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ENGINE 3-37

CRANKSHAFT AND CONROD

CONROD SMALL END I.D.

Measure the conrod small end inside diameter using the dial cal-
ipers. If the conrod small end inside diameter exceeds the ser-
vice limit, replace the conrod.

$

Conrod small end I.D.

Service Limit: 14.040 mm

%

09900-20605: Dial calipers

1

Crankshaft, RH

2

Conrod

3

Bearing

4

Crank pin

5

Crankshaft, LH

ITEM

N·m

kgf-m

A

50

5.0

@

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Summary of Contents for RV125

Page 1: ...9 9 5 0 0 3 1 2 3 3 0 1 E...

Page 2: ...COPYRIGHT SUZUKI MOTOR CORPORATION 2003 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 e...

Page 3: ...st page of each section to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit there is an exploded view which provides work instructions...

Page 4: ...ified Apply THREAD LOCK SUPER 1360 99000 32130 Apply molybdenum oil solution mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 1 Apply or use brake fluid Apply SUZUKI SUPER GREASE A 99000 25...

Page 5: ...3 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL AND OIL RECOMMENDATION 1 4 FUEL 1 4 ENGINE OIL 1 5 BRAKE FLUID 1 5 FRONT FORK OIL 1 5 BREAK lN PROCEDURES 1 5 INFORMATION LABELS 1 6 SPECIFICATIONS 1 7 DIME...

Page 6: ...ust use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Prope...

Page 7: ...case bolts and nuts tighten the larger sizes first Always tighten the bolts and nuts from the inside working out in a crisscross manner Whenever you remove oil seals gaskets packing O rings locking w...

Page 8: ...t side of the steering head pipe The engine serial number 2 is located on the left side of the crankcase These numbers are required especially for registering the machine and ordering spare parts FUEL...

Page 9: ...and reliability of the engine depends on the care and restraint exercised during its early life The general rules are as follows Keep to these break in throttle opening limits Initial 800 km Less tha...

Page 10: ...AL INFORMATION INFORMATION LABELS NO LABEL or PLATE NAME 1 Fuel caution label 2 Tire information label 3 Warning safety label 4 Warning rear carrier label 5 ID plate 6 Anti tamparing label Head pipe R...

Page 11: ...Displacement 125 cm Compression ratio 9 2 1 Carburetor MIKUNI BS26 Air cleaner Polyurethane foam element Starter system Electric Lubrication system Wet sump Idle speed 1 500 100 r min DRIVE TRAIN Clu...

Page 12: ...orized lgnition timing 13 B T D C at 1 500 r min Spark plug NGK CR8E or DENSO U24ESR N Battery 12 V 21 6 kC 6 Ah 10 HR Generator Three phase A C generator Fuse 20 A Headlight 12 V 60 55 W Brake light...

Page 13: ...GENERAL INFORMATION 1 9 COUNTRY AND AREA CODES The following codes stand for the applicable countries and areas CODE COUNTRY OR AREA E 02 E 19 U K EU...

Page 14: ...5 SPARK PLUG 2 7 THROTTLE CABLE PLAY 2 8 ENGINE IDLE SPEED 2 8 FUEL HOSE 2 9 CLUTCH 2 9 ENGINE OIL AND OIL FILTER 2 10 DRIVE CHAIN 2 11 BRAKES 2 13 STEERING 2 17 TIRE AND WHEEL 2 18 EXHAUST PIPE BOLT...

Page 15: ...ce or lubricate as necessary C Clean R Replace T Tighten Interval Item km 1 000 4 000 8 000 months 5 20 40 Air cleaner element I I Exhaust pipe bolts and muffler mounting bolts T T T Valve clearance I...

Page 16: ...elow NOTE Before lubricating 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 especially w...

Page 17: ...air cleaner cover 1 Remove the air cleaner element 2 Fill a container with a non flammable cleaning solvent Immerse the air cleaner element in the cleaning solvent and wash it Squeeze the cleaning so...

Page 18: ...lement snugly and correctly so that no incoming air will by pass it Remember the rapid wear of piston rings and the cylinder bore is often caused by a defective or poorly fitted element If driving und...

Page 19: ...t valve clear ance The clearance specification is for COLD state To turn the crankshaft for clearance checking rotate in the nor mal running direction The spark plug should be removed Turn crankshaft...

Page 20: ...Check the spark plug for burns If any abnormalities are found replace the spark plug Tighten the spark plug to the specified torque using the spe cial tool Spark plug 18 N m 1 8 kgf m 09930 10121 Spa...

Page 21: ...s adjustment when the engine is hot Start the engine turn the throttle stop screw 1 and set the engine idle speed as follows Connect the electric tachometer or the multi circuit tester to the high ten...

Page 22: ...ut 1 and turn the adjuster 2 fully in Loosen the lock nut 3 and turn the adjuster 4 until the clutch lever play A is within specification Clutch lever play A 10 15 mm Tighten the lock nuts 1 3 Inspect...

Page 23: ...8 kgf m Make sure that the engine is cooled Place the motorcycle on level ground and hold it vertically Install the oil filler cap 2 Start the engine and allow it to run for a few minutes at idling s...

Page 24: ...inspect the drive chain for the possible defects listed below Loose pins Twisted or seized links Damaged rollers Excessive wear Rusted links Kinked or binding links If any defects are found the drive...

Page 25: ...ts as a set Place the motorcycle on the side stand Loosen or tighten both chain adjusters 1 until the chain has 15 25 mm of slack at the middle of the chain between the engine and rear sprockets as sh...

Page 26: ...A on the brake pad When the wear exceeds the grooved limit line replace the pads with new ones 5 11 The drive chain joint clip should be attached in the way that the slit end will face opposite to the...

Page 27: ...d brake fluid which is classified DOT 4 Do not use or mix other types of brake fluid such as silicone based and petroleum based brake flu ids when refilling the brake system otherwise serious damage t...

Page 28: ...sert the free end of the hose into a receptacle Bleed air from the brake system Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it L...

Page 29: ...15 mm A below the top face of the footrest Retighten the lock nut 1 to secure the adjusting bolt 2 in the proper position Brake pedal height A 5 15 mm REAR BRAKE ADJUSTING By repositioning the adjust...

Page 30: ...IGHT SWITCH Adjust the rear brake light switch so that the brake light will come on just before pressure is fell when the brake pedal is depressed STEERING The steering should be adjusted properly for...

Page 31: ...nflation tire pressure is as follows WHEEL Make sure that the wheel runout axial and radial does not exceed the service limit when checked as shown An excessive amount of runout is usually due to worn...

Page 32: ...ting bolts to the specified torque Exhaust pipe bolt 1 23 N m 2 3 kgf m Muffler connecting bolt 2 20 N m 2 0 kgf m Muffler mounting bolt 3 4 23 N m 2 3 kgf m FRONT FORK Inspect the front forks for oil...

Page 33: ...0 3 Front fork upper clamp bolt 23 2 3 4 Front fork lower clamp bolt 33 3 3 5 Front fork cap bolt 23 2 3 6 Front axle 65 6 5 7 Front axle pinch bolt 23 2 3 8 Front brake caliper mounting bolt 39 3 9...

