Suzuki UY125 Service Manual Download Page 152 | Manualshive

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5-28 CHASSIS

MASTER CYLINDER REMOVAL AND DISAS-
SEMBLY

• Remove the front and rear handlebar covers. (

"

5-5)

• Place a rag underneath the brake hose union bolt

1

on the

master cylinder to catch any spilt brake fluid. (

"

5-25)

%

• Disconnect the front brake light switch lead wires

2

.

• Remove the front brake master cylinder

3

.

• Remove the brake lever

4

and brake switch

5

.

• Remove the reservoir cap

6

, diaphragm plate

7

and dia-

phragm

8

.

Immediately wipe off any brake fluid contacting any
part of the motorcycle. The brake fluid reacts chemi-
cally with paint, plastics, rubber materials, etc., and
will damage them severely.

http://mototh.com

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Summary of Contents for UY125

Page 1: ...KI MOTOR CO LTD 2005 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 con tent of this manual and the actual motorcycle Illustrations in this manual are used to show the basic principles of operation and work procedures They may not represent the actual motorcycle exactly...

Page 2: ... 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 tightening torque lubricating points and locking agent points are provided Example Front wheel 1 Spacer 2 Dust seal 3 Bearing 4 Front wheel spacer 5 Front wheel 6 Bearing 7 Front brake shoe 8 Dust seal 9 Speedometer drive gear 0 Front brake camshaft A Front brake ...

Page 3: ...0 99044 10G Apply molybdenum oil solution Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 1 Apply or use brake fluid Apply SUZUKI SUPER GREASE A 99000 25010 Measure in voltage range Apply SUZUKI SILICONE GREASE 99000 25100 Measure in current range Apply SUZUKI MOLY PASTE 99000 25140 Measure in resistance range Apply SUZUKI BOND 1215 99000 31110 Measure in diode test range Apply SUZUKI ...

Page 4: ...White Page http mototh com ...

Page 5: ...EL AND OIL RECOMMENDATION 1 5 FUEL 1 5 ENGINE OIL 1 5 REDUCTION GEAR OIL 1 5 BRAKE FLUID UY125S 1 5 FRONT FORK OIL 1 5 BREAK IN PROCEDURES 1 5 SPECIFICATIONS 1 6 COUNTRY AND AREA CODES The following codes stand for the applicable country ies and area s CODE COUNTRY or AREA EFFECTIVE FRAME NO P 14 UY125 P 14 UY125S Thailand Thailand CF48A TH CF48B TH http mototh com ...

Page 6: ...ood 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 Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the motorcycle When 2 or more persons work together pay attention to the safety of each ot...

Page 7: ...nd nuts tighten the larger sizes first Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci fied tightening torque Whenever you remove oil seals gaskets packing O rings locking washers self locking nuts cotter pins circlips and certain other parts as specified be sure to replace them with new ones Also before installing these new parts be sure to remove any ...

Page 8: ... I N Vehicle Identification Number 1 is stamped on the left side of the steer ing head pipe The engine serial number 2 is located on the left side of the crankcase These numbers are required especially for registering the machine and ordering spare parts LEFT SIDE UY125 RIGHT SIDE UY125S http mototh com ...

Page 9: ...gh standard but 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 exercised during its early life Refer to the following throttle position recommendations Keep to these break in throttle positions Initial 800 km Less than 1 2 throttle Up to 1 600 km Less...

Page 10: ...ick Lubrication system Wet sump Idle speed 1 600 100 rpm TRANSMISSION Clutch Dry shoe automatic centrifugal type Reduction ratio Variable change 2 700 0 825 Final reduction ratio 9 264 49 17 45 14 Drive system V belt drive CHASSIS Front suspension Telescopic coil spring oil damped Rear suspension Swingarm type coil spring oil damped Front fork stroke 85 mm Rear wheel travel 80 mm Steering angle 45...

Page 11: ...use 10 A Headlight 12 V 30 30 W Turn signal light 12 V 10 W Brake light Taillight 12 V 18 5 W Speedometer light 12 V 3 4 W High beam indicator light 12 V 1 7 W Turn signal indicator light 12 V 1 7 W CAPACITIES Fuel tank 3 7 L Engine oil oil change 950 ml with filter change 1 050 ml overhaul 1 100 ml Reduction gear oil oil change 100 ml overhaul 110 ml These specifications are subject to change wit...

Page 12: ...White Page http mototh com ...

Page 13: ...E 2 8 ENGINE OIL AND OIL FILTER 2 8 ENGINE IDLE SPEED 2 10 THROTTLE CABLE PLAY 2 10 DRIVE BELT 2 11 REDUCTION GEAR BOX OIL 2 11 BRAKE 2 12 BRAKE HOSE AND BRAKE FLUID UY125S 2 13 TIRE AND WHEELS 2 15 STEERING 2 17 FRONT FORK 2 17 REAR SUSPENSION 2 17 CHASSIS BOLTS AND NUTS 2 18 COMPRESSION PRESSURE CHECK 2 20 COMPRESSION TEST PROCEDURE 2 20 OIL PRESSURE CHECK 2 21 OIL PRESSURE TEST PROCEDURE 2 21 A...

Page 14: ...st 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 bolt and muffler bolt T T Cooling fan filter Clean every 3 000 km Valve clearance I I I Spark plug I R Fuel line I I Replace every four years Engine oil R R R Engine oil filter R R Idle rpm I I I Throttle cable play I I I Drive belt I...

Page 15: ...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 operated under wet or rainy conditions Rear brake lever holder Speedometer cable Center stand pivot and spring hook Speedometer gearbox Side stand pivot and spring hook Footrest pivot Throttle cable Front brake le...

Page 16: ...ment 3 Inspect the air cleaner element for clogging If the air cleaner element is clogged with dust replace the air cleaner element with a new one NOTE If driving under dusty conditions replace the air cleaner element more frequently Make sure that the air cleaner is in good condi tion at all times The life of the engine depends largely on this component Install a new air cleaner element in the re...

Page 17: ...s 2 COOLING FAN FILTER Remove the cooling fan cover 1 Remove the holder 2 and cooling fan filter 3 Clean the fan filter in the same manner of the air cleaner ele ment Reinstall the cleaned or new filter in the reverse order of removal Tighten initially at 1 000 km 5 months and every 8 000 km 40 months thereafter Clean every 3 000 km Do not apply engine oil to the filter after cleaning it http moto...

Page 18: ...he valve clearance or to adjust 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 to bring the TDC mark A on the cooling fan to the index mark B on the crankcase Insert a thickness gauge between the valve stem end and the adjusting screw on the rocker ...

Page 19: ...nd SPARK PLUG GAP Measure the plug gap with a thickness gauge if it 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 to see the worn or burnt condition of the electrodes If it is extremely worn or burnt replace the plug And also replace the plug if it has a broken insulator damaged thread etc Inspect at 4 00...

Page 20: ...rough the oil filler hole When performing an oil change without oil filter replacement the engine will hold about 950 ml of oil Use an engine oil that meets API service classifications SF or SG and that has a viscosity rating of SAE 10W 40 Engine oil drain plug 1 18 N m 1 8 kgf m Make sure that the engine is cooled Place the motorcycle on level ground and hold it vertically Install the oil filler ...

Page 21: ...l filter cap bolt 10 N m 1 0 kgf m NOTE Before installing the new oil filter and oil filter cap make sure that the spring 3 and new O rings 4 5 are installed cor rectly The arrow mark A on the oil filter cap should be positioned down Fit the clamp to the bolt B Add new engine oil and check the oil level as described in the engine oil replacement procedure Oil viscosity and classification 10W 40 SA...

Page 22: ...ottle cable Turn the adjuster 2 in or out until the throttle cable play A should be 2 0 4 0 mm at the throttle grip Tighten the lock nut 1 while holding the adjuster 2 Throttle cable play A 2 0 4 0 mm NOTE Major adjustment can be made by the carburetor side adjuster Inspect initially at 1 000 km 5 months and every 4 000 km 20 months thereafter Inspect initially at 1 000 km 5 months and every 4 000...

Page 23: ...N GEAR BOX OIL Keep the motorcycle upright Place an oil pan below the gear case and drain oil by remov ing the oil drain plug 1 and filler cap 2 Tighten the drain plug 1 and pour fresh oil through the oil filler Oil viscosity and classification SAE 10W 40 with SF or SG NECESSARY AMOUNT OF REDUCTION GEAR OIL Oil change 100 ml Overhaul 110 ml Inspect every 4 000 km 20 months thereafter If grease or ...

Page 24: ...rcycle is equipped with the brake lining wear limit indi cator on the brake To check wear of the brake lining perform the following steps First check if the brake system is properly adjusted While operating the brake check to see that the tip of indica tor 1 is within the range 2 on the brake panel If the tip of indicator 1 is beyond the range the brake shoe assembly should be replaced with a new ...

Page 25: ...pecification Specification and classification DOT 4 Inspect every 4 000 km 20 months Replace hoses every 4 years Replace fluid every 2 years The brake system of this motorcycle is filled with a glycol based brake fluid Do not use or mix different types of fluid such as silicone based and petro leum based fluids Do not use any brake fluid taken from old used or unsealed containers Never re use brak...

Page 26: ...r bleeder valve 7 5 N m 0 75 kgf m AIR BLEEDING FOR THE FRONT BRAKE FLUID CIRCUIT Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylin der and thus interferes with the full braking performance of the brake caliper The presence of air is indicated by sponginess of the brake lever and also by lack of braking force Considering...

Page 27: ...le bleeding the brake system Make sure that there is always some fluid visible in the reservoir Close the bleeder valve and disconnect the clear hose Air bleeder valve 7 5 N m 0 75 kgf m Fill the reservoir with brake fluid to the UPPER line TIRE AND WHEELS TIRE TREAD CONDITION Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous si...

Page 28: ... bearings and can be corrected by replacing the bearings If bearing replacement fails to reduce the runout replace the wheel Wheel runout Service Limit axial and radial 2 0 mm SPOKE NIPPLES Make sure that the nipples are tight If necessary tighten them with a spoke nipple wrench Spoke nipple 4 5 N m 0 45 kgf m 09940 60113 Spoke nipple wrench COLD INFLATION TIRE PRESSURE kPa kgf cm2 FRONT 175 1 75 ...

Page 29: ... the lower fork tubes near the axle and pull forward If play is found readjust the steering 5 46 FRONT FORK Inspect the front forks for oil leakage scoring or scratches on the outer surface of the inner tubes Replace any defective parts if necessary 5 34 REAR SUSPENSION Inspect the rear shock absorber for oil leakage and mounting rubbers including engine mounting for wear and damage Replace any de...

Page 30: ...ing stem lock nut 90 9 0 3 Front fork clamp bolt 28 2 8 4 Front fork cap bolt 33 3 3 5 Front axle nut 42 4 2 6 Engine mounting nut 85 8 5 7 Rear axle nut 120 12 0 8 Front brake caliper mounting bolt UY125S 25 2 5 9 Front brake hose union bolt UY125S 23 2 3 0 Front brake disc bolt UY125S 23 2 3 A Air breeder valve UY125S 7 5 0 75 B Front brake master cylinder bolt UY125S 10 1 0 C Rear shock absorbe...

Page 31: ...PERIODIC MAINTENANCE 2 19 http mototh com ...

