Suzuki fl125sdwk7 Setup Manual

Brand: Suzuki

Model: fl125sdwk7

Type: Setup Manual

February ’07 Printed in Japan (TK) 19

99505-01107-01E

FOREWORD

This motorcycle has been designed and produced utilizing Suzuki’s most modern

technology. The finest product, however, cannot perform properly unless it is cor-

rectly assembled and serviced. This set-up manual has been produced to aid you in

properly assembling and servicing this motorcycle.

Please review this set-up manual carefully before performing any work. Take spe-

cial care to properly perform the required assembly and servicing marked by either

a Warning or a Caution. Failure to follow the directions in either of these two (2) cat-

egories could lead to serious problems. # and  areas are

denoted to emphasize certain areas and carry the following meanings:

Indicates a potential hazard that could result in death or injury.



Indicates a potential hazard that could result in motorcycle damage.

This set-up manual is based on a motorcycle of standard specification. Some minor

differences from this manual may be found in other specifications.

PREPARATION

WORKSHOP

A: Packed motorcycle

B: Working space

SELF PROTECTION

UNCRATING THE MOTORCYCLE

Remove the carton.

A: Crate

Remove the strap.

Take out the front wheel assembly and component

parts from the crate base.

A: Strap

B: Front wheel assembly

C: Component parts

The workshop where the machine is assembled

should be clean, spacious, and have a level

floor.

The technician should wear protective clothing

such as leather gloves, a long sleeve shirt, eye

protection and safety shoes as shown in the

illustration when handling metal crates.

Metal crates may have sharp edges and may

cause injury.

Remove the nut to take off the handlebar holding

bracket and stay.

A: Nut

B: Bracket

C: Stay

D: Protection cover

Remove the bolts

A used to mount the steel frame on

the crate base.



Lift the steel frame to separate it from the base of the

crate.



A: Steel frame

B: Crate base

NOTE:

The brackets, stay and nuts are no longer

needed and these may be discarded.

Remove the protection cover after taking out

the motorcycle.

Don’t remove the bolt

B of the motorcycle sup-

porting bracket

Handling crates requires two operators.

Be careful not to scratch the motorcycle.

LOCATION OF PARTS

Check all the components which have been removed from the crate.

Parts listed above are installed respectively into the positions as follows.

Item Part Name Q’ty Remarks

Front fender front 1

Stepped screw 1 6 × 16 mm

Screw 2 6 × 16 mm

Stepped washer 2

OD:16.0 ID:6.5

T:5.0

B Rear view mirror 2 Right and Left

C Front wheel spacer 1

Item Part Name Q’ty Remarks

Speedometer drive

gearbox

E Front wheel assembly 1

Battery electrolyte

container

G Owner’s manual set 1

OD : Outside diameter (mm)

ID : Inside diameter (mm)

L : Length (mm)

T : Thickness (mm)

OD ID

The photograph shown indicates the parts dismounted

from the motorcycle in addition to the items shown in

the preceding page.

A: Speedometer cable

Before assembling the motorcycle, thoroughly

understand the “Safety Check Out” described on

page 26.

After completion of assembly, carefully check the

motorcycle referring to the “Safety Check Out”,

then deliver the motorcycle to the customer.

ASSEMBLY

Loosen the rear axle nut.

Remove the bolt.

Remove the motorcycle supporting bracket.

A: Bracket

B: Bolt

C: Rear axle nut

Make sure that the washer is placed on the rear axle.

Tighten the axle nut to the specified torque.

" Rear axle nut: 54 N·m (5.4 kgf-m)

A: Washer

B: Rear axle nut

Attach a hoist band onto the handlebar as shown in

the photograph.

A: Hoist band

B: Protection cover

NOTE:

The bracket and bolt are no longer needed and

may be discarded.

Remove the crate axle bracket from the crate base.

A: Crate axle bracket

B: Bolt

1. Lift the front of motorcycle by using a hoist.

2. Raise the rear of motorcycle.

3. Take out the motorcycle from the crate base, then

balance the motorcycle.

FRONT FENDER

Remove the bolt of front brake hose guide.

A: Bolt

B: Front brake hose guide

Set the front fender front to the front fender rear.

A: Front fender front

B: Front fender rear

C: Hook

D: Hole

NOTE:

The bracket and bolts are no longer needed and

these may be discarded.

Install the front fender front to the front fork lower

bracket.

A: Front fender front

B: 6 × 16 mm stepped screw

C: 6 × 16 mm screw

D: Stepped washer OD:16.0 mm ID:6.5 mm T:5.0 mm

Reinstall the front brake hose guide.