Page 34: ...PERIODIC MAINTENANCE 2 21...

Page 35: ...pecification check 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...

Page 36: ...ty 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 pressure...

Page 37: ...FT 3 32 CYLINDER 3 33 CAM CHAIN TENSION ADJUSTER 3 34 CAM CHAIN GUIDE 3 34 PISTON AND PISTON PIN 3 34 CRANKSHAFT AND CONROD 3 37 STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING 3 39 GENERATOR STATOR AN...

Page 38: ...58 Neutral switch 3 18 3 52 PARTS REMOVAL INSTALLATION Clutch cover 3 14 3 58 Clutch 3 14 3 56 Oil pump 3 16 3 55 Gearshift shaft 3 16 3 55 Gearshift cam driven gear 3 16 3 54 Primary driven gear 3 15...

Page 39: ...LLATION ENGINE REMOVAL Remove the seat 5 3 Remove the fuel tank 4 2 Drain engine oil 2 10 Disconnect the battery lead wire 1 Loosen the muffler connecting bolt Remove the exhaust pipe 2 Disconnect the...

Page 40: ...the throttle cable from the carburetor Disconnect the neutral switch lead wire coupler 2 pick up coil lead wire coupler 3 and generator lead wire coupler 4 Disconnect the throttle position sensor lea...

Page 41: ...he carburetor Remove the clutch release arm 1 along with the clutch cable Disconnect the crankcase breather hose 2 Remove the gearshift lever 3 Remove the engine sprocket cover 4 Sprocket cover Bolt S...

Page 42: ...e sprocket nut 1 NOTE When loosening the engine sprocket nut 1 depress the brake pedal Remove the drive chain joint clip 2 Release the chain Disconnect the engine ground wire 3 Remove the engine mount...

Page 43: ...ENGINE 3 7 Remove the swingarm pivot nut 1 Partially remove the swingarm pivot shaft so that the engine can be removed NOTE Be careful not to draw out the pivot shaft Gradually lower the engine...

Page 44: ...The engine mounting nuts are self locking Once the nuts have been removed they are no longer of any use Tighten the engine sprocket nut 1 to the specified torque Engine sprocket nut 90 N m 9 0 kgf m...

Page 45: ...Install the gasket 1 to the cylinder side Install the PAIR air pipe and tighten the nuts to the specified torque PAIR air pipe nut 10 N m 1 0 kgf m Install a new exhaust pipe muffler connector 2 into...

Page 46: ...and gearshift lever top After remounting the engine the following adjustments are necessary Clutch lever play 2 9 Throttle cable play 2 8 Engine idle speed 2 8 Drive chain slack 2 12 Pour 1 200 ml of...

Page 47: ...ps Remove the spark plug 1 09930 10121 Spark plug wrench set Remove the engine sprocket 2 Remove the timing inspection plug 3 and generator cover plug 4 Rotate the crankshaft and align the line A on t...

Page 48: ...OVER Remove the cylinder head cover CAMSHAFT Remove the camshaft end cap 2 Flatten the lock washer and remove the camshaft sprocket bolts Remove the camshaft 3 and camshaft sprocket 4 Remove the C rin...

Page 49: ...asket 1 Remove the cam chain guide 2 Remove the cylinder by removing the cylinder base nuts NOTE If the cylinder does not come off lightly tap on the finless portion of it with a plastic hammer PISTON...

Page 50: ...spacer 2 shaft 3 and starter idle gear 4 Remove the starter motor 5 CLUTCH COVER Remove the clutch cover 6 CLUTCH With the generator rotor nut held immovable remove the clutch spring mounting bolts i...

Page 51: ...4 Remove the clutch drive and driven plates Flatten the lock washer and remove the clutch sleeve hub nut 5 with the special tool 09920 53740 Clutch sleeve hub holder Remove the clutch sleeve hub 6 Re...

Page 52: ...move the gearshift shaft 5 Remove the pawl lifter 6 and cam guide 7 Remove the gearshift cam driven gear 8 NOTE When removing the cam driven gear 8 do not lose the pawls 9 pins 0 and springs A PRIMARY...

Page 53: ...mp drive gear 1 and primary drive gear 2 Remove the key 3 GENERATOR ROTOR Remove the generator rotor nut with the special tool 09930 44530 Rotor holder Remove the generator rotor with the special tool...

Page 54: ...1 NEUTRAL SWITCH Remove the plate 2 and neutral switch 3 Remove the O ring 4 switch contact 5 and spring 6 Remove the engine sprocket spacer 7 Remove the oil seal retainer 8 Remove the gearshift cam s...

Page 55: ...nkshaft and transmission components should remain in the left crankcase half When separating the crankcase tap the end of the counter shaft with a plastic mallet Remove the gearshift fork shafts 1 2 a...

Page 56: ...3 20 ENGINE CRANKSHAFT Remove the crankshaft with the special tool 09920 13120 Crankcase separator...

Page 57: ...r on a surface plate and check for distortion with a thickness gauge Check points are shown in Fig Cylinder head cover distortion Service Limit 0 05 mm 09900 20803 Thickness gauge If the distortion ex...

Page 58: ...REASSEMBLY Reassemble the cylinder head cover in the reverse order of dis assembly Pay attention to the following points Apply engine oil to the rocker arm shafts Install the rocker arms 1 wave washer...

Page 59: ...alve lifter 09916 14910 Valve lifter attachment Remove the valve cotters 3 from the valve stem 09916 84511 Tweezers Remove the valve spring retainer 4 and inner and outer valve springs 5 6 Identify th...

Page 60: ...00 20803 Thickness gauge VALVE FACE WEAR The thickness of the valve face decreases as the face wears Visually inspect each valve face for wear and replace any valve with an abnormally worn face Measur...

Page 61: ...eplaced with a new one Valve stem deflection Service Limit IN EX 0 35 mm 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand VALVE STEM WEAR Measure the valve stem O D using the micrometer If i...

Page 62: ...n and oil the guides after reaming 09916 34550 Valve guide reamer 5 5 mm 09916 34542 Handle VALVE SEAT WIDTH INSPECTION Visually check for valve seat width on each valve face If the valve face has wor...

Page 63: ...16 24480 Solid pivot N 140 5 5 09916 24920 Valve seat cutter N 212 NOTE Use the solid pilot N 140 5 5 along with the valve seat cutter N 121 122 and 212 When installing the solid pilot 1 rotate it sli...

Page 64: ...the contact area is too high on the valve or if it is too wide use the 15 cutter to lower and narrow the contact area Use the 15 cutter FINAL SEAT CUT If the contact area is too low or too narrow use...

Page 65: ...5 mm replace the valve Valve stem end length Service Limit 2 5 mm VALVE SPRINGS Check the valve springs for proper strength by measuring their free length and also the force required to compress them...

Page 66: ...new one REASSEMBLY Reassemble the cylinder head in the reverse order of disassem bly Pay attention to the following points Install each valve spring seat 1 Apply molybdenum oil solution to the valve s...