Page 32: ...below specification 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 specified torque values and the valves are properly adjusted Warm up the engine before testing Make sure that the battery is fully charged Remove the related parts and test the compression pres...

Page 33: ...cosity 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 gauge and adaptor into the main oil gallery Warm up the engine as follows Summer 10 minutes at 2 000 rpm Winter 20 minutes at 2 000 rpm After warming up the engine increase the engine speed to 3 0...

Page 34: ...emperature Remove the front frame cover 5 8 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 motorcycle begins to move forward 09900 26006 Tachometer Engagement rpm 2 900 3 500 rpm 2 CLUTCH LOCK UP INSPECTION Perform this inspection to determine if the clutch is engaging...

Page 35: ...T 3 36 OIL PUMP 3 37 MOVABLE DRIVE FACE 3 37 CLUTCH SHOE MOVABLE DRIVEN FACE 3 39 DRIVE BELT 3 44 DRIVE BELT FILTER 3 44 STARTER CLUTCH 3 45 MAGNETO COVER 3 46 KICK STARTER 3 47 REDUCTION GEAR 3 49 BEARING INSPECTION 3 51 RIGHT CRANKCASE 3 51 ENGINE MOUNTING BUSHING 3 51 LEFT CRANKCASE 3 52 ENGINE MOUNTING BUSHINGS 3 54 CRANKSHAFT SHIM SELECTION 3 55 ENGINE REASSEMBLY 3 56 PAIR AIR SUPPLY SYSTEM 3...

Page 36: ...inder head 3 12 3 67 Cylinder 3 12 3 67 Piston 3 13 3 66 Intake pipe 3 11 3 71 Crankcase tube grommet 3 10 3 72 ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION Fixed drive face 3 17 3 61 Movable drive face assembly 3 17 3 60 Clutch housing 3 17 3 60 Clutch shoe movable driven face assembly 3 17 3 60 Drive belt 3 17 3 60 Reduction gear cover 3 18 3 59 Oil sump filter 3 19 3 57 Drive shaft 3 49 3 59 Air...

Page 37: ... REMOVAL INSTALLATION Muffler 3 5 3 9 Fan cowling cover 3 11 3 71 Cooling fan 3 13 3 65 Starter idle gear 3 15 3 63 Magneto cover 3 14 3 63 Magnetorotor 3 15 3 62 Oil pump 3 16 3 61 Cylinder cowling right cover 3 11 3 71 http mototh com ...

Page 38: ...owing steps Reinstall the engine by reversing the removal procedure Remove the front frame cover 5 8 Remove the luggage box 5 9 Remove the frame covers left and right 5 10 Disconnect the battery lead wire Remove the fuel tank 4 2 Drain engine oil 2 8 Disconnect the starter motor lead wire Remove the carburetor 1 4 8 Disconnect the head cover breather hose 2 and PAIR hose 3 http mototh com ...

Page 39: ...emove the air cleaner box Disconnect the magneto lead wire coupler 4 and pick up coil lead wire coupler 5 Remove the engine ground bolt Disconnect the spark plug cap 6 Remove the exhaust pipe bolts http mototh com ...

Page 40: ...and then remove the muf fler 7 Remove the rear brake cable clamp bracket 8 Remove the rear brake cable adjuster nut 9 spring 0 and pin A Remove the rear brake cable clamp Remove the clutch upper cover B Remove the crankcase tube C http mototh com ...

Page 41: ...the engine using a jack Remove the rear shock absorber lower mounting bolt Remove the engine mounting bolt and nut NOTE Never remove the crankcase bracket D from the frame Remove the engine from the frame http mototh com ...

Page 42: ...0 2 kgf m Install the engine and tighten the engine mounting nut 3 to the specified torque Engine mounting nut 85 N m 8 5 kgf m NOTE When tightening the engine mounting nut make sure that the front wheel is elevated Tighten the rear shock absorber lower mounting nut 4 to the specified torque Rear shock absorber mounting bolt 29 N m 2 9 kgf m NOTE Place 65 kg on the seat after installing the engine...

Page 43: ... routing sec tions 7 12 to 19 Refer to the following sections to adjust the respective items to specification ENGINE OIL 2 8 REDUCTION GEAR OIL 2 11 THROTTLE CABLE PLAY 2 10 ENGINE IDLE SPEED 2 10 REAR BRAKE CABLE ADJUSTMENT 2 12 Check for leakage of the engine oil and reduction gear oil Replace the gasket with new one http mototh com ...

Page 44: ...ver assembly 1 CRANKCASE TUBE GROMMET Remove the crankcase tube grommet No 1 1 and No 2 2 STARTER MOTOR Remove the starter motor 1 Identify the position of each removed part Organize the parts in their respective groups so that they can be reinstalled in their original positions http mototh com ...

Page 45: ... valve 3 FAN COWLING COVER CYLINDER COWLING INTAKE PIPE Remove the fan cowling cover 1 and cylinder cowling right cover 2 Remove the intake pipe 3 and cylinder cowling left cover 4 SPARK PLUG Remove the spark plug CYLINDER HEAD COVER Remove the cylinder head cover 1 and gasket http mototh com ...

Page 46: ...m assembly 1 and camshaft sprocket 2 CYLINDER HEAD Remove the cylinder head side nuts 1 and cylinder head nuts 2 Remove the cylinder head NOTE When loosening the cylinder head nuts loosen each nut little by little diagonally If the cylinder head does not come off lightly tap on the finless portion of it with a plastic hammer CYLINDER Remove the dowel pins 1 gasket 2 and cam chain guide 3 Remove th...

Page 47: ...riving out the piston pin NOTE Place a clean rag over the cylinder base so as not to drop the piston pin circlip into the crankcase COOLING FAN Remove the cooling fan 1 Remove the cooling fan holder nut with the special tool 09930 40113 Rotor holder Remove the washer 2 and cooling fan holder 3 http mototh com ...

Page 48: ...EL REAR BRAKE Remove the rear wheel Remove the brake shoes CENTER STAND Remove the center stand spring 1 Remove the cotter pin 2 washer 3 shaft 4 and center stand 5 MAGNETO COVER Remove the magneto cover 1 http mototh com ...

Page 49: ...ove the starter idle gear 1 and shaft 2 MAGNETOROTOR Hold the fixed drive face with the special tool 09930 40113 Rotor holder Remove the magnetorotor nut Remove the magnetorotor 1 with the special tool 09930 34980 Rotor remover Remove the starter clutch 2 http mototh com ...

Page 50: ...n the oil pump sprocket and align the oil pump sprocket hole on the oil pump mounting screw 2 Remove the oil pump screw 2 Remove the oil pump assembly 3 along with the chain 4 NOTE The oil pump assembly is a non disassemblable type Remove the cam chain 5 http mototh com ...

Page 51: ... kick starter 2 and fixed drive face 3 MOVABLE DRIVEN FACE CLUTCH HOUSING Remove the clutch housing nut with the special tool 09930 40113 Rotor holder Remove the clutch hosing 1 Remove the clutch shoe movable driven face assembly 2 along with the drive belt 3 Remove the movable drive face assembly 4 and spacer 5 http mototh com ...

Page 52: ...ction gear oil 2 11 Remove the reduction gear cover 1 Remove the gasket 2 and dowel pins 3 Remove the washer 4 idle driven gear 5 and rear axle shaft 6 OIL FILTER Remove the oil filter cap 1 Remove the oil filter 2 and O ring 3 http mototh com ...

Page 53: ...e bolts Separator the crankcase into 2 parts right and left with the crankcase separating tool 09920 13120 Crankcase separating tool NOTE Fit the crankcase separating tool so that the tool arms are in parallel with the side of crankcase The crankshaft component should remain in the left crankcase half CRANKSHAFT Remove the crankshaft with the special tool 09920 13120 Crankcase separating tool http...

Page 54: ...ather cover 3 oil separator 4 and gasket 5 INSPECTION REED VALVE Inspect the reed valve for the carbon deposit If the carbon deposit is found in the reed valve replace the PAIR reed valve with a new one OIL SEPARATOR Check the oil separator for any damage or clogs If they are clogged clean the oil separator with a compressed air or replace http mototh com ...

Page 55: ...t 10 N m 1 0 kgf m Apply THREAD LOCK to the PAIR reed valve cover bolts and tighten them 99000 32050 THREAD LOCK 1342 CYLINDER HEAD DISASSEMBLY Remove the cam chain tensioner 1 Remove the camshaft retainer 2 Replace the removed breather gasket with a new one Identify the position of each removed part Organize the parts in their respective groups i e intake or exhaust so that they can be installed ...

Page 56: ...rms 4 Remove the camshaft 5 Compress the valve spring with the valve spring compressor Remove the valve cotters from the valve stem 09916 14510 Valve spring compressor 09916 14521 Attachment 09916 84511 Tweezers Remove the valve spring retainer 6 and valve spring 7 Remove the valve 8 from the combustion chamber side http mototh com ...

Page 57: ...aft contacting surface should be checked Rocker arm I D IN EX Standard 10 003 10 018 mm 09900 20605 Dial calipers CYLINDER HEAD DISTORTION Decarbon the combustion chamber Check the gasketed surfaced of the cylinder head for distortion with a straightedge and thickness gauge taking a clearance reading at several places as indicated If the largest reading at any position of the straightedge exceeds ...

Page 58: ...l gauge 1 100 mm 09900 21304 V block 100 mm VALVE HEAD RADIAL 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 0 03 mm 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block 100 mm VALVE STEM DEFLECTION Lift the valve about 10 ...

Page 59: ...970 mm 09900 20205 Micrometer 0 25 mm VALVE GUIDE SERVICE Remove the valve guide with the valve guide remover 09916 44310 Valve guide remover Re finish the valve guide holes in cylinder head with the han dle and reamer 09916 34542 Handle 09916 34580 Valve guide reamer 10 8 mm Fit a ring to each valve guide Lubricate each valve guide with oil and drive the guide into the guide hole with the special...

Page 60: ...at with Prussian Blue and set the valve in place Rotate the valve with light pressure Check that the transferred blue on the valve face is uniform all around and in center of the valve face If the seat width W measured exceeds the standard value or seat width is not uniform reface the seat using the seat cutter Valve seat width W Standard IN 0 90 1 10 mm EX 0 92 1 12 mm Service Limit Reface if mea...

Page 61: ...utter N 121 09916 20620 Valve seat cutter N 122 09916 20630 Valve seat cutter N 126 09916 24311 Solid pilot N 100 5 0 NOTE Use the solid pilot N 100 5 0 along with the valve seat cutter N 121 122 and 126 When installing the solid pilot 2 rotate it slightly INTAKE SIDE EXHAUST SIDE 45 N 122 N 122 15 N 121 30 N 126 For intake The valve seat contact area must be inspected after each cut For exhaust 1...

Page 62: ...or burned use the 45 cutter to con dition the seat some more NOTE Cut only the minimum amount necessary from the seat to pre vent the possibility of the valve stem becoming too close to the rocker arm for correct valve contact angle TOP NARROWING CUT If the contact area W is too high on the valve or if it is too wide use the 15 for exhaust side and the 30 for the intake side to lower and narrow th...

Page 63: ...haust 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 sealing VALVE STEM END CONDITION Inspect the valve stem end face for pitting and wear If pitting or wear is present resurface the valve stem end Make sure that the length A is not less than 2 2 mm If this length becomes less than 2 2 mm replace...

