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8-2 RV125K4/K5 (’04, ’05-MODELS)

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length ......................................................................................

2 140 mm (84.3 in)

Overall width .......................................................................................

860 mm (33.9 in)

Overall height ......................................................................................

1 120 mm (44.1 in)

Wheelbase ..........................................................................................

1 385 mm (54.5 in)

Ground clearance................................................................................

215 mm ( 8.5 in)

Seat height ..........................................................................................

770 mm (30.3 in)

Dry mass.............................................................................................

117 kg (257 lbs)

ENGINE

Type.....................................................................................................

Four-stroke, air-cooled, OHC

Number of cylinders ............................................................................

Bore ....................................................................................................

57.0 mm (2.244 in)

Stroke..................................................................................................

48.8 mm (1.921 in)

Displacement ......................................................................................

125 cm

(7.6 cu. in)

Compression ratio ...............................................................................

9.2 : 1

Carburetor ...........................................................................................

MIKUNI BS26

Air cleaner ...........................................................................................

Polyurethane foam element

Starter system.....................................................................................

Electric

Lubrication system ..............................................................................

Wet sump

Idle speed ...........................................................................................

1 500 ± 100 r/min

DRIVE TRAIN

Clutch ..................................................................................................

Wet multi-plate type

Transmission .......................................................................................

6-speed constant mesh

Gearshift pattern .................................................................................

1-down, 5-up

Primary reduction ratio........................................................................

3.470 (59/17)

Gear ratios, Low ...............................................................................

3.000 (33/11)

2nd ...............................................................................

1.857 (26/14)

3rd ................................................................................

1.368 (26/19)

4th ................................................................................

1.095 (23/21)

5th ................................................................................

0.923 (24/26)

Top................................................................................

0.833 (20/24)

Final reduction ratio.............................................................................

3.400 (51/15)

Drive chain ..........................................................................................

D.I.D. 428, 134 links

CHASSIS

Front suspension.................................................................................

Telescopic, coil spring, oil damped

Rear suspension .................................................................................

Swingarm type, coil spring, oil damped

Front suspension stroke ......................................................................

110 mm (4.3 in)

Rear wheel travel ................................................................................

136 mm (5.4 in)

Caster .................................................................................................

26°

Trail......................................................................................................

91 mm (3.6 in)

Steering angle .....................................................................................

45° (right & left)

Turning radius .....................................................................................

2.1 m (6.9 ft)

Front brake ..........................................................................................

Disc brake

Rear brake ..........................................................................................

Drum brake

Front tire size ......................................................................................

130/80-18 M/C 66P, tube type

Rear tire size .......................................................................................

180/80-14 M/C 78P, tube type

ELECTRICAL

Ignition type.........................................................................................

Electronic ignition (Transistorized)

Ignition timing ......................................................................................

13° B.T.D.C. at 1 500 r/min

Spark plug ...........................................................................................

NGK CR8E or DENSO U24ESR-N

Battery.................................................................................................

12 V 21.6 kC (6 Ah)/10 HR

Generator ............................................................................................

Three-phase A.C. generator.

Fuse ....................................................................................................

20 A

Headlight .............................................................................................

12 V 60/55 W

Brake light/Taillight ..............................................................................

12 V 21/5 W

Position light ........................................................................................

12 V 4 W ..............................E-19

12 V 5 W .............................. E-02

Turn signal light ...................................................................................

12 V 21 W

Speedometer light ...............................................................................

12 V 1.7 W

Neutral indicator light ..........................................................................

12 V 3.4 W

High beam indicator light ....................................................................

12 V 1.7 W

Turn signal indicator light ....................................................................

12 V 3.4 W

CAPACITIES

Fuel tank, including reserve ..............................................................

7.5 L (2.0/1.6 US/Imp gal)

Reserve............................................................................

1.8 L (0.5/0.4 US/Imp gal)

Engine oil, oil change ........................................................................

850 ml (0.9/0.7 US/Imp qt)

filter change.....................................................................

950 ml (1.0/0.8 US/Imp qt)

overhaul...........................................................................

1 200 ml (1.3/1.1 US/Imp qt)

Содержание RV125

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

Страница 2: ...COPYRIGHT SUZUKI MOTOR CORPORATION 2003 This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have been made since then differences may e...

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 16: ...elow NOTE Before lubricating each part clean off any rusty spots and wipe off any grease oil dirt or grime Lubricate exposed parts which are subject to rust with a rust preventative spray especially w...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 34: ...PERIODIC MAINTENANCE 2 21...

Страница 35: ...pecification check the engine for conditions listed above COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head nuts are tightened to the...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 192: ...LAMPS HEADLIGHT BRAKE LIGHT TAILLIGHT If you touch the bulb with your bare hands clean the bulb with a cloth moistened with alcohol or soapy water to prevent premature bulb failure Do not overtighten...

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

Страница 194: ...e turn signal light If the turn signal light does not illuminate inspect the bulb turn signal switch and circuit connection If the bulb turn signal switch and circuit connection are OK the turn signal...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 225: ...r to this chart Bolt Diameter A mm Conventional or 4 marked bolt 7 marked bolt N m kgf m N m kgf m 4 1 5 0 15 2 3 0 23 5 3 0 3 4 5 0 45 6 5 5 0 55 10 1 0 8 13 1 3 23 2 3 10 29 2 9 50 5 0 12 45 4 5 85...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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