Page 67: ...iner and the valve stem Be sure that the rounded lip 3 of the cotter fits snugly into the groove 4 in the stem end 09916 14510 Valve lifter 09916 14910 Valve lifter attachment 09916 84511 Tweezers INT...

Page 68: ...d power output Measure the cam height H using the micrometer Replace a camshaft if the cams are worn to the service limit Cam height H Service Limit IN 33 87 mm EX 33 50 mm 09900 20202 Micrometer 25 5...

Page 69: ...pecifica tion Camshaft journal holder I D Standard 22 012 22 025 mm 09900 22403 Small bore gauge Camshaft journal O D Standard 21 959 21 980 mm 09900 20205 Micrometer 0 25 mm CAMSHAFT RUNOUT Measure t...

Page 70: ...rod movement If the push rod is stuck or spring mechanism failed replace the cam chain tension adjuster assembly with a new one CAM CHAIN GUIDE Inspect the cam chain guide for damage If any damage ar...

Page 71: ...0 15 mm 09900 20803 Thickness gauge 09900 20205 Micrometer 0 25 mm Piston ring groove width Standard 1st and 2nd 1 01 1 03 mm Oil 2 01 2 03 mm Piston ring thickness Standard 1st and 2nd 0 970 0 990 mm...

Page 72: ...de rail Measure the outside diameter to identify the size PISTON PIN BORE Measure the piston pin bore inside diameter using the caliper gauge and measure the piston pin outside diameter using the micr...

Page 73: ...d inside diameter using the dial cal ipers If the conrod small end inside diameter exceeds the ser vice limit replace the conrod Conrod small end I D Service Limit 14 040 mm 09900 20605 Dial calipers...

Page 74: ...03 Thickness gauge If the clearance exceeds the service limit replace crankshaft assembly or bring the deflection and side clearance into specifi cation by replacing the worn parts e g conrod big end...

Page 75: ...ven gear which contacts the starter clutch for wear or damage If any wear or damage is found replace the defective part s STARTER DRIVEN GEAR BEARING Install the starter driven gear bearing 1 and gear...

Page 76: ...tch bolts and tighten them to the specified torque while holding the rotor holder 99000 32030 THREAD LOCK SUPER 1303 09930 44530 Rotor holder Starter clutch bolt 10 N m 1 0 kgf m GENERATOR STATOR AND...

Page 77: ...f the each gear Never reuse a snap ring After a snap ring has been removed from a shaft it should be dis carded and a new snap ring must be installed When installing a new snap ring do not expand the...

Page 78: ...be against the gear surface Press fitted 2nd drive gear onto the countershaft Before reas sembling coat the internal face of the 2nd drive gear with THREAD LOCK SUPER and install the gears so that the...

Page 79: ...ushes the gear axially If the clearance is too great the meshed gears may slip apart If the clearance exceeds the specification replace the fork its respective gear or both Gearshift fork to groove cl...

Page 80: ...t within the service limit replace the clutch plates as a set Clutch driven plate distortion Service Limit 0 10 mm 09900 20803 Thickness gauge CLUTCH SPRING FREE LENGTH Measure the free length of each...

Page 81: ...rings 4 5 are installed cor rectly Apply engine oil to the O rings 4 and 5 Install the oil filter cap OIL SUMP FILTER REMOVAL Remove the oil sump filter cap 1 Remove the oil sump filter 2 CLEANING AN...

Page 82: ...OVAL Remove the bearing retainers 1 and 2 Remove the oil seals 3 and 4 with the special tool 09913 50121 Oil seal remover Remove the washer 5 Remove the bearings 09921 20240 Bearing remover set for 67...

Page 83: ...ll the oil seal using the special tool 09913 70210 Bearing installer set Install the bearing retainer 2 NOTE Apply a small quantity of THREAD LOCK to the bearing retainer screws 99000 32050 THREAD LOC...

Page 84: ...e the dust seal 3 09913 70210 Bearing installer set INSTLLATION Install the dust seals and bearing with the special tool 09913 70210 Bearing installer set Apply a small quantity of SUZUKI SUPER GREASE...

Page 85: ...1 Remove the clutch release camshaft 2 REASSEMBLY AND INSTALLATION Apply a small quantity of SUZUKI SUPER GREASE to the lip of the oil seal 99000 25010 SUZUKI SUPER GREASE A Install the clutch releas...

Page 86: ...t installer 09910 20116 Conrod holder Apply engine oil to the crankshaft bearings TRANSMISSION Install the countershaft and driveshaft assemblies GEARSHIFT CAM AND GEARSHIFT FORKS Align the pin groove...

Page 87: ...both crankcase mating surfaces with a cleaning solvent Apply SUZUKI BOND uniformly to the mating surface of the right crankcase and assemble the cases within a few minutes 99104 31140 SUZUKI BOND 1207...

Page 88: ...SUZUKI SUPER GREASE to the oil seal lip 99000 25010 SUZUKI SUPER GREASE A Install the oil seal retainer 1 Install the clamp to the bolt A Apply SUZUKI SUPER GREASE to the O ring of the engine sprocket...

Page 89: ...D LOCK SUPER to the gen erator rotor nut 2 99000 32030 THREAD LOCK SUPER 1303 With the generator rotor locked using the special tool tighten the generator rotor nut to the specified torque with a torq...

Page 90: ...hile holding the generator rotor with the special tool tighten the primary drive gear oil pump drive gear nut 3 to the speci fied torque with a torque wrench 09930 44530 Rotor holder Primary drive gea...

Page 91: ...4 Install the gearshift shaft NOTE Align the center teeth on the gearshift shaft with the center teeth on the gearshift cam driven gear OIL PUMP Apply engine oil to the sliding surfaces of the oil pu...

Page 92: ...hen engaging the primary drive and driven gears turn the pri mary driven gear assembly to the counterclockwise Install the clutch sleeve hub 5 and lock washer 6 1Primary driven gear assembly 2Clutch s...

Page 93: ...ce 3 bearing 4 and washer 5 Install the clutch drive and driven plates one by one into the clutch sleeve hub Install the clutch pressure plate 6 clutch springs and clutch spring mounting bolts Hold th...

Page 94: ...l the starter motor NOTE Apply grease to the O ring 99000 25010 SUZUKI SUPER GREASE A GENERATOR COVER Install the starter idle gear 2 shaft and spacer Install the dowel pin and new gasket 3 Tighten th...

Page 95: ...he 2nd ring and 1st ring NOTE 1st ring and 2nd ring differ in shape The 1st and 2nd piston rings should be installed with their marks facing up Position the piston ring gaps as shown NOTE Before inser...

Page 96: ...conrod and also the sliding surface of the piston Install the dowel pins into the crankcase and then install the cylinder gasket 3 Make sure that the piston rings are properly positioned and insert th...

Page 97: ...que Cylinder base nut 1 10 N m 1 0 kgf m Cylinder head nut 2 10 N m 1 0 kgf m CAMSHAFT Turn the crankshaft counterclockwise and align the line A on the generator rotor with the mark B on the generator...

