To start a Suzuki RV125 motorbike, ensure the battery is properly connected by attaching the + (positive) lead first and the - (negative) lead second. If the bike has been sitting unused, you may need to mix petrol with two-stroke oil, add it to the tank, and let the fuel lines fill. Once the lines are filled and the engine starts running properly, you can then fill the tank with petrol. Ensure all electrical connections and the throttle are functioning correctly before attempting to start the bike.

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Summary of Contents for Suzuki RV125

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Page 2: Table Of Contents
FOREWORD GROUP INDEX This manual contains an introductory description on the SUZUKI RV125 and procedures for its inspec- tion/service and overhaul of its main components. GENERAL INFORMATION Other information considered as generally known is not included. Read the GENERAL INFORMATION section to...
Page 3 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.
Page 4 Apply molybdenum oil solution. (mixture of engine oil and SUZUKl Apply or use brake fluid. MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI SUPER GREASE “A”. Measure in voltage range. 99000-25010 Apply SUZUKI SILICONE GREASE. Measure in resistance range.
Page 5 GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE .................1- 2 GENERAL PRECAUTIONS ................1- 2 SUZUKI RV125K3 (’03-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...
Page 6: Warning/Caution/Note
GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
Page 7 GENERAL INFORMATION " * If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equiv- alent. * When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
Page 8: Suzuki Rv125K3 ('03-Model)
GENERAL INFORMATION SUZUKI RV125K3 (’03-MODEL) LEFT SIDE RIGHT SIDE SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right 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.
Page 9: Engine Oil
Never re-use brake fluid left over from a previous servicing, which has been stored for a long period. FRONT FORK OIL SUZUKI FORK OIL #10 or an equivalent fork oil. BREAK-lN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN”...
Page 10: Information Labels
GENERAL INFORMATION INFORMATION LABELS LABEL or PLATE NAME Fuel caution label Tire information label Warning safety label Warning rear carrier label ID plate Anti-tamparing label Head pipe (Right side)
Page 11: Specifications
GENERAL INFORMATION SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length ............2 140 mm Overall width ............860 mm Overall height ............1 120 mm Wheelbase ............1 385 mm Ground clearance..........215 mm Seat height ............770 mm Dry mass ............. 117 kg ENGINE Type ..............
Page 12: Chassis
GENERAL INFORMATION CHASSIS Front suspension ..........Telescopic, coil spring, oil damped Rear suspension ..........Swingarm type, coil spring, oil damped Front suspension stroke........110 mm Rear wheel travel ..........136 mm Caster ..............26° Trail ..............91 mm Steering angle............45° (right & left) Turning radius ............2.1 m Front brake............Disc brake Rear brake ............Drum brake Front tire size ............130/80-18M/C 66P, tube type...
Page 13: Country And Area Codes
GENERAL INFORMATION COUNTRY AND AREA CODES The following codes stand for the applicable countries and areas. CODE COUNTRY OR AREA E-02 U. K. E-19...
Page 14 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ............2- 2 PERIODIC MAINTENANCE CHART .............2- 2 LUBRICATION POINTS .................2- 3 MAINTENANCE AND TUNE-UP PROCEDURES ..........2- 4 AIR CLEANER ..................2- 4 VALVE CLEARANCE ................2- 5 SPARK PLUG ..................2- 7 THROTTLE CABLE PLAY ..............2- 8 ENGINE IDLE SPEED ................2- 8 FUEL HOSE ...................2- 9 CLUTCH ....................2- 9...
Page 15: Periodic Maintenance Schedule
PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. NOTE: More frequent servicing may be performed on motorcycles that are use under severe conditions. PERIODIC MAINTENANCE CHART Interval 1 000...
Page 16: Lubrication Points
PERIODIC MAINTENANCE LUBRICATION POINTS Proper lubrication is important for smooth operation and long life of each working part of the motorcycle. Major lubrication points are indicated below. Clutch lever holder Drive chain Side-stand pivot and spring hook Brake lever holder and throttle cable Brake pedal pivot NOTE:...
Page 17: Maintenance And Tune-Up Procedures
PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item in the Periodic Maintenance chart. AIR CLEANER Inspect every 4 000 km (20 months). If the air cleaner is clogged with dust, intake resistance will be increase, resulting in a decrease in engine output and an increase in fuel consumption.
Page 18: Valve Clearance
PERIODIC MAINTENANCE • Remove the drain plug 1 to allow any water to drain out. • Reinstall the cleaned air cleaner element in the reverse order of removal. " Be sure to position the element 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.
Page 19 PERIODIC MAINTENANCE INSPECTION The valve clearance specification is same for both valves. Valve clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is ser- viced, and 3) when the camshaft is disturbed by removing it for servicing.
Page 20: Spark Plug
PERIODIC MAINTENANCE SPARK PLUG Inspect every 4 000 km (20 months). Replace every 8 000 km (40 months). Cold type Hot type CR8E CR7E CR9E DENSO U24ESR-N U22ESR-N U27ESR-N • Disconnect the spark plug cap and remove the spark plug. # 09930-10121: Spark plug wrench set "...
Page 21: Throttle Cable Play
PERIODIC MAINTENANCE THROTTLE CABLE PLAY Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter. Throttle cable play A should be 2.0 – 4.0 mm as measured at throttle grip when turning the throttle grip lightly. If the play A is incorrect, adjust it as follows: •...
Page 22: Fuel Hose
PERIODIC MAINTENANCE FUEL HOSE Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter. Replace every 4 years. Inspect the fuel hose for damage and fuel leakage. If any dam- ages are found, replace the fuel hose with a new one. CLUTCH Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter.
Page 23: Engine Oil And Oil Filter
2-10 PERIODIC MAINTENANCE ENGINE OIL AND OIL FILTER ENGINE OIL REPLACEMENT Replace initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter. • Place an oil pan below the engine. Drain oil by removing the engine oil drain plug 1.
Page 24: Drive Chain
* Rusted links * Kinked or binding links If any defects are found, the drive chain must be replaced. " The standard drive chain is DID 428 SUZUKI recom- mends to use this standard drive chain as a replace- ment.
Page 25 2-12 PERIODIC MAINTENANCE CHECKING AND ADJUSTING • Loosen the rear axle nut 1. • Tense the drive chain fully by turning both chain adjusters 2. • Count out 21 pins (20-pitch) on the chain measure the dis- tance between the two points. If the distance exceeds the ser- vice limit, the chain must be replaced.
Page 26: Brakes
PERIODIC MAINTENANCE 2-13 CLEANING AND LUBRICATING • Clean the drive chain with kerosine. If the drive chain tends to rust quickly, the intervals must be shortened. • After cleaning and drying the chain, oil it with a heavy-weight engine oil. "...
Page 27 2-14 PERIODIC MAINTENANCE BRAKE HOSES Check the brake hose for leakage, cracks, wear and damage. If any damages are found, replace the brake hoses with new a one. BRAKE FLUID LEVEL Inspect every 4 000 km (20 months). Replace every 2 years. •...
Page 28 PERIODIC MAINTENANCE 2-15 AIR BLEEDING THE BRAKE FLUID CIRCUIT Air trapped in the brake fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cyl- inder and thus interferes with the full braking performance of the brake caliper.
Page 29 2-16 PERIODIC MAINTENANCE REAR BRAKE PEDAL HEIGHT • Loosen the lock nut 1 and rotate the adjusting bolt 2 to locate brake pedal 5 – 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.
Page 30: Steering
PERIODIC MAINTENANCE 2-17 REAR BRAKE SHOE WEAR This motorcycle is equipped with the brake lining wear limit indi- cator on the rear brake. To check wear of the brake lining, perform the following steps: • First, check if the brake system is properly adjusted. •...
Page 31: Tire And Wheel
2-18 PERIODIC MAINTENANCE TIRE AND WHEEL TIRE TREAD CONDITION Inspect every 4 000 km (20 months). Operating the motorcycle with excessively worn tires will decrease riding stability and consequently invite a dangerous situation. It is highly recommended to replace a tire when the remaining depth of the tire tread reaches the following specifica- tion.
Page 32: Exhaust Pipe Bolts And Muffler Mounting Bolts
PERIODIC MAINTENANCE 2-19 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 EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS Tighten initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter.
Page 33: Chassis Bolts And Nuts
2-20 PERIODIC MAINTENANCE CHASSIS BOLTS AND NUTS Tighten initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter. Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-21 for the loca- tions of the following bolts and nuts on the motorcycle.) Item N·m...
Page 34 PERIODIC MAINTENANCE 2-21...
Page 35: Compression Pressure Check
2-22 PERIODIC MAINTENANCE COMPRESSION PRESSURE CHECK The compression pressure reading of a cylinder is a good indicator of its internal condition. The decision to overhaul the cylinder is often based on the results of a compression test. Periodic mainte- nance records kept at your dealership should include compression readings for each maintenance service. CONPRESSION PRESSURE SPECIFICATION Standard Limit...
