Suzuki UY125 Manuals

Manuals and User Guides for Suzuki UY125. We have 1 Suzuki UY125 manual available for free PDF download: Service Manual

Suzuki UY125 Service Manual

Suzuki UY125 Service Manual (258 pages)

Brand: Suzuki | Category: Scooter | Size: 9.88 MB

Table of Contents

General Information 1

5
- Electrical System
  1
- General Information
  1
- Periodic Maintenance
  1
- Table of Contents
  5
- Warning/Caution/Note
  6
- General Precautions
  6
- Suzuki Uy125K6/Sk6 ('06-Model)
  8
- Serial Number Location
  8
- Fuel and Oil Recommendation
  9
  - Fuel
    9
  - Engine Oil
    9
  - Reduction Gear Oil
    9
  - Brake Fluid (Uy125S)
    9
  - Front Fork Oil
    9
- Break-In Procedures
  9
- Specifications
  10
Periodic Maintenance

13
- Periodic Maintenance Schedule
  14
  - Periodic Maintenance Chart
    14
  - Lubrication Points
    15
- Maintenance and Tune-Up Procedures
  16
  - Air Cleaner
    16
  - Exhaust Pipe Bolt and Muffler Mounting Nut
    17
  - Cooling Fan Filter
    17
  - Valve Clearance
    18
  - Spark Plug
    19
  - Fuel Line
    20
  - Engine Oil and Oil Filter
    20
  - Engine Idle Speed
    22
  - Throttle Cable Play
    22
  - Drive Belt
    23
  - Reduction Gear Box Oil
    23
  - Brake
    24
  - Brake Hose and Brake Fluid (Uy125S)
    25
  - Tire and Wheels
    27
  - Steering
    29
  - Front Fork
    29
  - Rear Suspension
    29
  - Chassis Bolts and Nuts
    30
- Compression Pressure Check
  32
  - Compression Test Procedure
    32
- Oil Pressure Check
  33
  - Oil Pressure Test Procedure
    33
- Automatic Clutch Inspection
  34
  - Initial Engagement Inspection
    34
  - Clutch "Lock-Up" Inspection
    34
Engine

35
- Engine Components Removable with the Engine in Place
  36
- Engine Removal and Installation
  38
  - Engine Removal
    38
  - Engine Remounting
    42
- Engine Disassembly
  44
- Engine Component Inspection and Service
  54
  - Cylinder Head Cover
    54
  - Cylinder Head
    55
  - Cylinder Head Distortion
    57
  - Cylinder
    67
  - Piston
    68
  - Crankshaft
    70
  - Oil Pump
    71
  - Movable Drive Face
    71
  - Clutch Shoe/Movable Driven Face
    73
  - Drive Belt
    78
  - Drive Belt Filter
    78
  - Starter Clutch
    79
  - Magneto Cover
    80
  - Kick Starter
    81
  - Reduction Gear
    83
  - Bearing Inspection
    85
  - Right Crankcase
    85
  - Engine Mounting Bushing
    85
  - Left Crankcase
    86
  - Engine Mounting Bushings
    88
  - Crankshaft Shim Selection
    89
- Engine Reassembly
  90
- Pair (Air Supply) System
  107
  - Pair Hoses Inspection
    107
  - Pair Reed Valve Inspection
    107
  - Pair Control Valve Inspection
    107
Fuel and Lubrication System

109
- Fuel Tank and Fuel Tap
  
  110
  - Removal
    110
  - Inspection
    111
  - Remounting
    112
- Fuel Level Gauge
  
  113
  - Removal
    113
  - Inspection
    114
- Carburetor
  
  115
  - Construction
    115
  - Specifications
    116
  - I.D. Location
    116
  - Removal
    116
  - Disassembly
    117
  - Carburetor Cleaning
    120
  - Carburetor Jet Inspection
    120
  - Needle Valve Inspection
    121
  - Float Height Adjustment
    121
  - Reassembly and Remounting
    121
- Lubrication System
  
  123
  - Oil Filter
    123
  - Oil Sump Filter
    123
  - Engine Lubrication System Chart
    124
Chassis

