Page 311: ...None 12 CKP sensor 8 43 Pick up coil signal 13 IAP sensor 8 46 14 TP sensor 8 51 15 ET sensor 8 56 21 IAT sensor 8 60 23 TO sensor 8 64 24 Ignition coil 8 68 32 Fuel injector 8 68 40 ISC valve 8 70 4...

Page 312: ...he malfunction is cleared Disconnect the special tool from the dealer mode coupler NOTE Even though the Current DTC is cleared Past DTC previous malfunction history code still remains stored in the EC...

Page 313: ...8 12 before inspection and observe what is written there Remove the battery box lid 6 9 Set up the SDS tool Refer to the SDS operation manual for further details Read the DTC Diagnostic Trouble Code a...

Page 314: ...ECM Therefore erase the history code memorized in the ECM using SDS tool NOTE The malfunction code is memorized in the ECM also when the wire coupler of any sensor is disconnected Therefore when a wir...

Page 315: ...topped when a malfunction was detected by checking the show data when trouble This show data when trouble function can record the maximum of two Diagnostic Trouble Codes in the ECM Also ECM has a func...

Page 316: ...e above range 14 P0120 is indicated TP sensor lead wire coupler connection P0120 H Sensor voltage is higher than specified value TP sensor circuit shorted to VCC or ground circuit open L Sensor voltag...

Page 317: ...10 times or more continuously In this case the code 32 P0201 is indicated Primary fuel injector wiring cou pler connection power supply to the injector P0201 40 ISC valve When the ISC operation volta...

Page 318: ...ct the CKP sensor coupler and measure the resis tance CKP sensor resistance 180 280 Bl Y G W DETECTED CONDITION POSSIBLE CAUSE The CKP sensor signal does not reach ECM for 4 sec or more after receivin...

Page 319: ...P sensor continuity Infinity Bl Y Ground G W Ground 09900 25008 Multi circuit tester set Tester knob indication Resistance Are the resistance and continuity OK 6 After repairing the trouble clear the...

Page 320: ...ground Loose or poor contacts on the CKP sensor cou pler or ECM coupler terminal P or 4 If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for ope...

Page 321: ...ge 4 5 V NOTE Note that atmospheric pressure varies depending on weather conditions as well as altitude Take that into consideration when inspecting voltage Clogged vacuum passage between throttle bod...

Page 322: ...e voltage OK Step 1 When indicating P0105 H 1 Turn the ignition switch OFF 2 Remove the right leg shield 5 6 3 Check the IAP sensor coupler 1 for loose or poor contacts If OK then check the IAP sensor...

Page 323: ...ion switch OFF 2 Remove the right leg shield 5 6 3 Check the IAP sensor coupler 1 for loose or poor contacts If OK then check the IAP sensor lead wire continuity 4 Disconnect the IAP sensor coupler 5...

Page 324: ...nted probe set Tester knob indication Continuity test Is the continuity OK 9 After repairing the trouble clear the DTC using SDS tool 8 39 When using the multi circuit tester do not strongly touch the...

Page 325: ...trouble clear the DTC using SDS tool 8 39 YES G B R or Br B wire open or shorted to ground or poor N 9 or 4 connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each te...

Page 326: ...ITION POSSIBLE CAUSE 14 Output voltage is not within the following value Difference between actual throttle open ing and opening calculated by ECM is larger than specified value 0 3 V Sensor voltage 4...

Page 327: ...the voltage OK Step 1 When indicating P0120 H 1 Turn the ignition switch OFF 2 Remove the right leg shield 5 6 3 Check the TP sensor coupler 1 for loose or poor contacts If OK then check the TP sensor...

Page 328: ...e right leg shield 5 6 3 Check the TP sensor coupler 1 for loose or poor contacts If OK then check the TP sensor lead wire continuity 4 Disconnect the TP sensor coupler 5 Check the continuity between...