Page 98: ...just past top position NOTE Do not rotate the crankshaft while installing the camshaft or cam chain Install the lock washer 2 so that it is covering the locating pin NOTE Apply a small quantity of TH...

Page 99: ...urface of the cylinder head cover and install it within a few minutes 99000 31230 SUZUKI BOND 1216B NOTE When installing the cylinder head cover the piston must be at the top dead center on the compre...

Page 100: ...ded screw driver until the push rod locked Fit a new gasket to the cam chain tension adjuster body Install the cam chain tension adjuster body to the cylinder and tighten the bolts to the specified to...

Page 101: ...ce the PAIR control valve with a new one Connect the vacuum pump gauge to the vacuum port of the control valve as shown in the photograph Apply negative pressure slowly to the control valve and inspec...

Page 102: ...NO LOCATION 4 5 REMOVAL 4 5 DISASSEMBLY 4 6 CLEANING 4 9 INSPECTION 4 9 FLOAT HEIGHT ADJUSTMENT 4 10 FUEL LEVEL ADJUSTMENT 4 10 CARBURETOR HEATER INSPECTION 4 11 CARBURETOR THERMO SWITCH INSPECTION 4...

Page 103: ...the fuel hose 1 from the fuel valve Remove the fuel tank Remove the fuel valve INSPECTION FUEL VALVE If the fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss in engine po...

Page 104: ...ON SYSTEM 4 3 REMOUNTING Remount the fuel valve and tank in the reverse order of removal Gasoline is very explosive Extreme care must be taken The gaskets 2 and 3 must be replaced with new ones to pre...

Page 105: ...cap 2Spring 3Spring retainer 4Jet needle 5Diaphragm 6Piston valve 7Throttle stop screw 8Needle jet 9Needle jet holder 0Main jet APilot jet BFloat CNeedle valve DFloat pin EPilot screw FGasket GDrain...

Page 106: ...L See page 3 4 ITEM SPECIFICATION Carburetor type MIKUNI BS26 Bore size 26 mm I D No 13GA Idle r min 1 500 100 r min Float height 17 1 1 0 mm Main jet M J 115 Jet needle J N 4EJ44 2nd Needle jet N J P...

Page 107: ...e fuel hose 1 air vent hose 2 vacuum hose 3 and carburetor overflow hose 4 Remove the carburetor top cap 5 Remove the spring 6 diaphragm 7 and piston valve 8 Remove the spring seat 9 Remove the spring...

Page 108: ...bit with a drill stop to remove the pilot screw plug Set the drill stop 6 mm from the end of the bit to prevent drilling into the pilot screw Carefully drill through the plug Thread a self tapping she...

Page 109: ...ew is lightly seated Make a note of how many turns were made so the screw can be reset cor rectly after cleaning Remove the pilot screw 2 spring 3 washer 4 and O ring 5 NOTE Prior to disassembly mark...

Page 110: ...e dle the gasoline will continue flowing and cause it to overflow If the seat and needle are worn beyond the permissible limits sim ilar trouble will occur Conversely if the needle sticks the gaso lin...

Page 111: ...angle holding the body with a vice or the like Fill gasoline in the carburetor Remove air completely from the fuel level gauge With the level gauge held vertical lower the gauge slowly and align the d...

Page 112: ...is heated in 5 minutes after the battery has been connected Measure the resistance between the terminals 09900 25008 Multi circuit tester Carburetor heater resistance 12 18 CARBURETOR THERMO SWITCH I...

Page 113: ...number of turns counted during disassembly Install the new plug 1 by tapping into its place with a punch DIAGRAHM PISTON VALVE When installing the piston valve make sure the tab of the dia phragm is a...

Page 114: ...x 5 k Measure the resistance between the throttle position sensor terminals as shown in the illustration Fully open the throttle valve with the throttle lever Position the throttle position sensor unt...

Page 115: ...ALL CONROD SMALL END BY PASS PRIMARY DRIVEN GEAR SPACER COUNTERSHAFT AND GEARS COUNTERSHAFT LEFT SIDE BEARING OIL SUMP FILTER CAM FACES ROCKER ARM SHAFTS CONROD BIG END BEARING CLUTCH PLATES DRIVESHAF...

Page 116: ...CATION SYSTEM 4 15 OIL PRESSURE 2 23 OIL FILTER 2 10 OIL SUMP FILTER 3 45 NOTE When separating the crankcase wash the oil sump filter with cleaning solvent and then blow compressed air through it to d...

Page 117: ...MASTER CYLINDER REMOVAL AND DISASSEMBLY 5 15 MASTER CYLINDER INSPECTION 5 16 MASTER CYLINDER REASSEMBLY AND REMOUNTING 5 16 HANDLEBARS 5 18 REMOVAL 5 18 REMOUNTING 5 19 FRONT FORK 5 20 REMOVAL AND DIS...

Page 118: ...EMBLY AND REMOUNTING 5 44 REAR SHOCK ABSORBER DISPOSAL 5 45 SWINGARM 5 46 REMOVAL 5 46 INSPECTION AND REPLACEMENT 5 47 SWINGARM PIVOT SHAFT INSTALLATION 5 49 REMOUNTING 5 49 FINAL INSPECTION AND ADJUS...

Page 119: ...d right Remove the seat by taking off the fastener 1 LEFT FRAME COVER Remove the screw Remove the left frame cover Hooked part RIGHT FRAME COVER Remove the screw Remove the right frame cover Hooked pa...

Page 120: ...t axle 3 by using the special tool 09900 18710 Hexagon socket 12 mm 1Collar 2Bearing 3Front axle spacer 4Bearing 5Brake disc 6Speedometer gearbox 7Balancer weight AFront axle BBrake disc bolt CSpoke n...

Page 121: ...that the gear turns smoothly together with the speedometer pinion WHEEL 2 18 SPOKE NIPPLE 2 19 WHEEL BEARINGS Inspect the play of the wheel bearings by finger while they are in the wheel Rotate the in...

Page 122: ...0 mm TIRE 5 50 REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly Pay special attention to the following points WHEEL BEARINGS Apply SUZUKI SUPER GREASE...

Page 123: ...C Apply THREAD LOCK SUPER to the brake disc bolts Tighten the bolts to the specified torque 99000 32130 THREAD LOCK SUPER 1360 Brake disc bolt 23 N m 2 3 kgf m Clearance Keep the brake disc clean free...

Page 124: ...ghten the front axle to the specified torque Tighten the front axle pinch bolt 5 to the specified torque 09900 18710 Hexagon socket 12 mm Front axle 65 N m 6 5 kgf m Front axle pinch bolt 23 N m 2 3 k...

Page 125: ...any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for long periods When storing the brake fluid seal the container complete...

Page 126: ...r end of the hose into a receptacle Loosen the air bleeder valve and pump the brake lever until the old brake fluid is completely out of the brake system Close the air bleeder valve and disconnect a c...

Page 127: ...peration and then check the brake fluid level BRAKE CALIPER REMOVAL AND DISASSEMBLY Remove the brake hose union bolt 1 NOTE Place a rag underneath the union bolt on the brake caliper to catch any spil...