A: Bolt

B: Front brake hose guide

BRAKE DISC

To prevent brake squeaking and pad contamination,

carefully clean the front brake disc plate with alcohol or

other non-petroleum based solvent.

This will remove the rust-preventive coating and dirt.

FRONT WHEEL

Remove the front axle nut.

Remove the front axle from the fork legs.

A: Front axle nut

B: Front axle

C: Rubber spacer

D: Vinyl tube

NOTE:

The rubber spacer and vinyl tube are no longer

needed and these may be discarded.

Mount the front wheel assembly properly.

A: Right fork leg

B: Left fork leg

C: Front axle

D: Front axle nut

E: Front wheel spacer

F: Speedometer drive gear box

Remove the supporter from the brake pad of the front

brake caliper.

A: Supporter

Carefully insert the front brake disc plate between the

caliper brake pads.

Attach the front wheel spacer between the front wheel

hub and right fork leg.

A: Pads

B: Disc plate

C: Front wheel spacer

Insert tabs of the speedometer drive gearbox into front

wheel hub grooves.

A: Tabs

B: Grooves

NOTE:

The flange side of the spacer faces the hub.

Insert the front axle from the right side of fork leg.

Fix the front wheel assembly to the front fork.



A: Front axle

Align the edge slit of the meter cable with the blade in

the gearbox.

Connect the speedometer cable to the drive gearbox.

Tighten the nut securely.

A: Speedometer cable

B: Speedometer drive gearbox

C: Nut

Before tightening the front axle nut, position the speed-

ometer drive gearbox correctly.



A: Speedometer drive gearbox

B: Left fork leg

Tighten the front axle nut to the specified torque.

" Front axle nut: 42 N·m (4.2 kgf-m)

A: Front axle nut

Never use force to install the front axle.

If it cannot be installed by hand, it is not cor-

rectly aligned.

Align the curved surface of speedometer drive

gearbox to curved surface of left fork leg, with

the clearances equalized as shown in the pho-

tograph.

Place the motorcycle on the center-stand, then remove

the hoist hook.

Remove the protection cover from the motorcycle.

A: Protection cover

REAR VIEW MIRROR

Remove the lock bolt.

A: Lock bolt

B: Rear view mirror stay

C: Lock nut

D: Opposite thread

Tighten the lock bolt.

Install the rear view mirror and tighten lock nuts

securely after positioning them properly.

Reinstall the rubber boots in the correct position.

A: Lock bolt

B: Rear view mirror

C: Lock nut

D: Rubber boots

E: Flange (Rubber boot)

NOTE:

Part

D of the rear view mirror stay is opposite

threaded.

NOTE:

Fix the mirror in the position so as to secure

rear view.

Align the flange of rubber boots face with han-

dlebar cover.

OWNER’S MANUAL

Push down and turn the key clockwise to release the

seat lock.

Open the seat.

A: Key

B: Seat

Store the owner’s manual in place.

A: Trunk

B: Owner’s manual

SERVICING

BATTERY

The battery is located under the seat.

Open the seat.

Remove the screws to take off the battery box lid.

Remove the battery from the motorcycle.

A: Battery box lid

B: Screw

Filling electrolyte

Remove the aluminium tape sealing the battery elec-

trolyte filler holes.

A: Aluminium tape

B: Electrolyte filler hole

Remove the caps from the electrolyte container.

A: Caps

B: Sealed area

NOTE:

Use the removed caps as the sealed caps of

battery filler holes.

Do not remove or pierce the sealed areas of the

electrolyte container.

With just enough force to break the nozzle seal of elec-

trolyte container, push each nozzle of the electrolyte

container into the battery’s electrolyte filler ports and

hold the container firmly so that it does not fall.

Take precaution not to allow any of the fluid to spill.

A: Electrolyte containers

Make sure air bubbles are coming up in each electro-

lyte container, and leave in this position for about 20

minutes.

A: Air bubbles

After confirming that the electrolyte has entered the

battery completely, remove the electrolyte containers

from the battery.

Wait for around 20 minutes.

Insert the caps into the filler holes, pressing in firmly so

that the top of the each caps does not protrude above

the upper surface of the battery’s top cover.

A: Caps



NOTE:

If no air bubbles are coming up from a filler

port, tap the bottom of the container two or

three times.

Never remove the container from the battery.

Never use anything except the specified battery

electrolyte.

Once the sealing cap has been installed in the

battery, do not remove the sealing cap.

Charge the battery with a battery charger.



After charging the battery, install the battery in the

motorcycle as follows.



1. Reinstall the battery in the motorcycle.

2. First connect the

+ lead to the + positive terminal

of the battery.

3. Cover

+ terminal with rubber boot.

4. Connect the

- lead to the - negative terminal of

the battery.