Page 64: ...e replace both the inner and outer springs as a set Valve spring free length IN EX Service Limit 32 9 mm 09900 20102 Vernier calipers Valve spring tension IN EX Standard 118 N 12 0 kgf 26 8mm CAMSHAFT CAM WEAR Check for abnormal surface damage or wear on the cam face Measure the cam height H with a micrometer Replace the camshaft if found worn down to the service limit Cam height H Service Limit I...

Page 65: ...earing installer 49 mm 09913 70210 Bearing installer 32 mm CAM CHAIN TENSIONER Inspect the cam chain tensioner for damage If any damage are found replace the cam chain tensioner with a new one REASSEMBLY Insert the valves with their stems coated with molybdenum oil solution all around and along the full stem length without any break Similarly oil the lip of the stem seal MOLYBDNUM OIL SOLUTION The...

Page 66: ...ease the lifter to allow the cotter 1 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 lifter 09916 14521 Valve lifter attachment 09916 84511 Tweezers NOTE Just before installing the camshaft into the cylinder head apply molybdenum oil solution to the cam faces MOLYBDNUM OIL SOLUTION Apply engine oil ...

Page 67: ...ge exceeds 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 damage Measure the cylinder bore diameter at six places Cylinder bore Service Limit 53 610 mm 09900 20530 Cylinder bore gauge set CAM CHAIN TENSION ADJUSTER Make sure the push rod movement If the push rod is stuck o...

Page 68: ...he piston or both Piston to cylinder clearance Service Limit 0 120 mm PISTON RING TO GROOVE CLEARANCE Measure the side clearances of the 1st and 2nd piston rings using the thickness gauge If any of the clearances exceeds the limit replace both the piston and piston rings Piston ring to groove clearance Service Limit 1st 0 180 mm 2nd 0 150 mm Piston ring groove width Standard 1st 1 01 1 03 mm 2nd 1...

Page 69: ...it 1st 0 50 mm 2nd 0 50 mm 09900 20803 Thickness gauge PISTON PIN AND PIN BORE Measure the piston pin bore diameter using the small bore gauge If the measurement is out of specification replace the piston Piston pin bore I D Service Limit 14 038 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 micrometer ...

Page 70: ...09900 20607 Dial gauge 1 100 mm 09900 21304 V block Push the big end of the conrod to one side and measure the side clearance using a thickness gauge Conrod big end side clearance Service Limit 1 0 mm 09900 20803 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 conro...

Page 71: ...here is anything unusual replace the oil pump REASSEMBLY Reassemble the oil pump driven gear in the reverse order of disassembly When installing a new circlip pay attention to the direction of the circlip Fit it to the side where the thrust is as shown in the illustration MOVABLE DRIVE FACE SPACER INSPECTION Remove the spacer Check the spacer for any damage or wear If any defects are found replace...

Page 72: ... rollers 3 ROLLER INSPECTION Check that there is no abnormal wear or damage on the roller If any defects are found replace the rollers as a set REASSEMBLY Reassemble the movable drive face in the reverse order of disassembly Pay attention to the following points Mount the three dampers 1 on the movable drive plate 2 and install it onto the movable drive face NOTE Make sure the movable drive plate ...

Page 73: ... spring compressor Loosen the special tool handle slowly and remove the clutch shoe assembly 1 Nut 2 Clutch shoe assembly 3 Spring Remove the movable driven face seat 4 with a thin blade screwdriver Do not remove the clutch shoe nut at this time Since a high spring force applies to the clutch shoe assembly care must be used so as not to cause the clutch shoe assembly and movable driven face to com...

Page 74: ...ring remover set Remove the snap ring Remove the bearing with the special tool 09913 70210 Bearing remover Remove the oil seals 8 and O rings 9 The removed bearing should be replaced with a new one The removed bearing should be replaced with a new one The removed oil seals and O rings should be replaced with new ones http mototh com ...

Page 75: ...e clutch housing with inside calipers Measure the diameter at several points to check for out of round and wear If any damages are found or if the inside diameter exceeds the service limit replace the clutch housing with a new one Clutch housing l D Service Limit 125 5 mm DRIVEN FACE SPRING INSPECTION Measure the free length of the driven face spring If the length is shorter than the service limit...

Page 76: ...in the fixed driven face 1 with the spe cial tool 09943 88211 Bearing installer Apply SUZUKI SUPER GREASE A to the bearing 2 99000 25010 SUZUKI SUPER GREASE A Securely install the snap ring Install the bearing with the special tool 09924 84510 Bearing installer NOTE Face the stamped side of the bearing out Apply SUZUKI SUPER GREASE A between the sliding sur face of the fixed driven face and movabl...

Page 77: ... face spring guide 5 Slowly turn the special tool handle to tighten and align the flats A at the movable driven face end with clutch shoe plate hole B 09922 31430 Clutch spring compressor Check that the special tool dogs are engaged with the clutch shoe plate holes and screw the clutch shoe nut 6 Tighten the clutch shoe nut to the specified torque with the special tool 09930 40113 Rotor holder 099...

Page 78: ...t is less than the service limit replace the drive belt with a new one Drive belt width Service Limit 18 9 mm 09900 20101 Vernier calipers DRIVE BELT FILTER DISASSEMBLY Remove the cooling belt cover 1 and duct 2 Remove the plate 3 and filter 4 INSPECTION Check the drive belt filter for clogging If they are clogged clean or replace Always keep the drive belt away from grease oil etc http mototh com...

Page 79: ... direction of arrow as shown and check that rotation is smooth Also check that the gear is locked when attempted to turn in the other direction If a large resistance is felt or noise occurs when turning the gear check the starter driven gear sliding surface for wear or damage If any abnormal condition is found replace the starter clutch with a new one DISASSEMBLY Remove the starter clutch gear Wit...

Page 80: ...rder of disas sembly Pay attention to the following points Apply THREAD LOCK on the starter clutch bolts and tighten them to the specified torque Starter clutch bolt 10 N m 1 0 kgf m 99000 32110 THREAD LOCK SUPER 1322 09930 34980 Rotor holder MAGNETO COVER DISASSEMBLY Remove the startor coil 1 and pick up coil 2 Remove the oil seal with the special tool 09913 50121 Oil seal remover Replace the rem...

Page 81: ...010 SUZUKI SUPER GREASE A When replacing the stator coil 2 or pick up coil 3 apply THREAD LOCK to the stator coil set bolts and pick up coil set screws and tighten them to the specified torque Stator coil bolt 6 N m 0 6 kgf m 99000 32110 THREAD LOCK SUPER 1322 KICK STARTER DISASSEMBLY Remove the clutch cover air intake plate 1 Remove the oil seal 2 snap ring 3 and washer 4 Install the oil seal 1 w...

Page 82: ...one Remove the kick starter shaft bearing with the special tool 09921 20240 Bearing remover set 10 mm REASSEMBLY Reassemble the kick starter in the reverse order of disassem bly Pay attention to the following points Apply SUZUKI SUPER GREASE A onto the inside of the kick starter shaft spacer 99000 25010 SUZUKI SUPER GREASE A Apply a light coat of SUZUKI SUPER GREASE A onto the end of the kick star...

Page 83: ... 25010 SUZUKI SUPER GREASE A Install the kick starter shaft new oil seal with the special tool 09925 98221 Bearing installer REDUCTION GEAR DISASSEMBLY Remove the driveshaft 1 Remove the driveshaft oil seal with the special tool 09913 50121 Oil seal remover INSPECTION Drive gear idle gear and driveshaft damage or wear Improper tooth contact Shaft spline damage Replace the removed oil seal with a n...

Page 84: ... Remove the bearing with the special tool 09921 20240 Bearing remover set 1 12 mm 2 20 mm 09923 73210 Bearing remover 3 17 mm 09930 30104 Sliding shaft REASSEMBLY Reassemble the reduction gear in the reverse order of disas sembly Pay attention to the following points Install the bearing with the special tool 09913 70210 Bearing installer set 1 40 mm 2 35 mm 3 47 mm Install the driveshaft oil seal ...

Page 85: ...ove the crankshaft right bearing with the special tool 09913 70210 Bearing installer set 42 mm BEARING INSTALL Install the bearing with the special tool 09913 70210 Bearing installer set 62 mm ENGINE MOUNTING BUSHING Inspect each engine mounting bushing 1 for damage If any damage is found replace the engine mounting bushing with a new one Press out the engine mounting bushings in a vise using two ...

Page 86: ... rear axle shaft bearing with the special tool 09921 20240 Bearing remover set 20 mm Remove the rear axle shaft oil seal with the special tool 09913 50121 Oil seal remover Remove the idle shaft bearing 2 and driveshaft bearing 3 with the special tool 09921 20240 Bearing remover set 2 15 mm 3 12 mm Replace the removed bearing with a new one Replace the removed oil seal with a new one Replace the re...

Page 87: ...nstall the driveshaft bearing 1 and idle shaft 2 bearing with the special tool 09913 70210 Bearing installer set 32 mm Install the rear axle shaft oil seal with the special tool 09913 70210 Bearing installer set 40 mm Install the rear axle shaft bearing with the special tool 09913 70210 Bearing installer set 42 mm Replace the removed oil seal with a new one Replace the removed bearing with a new o...

Page 88: ...ler set 52 mm Install the crankshaft oil seal with the special tool 09913 70210 Bearing installer set 42 mm Install the bearing retainer NOTE When installing the bearing retainers apply THREAD LOCK to the screws 99000 32110 THREAD LOCK SUPER 1322 ENGINE MOUNTING BUSHINGS 3 51 http mototh com ...

Page 89: ...lect the proper size of shim The shim size is printed on the shim surface After selecting the proper size of shim place it on the right crankshaft LIST OF SHIMS Part number Shim thickness Thrust clearance 09181 35101 0 50 0 02 mm 0 50 0 55 mm 09181 35025 0 55 0 02 mm 0 55 0 60 mm 09181 35103 0 60 0 02 mm 0 60 0 65 mm 09181 35026 0 65 0 02 mm 0 65 0 70 mm 09181 35104 0 70 0 02 mm 0 70 0 75 mm 09181...

Page 90: ...09910 20116 Conrod holder 09911 11310 Attachment CRANKCASE Clean and degrease the crankcase mating surfaces both sur faces with a cleaning solvent Fit the dowel pins 1 into the left crankcase Install the shim 2 3 55 Make sure to coat the rotating and sliding sections with engine oil Care must be taken so that the drive belt drive face and driven face are completely free from oil and grease Never f...

Page 91: ... crankshaft rotates smoothly If the crankshaft does not rotate smoothly try to free it by tap ping it with a plastic hammer OIL SUMP FILTER Clean the oil sump filter using compressed air Fit a new gasket 1 Install the oil sump filter 2 Coat the sealant evenly without break Application of sealant must be performed within a short period of time Take extreme care not to let sealant enter into the oil...

Page 92: ...ER Fit the O ring 1 Position the oil filter 2 Fit the O ring 3 and spring 4 Install the oil filter cap 5 The lip A of the oil sump filter should be positioned downward The thinner side B of the oil sump filter should be positioned inside Make sure to replace the O ring with a new one Position the oil filter so that the valve A comes out side http mototh com ...