Page 36: Oil Pressure Check
PERIODIC MAINTENANCE 2-23 OIL PRESSURE CHECK Check the oil pressure periodically. This will give a good indication of the condition of the moving parts. $ Oil pressure: Above 15 kPa (0.15 kgf/cm²) at 3 000 r/min, oil temp. at 60 °C (140 °F) Below 35 kPa (0.35 kgf/cm²) Low or high oil pressure can indicate any of the following conditions: LOW OIL PRESSURE...
Page 37 ENGINE ENGINE CONTENTS ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE ....3- 2 ENGINE REMOVAL AND INSTALLATION ............3- 3 ENGINE REMOVAL ................3- 3 ENGINE INSTALLATION ...............3- 8 ENGINE DISASSEMBLY ................3-11 ENGINE COMPONENTS INSPECTION AND SERVICE ........3-21 CYLINDER HEAD COVER ..............3-21 CYLINDER HEAD ..................3-23 CAMSHAFT ....................3-32 CYLINDER ....................3-33 CAM CHAIN TENSION ADJUSTER ............3-34...
Page 38: Engine Components Removable With Engine In Place
ENGINE ENGINE COMPONENTS REMOVABLE WITH ENGINE IN PLACE The parts listed below can be removed and reinstalled without removing the engine from the frame. Refer to the pages listed in each section for removal and reinstallation instructions. ENGINE LEFT SIDE PARTS REMOVAL INSTALLATION...
Page 39: Engine Removal And Installation
ENGINE ENGINE REMOVAL AND INSTALLATION 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. •...
Page 40 ENGINE • Disconnect the starter motor lead wire 1. • Disconnect 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 lead wire coupler 5. •...
Page 41 ENGINE • Remove the 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 Collar Collar Spacer...
Page 42 ENGINE • Loosen the engine 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 mounting nuts, bolts and brackets.
Page 43 ENGINE • Remove the swingarm pivot nut 1. • Partially remove the swingarm pivot shaft so that the engine can be removed. NOTE: Be careful not to draw out the pivot shaft. • Gradually lower the engine.
Page 44: Engine Installation
ENGINE ENGINE INSTALLATION Reinstall the engine in the reverse order of engine removal. • Install the engine mounting bolts and nuts as shown in the following illustration. • Tighten the engine mounting nuts to the specified torque. NOTE: The engine mounting nuts are self-locking. Once the nuts have been removed, they are no longer of any use.
Page 45 ENGINE • Install the clutch release arm as shown in the illustration. NOTE: Align the release arm slit surface A with the notch mark B on the release camshaft. • Position the carburetor clamps as shown in the illustration. Left Right Right Left...
Page 46 3-10 ENGINE • Tighten the exhaust pipe bolts to the specified torque. # Exhaust pipe bolt: 23 N·m (2.3 kgf-m) • Tighten the muffler connecting bolt to the specified torque. # Muffler connecting bolt: 20 N·m (2.0 kgf-m) • Install the gearshift lever to the gearshift shaft in the correct position.
Page 47: Engine Disassembly
ENGINE 3-11 ENGINE DISASSEMBLY The procedure for engine disassembly is sequentially explained in the following steps: • 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.
Page 48 3-12 ENGINE CAM CHAIN TENSION ADJUSTER • Remove the cam chain tension adjuster 1. CYLINDER HEAD COVER • Remove the cylinder head cover. CAMSHAFT • Remove the camshaft end cap 2. • Flatten the lock washer and remove the camshaft sprocket bolts.
Page 49 ENGINE 3-13 CYLINDER HEAD • Remove the cylinder head nuts (M6). • Remove the cylinder head nuts (M8) diagonally. • Remove the cylinder head. NOTE: If the cylinder head does not come off, lightly tap on the finless portion of it with a plastic hammer. CYLINDER •...
Page 50 3-14 ENGINE GENERATOR COVER • Remove the generator cover 1. STARTER MOTOR • Remove the 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 in a crisscross pattern, and remove the clutch springs and clutch pressure plate 7.
Page 51 ENGINE 3-15 • Remove the washer 1, bearing 2, clutch push piece 3 and clutch push rod 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 •...
Page 52 3-16 ENGINE OIL PUMP • Remove the circlip 1 and oil pump driven gear 2. • Remove the pin 3. • Remove the oil pump 4. " Do not attempt to disassemble the oil pump assembly. GEARSHIFT • Remove the gearshift shaft 5. •...
Page 53 ENGINE 3-17 • While holding the generator rotor with the special tool, remove the primary drive gear/oil pump drive gear nut. % 09930-44530: Rotor holder " The primary drive gear/oil pump drive gear nut has left-hand threads. • Remove the oil pump drive gear 1 and primary drive gear 2. •...
Page 54 3-18 ENGINE • Remove the cam chain 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. •...
Page 55 ENGINE 3-19 • Separate the left and right crankcases with the special tool. % 09920-13120: Crankcase separator NOTE: * Fit the crankcase separator, so that the tool arms are in paral- lel with the side of crankcase. * The crankshaft and transmission components should remain in the left crankcase half.
Page 56 3-20 ENGINE CRANKSHAFT • Remove the crankshaft with the special tool. % 09920-13120: Crankcase separator...
Page 57: Engine Components Inspection And Service
ENGINE 3-21 ENGINE COMPONENTS INSPECTION AND SERVICE CYLINDER HEAD COVER " 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 in their original locations. DISASSEMBLY •...
Page 58 3-22 ENGINE ROCKER ARM I.D. Measure the inside diameter of the rocker arm and check the wear of the camshaft contacting surface. $ Rocker arm I.D. Standard (IN. & EX.): 12.000 – 12.018 mm % 09900-20605: Dial calipers REASSEMBLY Reassemble the cylinder head cover in the reverse order of dis- assembly.
Page 59: Cylinder Head
ENGINE 3-23 CYLINDER HEAD " 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 in their original locations. DISASSEMBLY • Remove the cam chain tensioner 1. •...
Page 60 3-24 ENGINE • Remove the valve from the combustion chamber side. • Remove the valve stem seal 1. • Remove the valve spring seat 2. CYLINDER HEAD DISTORTION Decarbonize the combustion chamber. Check the gasket surface of the cylinder head for distortion using a straightedge and thickness gauge.
Page 61 ENGINE 3-25 VALVE HEAD RADIAL RUNOUT Place the dial gauge at a right angle to the valve head face and measure the valve head radial runout. If it measures more than the service limit, replace the valve. $ Valve head radial runout Service Limit: 0.03 mm % 09900-20606: Dial gauge (1/100 mm) 09900-20701: Magnetic stand...
Page 62 3-26 ENGINE • Re-finish the valve guide holes in the cylinder head using the special tools. % 09916-34561: Valve guide reamer (11.3 mm) 09916-34542: Handle NOTE: Insert the reamer from the combustion chamber side and always turn the reamer handle clockwise. •...
Page 63 ENGINE 3-27 VALVE SEAT SERVICE 45˚ 15˚ The valve seats for both intake and exhaust valves are machined to two different angles. (The seat contact surface is cut at 45°.) INTAKE SIDE EXHAUST SIDE Valve seat 15° N-212 15° N-121 45°...
Page 64 3-28 ENGINE INITIAL SEAT CUT • Using the 45° cutter, descale and clean up the seat. Rotate the cutter one or two turns. • Measure the valve seat width W after every cut. 45˚ • If the valve seat is pitted or burned, use the 45° cutter to con- dition the seat some more.
Page 65 ENGINE 3-29 " Do not use lapping compound after the final cut is made. The finished valve seat should have a velvety smooth finish but not a highly polished or shiny fin- ish. This will provide a soft surface for the final seat- ing of the valve which will occur during the first few seconds of engine operation.
Page 66 3-30 ENGINE ! Valve spring tension (IN. & EX.) Standard INNER : 76 – 90 N/32.5 mm (7.8 – 9.2 kgf/32.5 mm) OUTER: 186 – 219 N/36.0 mm (18.9 – 22.3 kgf/36.0 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.
Page 67 Be sure to install all of the parts in their original posi- tions. INTAKE PIPE • When installing the intake pipe, apply grease to the O-ring. ( 99000-25010: SUZUKI SUPER GREASE “A” " Use the new O-ring to prevent sucking air from the joint.
Page 68: Camshaft
3-32 ENGINE CAM CHAIN TENSIONER • Install the cam chain tensioner 1. • Tighten the cam chain tensioner bolt 2 to the specified torque. # Cam chain tensioner bolt: 13 N·m (1.3 kgf-m) CAMSHAFT CAMSHAFT INSPECTION If the engine produces abnormal noises, vibration or lacks power, a camshaft may be distorted or worn to the service limit.
Page 69: Cylinder
ENGINE 3-33 Remove the cylinder head cover and measure the width of the compressed plastigauge using the envelope scale. This mea- surement should be taken at the widest part of the compressed plastigauge. $ Camshaft journal oil clearance Service Limit: 0.150 mm If the camshaft journal oil clearance exceeds the limit, measure the inside diameter of the camshaft journal holder and outside diameter of the camshaft journal.
Page 70: Cam Chain Tension Adjuster
3-34 ENGINE CYLINDER BORE Measure the cylinder bore diameter at six places. If any one of the measurements exceed the limit, overhaul the cylinder and replace the piston with an oversize piston, or replace the cylinder. ! Cylinder bore Service Limit: 57.090 mm "...