Page 329: ...et 09900 25009 Needle pointed probe set Tester knob indication Continuity test Is the continuity OK 10 After repairing the trouble clear the DTC using SDS tool 8 39 When using the multi circuit tester...

Page 330: ...ltage Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool 8 39 YES P R or Br B wire open or shorted to ground or poor M 9 or 4 connection If wire and connection are OK intermi...

Page 331: ...re the ET sensor voltage at the coupler DETECTED CONDITION POSSIBLE CAUSE 15 Output voltage is not within the following value 0 1 V Sensor voltage 4 7 V ET sensor circuit open or short ET sensor malfu...

Page 332: ...sensor coupler and ECM coupler 5 Check the continuity between O B wire A and terminal K 6 Also check the continuity between Br B wire B and terminal 4 ET sensor lead wire continuity Continuity 09900 2...

Page 333: ...then check the ET sensor lead wire continuity 4 Disconnect the ET sensor coupler 5 Check the continuity between O B wire A and ground If the sound is not heard from the tester the circuit condition i...

Page 334: ...YES O B or Br B wire open or shorted to ground or poor K or 4 connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and p...

Page 335: ...B wire B IAT sensor input voltage 4 5 5 5 V Dg Ground Dg Br B 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Voltage Is the voltage OK DETECTED CONDI...

Page 336: ...ck the continuity between Br B wire B and terminal 4 IAT sensor lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set Tester knob indication Continu...

Page 337: ...condition is OK Tester knob indication Continuity test 6 Connect the IAT sensor coupler and turn the ignition switch ON 7 Insert the needle pointed probes to the lead wire coupler 8 Measure the voltag...

Page 338: ...wire open or shorted to ground or poor L or 4 connection If wire and connection are OK intermittent trou ble or faulty ECM Recheck each terminal and wire harness for open circuit and poor connection R...

Page 339: ...rcuit tester set Tester knob indication Resistance Is the resistance OK DETECTED CONDITION POSSIBLE CAUSE 23 The sensor voltage should be the follow ing for 2 sec or more after ignition switch is turn...

Page 340: ...continuity between Bl W wire B and terminal A 8 Also check the continuity between Br B wire C and terminal 4 TO sensor lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 25009...

Page 341: ...he circuit condition is OK 7 Disconnect the ECM coupler 8 Check the continuity between R wire A and terminal 9 TO sensor lead wire continuity Continuity 09900 25008 Multi circuit tester set 09900 2500...

Page 342: ...ob indication Voltage Is the voltage OK 6 After repairing the trouble clear the DTC using SDS tool 8 39 24 P0351 IGNITION SYSTEM MALFUNCTION Refer to the IGNITION SYSTEM for details 8 96 2 V 2 V 65 YE...

Page 343: ...el injector coupler 1 for loose or poor contacts If OK then measure the fuel injector resistance 4 Disconnect the fuel injector coupler 5 Measure the fuel injector resistance Fuel injector resistance...

Page 344: ...5 V 09900 25008 Multi circuit tester set Tester knob indication Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool 8 39 YES Go to Step 2 NO Replace the fuel injector...

Page 345: ...asure the ISC valve resistance ISC valve resistance Approx 35 Terminal Terminal DETECTED CONDITION POSSIBLE CAUSE 40 P0505 When the ISC operation voltage remains at 1 0 V or lower continuously for 2 s...

Page 346: ...ester knob indication Voltage Is the voltage OK 3 After repairing the trouble clear the DTC using SDS tool 8 39 YES Go to Step 2 NO Replace the ISC valve with a new one 8 84 1 2 V YES O or Y R wire op...

Page 347: ...control 1 6 Check that the Spec 2 is idle speed 1 500 100 7 Check that the Desired idle speed 3 is within the specified idle Check 2 1 Input 2 000 to the ISC rpm control Spec field 1 2 Check that the...