Page 93: ...haft 2 Install the idle driven gear 3 and washer 4 Install the dowel pins 5 and new gasket 6 Install the reduction gear cover 7 Tighten the reduction gear cover bolts to the specified torque Reduction gear cover bolt 10 N m 1 0 kgf m Apply engine oil to each gear and shaft http mototh com ...

Page 94: ... housing 6 and lock the clutch housing 6 with the special tool and tighten the clutch housing nut to the specified torque 09930 40113 Rotor holder Clutch housing nut 50 N m 5 0 kgf m The assembly work should be carefully performed so as not to allow the roller to dislocate Position the drive belt so that the arrow points the engine rotating direction Degrease the drive belt contact surface pulley ...

Page 95: ...holder Turn the fixed drive face A by hand until the drive belt is properly seated and both the drive and driven faces rotate together smoothly and without slipping CAM CHAIN Install the cam chain 1 OIL PUMP Install the cam chain 1 with the oil pump gear Check that the fixed drive face is not fouled with grease or other substance and if found clean and degrease completely Check that the parts are ...

Page 96: ... 8 kgf m Install the oil pump cover 2 Tighten the oil pump cover bolts to the specified torque Oil pump cover bolt 10 N m 1 0 kgf m MAGNETOROTOR Install the key 1 NOTE Remove any grease from the tapered portion of the magnetoro tor and crankshaft Install the magnetorotor 2 together with the starter clutch gear 3 With the fixed drive face locked tighten the magnetorotor nut to the specified torque ...

Page 97: ...olt A as shown Magneto cover nut 10 N m 1 0 kgf m CENTER STAND Install the center stand Apply SUZUKI SUPER GREASE A to the center stand spring and shaft 7 26 99000 25010 SUZUKI SUPER GREASE A BRAKE CAM Apply SUZUKI SUPER GREASE A to the brake cam and then install the brake cam into the crankcase 99000 25010 SUZUKI SUPER GREASE A Apply engine oil to each gear and shaft Make sure to replace the gask...

Page 98: ...stall the return spring and brake cam lever onto the brake cam and tighten the brake cam lever nut to the specified torque Brake cam lever nut 11 N m 1 1 kgf m REAR WHEEL Install the brake shoes and rear wheel Install the washer and nut Tighten the rear axle nut to the specified torque Rear axle nut 120 N m 12 0 kgf m COOLING FAN Install the cooling fan holder 1 NOTE When installing the cooling fa...

Page 99: ...groove D of the cooling fan holder Tighten the cooling fan bolt to the specified torque Cooling fan bolt 10 N m 1 0 kgf m POSTON RING Install the spacer 1 into the oil ring groove first Then install both side rails 2 one on each side 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 d...

Page 100: ...inserting piston into the cylinder check that the gaps are so located PISTON Rub a small quantity of molybdenum oil solution onto the pis ton pin Place a clean rag over the cylinder base to prevent the piston pin circlips from dropping into the crankcase Install the piston with the arrow mark A facing towards the exhaust side MOLYBDNUM OIL SOLUTION When installing the spacer be careful not to allo...

Page 101: ... the piston into the cylinder NOTE When mounting the cylinder keep the camshaft drive chain taut Install the cam chain guide 2 CYLINDER HEAD Install the dowel pins and a new gasket 3 Replace the circlip with a new one Place a piece of rag under the piston when installing the circlip to prevent it from falling into the crank case The circlip end gap must be positioned so as not to coincide with the...

Page 102: ...ckwise with a box wrench and align the TOP mark A on the cooling fan with the index mark B on the magneto cover keeping the camshaft drive chain pulled upward Engage the chain on the cam sprocket with the locating pin C at just top position Align the engraved line mark D on the cam sprocket so it is parallel with the surface of the cylinder head If crankshaft is turned without drawing the camshaft...

Page 103: ... slit and hole of cam sprocket 8 Turn the decompression cam 9 clockwise and install the decomp cam stopper 0 Tighten the camshaft sprocket bolts to the specified torque Camshaft sprocket bolt 11 N m 1 1 kgf m CAM CHAIN TENSION ADJUSTER Apply engine oil to the push rod Turn the adjusting screw clockwise with a flat bladed screw driver to lock http mototh com ...

Page 104: ...shaft some turns and recheck the positions of the cam shafts CYLINDER HEAD COVER Fit a new gasket 1 to the cylinder head cover Apply sealant to cam end cap 99104 31140 SUZUKI BOND 1207B Place the cylinder head cover on the cylinder head Fit a new gasket 2 to each head cover bolt 3 Tighten the head cover bolts to the specified torque Head cover bolt Intial 10 N m 1 0 kgf m Final 14 N m 1 4 kgf m In...

Page 105: ... mounting bolt 10 N m 1 0 kgf m FAN COWLING COVER Install the fan cylinder cowling right cover 1 and fan cowling cover 2 PAIR CONTROL VALVE Install the PAIR control valve 1 7 18 STARTER MOTOR Fit the O ring 1 to the starter motor Apply a small amount of grease to the O ring 1 99000 25010 SUZUKI SUPER GREASE A Use a new O ring 1 to prevent sucking air from the joint http mototh com ...

Page 106: ...o 1 1 and No 2 2 NOTE The boss A of the crankcase tube grommet faces front side CLUTCH COVER Install the dowel pins and new gasket 1 Install the clutch cover and its bolts to the specified torque Clutch cover bolt 10 N m 1 0 kgf m KICK STARTER LEVER Install the kick starter lever and bolt to the specified torque Kick starter lever bolt 26 N m 2 6 kgf m Use a new gasket to the prevent oil leakage h...

Page 107: ...valve 3 11 Inspect that air flows through the PAIR control valve air inlet port to the air outlet port If air does not flow out replace 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 inspect the air flow If air does not flow out the control valve and is in...

Page 108: ...White Page http mototh com ...

Page 109: ... 4 5 INSPECTION 4 6 CARBURETOR 4 7 CONSTRUCTION 4 7 SPECIFICATIONS 4 8 I D LOCATION 4 8 REMOVAL 4 8 DISASSEMBLY 4 9 CARBURETOR CLEANING 4 12 CARBURETOR JET INSPECTION 4 12 NEEDLE VALVE INSPECTION 4 13 FLOAT HEIGHT ADJUSTMENT 4 13 REASSEMBLY AND REMOUNTING 4 13 LUBRICATION SYSTEM 4 15 OIL FILTER 4 15 OIL SUMP FILTER 4 15 ENGINE LUBRICATION SYSTEM CHART 4 16 http mototh com ...

Page 110: ...rame front cover 5 8 Remove the luggage box 5 9 Remove the E ring 1 and pin 2 Disconnect the fuel hose 3 and vacuum hose 4 Remove the retainer 5 Disconnect the fuel level gauge coupler 6 Gasoline is highly flammable and explosive Keep heat spark and flame away http mototh com ...

Page 111: ... 7 Remove the fuel tap 8 INSPECTION FUEL FILTER If the filter is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel fil ter with compressed air Also check the fuel filter for cracks http mototh com ...

Page 112: ... not flow out replace the fuel tap with a new one Specified vacuum Approx 4 kPa 09917 47010 Vacuum pump gauge REMOUNTING Remount the fuel tank and fuel valve in the reverse order of removal Use a hand operated vacuum pump Do not apply high negative pressure to prevent the fuel tap damage Replace the removed gasket 1 and seal washers 2 with new ones to prevent leakage of fuel http mototh com ...

Page 113: ...AND LUBRICATION SYSTEM 4 5 FUEL LEVEL GAUGE REMOVAL Open the seat 5 8 Remove the retainer 1 Disconnect the fuel level gauge coupler 2 Remove the rubber cushion 3 Remove the fuel level gauge 4 http mototh com ...

Page 114: ...t is at the position listed below 09900 25008 Multi circuit tester If the resistance measured is out of the specification replace the gauge assembly with a new one Float position Resistance between terminals Full 4 10 Ω 1 2 Approx 38 Ω Empty 90 100 Ω 73 1 3 5 mm 27 1 3 5 mm 50 3 mm http mototh com ...

Page 115: ...ONSTRUCTION 1 Top cap 6 Starter body A Needle valve 2 Spring 7 Pilot screw B Float 3 Holder 8 Air vent hose C Pilot jet 4 Jet needle 9 Needle jet holder D Float chamber 5 Piston valve assembly 0 Main jet E Throttle stop screw I L http mototh com ...

Page 116: ...e the air cleaner box backward Loosen the clamp screws ITEM SPECIFICATION I D LOCATION The carburetor has I D Number A stamped on the carburetor body Carburetor type MIKUNI BS26 Bore size 26 mm I D No 46G0 Idle rpm 1 600 100 rpm Float height XX X X X mm Main jet M J 95 Jet needle J N 4CJ11 2 Needle jet N J E 3M Throttle valve Th V 105 Pilot jet P J 15 Pilot screw P S 2 1 4 turns back Throttle cabl...

Page 117: ...e carburetor DISASSEMBLY Disconnect the fuel hose 1 air vent hose 2 fuel drain hose 3 and vacuum hose 4 Remove the throttle stop screw 5 Remove the carburetor top cap 6 Do not blow the carburetor body with compressed air before removing the diaphragm It may cause a dam age to the diaphragm http mototh com ...

Page 118: ...er 9 by turning it counterclockwise with a screwdriver Remove the following parts 0 Holder A Spring B Washers C Jet needle Remove the float chamber body D Remove the float assembly E and needle valve F by remov ing the pin G Do not use a wire for cleaning the valve seat http mototh com ...

Page 119: ...er O and O ring P NOTE Before removing the pilot screw M determine the setting by slowly turning it clockwise and count the number of turns required to lightly seat the screw This counted number is impor tant when reassembling pilot screw to original position Remove the throttle stop screw Q washer R and spring S Do not use a wire for cleaning of passage and jets http mototh com ...

Page 120: ...t Needle jet air bleeding hole Main jet Diaphragm Main air jet Pilot outlet and by pass ports Pilot air jet Float Needle valve Starter passage Needle jet Pilot screw Needle jet holder Some carburetor cleaning chemicals especially dip type soaking solutions are very corrosive and must be handled carefully Always follow the chemical man ufacturer s instructions on proper use handling and storage Do ...

Page 121: ...seat Clean the fuel passage of the mixing chamber with compressed air FLOAT HEIGHT ADJUSTMENT To check the 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 venier calipers Bend the tongue 1 as necessary to bring the height A to this value Float height A XX X X X mm 09900 20102 Vernier caliper...

Page 122: ...he starter body 3 4 11 Install the gasket 4 to the float chamber body 5 4 10 Reassemble the clip 6 ring 7 and washers 8 4 10 Fit the jet needle assembly and spring to the piston valve Install the holder 9 by turning it clockwise with a screwdriver Replace the removed O ring with a new one Replace the removed gasket with a new one Replace the removed gasket with a new one http mototh com ...

Page 123: ... body properly Align the lug on the carburetor with the intake pipe cutout A Adjust the following items to the specification Idling adjustment 2 10 Throttle cable play 2 10 LUBRICATION SYSTEM OIL PRESSURE 2 21 OIL FILTER 2 9 OIL SUMP FILTER 3 57 OIL PUMP 3 37 http mototh com ...

Page 124: ...STEM CHART PISTON AND PISTON PIN CYLINDER WALL CONROD SMALL END ORIFICE CRANK BEARING L BY PASS CYLINDER HEAD CYLINDER MAIN GALLERY OIL FILTER OIL PUMP OIL SUMP FILTER CAMSHAFT ROCKER ARM ROCKER ARM SHAFT CAM CHAIN CRANK PIN CONROD BIG END http mototh com ...