Page 71 ENGINE 3-35 PISTON-TO-CYLINDER CLEARANCE Subtract the piston diameter from the cylinder bore diameter. If the piston-to-cylinder clearance exceeds the service limit, rebore the cylinder and use an oversize piston or replace both the cylin- der and the piston. $ Piston-to-cylinder clearance Service Limit: 0.120 mm PISTON RING GROOVE CLEARANCE Measure the side clearance of the 1st and 2nd rings using the...
Page 72 3-36 ENGINE OVERSIZE RINGS Oversize piston ring The following oversize piston ring is used. It bears the following 0.5 mm O.S. identification number. Piston ring 1st and 2nd 0.5 mm: 50 Oil ring spacer Oversize oil ring The following oversize oil ring is used. It bears the following identification mark.
Page 73: Crankshaft And Conrod
ENGINE 3-37 CRANKSHAFT AND CONROD Crankshaft, RH Conrod " Bearing Crank pin Crankshaft, LH ITEM N·m kgf-m CONROD SMALL END I.D. Measure the conrod small end inside diameter using the dial cal- ipers. If the conrod small end inside diameter exceeds the ser- vice limit, replace the conrod.
Page 74 3-38 ENGINE CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod. This method can also check the extent of wear on the parts of the conrod’s big end. $ Conrod deflection Service Limit: 3.0 mm % 09900-20701: Magnetic stand...
Page 75: Starter Clutch And Starter Driven Gear Bearing
ENGINE 3-39 STARTER CLUTCH AND STARTER DRIVEN GEAR BEARING 10 N . m (1.0 kgf-m) Starter driven gear Roller Push piece Spring Generator motor STARTER CLUTCH Install the starter driven gear onto the starter clutch and turn the starter driven gear by hand (the gear turns in only one direction). The starter driven gear should turn smoothly.
Page 76: Generator Stator And Pick-Up Coil
3-40 ENGINE • Hold the generator rotor with the rotor holder and remove the starter clutch bolts. % 09930-44530: Rotor holder REASSEMBLY • Apply a small quantity of THREAD LOCK SUPER to the starter clutch bolts and tighten them to the specified torque while holding the rotor holder.
Page 77: Transmission
ENGINE 3-41 TRANSMISSION DISASSEMBLY • Disassemble the transmission gears as shown in the illustration. NOTE: When removing the 2nd drive gear, use a gear puller and a proper attachment. 1st driven gear 5th driven gear " 4th driven gear 3rd driven gear Top driven gear 2nd driven gear &...
Page 78 3-42 ENGINE • When installing a new snap ring, pay attention to the direction of the snap ring. Fit the snap ring to the side where the thrust Thrust is as shown in the illustration. The rounded side should be against the gear surface.
Page 79: Primary Driven Gear
ENGINE 3-43 GEARSHIFT FORKS Measure the gearshift fork clearance in the groove of its respec- tive gear using the thickness gauge. The clearance for each of the two gearshift forks plays an impor- tant role in the smoothness and positiveness of the shifting action.
Page 80: Clutch
3-44 ENGINE CLUTCH CLUTCH DRIVE PLATES Measure the thickness and claw width of the clutch drive plates using vernier calipers. If a clutch drive plate is not within the ser- vice limit, replace the clutch plates as a set. $ Clutch drive plate thickness Service Limit: 2.65 mm % 09900-20101: Venier calipers $ Clutch drive plate claw width...
Page 81: Oil Filter
ENGINE 3-45 OIL FILTER REMOVAL AND INSTALLATION • Remove the oil filter cap 1. • Remove the oil filter 2 and install a new one. 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.
Page 82: Crankcase Bearings
3-46 ENGINE CRANKCASE BEARINGS Play Play BEARING INSPECTION While the bearing is in the crankcase, rotate its inner race and check to see that it turns smoothly. If it does not turn quietly and smoothly, or if there are signs of any abnormalities, the bearing is defective and must be replaced as follows: BEARING REMOVAL •...
Page 83 • Install the driveshaft bearings using the special tool. % 09913-70210: Bearing installer set • Install the washer 1. • Apply a small quantity of SUZUKI SUPER GREASE to the lip of the oil seal. ( 99000-25010: SUZUKI SUPER GREASE “A”...
Page 84: Generator Cover Bearing
% 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 to the lip of the dust seal. ( 99000-25010: SUZUKI SUPER GREASE “A”...
Page 85: Clutch Release Camshaft
• Remove the oil seal retainer 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 release camshaft 2, washer 3 and new oil seal 4.
Page 86: Engine Reassembly
3-50 ENGINE ENGINE REASSEMBLY Reassemble the engine in the reverse order of disassembly. The following steps require special attention or precautionary measures should be taken. NOTE: Apply engine oil to each running and sliding part before reassembling. CRANKSHAFT • When installing the crankshaft into the crankcase, it is neces- sary to pull its left end into the left crankcase with the special tools.
Page 87 CRANKCASE • Wipe 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 “1207B”...
Page 88 • 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 spacer. When installing the engine sprocket spacer onto the driveshaft, face its grooves B toward inside.
Page 89 ENGINE 3-53 GENERATOR ROTOR • Install the cam chain. • Remove any grease from the tapered portion of the generator rotor and crankshaft. • Install the generator rotor key 1. • Install the generator rotor securely. • Apply a small quantity of THREAD LOCK SUPER to the gen- erator rotor nut 2.
Page 90 3-54 ENGINE • Install the primary drive gear 1 and oil pump drive gear 2. NOTE: Position the oil pump drive gear 2, as shown in the illustration. • Install the washer and primary drive gear/oil pump drive gear nut 3. NOTE: This nut 3 has left hand threads.
Page 91 ENGINE 3-55 • Install the gearshift cam driven gear assembly. • Install the pawl lifter 1 and cam guide 2. NOTE: Apply a small quantity of THREAD LOCK to the threads of the screws. * 99000-32050: THREAD LOCK “1342” • Install the return spring 3 to the gearshift shaft 4. •...
Page 92 3-56 ENGINE CLUTCH Primary driven gear assembly Clutch sleeve hub " Clutch push rod Clutch driven plate Clutch drive plate Push piece Clutch pressure plate ITEM N·m kgf-m • Install the washer 1 and spacer 2 onto the countershaft. NOTE: Apply engine oil to the inside and outside surfaces of the spacer.
Page 93 ENGINE 3-57 • Install the clutch sleeve hub nut, and tighten it to the specified torque with the special tool. # Clutch sleeve hub nut: 50 N·m (5.0 kgf-m) % 09920-53740: Clutch sleeve hub holder • Bend the lock washer 1 securely. •...
Page 94 STARTER MOTOR • Install the starter motor. NOTE: Apply grease to the O-ring. ( 99000-25010: SUZUKI SUPER GREASE “A” " Use a new O-ring to prevent oil leakage. GENERATOR COVER • Install the starter idle gear 2, shaft and spacer.
Page 95 ENGINE 3-59 PISTON/PISTON RING • First, install a spacer 1 into the oil ring groove and then install two side rails 2. The spacer and side rails do not have a spe- cific top or bottom when they are new. When reassembling used parts, install them in their original place and direction.
Page 96 3-60 ENGINE The followings are reminders for piston installation: • Before installing the piston pin, apply molybdenum oil solution onto its surface. • Apply molybdenum oil solution to the big and small ends of the conrod. • Place a clean rag over the cylinder base to prevent the piston pin circlip from dropping into crankcase.
Page 97 ENGINE 3-61 • Place the cylinder head onto the cylinder. • Cylinder head nuts and washers must be installed correctly as shown in the illustration. A Copper washer B Steel washer • Tighten the cylinder head nuts to the specified torque in a crisscross pattern.
Page 98 3-62 ENGINE • Install the C-ring 1 into the ring groove of the cylinder head. • Align the engraved line marks A on the camshaft so it is par- allel with mating surface of the cylinder head and cylinder head cover. •...
Page 99 • Clean the mating surfaces of the cylinder head and head cover. • Install the dowel pins. • Apply SUZUKI BOND uniformly to the mating surface of the cylinder head cover and install it within a few minutes. -99000-31230: SUZUKI BOND “1216B”...
Page 100 3-64 ENGINE CAM CHAIN TENSION ADJUSTER Install the cam chain tension adjuster. Pay attention to the fol- lowing points: • Apply engine oil to the push rod. • Turn the adjusting screw clockwise with a flat-bladed screw driver until the push rod locked. •...
Page 101: Pair (Air Supply) System
ENGINE 3-65 PAIR (AIR SUPPLY) SYSTEM PAIR HOSE INSPECTION • Inspect the PAIR hoses for wear or damage. • Inspect the PAIR hoses are securely connected. PAIR CONTROL VALVE REMOVAL • Disconnect the hoses and remove the PAIR control valve 1. INSPECTION •...
Page 102: Fuel And Lubrication
FUEL AND LUBRICATION SYSTEM 4-1 FUEL AND LUBRICATION SYSTEM CONTENTS FUEL TANK/FUEL VALVE ................4- 2 REMOVAL ....................4- 2 INSPECTION ..................4- 2 REMOUNTING ..................4- 3 CARBURETOR ....................4- 4 CONSTRUCTION ...................4- 4 SPECIFICATIONS ..................4- 5 I.D. NO. LOCATION ................4- 5 REMOVAL ....................4- 5 DISASSEMBLY ..................4- 6 CLEANING .....................4- 9 INSPECTION ..................4- 9...