Page 128: ...e brake caliper holder 2 Remove the pad spring 3 Remove the rubber parts 4 Remove the dust seal 5 and piston seal 6 Do not use high pressure air to prevent piston dam age Do not reuse the removed dust...

Page 129: ...liper bore and piston with the specified brake fluid Thoroughly wash the dust seal groove and piston seal groove Specification and classification DOT 4 PISTON SEALS Install the piston seal 1 and dust...

Page 130: ...th brake fluid and bleed air 2 14 BRAKE DISC INSPECTION Check the brake disc for cracks or damage and measure the thickness using the micrometer If any damages are found or if the thickness is less th...

Page 131: ...mirror right 2 Disconnect the front brake light switch lead wire coupler 3 Remove the front brake master cylinder 4 Remove the brake switch 5 and brake lever 6 Remove the reservoir cap 7 and diaphragm...

Page 132: ...ke caliper in the reverse order of removal and disassembly Pay attention to the following points Specification and classification DOT 4 Wash the master cylinder components with new brake fluid before...

Page 133: ...g surface with the punched mark A on the handlebars and then tighten the upper clamp bolt first Master cylinder bolt 10 N m 1 0 kgf m Install the brake hose union as shown and tighten the union bolt t...

Page 134: ...er 6 HANDLEBAR RIGHT SIDE PARTS Remove the rear view mirror 1 Disconnect the front brake light switch coupler 2 Remove the front brake master cylinder 3 Remove the right handlebar balancer 4 Remove th...

Page 135: ...olts 1 to the half of speci fied torque and then tighten the handlebar clamp bolts 1 and 2 to the specified torque Handlebar clamp bolt 23 N m 2 3 kgf m Apply grease to the throttle cables and assembl...

Page 136: ...ve the front fender 1 1O ring 2Spacer 3Washer 4Front fork spring 5Damper rod 6Rebound spring 7Inner tube 8Oil lock piece 9Dust seal 0Oil seal stopper ring AOil seal BOuter tube AFront fork cap bolt BF...

Page 137: ...Hold the front fork by the hand to prevent sliding out of the steer ing stem Loosen and remove the front fork cap bolt 5 Remove the spacer 6 washer 7 and spring 8 Invert the front fork and stroke it s...

Page 138: ...4520 T handle 09940 34561 Attachment D Remove the damper rod 1 and rebound spring 2 Remove the dust seal 3 and the oil seal stopper ring 4 Pull the inner tube out of the outer tube Remove the oil lock...

Page 139: ...ube sliding sur face for any scuffing or damage FRONT FORK SPRING Measure the fork spring free length If the fork spring free length is shorter than the service limit replace the fork spring with a ne...

Page 140: ...inner tube into the outer tube take care not to come off the oil lock piece from the inner tube OIL SEAL Apply fork oil to the lip of the oil seal 1 and install it into the outer tube using the front...

Page 141: ...nner tube Fit the gasket 3 coat the damper rod bolt 4 with the thread lock and tighten the bolt to the specified torque Damper rod bolt 30 N m 3 0 kgf m 99000 32050 THREAD LOCK 1322 09940 34520 T hand...

Page 142: ...he fork spring and com press the inner tube fully Front fork oil level without spring 171 0 mm 09943 74111 Fork oil level gauge FORK SPRING The end of the fork spring with the smaller pitch A should b...

Page 143: ...lower clamp bolt 33 N m 3 3 kgf m Front fork cap bolt 23 N m 2 3 kgf m Install the front fender and tighten the mounting bolts tempo rarily Install the front brake caliper 5 14 Install the front whee...

Page 144: ...ose guide 1 Remove the headlight 1Steering stem upper bracket 2Dust seal 3Upper inner race 4Steering stem upper bearing 5Lower inner race 6Steering stem lower bearing ASteering stem head nut BFront fo...

Page 145: ...CHASSIS 5 29 Disconnect the headlight and position light couplers Remove the headlight housing 2 Remove the speedometer 3 Remove the front turn signal lights 4 5 Remove the handlebar switch harness...

Page 146: ...tem nut socket wrench NOTE Hold the steering stem bracket by hand to prevent it from falling Remove the dust seal 0 and upper bearing inner race A Remove the steering stem upper bearing B Protect the...

Page 147: ...ring race wear and brinelling Bearing wear or damage Abnormal bearing noise Distortion of steering stem or handlebars Remove the steering stem lower inner race use a chisel Drive out the steering stem...

Page 148: ...Press in the steering stem lower race using the special tool 09941 74911 Steering bearing installer Apply SUZUKI SUPER GREASE to the steering stem upper and lower bearings 99000 25010 SUZUKI SUPER GRE...

Page 149: ...adjustment will vary from motorcycle to motorcycle Before tightening the steering stem head nut temporarily install the front forks Tighten the steering stem head nut 1 to the specified torque Steerin...

Page 150: ...washer 5 and pin 3 Remove the rear axle nut 6 1Rear axle 2Rear sprocket 3Spacer 4Bearing Right 5Collar 6Rear wheel 7Bearing Left 8Brake cam lever 9Brake panel 0Brake cam ABrake shoe BReturn spring AR...

Page 151: ...from the rear sprocket Remove the rear wheel Remove the rear brake panel 9 Remove the rear sprocket 0 Remove the bearings by using the special tool 09921 20240 Bearing remover set or 09941 50111 Wheel...

Page 152: ...e order of removal and disassembly Pay attention to the following points WHEEL BEARINGS Apply SUZUKI SUPER GREASE to the bearings before installing 99000 25010 SUZUKI SUPER GREASE A Install the wheel...

Page 153: ...ce to the outside REAR WHEEL Align the brake panel stopper 1 on the swingarm with the recess on the brake panel Install the rear axle shaft Adjust the drive chain slack after installing the rear wheel...

Page 154: ...BLY Remove the rear wheel 5 34 Remove the rear brake panel 1 Remove the brake shoes 2 3 from the brake panel Remove the brake cam lever nut 4 Remove the brake cam lever 5 1Brake shoe 2Cam lever bolt 3...

Page 155: ...mm BRAKE SHOES Check the brake shoe wear and decide whether it should be replaced or not Replace two brake shoes together as a set BRAKE CAM Inspect the brake cam for abnormal wear Place the brake cam...

Page 156: ...torque Brake cam lever nut 7 N m 0 7 kgf m Install the rear wheel 5 37 REAR BRAKE PEDAL REMOVAL Remove the rear brake adjuster nut 1 pin 2 spring 3 and washer 4 Remove the rear brake light switch spr...

Page 157: ...pedal in the reverse order of removal Pay attention to the following points Apply grease to the brake pedal shaft 99000 25010 SUZUKI SUPER GREASE A After assembling check the brake for operating condi...

Page 158: ...rear wheel 5 34 Remove the rear shock absorber lower nut and bolt Remove the rear shock absorber upper bolt Remove the rear shock absorber 1Rear shock absorber ARear shock absorber bolt BRear shock ab...

Page 159: ...flaws or other damage If any dam ages are found replace the spacer with a new one Inspect the shock absorber body and bushing for damage and oil leakage If any defects are found replace the shock abs...