Page 125: ...ASSEMBLY 5 26 CALIPER INSTALLATION 5 27 BRAKE DISC INSPECTION 5 27 MASTER CYLINDER REMOVAL AND DISASSEMBLY 5 28 MASTER CYLINDER INSPECTION 5 29 MASTER CYLINDER REASSEMBLY AND INSTALLATION 5 29 FRONT FORK 5 32 REMOVAL AND DISASSEMBLY 5 32 INSPECTION 5 34 REASSEMBLY AND INSTALLATION 5 35 HANDLEBARS 5 38 REMOVAL 5 38 INSTALLATION 5 39 STEERING 5 42 REMOVAL AND DISASSEMBLY 5 42 INSPECTION 5 44 REASSEM...

Page 126: ...INSTALLATION Let the center piece stick out toward the head so that the pawls 2 close Insert the fastener into the installation hole NOTE To prevent the pawl 2 from damage insert the fastener all the way into the installation hole Push in the head of center piece until it becomes flush with the fastener outside face http mototh com ...

Page 127: ...iew mirrors 1 Remove the front handlebar cover 2 Disconnect the headlight coupler 3 Disconnect the speedometer cable 4 and remove the rear handlebar cover 5 Disconnect the speedometer coupler 6 and right and left handlebar switch couplers 7 http mototh com ...

Page 128: ...ve the front leg shield mounting screws Hooked part Disconnect the front turn signal couplers 1 Remove the front leg shield 2 FRONT LEG LOWER SHIELD Remove the front leg shield Abobe Remove the front leg lower shield 1 http mototh com ...

Page 129: ...LD COVER Remove the frame front cover 5 8 Remove the luggage box 5 9 Remove the pillion rider handle 5 9 Remove the frame cover assembly 5 10 Remove the leg shield hook 1 Remove the ignition switch holder 2 Remove the leg shield cover mounting screws http mototh com ...

Page 130: ...using the ignition key Remove the frame front cover 2 LEG REAR SHIELD Remove the frame front cover 5 8 Remove the luggage box 5 9 Remove the pillion rider handle 5 9 Remove the frame cover assembly 5 10 Remove the leg rear shield 1 http mototh com ...

Page 131: ...5 7 LUGGAGE BOX Open the seat 5 8 Remove the luggage box mounting screws Remove the fuse box 1 from luggage box 2 Remove the luggage box 2 PILLION RIDER HANDLE Remove the pillion rider handle 1 http mototh com ...

Page 132: ...5 8 CHASSIS FRAME COVER R L Remove the frame front cover 5 8 Remove the luggage box 5 9 Remove the pillion rider handle 5 9 Remove the frame cover assembly mounting screws Hooked part http mototh com ...

Page 133: ...le 1 Disconnect the rear combination light coupler 2 Remove the frame cover assembly Remove the right frame cover 3 and left frame cover 4 Pull the ignition key stopper plate 5 Remove the ignition key 6 from left frame cover 4 http mototh com ...

Page 134: ... axle and front wheel with front brake 1 Collar 2 Dust seal 3 Bearing 4 Front wheel spacer 5 Front wheel 6 Bearing 7 Front brake shoe 8 Dust seal 9 Speedometer drive gear 0 Front brake camshaft A Front brake panel B Speedometer driven gear C Front brake cam lever D Front axle A Front axle nut B Spoke nipple C Front brake cam lever bolt ITEM N m kgf m A 42 4 2 B 4 5 0 45 C 8 0 8 http mototh com ...

Page 135: ... 11 Remove the front brake panel 1 Remove the brake shoes Remove the dust seal with the special tool 09913 50121 Oil seal remover Remove the speedometer drive gear 2 Remove the brake cam lever 3 http mototh com ...

Page 136: ...e the spacer 1 Inspect the dust seal 2 for damage If any defects are found replace the dust seal with a new one WHEEL BEARING Inspect the play of wheel bearings by hand while they are in the wheel Rotate the inner race by hand to inspect for abnormal noise and smooth rotation If any abnormal noise occurs or rough move ment is noted replace the wheel bearings with new ones Play Play http mototh com...

Page 137: ... service limit replace the front axle with a new one Front axle runout Service Limit 0 25 mm 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V block set WHEEL RIM Make sure that the wheel rim runout does not exceed the ser vice limit when checked as shown An excessive runout is usu ally due to worn or loose wheel bearings and can be corrected by replacing the bearings If bea...

Page 138: ...rake shoes wear or damage If any wear or dam ages are found replace the brake shoes as a set 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 brake drum with a new one Brake drum I D Service Limit 110 7 mm Replace the brake shoes as a set otherwise braking performance will be adversely affected...

Page 139: ...n to the following points WHEEL BEARING Apply SUZUKI SUPER GREASE A to the wheel bearings 99000 25010 SUZUKI SUPER GREASE A Install the wheel bearings using the special tool 09924 84521 Bearing installer set First install the left wheel bearing and then install the right wheel bearing The sealed cover on the bearing must face out Clearance http mototh com ...

Page 140: ... 99000 25010 SUZUKI SUPER GREASE A Install the spring 4 into the brake panel hole Install the indicator plate 5 NOTE When installing the indicator plate align the wide spline teeth A and B Install the brake lever 6 and tighten the brake cam lever nut NOTE Be sure to align the punch marks C on the brake cam lever and brake lever Brake cam lever nut 8 N m 0 8 kgf m Pinion outer bush Washer Pinion ge...

Page 141: ...ling the brake panel align groove D on the wheel hub with two drive pawls E on speedometer drive gear Align the groove F of the front brake panel with the lug G of the front fork Tighten the front axle nut to the specified torque Front axle nut 42 N m 4 2 kgf m Install the speedometer cable and front brake cable certainly Adjust the front brake lever play 2 12 Be careful not to apply too much grea...

Page 142: ...eel off the ground with a jack or wooden block Remove the front axle and front wheel 1 Spacer 2 Bearing 3 Front axle spacer 4 Bearing 5 Brake disc 6 Speedometer gearbox 7 Front axle A Front axle nut B Brake disc bolt ITEM N m kgf m A 42 4 2 B 23 2 3 Do not operate the brake lever after front wheel removal http mototh com ...

Page 143: ...oving its bolts INSPECTION AND DISASSEMBLY WHEEL BEARING 5 14 FRONT AXLE 5 15 WHEEL 5 15 TIRE 2 15 SPEEDOMETER GEARBOX Turn the speedometer gear and check to see that the gear turns smoothly together with the speedometer pinion http mototh com ...

Page 144: ...Install the wheel bearings using the special tool 09924 84521 Bearing installer set BRAKE DISC Apply THREAD LOCK SUPER to the brake disc bolts 99000 32130 THREAD LOCK SUPER 1360 Tighten the brake disc bolts to the specified torque Brake disc bolt 23 N m 2 3 kgf m First install the left wheel bearing and then install the right wheel bearing The sealed cover on the bearing must face out Keep the bra...

Page 145: ... the speed ometer gearbox protrusion 4 are installed as shown Tighten the front axle nut to the specified torque Front axle nut 42 N m 4 2 kgf m Connect the speedometer cable NOTE Move the front fork up and down four or five times After remounting the front wheel pump the brake lever a few times to check for proper brake operation When installing the front wheel position the brake disc between the...

Page 146: ...uch as silicone based or petroleum based Do not use any brake fluid taken from old used or unsealed containers Never reuse brake fluid left over from the last servicing or stored for a long periods When storing the brake fluid seal the container completely and keep away from children When replenishing brake fluid take care not to get dust into fluid When washing brake components use fresh brake fl...

Page 147: ... and insert the other 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 clear hose Fill the reservoir with new brake fluid to the upper level of the res ervoir BRAKE PAD REPLACEMENT Remove the cap 1 and loosen the brake pad mounting pin 2 Remove the bra...

Page 148: ...EMOVAL Loosen the brake pad mounting pin 5 25 Remove the brake hose union bolt 1 NOTE Place a rag underneath the union bolt on the brake caliper to catch any spilt brake fluid Remove the brake caliper 2 CALIPER DISASSEMBLY Remove the brake pads above Remove the brake caliper holder 1 Do not operate the brake lever after brake pad removal Replace the brake pad as a set otherwise braking performance...

Page 149: ...or scratch corrosion or other damages If any abnormal condition is found replace the caliper or caliper piston with a new one PAD SPRING Inspect the brake pad spring for damage excessive bend If any damage is found replace it with a new one RUBBER PARTS Inspect the boots for damage and cracks If any defects are found replace the rubbers with new ones Do not use high pressure air to prevent piston ...

Page 150: ...es and piston seal grooves Specification and classification DOT 4 PISTON SEAL Install the piston seal and dust seal as shown BRAKE CALIPER HOLDER Apply SUZUKI SILICON GREASE to the brake caliper holder pin 99000 25100 SUZUKI SILICONE GREASE Wash the brake caliper components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the components with a rag Replace the re...

Page 151: ...Brake hose union bolt 23 N m 2 3 kgf m Fill the system with 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 Replace the disc if the thickness is less than the service limit or if damage is found 5 21 22 Brake disc thickness Service Limit 3 0 mm 09900 20205 Micrometer 0 25 mm Measure the runout with a dial...

Page 152: ...id 5 25 Disconnect the front brake light switch lead wires 2 Remove the front brake master cylinder 3 Remove the brake lever 4 and brake switch 5 Remove the reservoir cap 6 diaphragm plate 7 and dia phragm 8 Immediately wipe off any brake fluid contacting any part of the motorcycle The brake fluid reacts chemi cally with paint plastics rubber materials etc and will damage them severely http mototh...

Page 153: ...NSTALLATION Reassemble and install the master cylinder 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 reassembly Do not wipe the brake fluid off after washing the components with a rag When washing the components use the specified brake fluid Never use diffe...

Page 154: ...UKI SUPER GREASE A When installing the master cylinder onto the handlebars align the master cylinder holder s mating surface A with the punched mark B on the handlebars and tighten the upper clamp bolt first Master cylinder bolt 10 N m 1 0 kgf m Connect the front brake light switch lead wires Piston Spring Primary cup Secondary cup Plate Snap ring Boot Master cylinder Upper clamp bolt Handlebar Cl...

Page 155: ...5 31 Install the brake hose union as shown and tighten the union bolt to the specified torque Brake hose union bolt 23 N m 2 3 kgf m Fill the master cylinder with brake fluid and bleed air 2 14 http mototh com ...

Page 156: ...UY125S 5 25 Loosen the front fork top cap 2 Remove the front fork clamp bolts NOTE Hold the front fork by the hand to prevent sliding out of the steer ing stem Remove the front fork 3 1 O ring 2 Spring 3 Damper rod ring 4 Damper rod 5 Rebound spring 6 Inner tube 7 Dust seal 8 Oil seal stopper ring 9 Oil seal 0 Outer tube A Front fork cap bolt B Damper rod bolt ITEM N m kgf m A 20 2 0 B 23 2 3 http...

Page 157: ...e fork inverted for a few minutes to drain the oil Remove the damper rod bolt using a 8 mm hexagon wrench and the special tools 09940 34520 T handle 09940 34561 Attachment D Remove the damper rod 5 and rebound spring 6 Remove the dust seal 7 and the oil seal stopper ring 8 The removed dust seal must be replaced with a new one http mototh com ...