Page 103: Fuel Tank/Fuel Valve
4-2 FUEL AND LUBRICATION SYSTEM FUEL TANK/FUEL VALVE REMOVAL Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the seat. ("5-3) • Turn the fuel valve to “OFF” position and disconnect the fuel hose 1 from the fuel valve. •...
Page 104: Remounting
FUEL AND LUBRICATION SYSTEM REMOUNTING Gasoline is very explosive. Extreme care must be taken. The gaskets ( 2 and 3) must be replaced with new ones to prevent fuel leakage. • Remount the fuel valve and tank in the reverse order of removal.
Page 105: Carburetor
4-4 FUEL AND LUBRICATION SYSTEM CARBURETOR CONSTRUCTION Top cap Spring Spring retainer Jet needle Diaphragm Piston valve Throttle stop screw Needle jet Needle jet holder Main jet Pilot jet Float Needle valve Float pin Pilot screw Gasket Drain plug Starter plunger Carburetor heater Thermo-switch...
Page 106: Specifications
FUEL AND LUBRICATION SYSTEM SPECIFICATIONS 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-0M...
Page 107: Disassembly
4-6 FUEL AND LUBRICATION SYSTEM DISASSEMBLY • Disconnect the 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. •...
Page 108 FUEL AND LUBRICATION SYSTEM • Remove the float pin 1. • Remove the floats 2 along with the needle valve 3. Do not use wire to clean the valve seat and jets. • Remove the main jet 4, needle jet holder 5, needle valve seat 6 and pilot jet 7.
Page 109 4-8 FUEL AND LUBRICATION SYSTEM • Slowly turn the pilot screw 1 in clockwise and count the num- ber of turns until the screw is lightly seated. Make a note of how many turns were made so the screw can be reset cor- rectly after cleaning.
Page 110: Cleaning
FUEL AND LUBRICATION SYSTEM CLEANING 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. • Clean all jets with a spray-type carburetor cleaner and blow dry with compressed air.
Page 111: Float Height Adjustment
4-10 FUEL AND LUBRICATION SYSTEM FLOAT HEIGHT ADJUSTMENT • To check the float height, invert the carburetor body, with the float arm kept free, measure the height A while float arm is just in contact with needle valve by using calipers. $ Float height A: 17.1 ±...
Page 112: Carburetor Heater Inspection
FUEL AND LUBRICATION SYSTEM 4-11 NOTE: The apparent fuel level measured in the level gauge is higher than the actual level in the float chamber because of meniscus effect. (Meniscus is approximately 1 mm.) Datum point Fuel level in gauge CARBURETOR HEATER INSPECTION •...
Page 113: Reassembly And Remounting
4-12 FUEL AND LUBRICATION SYSTEM REASSEMBLY AND REMOUNTING Reassemble and remount the carburetor in the reverse order of disassembly and removal. Pay attention to the following points: * Assemble the parts taking consideration of their function. * Replace O-rings and seals with new ones. PILOT SCREW •...
Page 114 FUEL AND LUBRICATION SYSTEM 4-13 THROTTLE POSITION SENSOR POSITIONING • Install the throttle position sensor with the flats on the throttle shaft end securely engaged with the slot on the throttle posi- tion sensor. Ω1 Ω2 Ω1 • Measure the resistance between the throttle position sensor terminals as shown in the illustration.
Page 115: Engine Lubrication System
4-14 FUEL AND LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM CHART CAMSHAFT CAMSHAFT JOURNAL (L) CAM CHAIN CAMSHAFT JOURNAL (R) CONROD SMALL END CAM FACES CYLINDER WALL ROCKER ARM SHAFTS CONROD BIG END BEARING ORIFICE CRANKSHAFT ORIFICE CLUTCH RELEASE COUNTERSHAFT LEFT SIDE BEARING OIL FILTER...
Page 116: Oil Pressure
FUEL AND LUBRICATION 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 dry off solvent.
Page 117 CHASSIS 5-1 CHASSIS CONTENTS EXTERIOR PARTS ..................5- 3 REMOVAL AND INSTALLATION ............5- 3 FRONT WHEEL .....................5- 4 REMOVAL AND DISASSEMBLY ............5- 4 INSPECTION AND DISASSEMBLY ............5- 5 REMOUNTING ..................5- 6 FRONT BRAKE .....................5- 9 BRAKE FLUID REPLACEMENT ............5-10 BRAKE PAD REPLACEMENT ..............5-11 BRAKE CALIPER REMOVAL AND DISASSEMBLY ......5-11 CALIPER INSPECTION .................5-13 CALIPER REASSEMBLY ..............5-13...
Page 118 CHASSIS CHASSIS CONTENTS REAR SHOCK ABSORBER ................. 5-42 REMOVAL ..................... 5-42 INSPECTION ..................5-43 REASSEMBLY 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 ..................
Page 119: Exterior Parts
CHASSIS EXTERIOR PARTS REMOVAL AND INSTALLATION SEAT • Remove the bolts (left and 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 •...
Page 120: Front Wheel
CHASSIS FRONT WHEEL Collar Bearing " Front axle spacer Bearing Brake disc Speedometer gearbox Balancer weight Front axle Brake disc bolt Spoke nipple ITEM N·m kgf-m 0.45 REMOVAL AND DISASSEMBLY • Raise the front wheel off the ground with a jack. When using a jack, take care not to cause scratches on the chassis.
Page 121: Inspection And Disassembly
CHASSIS • Remove the brake disc by removing its bolts. INSPECTION AND DISASSEMBLY SPEEDOMETER GEARBOX Turn the speedometer gear and check to see 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.
Page 122: 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 to the bearings before installing. % 99000-25010: SUZUKI SUPER GREASE “A” • Install the wheel bearings using the special tools as described below.
Page 123 CHASSIS Clearance BRAKE DISC • 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) Keep the brake disc clean, free from dirt and grease.
Page 124 CHASSIS SPEEDOMETER GEARBOX • Apply SUZUKI SUPER GREASE to the speedometer gear- box. ! 99000-25010: SUZUKI SUPER GREASE “A” • Align the lugs 1 on the speedometer gearbox with the recesses 2 on the front wheel. FRONT WHEEL • Make sure that the stopper 3 on the front fork and the speed- ometer gearbox protrusion 4 are installed as shown.
Page 125: Front Brake
CHASSIS FRONT BRAKE ITEM N·m kgf-m 0.75 Diaphragm " Master cylinder Piston set Brake hose Caliper holder & Caliper Pad set Piston Piston and dust seal Master cylinder mounting bolt Brake hose union bolt Brake caliper mounting bolt Air bleeder valve * This brake system is filled with an ethylene glycol-based DOT 4 brake fluid.
Page 126: Brake Fluid Replacement
5-10 CHASSIS BRAKE FLUID REPLACEMENT • Place the motorcycle on a level surface and keep the handle- bars straight. • Remove the master cylinder reservoir cap and diaphragm. • Suck up the old brake fluid as much as possible. • Connect a clear hose to the air bleeder valve 1 and insert the other end of the hose into a receptacle.
Page 127: Brake Pad Replacement
CHASSIS 5-11 BRAKE PAD REPLACEMENT • Remove the brake caliper. • Remove the pin 1. • Remove the brake pad mounting pin 2 and brake pads 3. * Do not operate the brake lever after brake pad removal. * Replace the brake pad as a set, otherwise braking performance will be adversely affected.
Page 128 5-12 CHASSIS • Remove the brake pads. (#5-11) • Remove the brake caliper holder 2. • Remove the pad spring 3. • Remove the rubber parts 4. Do not use high pressure air to prevent piston dam- age. • Remove the dust seal 5 and piston seal 6. Do not reuse the removed dust seals and piston seals to prevent fluid leakage.
Page 129: Caliper Inspection
CHASSIS 5-13 CALIPER INSPECTION Inspect the caliper cylinder wall and piston surface for scratch, corrosion or other damages. If any abnormal condition is noted, replace the caliper assembly with a new one. CALIPER REASSEMBLY Reassemble and remount the brake caliper in the reverse order of removal and disassembly.
Page 130: Caliper Remounting
5-14 CHASSIS BRAKE CALIPER HOLDER • Apply SUZUKI SILICON GREASE to the brake caliper holder pin. * 99000-25100: SUZUKI SILICONE GREASE CALIPER REMOUNTING • Tighten the brake caliper mounting bolts 1. ' Brake caliper mounting bolt: 39 N·m (3.9 kgf-m) •...
Page 131: Master Cylinder Removal And Disassembly
CHASSIS 5-15 MASTER CYLINDER REMOVAL AND DISASSEMBLY • Place a rag underneath the brake hose union bolt 1 on the master cylinder to catch any spilt brake fluid. (#5-10) 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.
Page 132: Master Cylinder Inspection
5-16 CHASSIS • Pull out the dust seal boot 1 and remove the snap ring 2. • Remove the piston 3 and spring 4. MASTER CYLINDER INSPECTION Inspect the master cylinder bore for any scratches or damage. If any damages are found, replace the master cylinder with a new one.