Page 160: ...ing care about its direction Install the rear shock absorber facing the stamp A forward Tighten the rear shock absorber upper mounting bolt and lower mounting nut to the specified torque Rear shock ab...

Page 161: ...ar shock absorber unit contains high pressure nitrogen gas Mishandling can cause explosion Keep away from fire and heat High gas pressure caused by heat can cause an explosion Release gas pressure bef...

Page 162: ...IS SWINGARM REMOVAL Remove the rear wheel 5 34 Remove the rear shock absorber lower mounting nut and bolt 1Pivot shaft 2Dust cover 3Washer 4Dust seal 5Bushing 6Collar ASwingarm pivot nut ITEM N m kgf...

Page 163: ...Remove the swingarm assembly Remove the dust seal covers 1 and collars 2 Remove the chain buffer 3 Remove the dust seals 4 INSPECTION AND REPLACEMENT SWINGARM Inspect the swingarm for damage If any d...

Page 164: ...09900 21304 V block SWINGARM PIVOT BUSHING Insert the collars into the swingarm bushings move the collar up and down and check for any play If there is excessive play replace the bushings with new one...

Page 165: ...and suspension in the reverse order of removal Pay attention to the following points Tighten the swingarm pivot nut to the specified torque Swingarm pivot nut 65 N m 6 5 kgf m Install the rear shock...

Page 166: ...osition Even though the tire is refitted to the original position after repairing puncture the tire may have to be balanced again since such a repair can cause imbalance INSPECTION WHEEL Wipe the whee...

Page 167: ...ut on the tire at the time of removal with the valve position For installation procedure of tire onto the wheel follow the instructions given by the tire changer manufacturer Be careful not to catch t...

Page 168: ...tely and unseat the bead for both sides Coat the bead with lubricant and fit the tire again When the bead has been fitted properly adjust the pressure to specification As necessary adjust the tire bal...

Page 169: ...11 TROUBLE SHOOTING 6 12 STARTER MOTOR REMOVAL AND DISASSEMBLY 6 13 STARTER MOTOR INSPECTION 6 13 STARTER MOTOR REASSEMBLY 6 14 STARTER RELAY INSPECTION 6 15 SIDE STAND IGNITION INTERLOCK SYSTEM PARTS...

Page 170: ...for corrosion and contamination CLAMP Clamp the wire harness at such positions as indicated in WIRE ROUTING 7 11 Bend the clamp properly so that the wire harness is clamped securely In clamping the wi...

Page 171: ...sconnect the battery lead wire first When connecting the battery lead wires be sure to connect the battery lead wire first If the terminal is corroded remove the battery pour warm water over it and cl...

Page 172: ...6 4 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Battery Regulator rectifier Side stand switch Neutral switch Generator Pick up coil Throttle position sensor...

Page 173: ...ELECTRICAL SYSTEM 6 5 Starter relay Fuse Turn signal side stand relay Ignitor Ignition coil Starter motor Rear brake light switch...

Page 174: ...6 6 ELECTRICAL SYSTEM CHARGING SYSTEM Generator Regulator rectifier SCR IG switch Battery Load SCR SCR SCR SCR Fuse IC...

Page 175: ...enerator coil 6 9 No continuity Faulty generator coil or disconnected lead wires Continuity Check the battery for current leaks 6 8 Check accessories which use excessive amounts of electricity Measure...

Page 176: ...ach part REGULATED VOLTAGE Remove the seat 5 3 Start the engine and keep it running at 5 000 r min with dim mer switch turned HI position Measure the DC voltage between the and battery termi nals usin...

Page 177: ...nce 0 4 0 8 Black Black Black Ground NOTE When making above test it is not necessary to remove the gen erator GENERATOR NO LOAD PERFORMANCE Remove the seat 5 3 Remove the fuel tank 4 2 Disconnect the...

Page 178: ...ied value replace the regulator rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode test More than 1 4 V tester s battery voltage Above are approximate values fo...

Page 179: ...ERLOCK SYSTEM OFF RUN PUSH FREE ON OFF LOCK PUSH FREE B L OFF ON Battery IG switch Engine stop switch Clutch lever position switch Neutral switch Side stand switch Starter motor Starter relay 1 Fuse 2...

Page 180: ...nectors between Y G and Y B when the starter button is pushed No voltage Faulty ignition switch Faulty engine stop switch Faulty clutch lever position switch Faulty neutral switch Faulty turn signal s...

Page 181: ...the brush holder If any damages are found replace the brush assembly with a new one COMMUTATOR Inspect the commutator for discoloration abnormal wear or undercut A If abnormal wear is found replace t...

Page 182: ...ation Continuity test OIL SEAL INSPECTION Check the oil seal lip for damage or leakage If any damage is found replace the housing end STARTER MOTOR REASSEMBLY Reassemble the starter motor in the rever...

Page 183: ...12 V to A and B terminals and check for continuity between the positive and negative terminals using the multi cir cuit tester If the starter relay clicks and continuity is found the relay is OK 09900...

Page 184: ...ion Diode test NOTE If the tester reads under 1 4 V when the tester probes are not connected replace its battery NEUTRAL SWITCH INSPECTION Remove the seat 5 3 Remove the fuel tank 4 2 Disconnect the n...

Page 185: ...to C and check the continuity between D and E If there is no continuity replace the turn signal side stand relay with a new one 09900 25008 Multi circuit tester set Tester knob indication Continuity...

Page 186: ...uts off the ignition primary current for the spark plug Under no load the engine can run over 10 000 r min though the ignition cut off circuit is effec tive which may possibly cause engine damage Do n...

Page 187: ...nal side stand relay Faulty engine stop switch Correct Broken wire harness or poor connection of related circuit couplers Measure the ignition coil primary peak voltage 6 20 Inspect the spark plug 2 7...

Page 188: ...ster set Shift the transmission into the neutral and then turn the igni tion switch to the ON position Squeeze the clutch lever Press the starter button and allow the engine to crank for a few seconds...

Page 189: ...al Secondary 18 26 k Plug cap terminal PICK UP COIL PEAK VOLTAGE Remove the right frame cover 5 3 Disconnect the wire harness coupler 1 at the ignitor NOTE Make sure that all of the couplers are conne...

Page 190: ...robe Green lead wire Measure the pick up coil peak voltage at the pick up coil lead wire coupler in the same manner as on the ignitor coupler Tester knob indication Voltage Pick up coil peak voltage M...

Page 191: ...ELECTRICAL SYSTEM 6 23 SPEEDOMETER Disassemble the speedometer as follows...

Page 192: ...LAMPS HEADLIGHT BRAKE LIGHT TAILLIGHT 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 overtighten...

Page 193: ...CTRICAL SYSTEM 6 25 TURN SIGNAL LIGHT HEADLIGHT BEAM ADJUSTMENT Adjust the headlight beam both vertical and horizontal A Vertical adjuster B Horizontal adjuster Do not overtighten the lens fitting scr...

Page 194: ...e 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 turn signal...