Page 158: ...or 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 new one Front fork spring free length Service limit 285 8 mm DAMPER ROD RING Inspect the damper rod ring for wear or damage If it is worn or damaged replace the damper rod ring with a new one The removed oil seal must be rep...

Page 159: ...the oil seal stopper ring 2 and dust seal 3 DAMPER ROD Fit the rebound spring 1 to the damper rod 2 and install them to the inner tube Thoroughly wash all the component parts being assembled When reassembling the front fork use new fork oil Use the specified fork oil for the front fork When reassembling replace the oil seal dust seal and damper rod bolt gasket with new ones Wash clean the front fo...

Page 160: ...y each leg 55 ml 99000 99044 10G SUZUKI FORK OIL G10 or equivalent fork oil Hold the front fork leg in a vertical position and adjust the fork oil level by using the special tool When adjusting the oil level remove the fork spring and com press the inner tube fully Front fork oil level without spring 93 mm 09943 74111 Fork oil level gauge FORK SPRING The end of the fork spring with the smaller pit...

Page 161: ...t 2 to the specified torque Front fork clamp bolt 28 N m 2 8 kgf m Front fork cap bolt 20 N m 2 0 kgf m Install the front brake caliper and front brake hose guide UY125S 5 29 Install the front fender and front wheel UY125 5 19 34 UY125S 5 23 34 Move the front fork up and down four or five times Use a new O ring to prevent oil leakage After assembling the front fork check each tighten ing part for ...

Page 162: ...ear handlebar covers 5 5 Remove the cable clamp HANDLEBAR LEFT SIDE PARTS Disconnect the rear brake cable 1 and brake switch 2 Remove the starter lever 3 Remove the rear brake lever holder 4 and left handle grip 5 1 Handlebars A Handlebar clamp nut ITEM N m kgf m A 60 6 0 http mototh com ...

Page 163: ... remove the front brake master cylinder UY125S 5 30 Remove the handlebars by removing the handlebar clamp nut 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 kgf m HANDLEBAR RIGHT SIDE PARTS Align the punch mark A on the handlebars with the front brake ho...

Page 164: ...UPER GREASE A Align the hole A on the handlebars with the hole B of the throttle grip case Tighten the throttle grip case screw HANDLEBAR LEFT SIDE PARTS Apply a handle grip bond onto the handlebars before installing the handlebar grip 39442 09D00 HANDLE GRIP BOND When remounting the rear brake holder onto the handlebars align the brake holder s mating surface with the punched mark A on the handle...

Page 165: ...KI SUPER GREASE A to the cable end and brake lever pivot 99000 25010 SUZUKI SUPER GREASE A After installing the handlebar route the wire harness properly 7 12 Adjust the throttle operation and cable play 2 10 http mototh com ...

Page 166: ... front fender and front forks 5 34 Remove the cable guide 1 Remove the steering stem lock nut with the special tool 09910 60611 Universal clamp wrench 1 Washer 2 Steering stem nut 3 Inner upper race 4 Inner lower race 5 Steel ball 6 Steering stem 7 Outer lower race A Steering stem lock nut ITEM N m kgf m A 90 9 0 http mototh com ...

Page 167: ... the steering stem nut 3 and dust cover 4 NOTE Hold the steering stem bracket to prevent it from falling Remove the upper bearing inner race 5 Remove the upper and lower steel balls Upper 22 pcs Lower 27 pcs Remove the outer lower race with a chisel The removed outer lower race should be replaced with a new one http mototh com ...

Page 168: ...5 44 CHASSIS Drive out the upper and lower races INSPECTION Inspect the steering stem for any damage Inspect the steel balls and race for corrosion wear or other dam age http mototh com ...

Page 169: ...ring installer set Attachment 1 Press in the outer lower race 2 with the special tools 09913 70210 Bearing installer set 3 09940 51710 Bearing installer 4 Apply SUZUKI SUPER GREASE A to the upper and lower races Install the steel balls 99000 25010 SUZUKI SUPER GREASE A Tighten the steering stem nut to the specified torque with the special tool 09910 60611 Universal clamp wrench Steering stem nut 4...

Page 170: ...teering stem lock nut to the specified torque with the special tool 09910 60611 Universal clamp wrench Steering stem lock nut 90 N m 9 0 kgf m NOTE Tightening the lock nut can affect the steering stem nut adjust ment Therefore after tightening the lock nut check the steering movement again and adjust if necessary Install the front forks and front fender 5 39 Install the front wheel UY125 5 19 UY12...

Page 171: ...e with the center stand Remove the muffler 3 6 Remove the rear wheel Remove the rear brake shoes 1 1 Rear wheel 2 Washer 3 Brake shoe 4 Spring 5 Brake camshaft 6 Brake cam lever 7 Brake cam lever bolt 8 Brake lining wear indi cator A Rear axle nut B Rear brake cam lever nut ITEM N m kgf m A 120 12 0 B 11 1 1 http mototh com ...

Page 172: ...ace the wheel hub The value of this limit is indicated inside the drum Brake drum I D Service Limit 130 7 mm 09900 20101 Vernier calipers BRAKE SHOE Inspect the brake shoes for wear or damage If any defects are found replace the brake shoes as a set REAR AXLE Check the rear axle spline for damage or wear If any abnormal condition is noted replace the rear axle shaft 3 18 59 REAR WHEEL 5 15 TIRE 2 ...

Page 173: ...ollowing points When installing the camshaft apply SUZUKI SUPER GREASE A to the camshaft 99000 25010 SUZUKI SUPER GREASE A Turn the punched mark A on the camshaft to the rear axle side Align the tang 1 on the brake lining wear indicator plate 2 with the cutaway 3 on the brake cam Then slide the brake lining wear indicator plate onto the brake cam http mototh com ...

Page 174: ...KI SUPER GREASE A to the camface and pin 99000 25010 SUZUKI SUPER GREASE A Install the brake shoes with spring hooks faced inside Tighten the rear axle nut to the specified torque Rear axle nut 120 N m 12 0 kgf m Install the muffler 3 9 Adjust the rear brake cable play 2 12 Be careful not to apply too much grease to the cam shaft and pin If grease gets on the lining brake effec tiveness will be lo...

Page 175: ...emove the luggage box 5 9 Remove the clutch upper cover 1 Remove the rear shock absorber 2 1 Rear shock absorber 2 Washer A Rear shock absorber mounting nut Upper B Rear shock absorber mounting bolt Lower ITEM N m kgf m A 29 2 9 B 29 2 9 http mototh com ...

Page 176: ...USHING Inspect the spacer and bushing for wear and damage If any defects are found replace the spacer or bushing 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 absorber mounting bolt and nut to the specified torque Rear shock absorber mounting bolt a...

Page 177: ...M 6 8 TROUBLESHOOTING 6 8 INSPECTION 6 10 STARTER SYSTEM 6 13 TROUBLESHOOTING 6 13 STARTER MOTOR REMOVAL 6 14 STARTER MOTOR DISASSEMBLY 6 15 STARTER MOTOR INSPECTION 6 17 STARTER MOTOR REASSEMBLY 6 18 STARTER RELAY INSPECTION 6 20 IGNITION SYSTEM 6 21 TROUBLESHOOTING 6 21 INSPECTION 6 23 SPEEDOMETER 6 26 REMOVAL AND DISASSEMBLY 6 26 INSPECTION 6 27 FUEL METER AND FUEL LEVEL GAUGE 6 28 FUEL METER I...

Page 178: ...6 30 HEADLIGHT 6 30 FRONT TURN SIGNAL LIGHT 6 31 BRAKE LIGHT TAILLIGHT AND REAR TURN SIGNAL LIGHT 6 32 SWITCHES 6 34 BATTERY 6 35 SPECIFICATIONS 6 35 INITIAL CHARGING 6 35 SERVICING 6 37 RECHARGING OPERATION 6 37 REMOVAL 6 37 REMOUNTING 6 37 http mototh com ...

Page 179: ...spect each terminal on the coupler for being loose or bent Inspect each terminal for corrosion and contamination CLAMP Clamp the wire harness at such positions as indicated in WIRING HARNESS ROUTING 7 12 13 Bend the clamp properly so that the wire harness is clamped securely In clamping the wire harness use care not to allow it to hang down Do not use wire or any other substitute for the band type...

Page 180: ...arging 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 not replace the MF battery with a conventional battery CONNECTING THE BATTERY When disconnecting terminals from the battery for disassem bly or servicing be sure to disconnect the battery lead wire first When conn...

Page 181: ... 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 using the tester be sure to turn the switch to the OFF position 09900 25008 Multi circuit tester set Before using the multi circuit tester read its instruc tion manual http mototh com ...

Page 182: ...6 6 ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS 1 Horn 2 Turn signal relay 3 Regulator rectifier 4 Magneto 5 Battery 6 Fuse 7 CDI unit http mototh com ...

Page 183: ...ELECTRICAL SYSTEM 6 7 8 Ignition coil 9 Starter relay 0 Starter motor http mototh com ...

Page 184: ...y Are accessories being installed Step 2 1 Check the battery for current leaks 6 10 Is the battery for current leaks OK YES Remove accessories NO Go to Step 2 YES Go to Step 3 NO Short circuit of wire harness Faulty electrical equipment Ignition coil CDI unit CDI unit B C A D E F Magneto AC DC Rectifire IG switch Fuse Battery H L M L T L DC Load http mototh com ...

Page 185: ...Step 6 1 Inspect the AC DC rectifier 6 12 Is the AC DC rectifier OK Step 7 1 Inspect wirings Is the wirings OK Battery overcharges Faulty AC DC rectifier Faulty battery Poor contact of stator lead wire coupler YES Faulty battery Abnormal driving condition NO Go to Step 4 YES Go to Step 5 NO Faulty stator coil Disconnected lead wires YES Go to Step 6 NO Faulty stator YES Go to Step 7 NO Faulty AC D...

Page 186: ...ery box lid above Start the engine and keep it running at 5 000 rpm with the dimmer switch turned HI position Measure the DC voltage between the and battery termi nals using the multi circuit tester If the voltage is not within the specified value inspect the stator coil and AC DC rectifier 6 11 12 NOTE When making this test be sure that the battery is in fully charged condition 09900 25008 Multi ...

Page 187: ...Red Ground Lamp side 0 4 0 9 Ω Yellow White Ground STATOR NO LOAD PERFORMANCE Remove the frame front cover 5 8 Disconnect the stator coupler above Start the engine and keep it running at 5 000 rpm Using the multi circuit tester measure the voltage between two lead wires I the tester reads under the specified value replace the stator coil with a new one 09900 25008 Multi circuit tester set Tester k...

Page 188: ...e table below If voltage is not within the specified value replace the AC DC rectifier with a new one 09900 25008 Multi circuit tester set Tester knob indication Diode test Unit V 1 4 V and more tester s battery voltage NOTE If the tester reads 1 4 V and below when the tester probes are not connected replace its battery Tester probe Tester probe Y W B W W R R Y W 1 0 1 6 B W 1 0 1 6 W R 0 9 1 4 R ...