Page 133 CHASSIS 5-17 • Install the piston/cup set. Boot Snap ring Spring Piston Primary cup Secondary cup • When installing the brake light switch, align the projection on the switch with the hole in the master cylinder. • When remounting the master cylinder on the handlebars, align the master cylinder holder’s mating surface with the punched mark A on the handlebars, and then tighten the upper clamp bolt first.
Page 134: Handlebars
5-18 CHASSIS HANDLEBARS Handlebars Balancer cap " Right grip Front brake lever Front brake switch Left grip & Clutch lever Clutch switch REMOVAL HANDLEBAR LEFT SIDE PARTS • Remove the rear view mirror 1. • Disconnect the clutch lever position switch coupler 2. •...
Page 135: Remounting
Front • Apply grease to the throttle cables and assemble them to the pulley. % 99000-25010: SUZUKI SUPER GREASE “A” • With the stopper 3 engaged with the handlebar hole, assem- ble the handlebar switch. • Install the brake master cylinder. (#5-17) •...
Page 136: Front Fork
5-20 CHASSIS FRONT FORK O-ring Spacer " Washer Front fork spring Damper rod Rebound spring & Inner tube Oil lock piece Dust seal Oil seal stopper ring Oil seal Outer tube Front fork cap bolt Front axle pinch bolt Damper rod bolt ITEM N·m kgf-m...
Page 137 CHASSIS 5-21 • Loosen the front fork upper clamp bolt 2. NOTE: Slightly loosen the front fork cap bolt 3 before loosening the lower clamp bolt to facilitate later disassembly. • Loosen the front fork lower clamp bolt 4. NOTE: Hold the front fork by the hand to prevent sliding out of the steer- ing stem.
Page 138 5-22 CHASSIS • Remove the damper rod bolt using a 6-mm hexagon wrench and the special tools. " 09940-34520: “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. Oil seal and dust seal must be replaced with the new ones when assembling the front fork.
Page 139: Inspection
CHASSIS 5-23 • Remove the oil seal by using the special tool. " " 09913-50121: Oil seal remover " " INSPECTION INNER AND OUTER TUBE Inspect the inner tube sliding surface and outer tube sliding sur- face for any scuffing or damage. FRONT FORK SPRING Measure the fork spring free length.
Page 140: Reassembly And Remounting
2. NOTE: Apply grease to the oil seal 2 lip lightly before installing it. % 99000-25010: SUZUKI SUPER GREASE “A” NOTE: * When installing the oil lock piece, insert the tapered end A of oil lock piece into the inner tube.
Page 141 CHASSIS 5-25 • Install the oil seal stopper ring 2 and dust seal 3. Make sure that the oil seal stopper ring is fitted securely. DAMPER ROD • Fit the rebound spring 1 to the damper rod 2 and install them to the inner tube.
Page 142 • Pour the specified fork oil into the inner tube. $ Front fork oil capacity (each leg): 230 ml , 99000-99044-10G: SUZUKI FORK OIL #10 or equivalent fork oil • Hold the front fork leg in a vertical position and adjust the fork oil level by using the special tool.
Page 143 CHASSIS 5-27 • Tighten the front fork lower clamp bolt 1 and front fork cap bolt 2 to the specified torque. • Tighten the front fork upper clamp bolt 3 to the specified torque. ' Front fork upper clamp bolt: 23 N·m (2.3 kgf-m) Front fork lower clamp bolt: 33 N·m (3.3 kgf-m) Front fork cap bolt: 23 N·m (2.3 kgf-m) •...
Page 144: Steering
5-28 CHASSIS STEERING Steering stem upper bracket Dust seal " Upper inner race Steering stem upper bearing Lower inner race Steering stem lower bearing Steering stem head nut Front fork upper clamp bolt Steering stem nut Front fork lower clamp bolt ITEM N·m kgf-m...
Page 145 CHASSIS 5-29 • Disconnect the headlight and position light couplers. • Remove the headlight housing 2. • Remove the speedometer 3. • Remove the front turn signal lights 4, 5. • Remove the handlebar switch harness.
Page 146 5-30 CHASSIS • Remove the handlebars 6. Protect the removed handlebars with a cloth to pre- vent it touching other parts directly. • Remove the steering stem head nut 7. The steering stem head may rotate together and dam- age the fuel tank. Use a cloth or the like to prevent such damage.
Page 147: Inspection
CHASSIS 5-31 • Remove the steering stem lower bearing C. • Remove the ignition switch D using the special tools. " 09930-11920: Torx bit JT40H 09930-11940: Bit holder INSPECTION Inspect the removed parts for the following abnormalities. If any damages are found, replace the respective parts with the new ones.
Page 148: Reassembly And Remounting
BEARINGS • 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 GREASE “A” • Install the bearings 1, inner race 2 and the dust seal 3.
Page 149 CHASSIS 5-33 • Turn the steering stem bracket about five or six times to the left and right so that the bearings seat properly. ¼ – ½ turn • Loosen the steering stem nut ¼ – ½ of a turn. •...
Page 150: Rear Wheel
5-34 CHASSIS REAR WHEEL Rear axle Rear sprocket " Spacer Bearing (Right) Collar Rear wheel & Bearing (Left) Brake cam lever Brake panel Brake cam Brake shoe Return spring Rear axle nut Rear sprocket mounting nut Rear brake cam lever nut ITEM N·m kgf-m...
Page 151: Inspection And Disassembly
CHASSIS 5-35 • Raise the rear wheel off the ground with a jack or wooden block. • Loosen the drive chain adjusters 7, left and right. • Remove the rear axle 8. • Disengage the drive chain from the rear sprocket. •...
Page 152: Reassembly And Remouning
Reassemble and remount the rear wheel and rear brake in the reverse 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 bearings using the special tool.
Page 153 CHASSIS 5-37 Clearance REAR SPROCKET • Tighten the sprocket mounting nuts to the specified torque. '-Rear sprocket mounting nut: 60 N·m (6.0 kgf-m) NOTE: The stamped mark A on the rear sprocket should face to the outside. REAR WHEEL • Align the brake panel stopper 1 on the swingarm with the recess on the brake panel.
Page 154: Rear Brake
5-38 CHASSIS REAR BRAKE Brake shoe Cam lever bolt " Brake cam lever Brake cam Spring Push rod REMOVAL AND DISASSEMBLY • Remove the rear wheel. (#5-34) • Remove the rear brake panel 1. • Remove the brake shoes 2, 3 from the brake panel. •...
Page 155: Inspection
Place the brake cam into the brake panel and check for smooth rotation. Check that the rotating parts are coated with sufficient grease. REASSEMBLY • When installing the brake camshaft, apply SUZUKI SUPER GREASE to the camshaft, cam face and pin. % 99000-25010: SUZUKI SUPER GREASE “A”...
Page 156: Rear Brake Pedal Removal
5-40 CHASSIS • Install the brake shoes with spring hooks faced inside. Be careful not to apply too much grease to the cam and pin. If grease gets on the lining, brake slippage will result. • When installing the brake cam lever, align the groove A of camshaft with slit of cam lever.
Page 157: Rear Brake Pedal Installation
Install the rear brake 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 condition, play and braking effect.
Page 158: Rear Shock Absorber
5-42 CHASSIS REAR SHOCK ABSORBER Rear shock absorber Rear shock absorber bolt Rear shock absorber bolt and nut ITEM N·m kgf-m REMOVAL • Remove the rear wheel. (#5-34) • Remove the rear shock absorber lower nut and bolt. • Remove the rear shock absorber upper bolt. •...
Page 159: Inspection
CHASSIS 5-43 • Remove the spacer 1. • Remove the dust seals 2. INSPECTION Inspect the spacer for any 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.
Page 160: Reassembly And Remounting
5-44 CHASSIS REASSEMBLY AND REMOUNTING • Apply grease to the spacer. % 99000-25010: SUZUKI SUPER GREASE “A” • Install the dust seal taking care about its direction. Outside Inside • Install the rear shock absorber facing the stamp A forward.
Page 161: Rear Shock Absorber Disposal
CHASSIS 5-45 REAR SHOCK ABSORBER DISPOSAL * The rear 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 before disposing. GAS PRESSURE RELEASE •...
Page 162: Swingarm
5-46 CHASSIS SWINGARM Pivot shaft Dust cover " Washer Dust seal Bushing Collar Swingarm pivot nut ITEM N·m kgf-m REMOVAL • Remove the rear wheel. (#5-34) • Remove the rear shock absorber lower mounting nut and bolt.
Page 163: Inspection And Replacement
CHASSIS 5-47 • Remove the swingarm pivot nut and shaft. • 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.
Page 164 5-48 CHASSIS CHAIN BUFFER Inspect the chain buffer for damage. If any damages are found, replace the chain buffer with a new one. SWINGARM PIVOT SHAFT Measure the pivot shaft runout using the dial gauge. If the runout exceeds the service limit, replace the pivot shaft. $ Swingarm pivot shaft runout Service limit: 0.6 mm "...