Page 195: ...l tank 4 2 Disconnect the ignition switch coupler Remove the ignition switch mounting bolts using the special tools 09930 11920 Torx bit JT40H 09930 11940 Bit holder 1 99000 32110 THREAD LOCK SUPER 13...

Page 196: ...ON OFF LOCK P Color Position O B O W OFF RUN Color Position IGNITION SWITCH HAZARD DIMMER SWITCH HORN BUTTON FRONT BRAKE SWITCH REAR BRAKE SWITCH CLUTCH LEVER POSITION SWITCH ENGINE STOP SWICH STARTE...

Page 197: ...y filler holes Do not remove or pierce the sealed areas 3 of the electrolyte container Insert the nozzles of the electrolyte container into the battery s electrolyte filler holes holding the container...

Page 198: ...at the top of the caps do not protrude above the upper surface of the battery s top cover For initial charging use the charger specially designed for MF battery Never use anything except the specified...

Page 199: ...5 to 10 hours or 3 A for one hour After recharging wait for more than 30 minutes and check the battery voltage with a multi circuit tester If the battery voltage is less than the 12 5 V recharge the...

Page 200: ...HOSE ROUTING 7 14 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 7 15 SPEEDOMETER CABLE ROUTING 7 16 SIDE STAND INSTALLATION 7 16 FUEL TANK INSTALLATION 7 17 REAR BRAKE PEDAL INSTALLTAION 7 17 DRIVE CHAIN GUIDE...

Page 201: ...ive generator 8 Defective ignitor unit 9 Defective pick up coil No fuel reaching the carburetor 1 Clogged fuel tank vent hose 2 Clogged or defective fuel valve 3 Defective carburetor needle valve 4 Cl...

Page 202: ...ubbing primary gear 5 Worn bearing Adjust Replace Replace Replace Replace Replace Clean Replace Replace Replace cam chain and sprockets Replace cam chain and sprockets Repair or replace Replace counte...

Page 203: ...ogged fuel hose resulting in inadequate fuel supply to carburetor Replace Replace Regap or replace Adjust Replace CDI unit Replace Replace Replace Adjust float height Clean or replace Clean and prime...

Page 204: ...Clean Tighten adjust or replace gas ket Tighten or replace defective part Adjust Idling or low speed trouble 1 Clogged or loose pilot jet 2 Clogged or loose pilot air jet 3 Air leaking from carbureto...

Page 205: ...just Front suspension too stiff 1 Excessively viscous fork oil 2 Excessive fork oil 3 Improper suspension setting Replace Check level and drain Adjust Front suspension too noisy 1 Insufficient fork oi...

Page 206: ...surface with sandpaper Readjust brake pad position or replace Replace Replace Change brake fluid Disassemble and clean master cylinder Tighten Brake squeaks REAR 1 Damaged wheel bearing 2 Brake shoe...

Page 207: ...or loose lead con nections 2 Short circuited grounded or open generator coils 3 Short circuited or panctured regulator rectifiers Repair or replace or retighten Replace Replace Generator does charge b...

Page 208: ...t of overcharging 3 Internal short circuit in the battery 4 Too low battery voltage 5 Too old battery Check the generator regulator rectifier and circuit connections and make necessary adjust ments to...

Page 209: ...Bl G Bl Bl B Bl B Y B W B W Gr Gr B W B W Lg B Lg B O G O G Lg Lg B B W B W Y O B W B W Lg B Lg B O Lg Lg B B W B W Y Bl Bl Bl Bl O B B B W B W O Bl O Bl O R O R O B O B O W O W B R B R B Bl B Bl Y G...

Page 210: ...lamp Clamp Clamp Cut the clamp end after clamping Front turn signal Guide Wiring harness Clamp Ignition switch Throttle cable Wiring harness Throttle cable Wiring harness Clamp Clamp Cut the clamp end...

Page 211: ...7 12 SERVICING INFORMATION ENGINE ELECTRICAL PARTS WIRE ROUTING Apply BOND to the groove of the grommet Generator lead wire Neutral switch lead wire Engine ground wire 90...

Page 212: ...ke hose Pass through the throttle cable under the harness Cable clamp Wiring harness B A Clutch cable 0 For installing the throttle cable install it so that the screw part should be located at the low...

Page 213: ...P VIEW OF FRONT Front brake hose Clamp the brake hose firmly Clamp the brake hose firmly 23 N m 2 3 kgf m 23 N m 2 3 kgf m Throttle cable Pass through the brake hose behind the throttle cable After th...

Page 214: ...TION 7 15 PAIR AIR SUPPLY SYSTEM HOSE ROUTING PAIR valve PAIR valve PAIR pipe PAIR hose Vacuum hose Matching mark PAIR cleaner hose PAIR valve PAIR valve PAIR pipe PAIR hose Vacuum hose Matching mark...

Page 215: ...7 16 SERVICING INFORMATION SPEEDOMETER CABLE ROUTING SIDE STAND INSTALLATION Speedometer cable Stopper Fork Protrusion Gearbox Cable guide Cable guide 45 A A 40 N m 4 0 kgf m Side stand...

Page 216: ...N m 0 45 kgf m Align the cushion concave part with the frame locating plate Install so that the clamp claw faces downward Install so that the clamp claw faces inward Cut the clamp end so the remaining...

Page 217: ...7 18 SERVICING INFORMATION DRIVE CHAIN GUIDE ROLLER INSTALLATION HANDLEBAR BALANCER INSTALLATION 36 44 N m 3 6 4 4 kgf m Frame Throttle grip Balancer weight 4 0 7 0 N m 0 4 0 7 kgf m...

Page 218: ...SERVICING INFORMATION 7 19 EXHAUST PIPE AND MUFFLER INSTALLATION 23 N m 2 3 kgf m 20 N m 2 0 kgf m 23 N m 2 3 kgf m 6 N m 0 6 kgf m Gasket Cushion Cushion...

Page 219: ...ER INSTALLATION LH LH RH RH Intake pipe side Air cleaner side 40 50 PAIR hose Carburetor overflow hose Crankcase breather hose PCV hose Forward Carburetor air vent hose Vacuum hose PAIR pipe Carbureto...

Page 220: ...meter 50 75 mm 09900 20205 Micrometer 0 25 mm 09900 20508 Cylinder gauge set 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 20803 Thicknes...

Page 221: ...0 Valve lifter 09916 14910 Attachment 09916 20620 Valve seat cutter N 122 09916 21111 Valve seat cutter set 09916 24920 Valve seat cutter N 212 09916 24480 Solid pilot N 140 5 5 09916 34542 Reamer han...

Page 222: ...Torx bit JT40H 09930 11940 Bit holder 09930 30102 Sliding shaft 09930 34932 Rotor remover 09930 44530 Rator holder 09940 14911 Steering stem nut socket wrench 09940 34520 T handle 09940 34561 Attachm...

Page 223: ...er connecting bolt 20 2 0 Cam chain tension adjuster bolt 7 0 7 Camshaft sprocket bolt 11 1 1 Rocker arm shaft bolt 9 0 9 Clutch sleeve hub nut 50 5 0 Clutch spring set bolt 5 0 5 Clutch cover bolt 10...