125
- Exterior Parts
  126
  - Fastener Removal and Installation
    126
  - Removal
    127
- Front Wheel and Front Brake (Uy125)
  134
  - Removal
    134
  - Inspection and Disassembly
    136
  - Reassembly and Installation
    139
- Front Wheel (Uy125S)
  142
  - Removal
    142
  - Inspection and Disassembly
    143
  - Reassembly and Installation
    144
- Front Brake (Uy125S)
  146
  - Brake Fluid Replacement
    147
  - Brake Pad Replacement
    147
  - Caliper Removal
    148
  - Caliper Disassembly
    148
  - Caliper Inspection
    149
  - Caliper Reassembly
    150
  - Caliper Installation
    151
  - Brake Disc Inspection
    151
  - Master Cylinder Removal and Disassembly
    152
  - Master Cylinder Inspection
    153
  - Master Cylinder Reassembly and Installation
    153
- Front Fork
  156
  - Removal and Disassembly
    156
  - Inspection
    158
  - Reassembly and Installation
    159
- Handlebars
  162
  - Removal
    162
  - Installation
    163
- Steering
  166
  - Removal and Disassembly
    166
  - Inspection
    168
  - Reassembly and Installation
    169
- Rear Wheel and Rear Brake
  171
  - Construction
    171
  - Removal and Disassembly
    171
  - Inspection
    172
  - Reassembly and Remounting
    173
- Rear Suspension
  175
  - Construction
    175
  - Removal
    175
  - Inspection and Disassembly
    176
  - Reassembly and Remounting
    176
Electrical System

177
- Cautions in Servicing
  179
  - Connector
    179
  - Coupler
    179
  - Clamp
    179
  - Fuse
    179
  - Semi-Conductor Equipped Part
    180
  - Battery
    180
  - Connecting the Battery
    180
  - Wiring Procedure
    180
  - Using the Multi-Circuit Tester
    181
- Location of Electrical Components
  182
- Charging and Lighting System
  184
  - Troubleshooting
    184
  - Inspection
    186
- Starter System
  189
  - Troubleshooting
    189
  - Starter Motor Removal
    190
  - Starter Motor Disassembly
    191
  - Starter Motor Inspection
    193
  - Starter Motor Reassembly
    194
  - Starter Relay Inspection
    196
- Ignition System
  197
  - Troubleshooting
    197
  - Inspection
    199
- Speedometer
  202
  - Removal and Disassembly
    202
  - Inspection
    203
- Fuel Meter and Fuel Level Gauge
  204
  - Fuel Meter Inspection
    204
  - Fuel Level Gauge Inspection
    204
- Relays
  205
  - Turn Signal Relay
    205
  - Starter Relay
    205
- Lamps
  206
  - Headlight
    206
  - Front Turn Signal Light
    207
  - Brake Light/Taillight and Rear Turn Signal Light
    208
- Switches
  210
- Battery
  211
  - Specifications
    211
  - Initial Charging
    211
  - Servicing
    213
  - Recharging Operation
    213
  - Removal
    213
  - Remounting
    213
Servicing Information

215
- Troubleshooting
  216
  - Engine
    216
  - Carburetor
    219
  - Chassis
    220
  - Brakes
    220
  - Electrical
    222
  - Battery
    223
- Wiring Diagram
  224
  - Uy125
    224
  - Uy125S
    225
- Wiring Harness, Cable and Hose Routing
  226
  - Wiring Harness Routing
    226
  - Cable Routing (Uy125)
    228
  - Cable Routing (Uy125S)
    229
  - Engine Electric Parts Installation
    230
  - Front Brake Hose Routing (Uy125S)
    231
  - Pair (Air Supply) System Hose Routing
    232
  - Fuel Hose Routing
    233
  - Cluth/Transmission/Drive Belt Installation
    234
  - Cooling Fan Installation
    235
  - Fuel Tank Installation
    236
  - Crankcase Installation
    237
  - Exterior Parts Construction
    238
  - Prop Stand Installation
    240
  - Center Stand Installation
    240
  - Rear Brake Cam Lever Installation
    241
  - Battery Installation
    242
  - Seat Hinge Installation
    243
  - Front Wheel (Uy125)
    244
  - Front Wheel (Uy125S)
    245
  - Rear Wheel
    246
- Special Tools
  247
- Tightening Torque
  250
  - Engine
    250
  - Chassis
    251
  - Tightening Torque Chart
    252
- Service Data
  253

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