Page 348: ...to more than 3 000 or the Engine speed may reach the upper limit Check 4 1 Input 1 300 to the ISC rpm control Spec field 1 2 Check that the Desired idle speed 2 is equal or close to the Spec 1 Also c...

Page 349: ...heard from the tester the circuit condition is OK 09900 25008 Multi circuit tester set Tester knob indication Continuity test DETECTED CONDITION POSSIBLE CAUSE 44 P0130 HO2 sensor output voltage is no...

Page 350: ...3 Warm up the engine enough 4 Measure the HO2 sensor output voltage between W G wire A and Br B wire B when idling condition HO2 sensor output voltage at idle speed 0 3 1 0 V W G Br B 5 If OK measure...

Page 351: ...W W 09900 25008 Multi circuit tester set Tester knob indication Resistance Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool 8 39 YES W G wire or Br B wire open or shorted t...

Page 352: ...ster knob indication Voltage Is the voltage OK 5 After repairing the trouble clear the DTC using SDS tool 8 39 2 V YES O or W wire open or shorted to ground or poor 6 connection Recheck each terminal...

Page 353: ...one and installed in the throttle body 8 46 51 and 60 ET SENSOR INSPECTION The engine temperature sensor is installed in the cylinder 8 56 Remove the ET sensor 8 79 Check the ET sensor by testing it...

Page 354: ...g shield 5 6 Disconnect the coupler 1 Remove the ET sensor 2 Install the ET sensor in the reverse order of removal ET sensor 9 N m 0 9 kgf m TO SENSOR INSPECTION The tip over sensor is located in fron...

Page 355: ...INSTALLATION Remove the frame covers left and right 5 7 Disconnect the HO2 sensor coupler 1 Remove the HO2 sensor 2 Installation is in the reverse order of removal Tighten the HO2 sensor to the specif...

Page 356: ...gh the port 3 smoothly Also check for clogging from the port 2 to 3 If any defects are found replace the fuel filter with a new one INSTALLATION Installation is in the reverse order of removal Pay att...

Page 357: ...ttle body 8 Return pipe 2 ISC valve 9 Upper cushion seal 3 O ring 0 Spacers 4 Intake pipe A Holder ITEM N m kgf m 5 Insulator A ISC valve screw A 2 0 2 6 Lower cushion seal B Throttle body bolt B 9 0...

Page 358: ...sensor coupler 3 Disconnect the throttle cables 4 from their drum Remove the throttle body 5 The throttle body is assembled precisely in factory Do not disassemble it other than shown in this manual D...

Page 359: ...g the adjuster 0 and throttle stop screw A Never remove the IAP TP IAT sensor 8 from the throt tle body Never remove the throttle valve 9 from the throttle body Never use carburetor cleaning chemicals...

Page 360: ...t removing it 8 71 If the resistance is not within the standard range replace the ISC valve with a new one REASSEMBLY AND INSTALLATION Reassembly and installation is in the reverse order of removal an...

Page 361: ...leg shield 5 6 Disconnect the fuel injector coupler 1 Place a rag under the fuel injector and disconnect the fuel hoses 2 and 3 Remove the holder 4 spacers 5 6 and fuel injector 7 Drain out fuel befor...

Page 362: ...r of removal Pay attention to the following points Apply thin coat of engine oil to the O ring 1 upper cushion seal 2 and lower cushion seal 3 Install the fuel injector as shown Tighten the fuel injec...

Page 363: ...e battery terminal is disconnected CHARGING SYSTEM TROUBLESHOOTING NOTE Make sure that the fuse is not blown and the battery is fully charged before diagnosing Battery runs down quickly Step 1 1 Check...

Page 364: ...the regulator rectifier 8 91 Is the regulator rectifier OK Step 8 1 Inspect wirings Are the wirings OK Engine runs but headlight does not light Step 1 1 Inspect the load cut off relay 8 101 Is the lo...