Page 189: ...urrent flows Does the starter motor run Step 3 1 Measure the starter relay voltage at the starter relay connectors between Y G and B W when the starter button is pushed Is a voltage OK YES Go to Step 2 NO Go to Step 3 YES Faulty starter relay Loose or disconnected starter motor lead wire Loose or disconnected between starter relay and battery terminal NO Faulty starter motor YES Go to Step 4 NO Fa...

Page 190: ...clutch Is the starter clutch OK STARTER MOTOR REMOVAL Disconnect the battery lead wire Remove the cooling fan duct 3 44 Remove the crankcase grommet No 1 and No 2 3 10 Disconnect the starter motor lead wire 1 Remove the starter motor 2 YES Poor contact of the starter relay NO Faulty starter relay YES Faulty starter motor NO Faulty starter clutch http mototh com ...

Page 191: ...tarter motor as shown in the illustration 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 O ring 4 Armature 2 Housing end inside 5 Housing end outside 3 Starter motor case http mototh com ...

Page 192: ...6 Remove the thrust washer 7 t 0 8 thrust washer 8 t 0 2 and brush holder 9 Remove the insulators 0 Remove the nut A washer B slip washer No 1 C slip washers No 2 D O ring E brush F and terminating holder G Remove the supporter H http mototh com ...

Page 193: ...tor 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 Segment ARMATURE COIL Check for continuity between each segment and between each segment and the armature shaft using the multi circuit tester If there is no continuity between the segments or there is conti nuity between the se...

Page 194: ...ay 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 PASTE to the arma ture shaft 99000 25140 SUZUKI MOLY PASTE Fit the depression of the starter motor case to the projection of the terminating holder Align the line on the starter motor case with the line on the housing end in...

Page 195: ...ELECTRICAL SYSTEM 6 19 Apply SUZUKI SUPER GREASE to the O ring 99000 25010 SUZUKI SUPER GREASE A Install the crankcase grommet No 1 and No 2 3 72 Install the cooling fan duct 3 45 http mototh com ...

Page 196: ...r If the starter relay clicks and continuity is found the relay is OK 09900 25008 Multi circuit tester set Tester knob indication Continuity test Measure the relay coil resistance between the terminals using the multi circuit tester If the resistance is not within the specified value replace the starter relay with a new one 09900 25008 Multi circuit tester set Tester krob indication Resistance Ω S...

Page 197: ... switch couplers Step 2 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 to Step 3 NO Faulty ignition switch Faulty wire harness Broken wire harness or poor connection of related circuit couplers W R BI Y Y W Regulator rectifier Battery Generator Fuse...

Page 198: ...OK Step 6 1 Measure the pickup coil peak voltage and its resistance 6 24 25 NOTE The pickup coil peak voltage inspection is applicable only with the multi circuit tester and peak volt adaptor Is the peak voltage and its resistance OK YES Go to Step 4 NO Go to Step 5 YES Poor connection of the spark plug Go to Step 5 NO Faulty spark plug YES Go to Step 6 NO Poor connection of the ignition coil Faul...

Page 199: ...9900 25008 Multi circuit tester set Turn the ignition switch to the ON position Squeez the brake lever Press the starter button and allow the engine to crank for a few seconds and then measure the ignition coil primary peak voltage Repeat the above procedure a few times and measure the highest ignition coil primary peak voltage Tester knob indication Voltage Ignition coil primary peak voltage 150 ...

Page 200: ... of the couplers are connected properly and the battery is fully charged Disconnect the CDI unit coil coupler Measure the pickup coil peak voltage in the following procedure Connect the multi circuit tester with the peak volt adaptor as follows Probe Blue Yellow lead wire Probe Ground 09900 25008 Multi circuit tester set Turn the ignition switch to the ON position Measure the pickup coil peak volt...

Page 201: ...e Pickup coil peak voltage 2 0 V and more If the peak voltage on the pickup coil coupler is within specifica tion but on the CDI unit coupler is not within specification replace the wire harness with a new one If both peak voltages are out of specification replace the pickup coil with a new one PICKUP COIL RESISTANCE Remove the frame front cover 5 8 Disconnect the pickup coil coupler Measure the r...

Page 202: ...6 26 ELECTRICAL SYSTEM SPEEDOMETER REMOVAL AND DISASSEMBLY Remove the handlebar covers 5 5 Remove the speedometer Disassemble the speedometer as shown i http mototh com ...

Page 203: ... 09900 25008 Multi circuit tester set Tester knob indication Continuity test Speedometer Fuel meter High beam indicator light Turn signal indicator light WIRE COLOR B Gr Lg O Y B W Y B Black Gray Light green Orange Yellow Black White Yellow Black Y B Fuel gauge Blank Gr Illumi O Fuel gauge B W GND Y High beam Blank Lg Turn signal R B Turn signal L http mototh com ...

Page 204: ...l 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 90 ohm resistor between the Y B and B W lead wires The fuel meter is operating correctly if the needle moves to E empty when the ignition switch is turned on Replace the 90 ohm resistor with a 10 ohm resistor The fuel meter is operating correctly if the needle...

Page 205: ...ation 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 turn signal relay may be faulty In this case replace the turn sig nal relay with a new one NOTE Make sure that the battery is fully charged STARTER RELAY 6 20 http mototh com ...

Page 206: ...V 30 30 W HEADLIGHT BULB REPLACEMENT Remove the front handlebar cover 5 5 Remove the headlight bulb If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure http mototh com ...

Page 207: ... W FRONT TURN SIGNAL LIGHT BULB REPLACEMENT Remove the front leg shield 5 6 Remove the front turn signal light bulb If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure http mototh com ...

Page 208: ...IGHT TAILLIGHT AND REAR TURN SIGNAL LIGHT Brake light taillight 12 V 18 5 W Turn signal light 12V 10 W BRAKE LIGHT TAILLIGHT BULB REPLACEMENT Remove the rear combination light lens 1 and brake light tail light lens 2 http mototh com ...

Page 209: ...ail light lens 6 32 Remove the rear turn signal light bulb If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure 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 http mototh com ...

Page 210: ...G Green O Orange Y Yellow Lbl Light blue R Red B W Black with White tracer W B White with Black tracer Y G Yellow with Green tracer Y W Yellow with White tracer REAR BRAKE LIGHT SWITCH O W B ON OFF Color Position FRONT BRAKE LIGHT SWITCH O W B ON OFF Color Position HORN BUTTON B W G PUSH Color Position STARTER BUTTON PUSH W B Y G Color Position IGNITION SWITCH OFF ON O R Color Position TURN SIGNAL...

Page 211: ... 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 the sealed areas 3 of the electrolyte container Insert the nozzles of the electrolyte container 4 into the bat tery s electrolyte filler holes holding the container firmly so that it does not fall Take precaution not to allow any of the fluid to spi...

Page 212: ...o 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 battery Once the caps have been installed to the battery do not remove the caps Do not tap the caps with a tool such as hammer when installing them CORRECT INCORRECT For charging the battery make sure to use the charger spe...

Page 213: ... 30 minutes and more and check the battery voltage with a multi circuit tester If the battery voltage is the 12 5 V and less recharge the bat tery again If battery voltage is still 12 5 V and less after recharging replace the battery with a new one When the motorcycle is not used for a long period check the battery every 1 month to prevent the battery discharge REMOVAL Remove the battery box lid 6...

Page 214: ...White Page http mototh com ...

Page 215: ...Y125S 7 17 PAIR AIR SUPPLY SYSTEM HOSE ROUTING 7 18 FUEL HOSE ROUTING 7 19 CLUTH TRANSMISSION DRIVE BELT INSTALLATION 7 20 COOLING FAN INSTALLATION 7 21 FUEL TANK INSTALLATION 7 22 CRANKCASE INSTALLATION 7 23 EXTERIOR PARTS CONSTRUCTION 7 24 PROP STAND INSTALLATION 7 26 CENTER STAND INSTALLATION 7 26 REAR BRAKE CAM LEVER INSTALLATION 7 27 BATTERY INSTALLATION 7 28 SEAT HINGE INSTALLATION 7 29 FRON...

Page 216: ...le 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 Replace Replace Repair or replace Replace Replace Clean or replace Clean or replace Replace Clean or replace Engine stalls often 1 Fouled spark plug 2 Defective pick up coil or CDI unit 3 Clogged fuel hose or fuel tank ...

Page 217: ... Replace Replace Replace Replace Replace Replace Replace Replace Slipping clutch 1 Worn or damaged clutch shoes 2 Weakened clutch shoe springs 3 Worn clutch housing 4 Worn or slipping drive belt Replace Replace Replace Replace Engine idles poorly 1 Valve clearance out of adjustment 2 Poor seating of valves 3 Defective valve guides 4 Worn down camshaft 5 Too wide spark plug gap 6 Defective ignition...

Page 218: ... or replace Replace Replace Replace Engine lacks power 1 Loss of valve clearance 2 Weakened valve spring 3 Out of adjustment valve timing 4 Worn piston rings or cylinder 5 Poor seating of valves 6 Fouled spark plug 7 Incorrect spark plug 8 Clogged jets in carburetor 9 Out of adjustment float chamber fuel level 10 Clogged air cleaner element 11 Slipping or worn drive belt 12 Sucking air from intake...

Page 219: ...ng 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 defective part Clean Clean Adjust Medium or high speed trouble 1 Clogged main jet 2 Clogged main air jet 3 Clogged needle jet 4 Improperly working throttle valve 5 Clogged fuel filter Clean Clean Clean Adjust Clean or replace Overflow and ...

Page 220: ... oil Replace Replenish Replace Front suspension too stiff 1 Too viscous fork oil 2 Too much fork oil Replace Drain excess oil Noisy front suspension 1 Not enough fork oil 2 Loose bolts on suspension Replenish Retighten Wobbly rear wheel 1 Distorted wheel rim 2 Worn gearbox bearing 3 Defective or incorrect tire 4 Worn crankcase bushing 5 Loose axle nut or engine mounting bolts nuts Replace Replace ...

Page 221: ... cylinder Repair surface with sandpaper Brake squeaking UY125 1 Carbon adhesion on shoe surface 2 Tilted shoe 3 Damaged wheel bearing 4 Loose front or rear axle nut 5 Brake pad surface glazed 6 Worn shoe Repair surface with sandpaper Correct shoe fitting or replace Replace Tighten Repair surface with sandpaper Replace Excessive brake lever stroke UY125S 1 Air in hydraulic system 2 Insufficient bra...

Page 222: ...nections 2 Short circuited grounded or open startor coils 3 Short circuited or punctured regulator rectifier Repair or replace or retighten Replace Replace Battery does charge but charg ing rate is below the specification 1 Lead wires tend to get shorted or open circuited or loosely connected at terminals 2 Grounded or open circuited stator coils 3 Defective regulator rectifier 4 Defective cell pl...

Page 223: ... 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 to obtain specified charging operation Replace the battery and correct the charging sys tem Replace the battery Recharge the battery fully Replace the battery Battery sulfation 1 Too low or too high charg...

Page 224: ...k tracer Yellow with Green tracer Yellow with White tracer HI HIGH BEAM INDICATOR LIGHT TU TURN SIGNAL INDICATOR LIGHT MAGNETO REGULATOR RECTIFIER REAR TURN SIGNAL LIGHT R BRAKE LIGHT TAILLIGHT REAR TURN SIGNAL LIGHT L WIRE COLORS Y Gr B W O Y B Lg B Y Gr B W O Y B Lg B Y Y W B W O Y B Lg B Y Y W B W O Y B Lg B O W B O W B O W B O W B O W B O W B O W B O W B W B Y G W B Y G R O R O R O R O B W W B...