Page 165: Swingarm Pivot Shaft Installation
CHASSIS 5-49 • Press the dust seals into the swingarm pivot by using the spe- cial tool and suitable size socket wrench 2. " 09924-84521: Bearing installer NOTE: Press the swingarm dust seals at 5 mm depth from the swing- arm edge.
Page 166: Tire And Wheel
5-50 CHASSIS TIRE AND WHEEL TIRE REMOVAL Tube tire is used for this model. When removing or installing the tire, be careful not to damage the tube. For operating procedures, refer to the instructions supplied by the tire changer manufacturer. NOTE: When removing the tire in the case of repair or inspection, mark the tire with a chalk to indicate the tire position relative to the...
Page 167: Tire Installation
CHASSIS 5-51 TUBE • Inspect the tube after the tire is removed from the rim. • If the tube has abnormality, replace the tube with a new one. TIRE INSTALLATION • Apply tire lubricant to the tire bead. Do not use oil, grease or gasoline on the tire bead in place of tire lubricant.
Page 168 5-52 CHASSIS • In this condition, check the “rim line” cast on the tire side walls. The line must be equidistant from the wheel rim all around. If the distance between the rim line and wheel rim Rim line varies, this indicates that the bead is not properly seated. If this is the case, deflate the tire completely and unseat the bead for both sides.
Page 169: Electrical System
ELECTRICAL SYSTEM ELECTRICAL SYSTEM CONTENTS CAUTIONS IN SERVICING ................6- 2 CONNECTOR ..................6- 2 COUPLER ....................6- 2 CLAMP ....................6- 2 FUSE ......................6- 2 SEMI-CONDUCTOR EQUIPPED PART ..........6- 2 BATTERY ....................6- 3 CONNECTING THE BATTERY ..............6- 3 WIRING PROCEDURE ................6- 3 USING THE MULTI CIRCUIT TESTER ..........6- 3 LOCATION OF ELECTRICAL COMPONENTS ..........6- 4 CHARGING SYSTEM ..................6- 6 TROUBLESHOOTING ................6- 7...
Page 170: Cautions In Servicing
ELECTRICAL SYSTEM CAUTIONS IN SERVICING CONNECTOR • When connecting a connector, be sure to push it in until a click is felt. • Inspect the connector for corrosion, contamination and break- age in its cover. COUPLER • With a lock type coupler, be sure to release the lock before disconnecting and push it in fully till the lock works when con- necting.
Page 171: Battery
ELECTRICAL SYSTEM BATTERY • The MF battery used in this motorcycle does not require main- tenance (e.g., electrolyte level inspection, distilled water replenishment). • During normal charging, no hydrogen gas is produced. How- ever, if the battery is overcharged, hydrogen gas may be pro- duced.
Page 172: Location Of Electrical Components
ELECTRICAL SYSTEM LOCATION OF ELECTRICAL COMPONENTS Battery Pick-up coil Regulator/rectifier Throttle position sensor Side-stand switch Neutral switch Generator...
Page 173 ELECTRICAL SYSTEM Starter motor Starter relay Rear brake light switch Fuse Turn signal/side-stand relay Ignitor Ignition coil...
Page 174: Charging System
ELECTRICAL SYSTEM CHARGING SYSTEM Regulator/rectifier IG. switch Generator Load...
Page 175: Troubleshooting
ELECTRICAL SYSTEM TROUBLESHOOTING Battery runs down quickly. Check accessories which use excessive Accessories • Remove accessories. amounts of electricity. are installed No accessories Check the battery for current • Short circuit of wire harness Current leaks leaks. ( 6-8) • Faulty electrical equipment No current leaks Measure the charging voltage between the battery terminals.
Page 176: Inspection
ELECTRICAL SYSTEM INSPECTION BATTERY CURRENT LEAKAGE • Remove the seat. (!5-3) • Turn the ignition switch to the “OFF” position. • Disconnect the - battery lead wire. Measure the current between the - battery terminal and - bat- tery lead wire using the multi circuit tester. If the reading exceeds the specified value, leakage is evident.
Page 177 ELECTRICAL SYSTEM GENERATOR COIL RESISTANCE • Remove the seat. (!5-3) • Remove the fuel tank. (!4-2) • Disconnect the generator coupler. Measure the resistance between three lead wires. If the resistance is not specified value, replace the stator with a new one.
Page 178 6-10 ELECTRICAL SYSTEM REGULATOR/RECTIFIER • Remove the engine sprocket cover. (!3-5) • Remove the regulator/rectifier. • Disconnect the regulator/rectifier coupler. Measure the voltage between the terminals using the multi cir- cuit tester as indicated in the table below. If the voltage is not within the specified value, replace the regulator/rectifier with a new one.
Page 179: Starter System And Side-Stand/Ignition Interlock System
ELECTRICAL SYSTEM 6-11 STARTER SYSTEM AND SIDE-STAND/IGNITION INTERLOCK SYSTEM Engine Starter stop Side-stand button switch switch Neutral IG. switch PUSH indicator PUSH FREE LOCK FREE Starter Battery Starter Turn signal/ Clutch relay Neutral motor side-stand relay lever 1 : Fuse 20 A switch position switch...
Page 180: Trouble Shooting
6-12 ELECTRICAL SYSTEM TROUBLE SHOOTING Starter motor will not run. Check if the starter motor runs The transmission is in neutral. Grasp the when its terminal is connected clutch lever, turn on the ignition switch to the battery terminal. (Do with the engine stop switch in the “RUN”...
Page 181: Starter Motor Removal And Disassembly
ELECTRICAL SYSTEM 6-13 STARTER MOTOR REMOVAL AND DISASSEMBLY • Disconnect the starter motor lead wire. • Remove the starter motor. • Disassemble the starter motor as shown in the illustration. O-ring (2pcs) O-ring Housing end O-ring (2pcs) Starter motor case Armature Housing end STARTER MOTOR INSPECTION...
Page 182: Starter Motor Reassembly
Pay attention to the following points: • Apply SUSUKI SUPER GREASE to the lip of the oil seal. - 99000-25010: SUZUKI SUPER GREASE “A” • Apply a small quantity of SUZUKI MOLY PASTE to the arma- ture shaft. . 99000-25140: SUZUKI MOLY PASTE •...
Page 183: Starter Relay Inspection
• Apply a small quantity of THREAD LOCK to the starter motor housing bolts. / 99000-32050: THREAD LOCK “1342” • Apply SUZUKI SUPER GREASE to the O-ring. - 99000-25010: SUZUKI SUPER GREASE “A” STARTER RELAY INSPECTION • Remove the right frame cover. (!5-3) •...
Page 184: Side-Stand/Ignition Interlock System Parts Inspection
6-16 ELECTRICAL SYSTEM SIDE-STAND/IGNITION INTERLOCK SYSTEM PARTS INSPECTION Check the interlock system for proper operation. If the interlock system does not operate properly, check each component for damage or abnormalities. If any abnormality is found, replace the component with a new one. SIDE-STAND SWITCH INSPECTION •...
Page 185 ELECTRICAL SYSTEM 6-17 TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. • Remove the right frame cover. (!5-3) • Remove the turn signal/side-stand relay. SIDE-STAND RELAY INSPECTION First check the insulation between D and E terminals with the tester.
Page 186: Ignition System
6-18 ELECTRICAL SYSTEM IGNITION SYSTEM Side-stand Engine stop IG. switch relay switch Fuse Pick-up coil Ignitor Fuse Battery IG. coil Neutral switch NOTE: The ignition cut-off circuit is incorporated in this ignitor to prevent over-running of engine. If engine rpm reaches 10 000 r/min, this circuit cuts off the ignition primary current for the spark plug.
Page 187: Troubleshooting
ELECTRICAL SYSTEM 6-19 TROUBLESHOOTING * Make sure the transmission is in neutral and the No spark or poor spark engine stop switch is in the “RUN” position. Grasp the clutch lever. Make sure the fuse is not blown and the battery is fully-charged before diagnosing. Check the ignition system couplers for Loose •...
Page 188: Inspection
6-20 ELECTRICAL SYSTEM INSPECTION IGNITION COIL PRIMARY PEAK VOLTAGE • Disconnect the spark plug cap. • Connect a new spark plug to the spark plug cap and ground it to the cylinder head. NOTE: Make sure that all couplers and spark plug are connected prop- erly and the battery is used in fully-charged condition.
Page 189 ELECTRICAL SYSTEM 6-21 IGNITION COIL RESISTANCE • Disconnect the ignition coil lead wires and plug cap. Measure the ignition coil resistance in both the primary and sec- ondary windings. If the resistance is not within the standard range, replace the ignition coil with a new one. # 09900-25008: Multi circuit tester set ( Tester knob indication: Resistance (Ω) &...
Page 190 6-22 ELECTRICAL SYSTEM • Shift the transmission into the neutral, and then turn the igni- tion switch to the “ON” position. Ignitor Pick-up coil • Squeeze the clutch lever. coupler coupler • Press the starter button and allow the engine to crank for a few seconds, and then measure the pick-up coil peak voltage.
Page 191: Speedometer
ELECTRICAL SYSTEM 6-23 SPEEDOMETER • Disassemble the speedometer as follows.