Page 365: ...ion Resistance Generator coil resistance 0 2 1 2 Yellow Yellow Yellow Ground NOTE When making above test it is not necessary to remove the gen erator Generator no load performance Remove the rear cent...

Page 366: ...specified value replace the regulator rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode test Unit V More than 1 4 V tester s battery voltage Above are approxim...

Page 367: ...s when its terminal is connected to the battery terminal Do not use thin wire because a large amount of current flows Does the starter motor run YES Go to Step 2 NO Go to Step 3 YES Faulty starter rel...

Page 368: ...sition other than neutral with the side stand up 2 Check the side stand switch 8 94 Is the side stand switch OK Step 2 1 Check the starter clutch Is the starter clutch OK YES Go to Step 4 NO Faulty fr...

Page 369: ...test NOTE If the tester reads under 1 4 V when the tester probes are not connected replace the battery of multi circuit tester Gear position switch Remove the right leg shield 5 6 Disconnect the gear...

Page 370: ...Multi circuit tester set Tester knob indication Continuity test Side stand diode Remove the front handlebar cover 5 4 Remove the side stand diode Measure the voltage between A and B terminals using t...

Page 371: ...1 1 Check the ignition system couplers for poor connections Are the ignition system couplers connected properly Step 2 1 Measure the battery voltage between input lead wires O and B W at the ECM with...

Page 372: ...CKP sensor peak voltage and its resistance 8 98 and 99 NOTE The CKP sensor peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Is the peak voltage and resis...

Page 373: ...roperly and the battery is fully charged Disconnect the ECM coupler 1 Connect the multi circuit tester with the peak volt adaptor as follows Measure the CKP sensor peak voltage between Bl wire and Br...

Page 374: ...ak voltage 2 0 V or more Bl Y G W If the peak voltage is lower than the specified value check each coupler connection or replace the CKP sensor and inspect it again CKP sensor resistance Remove the re...

Page 375: ...position Y B Fuel gauge WIRE COLOR B Gr Lg O B W Y B Y Bl W Y R B G Bl Black Gray Light green Orange Y Yellow Black White Yellow Black Yellow Blue White Yellow Red Black Green Blue Gr Illumi B Turn s...

Page 376: ...r 4 Make sure the Battery relay and Load cut off relay on the monitor are displayed Off 5 If the display is changed to On after starting the engine the operation is normal condition Relay check First...

Page 377: ...er 5 4 Remove the neutral diode 1 Install the neutral diode in the reveres order of removal INSPECTION Measure the voltage between A and B terminals using the multi circuit tester as indicated in the...

Page 378: ...TION PARKING LIGHT 1 Headlight bulb 12 V 35 35 W HS1 2 Position Parking light bulb 12 V 5 W If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water...

Page 379: ...LIGHT 1 Turn signal light bulb 12 V 21 W If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure Do not overtight...

Page 380: ...ILLIGHT 1 Brake light Taillight 12 V 21 5 W If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure Do not overti...

Page 381: ...W B B W W B B W Gr B Lg B W Lg B W B W B B W B Y B W W Y W Y B W W B W Gr B O Bl Lg Y Y W B W Y B O Bl W Y R B G Bl Y Bl B O Bl B Lg Y Y W B W Y B O Bl W Y R B G Bl Y Bl B G B W W B Y G W Y W Y B B Lb...

Page 382: ...or Front Seat lock cable Engine ground lead wire Clamp Generator lead wire Side stand switch coupler Face the terminal of the ignition coil downward Gear position switch Side stand switch Fuel tank Fr...

Page 383: ...ad wire Seat lock cable Top Ignition coil lead wire Engine ground lead wire Wiring harness Frame Clamp Clamp HO2 sensor lead wire Dealer mode coupler lead wire Battery lead wire Starter relay Pass thr...