Page 225: ...ETO REGULATOR RECTIFIER HEADLIGHT FRONT TURN SIGNAL LIGHT R FRONT TURN SIGNAL LIGHT L REAR TURN SIGNAL LIGHT R BRAKE LIGHT TAILLIGHT REAR TURN SIGNAL LIGHT L WIRE COLORS Y Gr B W O Y B Lg B Y Gr B W O Y B Lg B Y Y W B W O Y B Lg B Y Y W B W O Y B Lg B O W B O W B O W B O W B O W B O W B W B Y G W B Y G R O R O R O R O B W W Bl B W W Bl Y B B W Y B B W O Bl Y W Bl B W O Bl Y W Bl B W O Lbl O Lbl Lg...

Page 226: ...WIRING HARNESS CABLE AND HOSE ROUTING WIRING HARNESS ROUTING Guide Throttle cable Harness clamp Fuel gauge Guide Harness Harness Clamp Frame Engine side High tension cord IG coil Battery Fuse Relay Battery Cap Cap http mototh com ...

Page 227: ...e Throttle cable Rear brake cable Front brake cable Starter cable Throttle cable UY125 UY125S Front brake switch Front brake cable Steering lock Speedometer cable Head lamp coupler Rear brake switch Cushion Speedometer Speedometer coupler Handlebar Clamp Speedometer cable Harness Rear brake cable Front brake hose Starter cable Throttle cable Front brake switch Front brake hose Steering lock Speedo...

Page 228: ...le firmly Air cleaner Starter lever Clamp Speedometer cable Front brake cable Pass through the guide Handlebar Harness Starter cable Rear brake cable Speedometer cable Starter cable Pass through the guide Clamp Clamp Throttle cable Pass through the rear brake cable inside guide Clamp Rear brake cable Seat lock Clamp Vacuum hose Fuel hose Striker support bracket Clamp starter cable firmly Throttle ...

Page 229: ...able firmly Air cleaner Starter lever Clamp Speedometer cable Front brake hose Pass through the guide Handlebar Harness Starter cable Rear brake cable Speedometer cable Throttle cable Front brake hose Starter cable Pass through the guide Clamp Clamp Throttle cable Pass through the rear brake cable inside guide Clamp Rear brake cable Seat lock Clamp Vacuum hose Fuel hose Striker support bracket Cla...

Page 230: ...7 16 SERVICING INFORMATION ENGINE ELECTRIC PARTS INSTALLATION 6 9 N m 0 69 kgf m 30 Avoid twisting the lead wire when grommet installation 6 N m 0 6 kgf m 120 N m 12 0 kgf m http mototh com ...

Page 231: ...ROUTING UY125S Handlebar Front brake hose After brake hose touching to the stopper tighten the union bolt Set the brake hose firmly into the clamp Brake hose After brake hose touching to the stopper tighten the union bolt Outside http mototh com ...

Page 232: ...7 18 SERVICING INFORMATION PAIR AIR SUPPLY SYSTEM HOSE ROUTING Intake pipe Breather hose Match mark Carburetor Fuel tap vaccum hose Air cleaner http mototh com ...

Page 233: ...SERVICING INFORMATION 7 19 FUEL HOSE ROUTING Fuel hose Fuel tap Fuel tap Vacuum hose Carburetor Clip Fuel hose and vacuum hose must be wrap by clip at mark position Vacuum hose Clip http mototh com ...

Page 234: ...7 20 SERVICING INFORMATION CLUTCH TRANSMISSION DRIVE BELT INSTALLATION 1 1 1 1 1 Remove excess grease http mototh com ...

Page 235: ...SERVICING INFORMATION 7 21 COOLING FAN INSTALLATION 33 N m 3 3 kgf m 10 N m 1 0 kgf m http mototh com ...

Page 236: ...7 22 SERVICING INFORMATION FUEL TANK INSTALLATION Fuel tap Vacuum hose Fuel hose Clip http mototh com ...

Page 237: ...MATION 7 23 CRANKCASE INSTALLATION 37 mm 37 mm 2 mm 2 mm mm Ê 34 Ê 34 2 mm Ê 22 3 52 0 4 0 67 0 2 mm 63 0 4 0 Turn the projection with the assemble tube ahead Apply SUZUKI BOND 1215 to the gasket 45 mm http mototh com ...

Page 238: ...7 24 SERVICING INFORMATION EXTERIOR PARTS CONSTRUCTION 1Leg shield cover 2Leg shield rack 3Front leg shield 4Leg rear shield 5Front leg lower shield 6Leg lower shield http mototh com ...

Page 239: ...SERVICING INFORMATION 7 25 1Battery box lid 2Luggage box 3Rear front fender 4Pillion rider handle 5Rear fender 6Frame cover R 7Frame cover L 8Frame front cover http mototh com ...

Page 240: ...7 26 SERVICING INFORMATION PROP STAND INSTALLATION CENTER STAND INSTALLATION 40 N m 4 0 kgf m 10 N m 1 0 kgf m OUTSIDE RH LH Long Short http mototh com ...

Page 241: ...SERVICING INFORMATION 7 27 REAR BRAKE CAM LEVER INSTALLATION 33 40 35 Match Match Match Set position http mototh com ...

Page 242: ...7 28 SERVICING INFORMATION BATTERY INSTALLATION Starter relay Battery 18 mm 18 mm 5 mm Protector Front rear fender http mototh com ...

Page 243: ...SERVICING INFORMATION 7 29 SEAT HINGE INSTALLATION 96 Seat Assy E ring RH LH FWD http mototh com ...

Page 244: ...7 30 SERVICING INFORMATION FRONT WHEEL UY125 5 J _ http mototh com ...

Page 245: ...SERVICING INFORMATION 7 31 FRONT WHEEL UY125S Clearance 1 mm http mototh com ...

Page 246: ...7 32 SERVICING INFORMATION REAR WHEEL http mototh com ...

Page 247: ... 80 mm 09900 20602 Dial gauge 1 1 000 mm 1 mm 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20607 Dial gauge 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 22301 09900 22302 Plastigauge 09900 22401 Small bore gauge 10 18 mm 09900 25008 Multi circuit tester set 09900 26006 Tachometer 09910 11310 Crankshaft ...

Page 248: ...r N 126 09916 21111 Valve seat cutter set 09916 24311 Solid pilot N 100 5 0 09916 34542 Valve guide reamer handle 09916 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 47010 Vacuum pump gauge 09920 13120 Crankcase separator 09921 20240 Bearing remover set 09922 3...

Page 249: ...haft 09930 34980 Rotor remover 09930 40113 Rotor holder 09930 40120 Rotor holder attachment A 09940 34520 T handle 09940 34561 Attachment D 09940 51710 Bearing installer 09940 52861 Front fork oil seal installer set 09940 60113 Spoke nipple wrench 09941 34513 Steering outer race installer 09943 74111 Fork oil level gauge 09943 88211 Bearing installer 09951 16080 Bearing installer http mototh com ...

Page 250: ...shoe nut 60 6 0 Fixed drive face nut 50 5 0 Stator coil bolt 6 0 6 Crankcase bolt 10 1 0 Magneto cover bolt 10 1 0 Cam chain tensioner bolt 10 1 0 Cam chain tension adjuster mounting bolt 10 1 0 Oil drain plug 18 1 8 Main oil gallery plug 12 1 2 Camshaft sprocket bolt 11 1 1 Starter motor mounting bolt 10 1 0 Clutch cover bolt 10 1 0 Oil pump mounting screw 8 0 8 Reduction gear cover bolt 10 1 0 C...

Page 251: ...1 1 1 Rear axle nut 120 12 0 Rear shock absorber mounting nut 29 2 9 Front fork clamp bolt 28 2 8 Front fork cap bolt 33 3 3 Damper rod bolt 23 2 3 Front brake caliper mounting bolt UY125S 25 2 5 Brake hose union bolt UY125S 23 2 3 Brake disc bolt UY125S 23 2 3 Air breeder valve UY125S 7 5 0 75 Brake master cylinder bolt UY125S 10 1 0 Spoke nipple 4 5 0 45 http mototh com ...

Page 252: ...is 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 8 5 14 65 6 5 135 13 5 16 105 10 5 210 21 0 18 160 16 0 240 24 0 Conventional bolt 4 marked bolt 7 marked bolt A http mototh com ...

Page 253: ... 0 92 1 12 Valve head radial runout IN EX 0 03 Valve spring free length IN EX 32 9 Valve spring tension IN EX 118 N 12 0 kgf at length 26 8 mm ITEM STANDARD LIMIT Cam height IN 27 92 28 02 27 62 EX 27 77 27 87 27 47 Rocker arm I D IN EX 10 003 10 018 Rocker arm shaft O D IN EX 9 981 9 990 Cylinder head distortion 0 05 ITEM STANDARD LIMIT Compression pressure 750 1 200 kPa 7 5 12 kgf cm 650 kPa 6 5...

Page 254: ...lection 3 0 Conrod big end side clearance 0 10 0 45 1 0 Conrod big end width 16 95 17 00 Crank web to web width 48 9 49 1 Crankshaft thrust clearance 0 02 0 07 Crankshaft runout 0 08 ITEM STANDARD LIMIT Oil pressure at 60 C 18 40 kPa 0 18 0 40 kgf cm at 3 000 rpm ITEM STANDARD LIMIT Clutch housing I D 125 0 125 2 125 5 Clutch shoe thickness 2 5 Clutch engagement 2 900 3 500 rpm Clutch lock up 4 50...

Page 255: ...rformance 8 0 mm and over at 1 atm Pick up coil resistance 180 280 Ω Bl Y Ground Pick up coil peak voltage 2 0 V and more Bl Y B W Ignition coil resistance Primary 0 2 0 9 Ω W Bl B W Secondary 11 20 kΩ Plug cap B W Ignition coil primary peak voltage 150 V and more Ground W Bl Stator coil resistance Lamp 0 4 0 9 Ω Y W Ground Charge 0 6 1 1 Ω W R Ground Stator coil no load voltage when cold Lamp 4 V...

Page 256: ... UY125S Front 11 000 11 043 Master cylinder piston diam UY125S Front 10 957 10 984 Brake caliper cylinder bore UY125S Front 32 030 32 106 Brake caliper piston diam UY125S Front 31 950 32 000 Brake fluid type UY125S DOT 4 Wheel rim runout Axial 2 0 Radial 2 0 Wheel axle runout 0 25 Wheel rim size Front J14 1 40 Rear J14 1 60 ITEM STANDARD LIMIT Front fork stroke 85 Front fork spring free length 291...

Page 257: ... NR76 Tire tread depth Front 1 6 Rear 1 6 ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 91 octane or higher An unleaded gasoline is recommended Fuel tank capacity 3 7 L Engine oil type SAE 10W 40 API SF SG or SH SJ with JASO MA Engine oil capacity Change 950 ml Filter change 1 050 ml Overhaul 1 100 ml Reduction gear oil type SAE 10W 40 Reduction gear oil capacity Change 100 ml O...

Page 258: ...Prepared by August 2005 Part No 99500 31310 01E Printed in Thailand 260 THAI SUZUKI MOTOR CO LTD http mototh com ...

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