Page 192: Lamps
6-24 ELECTRICAL SYSTEM LAMPS HEADLIGHT " 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. BRAKE LIGHT/TAILLIGHT " Do not overtighten the lens fitting screws.
Page 193: Turn Signal Light
ELECTRICAL SYSTEM 6-25 TURN SIGNAL LIGHT " Do not overtighten the lens fitting screws. HEADLIGHT BEAM ADJUSTMENT • Adjust the headlight beam, both vertical and horizontal. A: Vertical adjuster B: Horizontal adjuster...
Page 194: Relays
6-26 ELECTRICAL SYSTEM RELAYS TURN SIGNAL/SIDE-STAND RELAY The turn signal/side-stand relay is composed of the turn signal relay, side-stand relay and diode. TURN SIGNAL INSPECTION Before removing the turn signal/side-stand relay, check the operation of the turn signal light. If the turn signal light does not illuminate, inspect the bulb, turn signal switch and circuit connection.
Page 195: Switches
ELECTRICAL SYSTEM 6-27 SWITCHES IGNITION SWITCH REMOVAL • Remove the seat. (!5-3) • Remove the fuel 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 "...
Page 196 6-28 ELECTRICAL SYSTEM Inspect each switch for continuity with a tester. If any abnormality is found, replace the respective switch assemblies with new ones. IGNITION SWITCH FRONT BRAKE SWITCH Color Color B/Bl Position Position LOCK REAR BRAKE SWITCH Color Position DIMMER SWITCH Color µ...
Page 197: Battery
ELECTRICAL SYSTEM 6-29 BATTERY SPECIFICATIONS Type designation YTX7L-BS Capacity 12 V, 21.6 kC (6 Ah)/10 HR INITIAL CHARGING FILLING ELECTROLYTE • Remove the aluminum tape 1 sealing the battery electrolyte filler holes. • Remove the caps 2. NOTE: * After filling the electrolyte completely, use the removed caps 2 as the sealed caps of battery filler holes.
Page 198 6-30 ELECTRICAL SYSTEM NOTE: If no air bubbles are coming up from a filler port, tap the bottom of the electrolyte container two or three times. Never remove the container from the battery. • After confirming that the electrolyte has entered the battery completely, remove the electrolyte containers from the bat- tery.
Page 199: Servicing
ELECTRICAL SYSTEM 6-31 SERVICING Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery have occurred, replace the battery with a new one. If the battery terminals are found to be coated with rust or an acidic white powdery substance, then this can be cleaned away with sandpa- per.
Page 200: Servicing Information
SERVICING INFORMATION SERVICING INFORMATION CONTENTS TROUBLESHOOTING ...................7- 2 ENGINE ....................7- 2 CARBURETOR ..................7- 5 CHASSIS ....................7- 6 BRAKES ....................7- 7 ELECTRICAL ..................7- 8 BATTERY ....................7- 9 WIRING DIAGRAM ..................7-10 WIRE ROUTING ....................7-11 ENGINE ELECTRICAL PARTS WIRE ROUTING .........7-12 CABLE ROUTING ..................7-13 FRONT BRAKE HOSE ROUTING ..............7-14 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING .........7-15 SPEEDOMETER CABLE ROUTING .............7-16...
Page 201: Troubleshooting
SERVICING INFORMATION TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1. Worn cylinder Replace. 2. Worn piston ring Replace. 3. Worn valve guide or improper valve seating Repair or replace. 4.
Page 202 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine is noisy. Excessive valve chatter 1. Excessive valve clearance Adjust. 2. Weak or broken valve spring Replace. 3. Worn camshaft Replace. 4. Worn or burnt camshaft journal Replace. Noise seems to come from the piston 1.
Page 203 SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine idles poorly. 1. Valve clearance out of adjustment Adjust. 2. Improper valve seating Repair or replace. 3. Worn valve guide Replace. 4. Worn camshaft Replace. 5. Excessive spark plug gap Adjust or replace. 6.
Page 204: Carburetor
SERVICING INFORMATION Complaint Symptom and possible causes Remedy Engine overheats. 1. Carbon buildup on piston crown Clean. 2. Insufficient amount of engine oil Check level and add. 3. Defective oil pump Replace. 4. Clogged oil circuit Clean. 5. Float chamber fuel level too low Adjust float height.
Page 205: Chassis
SERVICING INFORMATION CHASSIS Complaint Symptom and possible causes Remedy Steering is heavy. 1. Overtightened steering stem nut Adjust. 2. Broken bearing in steering stem Replace. 3. Distorted steering stem Replace. 4. Low tire pressure Regulate. Handlebar wobbles. 1. Loss of balance between right and left front forks Adjust or replace.
Page 206: Brakes
SERVICING INFORMATION BRAKES Complaint Symptom and possible causes Remedy Brake power insuffi- 1. Leakage of brake fluid Repair or replace. cient 2. Worn brake pad Replace. (FRONT) 3. Oil on brake pad surface Clean brake disc and brake pads. 4. Worn brake disc Replace.
Page 207: Electrical
SERVICING INFORMATION ELECTRICAL Complaint Symptom and possible causes Remedy No sparking or poor 1. Defective ignition coil Replace. sparking 2. Defective spark plug Replace. 3. Defective generator Replace. 4. Defective ignitor unit Replace. Spark plug is wet or 1. Excessively rich air/fuel mixture Adjust carburetor.
Page 208: Battery
SERVICING INFORMATION BATTERY Complaint Symptom and possible causes Remedy “Sulfation”, acidic 1. Cracked battery case Replace the battery. white powdery sub- 2. Battery has been left in a run-down condition for a long Replace the battery. stance or spots on time.
Page 209: Wiring Diagram
7-10 SERVICING INFORMATION WIRING DIAGRAM...
Page 210: Wire Routing
SERVICING INFORMATION 7-11 WIRE ROUTING...
Page 211: Engine Electrical Parts Wire Routing
7-12 SERVICING INFORMATION ENGINE ELECTRICAL PARTS WIRE ROUTING...
Page 212: Cable Routing
SERVICING INFORMATION 7-13 CABLE ROUTING...
Page 213: Front Brake Hose Routing
7-14 SERVICING INFORMATION FRONT BRAKE HOSE ROUTING VIEW OF TOP 42˚ VIEW OF FRONT 20˚ 23 N . m (2.3 kgf-m) Front brake hose Throttle cable Pass through the brake hose behind the throttle cable. Clamp the brake hose firmly. Clamp the brake hose firmly.
Page 214: Pair (Air Supply) System Hose Routing
SERVICING INFORMATION 7-15 PAIR (AIR SUPPLY) SYSTEM HOSE ROUTING PAIR pipe Vacuum hose PAIR pipe Vacuum hose PAIR valve PAIR valve PAIR hose PAIR hose PAIR valve PAIR valve Matching mark Matching mark PAIR cleaner hose PAIR cleaner hose...
Page 215: Speedometer Cable Routing
7-16 SERVICING INFORMATION SPEEDOMETER CABLE ROUTING 45˚ Cable guide Cable guide Protrusion (Gearbox) Speedometer cable Stopper (Fork) SIDE-STAND INSTALLATION 40 N . m (4.0 kgf-m) Side-stand...
Page 216: Fuel Tank Installation
SERVICING INFORMATION 7-17 FUEL TANK INSTALLATION Align the cushion concave part Cushion with the frame locating plate. Bolt Clamp Cushion Install so that the clamp Cushion claw faces downward. Spacer Cushion Fuel valve Install so that the clamp claw faces inward. Cut the clamp end, so the remaining part should be more or less 10 mm.
Page 217: Drive Chain Guide Roller Installation
7-18 SERVICING INFORMATION DRIVE CHAIN GUIDE ROLLER INSTALLATION Frame 36 – 44 N . m (3.6 – 4.4 kgf-m) HANDLEBAR BALANCER INSTALLATION Throttle grip Balancer weight 4.0 – 7.0 N . m (0.4 – 0.7 kgf-m)
Page 218: Exhaust Pipe And Muffler Installation
SERVICING INFORMATION 7-19 EXHAUST PIPE AND MUFFLER INSTALLATION...
Page 219: Carburetor And Air Cleaner Installation
7-20 SERVICING INFORMATION CARBURETOR AND AIR CLEANER INSTALLATION 40˚ – 50˚ Intake pipe side Air cleaner side Carburetor air vent hose PAIR hose Carburetor overflow hose Forward Crankcase breather hose (PCV hose) Vacuum hose PAIR valve PAIR pipe Carburetor overflow hose Carburetor overflow hose...
Page 220: Special Tools
SERVICING INFORMATION 7-21 SPECIAL TOOLS 09900-18710 09900-00401 09900-00410 09900-06107 09900-09004 Hexagon socket Hexagon wrench set Hexagon wrench set Snap ring pliers Impact driver set (12 mm) 09900-20202 09900-20203 09900-20205 09900-20101 09900-20102 Micrometer Micrometer Micrometer Vernier calipers Vernier calipers (25 – 50 mm) (50 –...