Page 224: ...em head nut 90 9 0 Steering stem nut 45 4 5 Handlebar clamp bolt 23 2 3 Front brake master cylinder mounting bolt 10 1 0 Front brake caliper mounting bolt 39 3 9 Front brake hose union bolt 23 2 3 Air...

Page 225: ...r 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 226: ...ength IN EX 2 5 Valve seat width IN EX 0 9 1 1 Valve head radial runout IN EX 0 03 Valve spring free length INNER 36 8 IN EX OUTER 40 1 Valve spring tension IN EX INNER 76 90 N 7 8 9 2 kgf at length 3...

Page 227: ...ove clearance 1st 0 18 2nd 0 15 Piston ring groove width 1st 1 01 1 03 2nd 1 01 1 03 Oil 2 01 2 03 Piston ring thickness 1st 0 970 0 990 2nd 0 970 0 990 Piston pin bore 14 002 14 008 14 030 Piston pin...

Page 228: ...ckness No 1 4 8 4 9 No 2 5 3 5 4 Countershaft length Low to 2nd Drive chain Type DID 428 Links 132 20 pitch length 259 0 Drive chain slack 15 25 Gearshift lever height 20 between footrest top and gear...

Page 229: ...rimary peak voltage More than 200 V B Ground Pick up coil resistance 172 288 G Bl G Ground Generator no load voltage when engine is cold More than 60 V AC at 5 000 r min Regulated voltage 14 0 15 5 V...

Page 230: ...ont 30 150 30 200 Brake fluid type DOT 4 Wheel rim runout Axial 2 0 Radial 2 0 Wheel axle runout Front 0 25 Rear 0 25 Wheel rim size Front 18 M C MT 2 50 Rear 14 M C MT 4 50 Tire size Front 130 80 18...

Page 231: ...el type Gasoline used should be graded 91 octane or higher An unleaded gasoline type is recom mended Fuel tank including reserve 7 5 L reserve 1 8 L Engine oil type SAE 10W 40 API SF or SG Engine oil...

Page 232: ...8 RV125K4 K5 04 05 MODELS 8 1 RV125K4 K5 04 05 MODELS CONTENTS SPECIFICATIONS 8 2 SERVICE DATA 8 3 WIRE ROUTING 8 9 REAR FENDER INSTALLATION 8 10...

Page 233: ...ront suspension Telescopic coil spring oil damped Rear suspension Swingarm type coil spring oil damped Front suspension stroke 110 mm 4 3 in Rear wheel travel 136 mm 5 4 in Caster 26 Trail 91 mm 3 6 i...

Page 234: ...ength IN EX 2 5 Valve seat width IN EX 0 9 1 1 Valve head radial runout IN EX 0 03 Valve spring free length INNER 36 8 IN EX OUTER 40 1 Valve spring tension IN EX INNER 76 90 N 7 8 9 2 kgf at length 3...

Page 235: ...oove clearance 1st 0 18 2nd 0 15 Piston ring groove width 1st 1 01 1 03 2nd 1 01 1 03 Oil 2 01 2 03 Piston ring thickness 1st 0 970 0 990 2nd 0 970 0 990 Piston pin bore 14 002 14 008 14 030 Piston pi...

Page 236: ...ickness No 1 4 8 4 9 No 2 5 3 5 4 Countershaft length Low to 2nd Drive chain Type DID 428 Links 132 20 pitch length 259 0 Drive chain slack 15 25 Gearshift lever height 20 between footrest top and gea...

Page 237: ...primary peak voltage More than 200 V B Ground Pick up coil resistance 172 288 G Bl G Ground Generator no load voltage when engine is cold More than 60 V AC at 5 000 r min Regulated voltage 14 0 15 5 V...

Page 238: ...ont 30 150 30 200 Brake fluid type DOT 4 Wheel rim runout Axial 2 0 Radial 2 0 Wheel axle runout Front 0 25 Rear 0 25 Wheel rim size Front 18 M C MT 2 50 Rear 14 M C MT 4 50 Tire size Front 130 80 18...

Page 239: ...uel type Gasoline used should be graded 91 octane or higher An unleaded gasoline type is recom mended Fuel tank including reserve 7 5 L reserve 1 8 L Engine oil type SAE 10W 40 API SF or SG Engine oil...

Page 240: ...amp Clamp Cut the clamp end after clamping Front turn signal Guide Wiring harness Clamp Ignition switch Throttle cable Wiring harness Throttle cable Wiring harness Clamp Clamp Cut the clamp end after...

Page 241: ...8 10 RV125K4 K5 04 05 MODELS REAR FENDER INSTALLATION 6 5 N m 0 65 kgf m...

Page 242: ...edurers which dif fer from those of the RV125K4 K5 04 05 MODEL NOTE Any differences between the RV125K4 K5 04 05 MODEL and RV125K6 06 MODEL in specifications are cleary indicated with an asterisk mark...

Page 243: ...suspension Telescopic coil spring oil damped Rear suspension Swingarm type coil spring oil damped Front suspension stroke 110 mm 4 3 in Rear wheel travel 136 mm 5 4 in Caster 26 Trail 91 mm 3 6 in St...

Page 244: ...IN EX 1 7 Valve seat width IN EX 0 9 1 1 Valve head radial runout IN EX 0 03 Valve spring free length INNER 31 3 IN EX OUTER 33 6 Valve spring tension IN EX INNER 38 1 43 9 N 3 9 4 4 kgf at length 26...

Page 245: ...1st 0 18 2nd 0 15 Piston ring groove width 1st 1 01 1 03 2nd 1 01 1 03 Oil 2 01 2 03 Piston ring thickness 1st 0 970 0 990 2nd 0 970 0 990 Piston pin bore 14 002 14 008 14 030 Piston pin O D 13 992 1...

Page 246: ...ickness No 1 4 8 4 9 No 2 5 3 5 4 Countershaft length Low to 2nd Drive chain Type DID 428 Links 134 20 pitch length 259 0 Drive chain slack 15 25 Gearshift lever height 20 between footrest top and gea...

Page 247: ...ary peak voltage More than 200 V B Ground Pick up coil resistance 172 288 G Bl G Ground Generator no load voltage when engine is cold More than 60 V AC at 5 000 r min Regulated voltage 14 0 15 5 V at...

Page 248: ...30 150 30 200 Brake fluid type DOT 4 Wheel rim runout Axial 2 0 Radial 2 0 Wheel axle runout Front 0 25 Rear 0 25 Wheel rim size Front 18 M C MT 2 50 Rear 14 M C MT 4 50 Tire size Front 130 80 18 M C...

Page 249: ...used should be graded 91 octane or higher An unleaded gasoline type is recom mended Fuel tank capacity including reserve 7 5 L reserve 1 8 L Engine oil type SAE 10W 40 API SF SG or SH SJ with JASO MA...

Page 250: ...Prepared by 2nd Ed January 2006 1st Ed January 2003 Part No 99500 31233 01E Printed in Japan 256...

Page 251: ...Printed in Japan K3 K4 K5 K6...

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