Page 384: ...rator cover Generator startor Grommet Generator rotor Generator cover Gear position switch lead wire Engine sprocket cover Gear position switch Crank case L CKP sensor Generator lead wire clamp CKP se...

Page 385: ...cable Throttle returning cable Throttle pulling cable Speedometer cable guide Wiring harness Front brake hose Speedometer cable Front brake hose Speedometer cable Speedometer cable Clamp the upside o...

Page 386: ...1 FL125SDW FUEL HOSE ROUTING Fuel filter Fuel hose 3 way union Fuel injector Fuel injector Marking Red Marking Red Upper Upper L o w e r Lower Lower Left Right Marking White Marking Yellow Marking Red...

Page 387: ...FL125SDW 8 112 EXTERIOR PARTS CONSTRUCTION Frame head cover Front right leg shield Front left leg shield Front center leg shield Rear center leg shield Rear left leg shield Frame Rear right leg shield...

Page 388: ...113 FL125SDW Front frame cover Right frame lower cover Battery box lid Right frame cover Rear fender Luggage box Frame Left lower frame cover Left frame cover Rear combination light Frame center cove...

Page 389: ...INSTALLATION 1 Throttle body 5 Spacer 2 Intake pipe 6 Holder 3 Fuel injector 7 Return pipe 4 Insulator 1 Adjust the clearance between the fuel injector coupler and bolt to provide 1 to 2 mm 9 N m 0 9...

Page 390: ...not TIGHTENING TORQUE 09900 25008 Multi circuit tester set 09900 25009 Needle pointed probe set 09904 41010 SDS set tool 09930 82720 Mode select switch 99565 01010 011 CD ROM Ver 11 ITEM N m kgf m ET...

Page 391: ...IN 4 975 4 990 EX 4 955 4 970 Valve stem deflection IN EX 0 35 Valve stem runout IN EX 0 05 Valve head thickness IN EX 0 5 Valve stem end length IN EX 2 2 Valve seat width IN EX 0 9 1 1 Valve head rad...

Page 392: ...2nd 0 150 Piston ring groove width 1st 1 01 1 03 2nd 1 01 1 03 Oil 2 01 2 03 Piston ring thickness 1st 0 97 0 99 2nd 0 97 0 99 Piston pin bore I D 14 002 14 008 14 030 Piston pin O D 13 996 14 000 13...

Page 393: ...ction ratio 2 428 34 14 Gear ratios Low 2 909 32 11 2nd 1 785 25 14 3rd 1 294 22 17 Top 1 052 20 19 Gearshift fork to groove clearance No 1 0 1 0 3 0 5 No 2 0 15 0 35 0 55 Gearshift fork groove width...

Page 394: ...4 5 5 5 V IAT sensor output voltage 1 8 3 1 V at 20 C IAT sensor resistance Approx 2 56 k at 20 C 1 20 k at 40 C ET sensor input voltage 4 5 5 5 V ET sensor resistance Approx 6 2 13 k at 20 40 C TO se...

Page 395: ...nal Secondary 25 40 k Plug cap Terminal Ignition coil primary peak voltage 150 V or more B W W Bl Generator coil resistance 0 2 1 2 Y Y Generator coil no load voltage when engine is cold 50 V or more...

Page 396: ...e disc thickness 4 0 0 2 3 5 Front brake disc runout 0 30 Master cylinder bore 12 700 12 743 Master cylinder piston diam 12 657 12 684 Brake caliper cylinder bore 27 000 27 050 Brake caliper piston di...

Page 397: ...0 kgf cm Tire size Front 70 90 17 M C 38P Rear 80 90 17 M C 50P Tire type Front IRC NF35 Rear IRC NR75 Tire tread depth Front 1 6 Rear 2 0 ITEM SPECIFICATION NOTE Fuel type Gasoline used should be gra...

Page 398: ...Prepared by March 2007 Part No 99500 31371 01E Printed in Japan 396...

Page 399: ...Printed in Japan K7...

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