Page 221 7-22 SERVICING INFORMATION 09915-63210 09913-10750 09913-10760 09913-50121 09913-70210 Compression gauge Adapter Fuel level gauge set Oil seal remover Bearing installer set adaptor 09915-64510 09915-74510 Compression gauge 09915-70610 Oil pressure gauge 09916-10911 09916-14510 Adaptor Valve lapper set Valve lifter 09916-20620 09916-24920 09916-24480 09916-14910 Valve seat cutter...
Page 222 SERVICING INFORMATION 7-23 09930-10121 09921-20240 09923-74510 09924-84521 Spark plug wrench 09930-11920 Bearing remover set Bearing remover Bearing installer set Torx bit JT40H 09940-14911 09930-11940 09930-30102 09930-34932 09930-44530 Steering stem nut Bit holder Sliding shaft Rotor remover Rator holder socket wrench 09940-52861 09940-60113 09940-34520...
Page 223: Tightening Torque
7-24 SERVICING INFORMATION TIGHTENING TORQUE ENGINE ITEM N·m kgf-m Cylinder head cover bolt Cylinder head nut Initial 8 mm Final 6 mm Cylinder base nut Primary drive gear nut Crankcase bolt Exhaust pipe bolt Muffler mounting bolt Muffler connecting bolt Cam chain tension adjuster bolt Camshaft sprocket bolt Rocker arm shaft bolt...
Page 224: Chassis
SERVICING INFORMATION 7-25 CHASSIS ITEM N·m kgf-m Front axle nut Front axle pinch bolt Front fork cap bolt Front fork damper rod bolt Front fork lower clamp bolt Front fork upper clamp bolt Steering stem head nut Steering stem nut Handlebar clamp bolt Front brake master cylinder mounting bolt Front brake caliper mounting bolt...
Page 225: Tightening Torque Chart
7-26 SERVICING INFORMATION TIGHTENING TORQUE CHART For other nuts and bolts not listed in the preceding page, refer to this chart: Bolt Diameter Conventional or “4” marked bolt “7” marked bolt A (mm) N·m kgf-m N·m kgf-m 0.15 0.23 0.45 0.55 13.5 10.5...
Page 226: Service Data
SERVICING INFORMATION 7-27 SERVICE DATA VALVE + GUIDE Unit: mm ITEM STANDARD LIMIT Valve diam. — — Valve clearance (when cold) 0.08 – 0.13 — 0.13 – 0.18 — Valve guide to valve stem 0.010 – 0.037 — clearance 0.030 – 0.057 —...
Page 227 7-28 SERVICING INFORMATION CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Compression pressure 980 kPa 1 300 – 1 700 kPa (9.8 kgf/cm (13 – 17 kgf/cm , 185 – 242 psi) 140 psi) Piston-to-cylinder clearance 0.040 – 0.055 0.120 Cylinder bore 57.000 –...
Page 228 SERVICING INFORMATION 7-29 DRIVE TRAIN + DRIVE CHAIN Unit: mm Except ratio ITEM STANDARD LIMIT Primary reduction ratio 3.470 (59/17) — Final reduction ratio 3.400 (51/15) — Gear ratios 3.000 (33/11) — 1.857 (26/14) — 1.368 (26/19) — 1.095 (23/21) —...
Page 229 7-30 SERVICING INFORMATION ELECTRICAL ITEM SPECIFICATION NOTE Spark plug DENSO: U24ESR-N Type NGK: CR8E 0.7 – 0.8 mm Spark performance Over 8 mm at 1 atm. + tap – Ignition coil resistance 1.6 – 2.7 Ω Primary - tap Plug cap – Secondary 18 –...
Page 230 Front fork stroke — Front fork spring free length 382.9 Front fork oil level — Front fork oil type SUZUKI FORK OIL #10 or an equivalent fork oil — Front fork oil capacity (each leg) 230 ml — Rear wheel travel —...
Page 231 7-32 SERVICING INFORMATION FUEL + OIL ITEM SPECIFICATION NOTE Fuel 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 capacity Change 850 ml...
Page 232: Rv125K4/K5 ('04, '05-Models)
RV125K4/K5 (’04, ’05-MODELS) RV125K4/K5 (’04, ’05-MODELS) CONTENTS SPECIFICATIONS ..................8- 2 SERVICE DATA .................... 8- 3 WIRE ROUTING ................... 8- 9 REAR FENDER INSTALLATION ..............8-10...
Page 233: Specifications
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 ..................
Page 234: Service Data
RV125K4/K5 (’04, ’05-MODELS) SERVICE DATA VALVE + GUIDE Unit: mm ITEM STANDARD LIMIT Valve diam. — — Valve clearance (when cold) 0.08 – 0.13 — 0.13 – 0.18 — Valve guide to valve stem 0.010 – 0.037 — clearance 0.030 – 0.057 —...
Page 235 RV125K4/K5 (’04, ’05-MODELS) CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Compression pressure 980 kPa 1 300 – 1 700 kPa (9.8 kgf/cm (13 – 17 kgf/cm , 185 – 242 psi) 140 psi) Piston-to-cylinder clearance 0.040 – 0.055 0.120 Cylinder bore 57.000 –...
Page 236 RV125K4/K5 (’04, ’05-MODELS) DRIVE TRAIN + DRIVE CHAIN Unit: mm (Except ratio) ITEM STANDARD LIMIT Primary reduction ratio 3.470 (59/17) — Final reduction ratio 3.400 (51/15) — Gear ratios 3.000 (33/11) — 1.857 (26/14) — 1.368 (26/19) — 1.095 (23/21) —...
Page 237 RV125K4/K5 (’04, ’05-MODELS) ELECTRICAL ITEM SPECIFICATION NOTE Spark plug DENSO: U24ESR-N Type NGK: CR8E 0.7 – 0.8 mm Spark performance Over 8 mm at 1 atm. + tap – Ignition coil resistance 1.6 – 2.7 Ω Primary - tap Plug cap – Secondary 18 –...
Page 238 Front fork stroke — Front fork spring free length 382.9 Front fork oil level — Front fork oil type SUZUKI FORK OIL #10 or an equivalent fork oil — Front fork oil capacity (each leg) 230 ml — Rear wheel travel —...
Page 239 RV125K4/K5 (’04, ’05-MODELS) FUEL + OIL ITEM SPECIFICATION NOTE Fuel 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 capacity Change 850 ml...
Page 240: Wire Routing
RV125K4/K5 (’04, ’05-MODELS) WIRE ROUTING...
Page 241: Rear Fender Installation
8-10 RV125K4/K5 (’04, ’05-MODELS) REAR FENDER INSTALLATION 6.5 N . m (0.65 kgf-m)
Page 242: Rv125K6 ('06-Models)
RV125K6 (’06-MODEL) RV125K6 (’06-MODEL) This chapter describes service specifications, service data and servicing procedurers 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. * Please refer to the chapters 1 through 8 for details which are not given in this chapter.
Page 243 RV125K6 (’06-MODEL) 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 ..................
Page 244 RV125K6 (’06-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm ITEM STANDARD LIMIT Valve diam. 25.5 — 22.5 — Valve clearance (when cold) 0.03 – 0.08 — 0.13 – 0.18 — Valve guide to valve stem 0.010 – 0.037 — clearance 0.030 –...
Page 245 RV125K6 (’06-MODEL) CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Compression pressure 1 100 – 1 500 kPa 800 kPa (11 – 15 kgf/cm (8.0 kgf/cm Piston-to-cylinder clearance 0.040 – 0.055 0.120 Cylinder bore 57.000 – 57.015 57.090 Piston diam.
Page 246 RV125K6 (’06-MODEL) DRIVE TRAIN + DRIVE CHAIN Unit: mm (Except ratio) ITEM STANDARD LIMIT Primary reduction ratio 3.470 (59/17) — Final reduction ratio 3.400 (51/15) — Gear ratios 3.000 (33/11) — 1.857 (26/14) — 1.368 (26/19) — 1.095 (23/21) — 0.923 (24/26) —...
Page 247 RV125K6 (’06-MODEL) ELECTRICAL ITEM SPECIFICATION NOTE Spark plug DENSO: U24ESR-N Type NGK: CR8E 0.7 – 0.8 mm Spark performance Over 8 mm at 1 atm. 1.6 – 2.7 Ω + tap – - tap Ignition coil resistance Primary Plug cap – Secondary 18 –...
Page 248 Front fork stroke — Front fork spring free length 382.9 Front fork oil level — Front fork oil type SUZUKI FORK OIL #10 or an equivalent fork oil — Front fork oil capacity (each leg) 230 ml — Rear wheel travel —...
Page 249 RV125K6 (’06-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 91 octane or higher. An unleaded gasoline type is recom- mended. Fuel tank capacity including 7.5 L reserve reserve 1.8 L Engine oil type * SAE 10W-40, API SF/SG or SH/SJ with JASO MA Engine oil capacity Change 850 ml...
Page 250 Prepared by 2nd Ed. January, 2006 1st Ed. January, 2003 Part No. 99500-31233-01E Printed in Japan...
Page 251 Printed in Japan K3 K4 K5 K6...

Suzuki RV125 Service Manual

Foreword Group Index

Periodic Maintenance

Engine

Fuel and Lubrication System

Chassis

Electrical System

Servicing Information

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Chapters

Troubleshooting

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