5. Reinstall the battery box lid.

A: + lead

- lead

C: Rubber boot

For charging the battery, make sure to use the

charger specially designed for MF battery.

Otherwise, the battery may be overcharged

resulting in shortened service life.

Do not remove the cap during charging.

Position the battery with the cap facing upward

during charging.

When attaching the wiring harness battery

leads to the battery terminals, observe the cor-

rect polarity.

NOTE:

The terminal bolts and nuts are attached to the

battery.

BRAKE FLUID

Keep the motorcycle upright and place the handlebars

straight.

Check the brake fluid level in the front master cylinder

reservoirs.

If the fluid level is below the “LOWER” level indicated

in the figure, add the correct type of brake fluid as fol-

lows.

LEFT RIGHT

Remove the rear view mirror assembly.

Remove the fastener.

A: Fastener

B: Outer

C: Center pin

D: Handlebar cover rear

Remove the screws.

A: Handlebar cover rear

B: Handlebar cover upper

C: Screw

D: Screw

LOWER

NOTE:

To remove the fastener, turn the center pin

counter clockwise while holding outer.

Remove the boss.

A: Handlebar cover front

B: Boss

Disconnect the headlight lead wire coupler to take off

the handlebar cover front.

A: Handlebar cover front

B: Coupler

Remove the front brake master cylinder reservoir tank

cap.

Add the correct type of brake fluid.

Refer to the chart below for the proper selection.



Reinstall the front brake master cylinder reservoir tank

cap.

Connect the headlight lead wire coupler.

Reinstall the handlebar cover front using the screw

and fastener.



A: Front brake master cylinder reservoir tank cap

Specification and Classification

DOT 4

Be careful not to spill any brake fluid on the

paint or plastic components as they will be

damaged.

Be careful not to pinch the lead wire.

NOTE:

To install the fastener, pull the center pin and

fix the fastener by pushing the center pin.

BRAKE AIR BLEEDING

Any air which may have been trapped in the brake fluid

circuit must be bled completely.

If the brake lever feels spongy or weak, then most

likely there is air in the hydraulic circuit.

To bleed the air from the front brake, use the following

procedure:

1. Connect a clear hose to the air bleeder valve and

run the hose into a suitable clear container.

2. Pour approximately 1/2 in of brake fluid into the con-

tainer so that the end of the clear hose is sub-

merged and cannot draw any additional air back into

the circuit during the air bleeding servicing.

3. Close the valve, pump and squeeze the lever, and

open the valve while squeezing brake lever.

4. Repeat this process until the fluid flowing into the

receptacle no longer contains air bubbles.

5. After bleeding the brake circuit, tighten the bleeder

valve to the specified torque.

Reinstall the rubber protective cap.

6. Be sure to check the brake fluid level in the reservoir

tank.

" Brake caliper air bleeder valve:

6.0 N·m (0.60 kgf-m)

A: Bleeder valve

NOTE:

Do not drop brake fluid level below lower level

line while bleeding air.

THROTTLE CABLE

This motorcycle has a twin throttle cable system.

Cable

A is for pulling cable and cable B is for return-

ing.

Check the throttle cable play at the throttle grip.

Throttle cable play: 2.0–4.0 mm

If adjustment is necessary, carry out the procedure

below:

1. Loosen the throttle cable adjuster lock nut

2. Turn the adjuster

D in or out until the correct play.

3. Tighten the lock nut

C while holding the adjuster D.

4. Place the rubber boot

DRIVE CHAIN

Remove the inspection hole cap.

Check the drive chain slack through the inspection

hole.

Drive chain slack: 15–25 mm

A: Inspection hole cap

B: Inspection hole

If it is too tight or too loose, follow these procedures.

1. Loosen the axle nut.

2. Turn the adjuster nuts and adjust the chain slack by

aligning the reference marks on the swingarm, right

and left pointing at the same position.

3. After adjusting, tighten the axle nut to the specified

torque.

4. Tighten the adjuster nuts securely.

5. Reinstall the inspection hole cap.

" Rear axle nut: 54 N·m (5.4 kgf-m)

A: Axle nut

B: Adjuster nut

C: Reference marks

2.0–4.0 mm

After the adjustment is completed, check that

handlebar movement does not raise the engine

idle speed and that the throttle grip returns

smoothly and automatically.

REAR BRAKE PEDAL

After the drive chain slack has been checked or

adjusted, check the brake pedal free travel.

Rear brake pedal free travel: 20–30 mm

If adjustment is necessary, adjust the free travel by

turning the brake rod adjuster nut

TIRE PRESSURE

Using an accurate air gauge, check the air pressure of

the front and rear tires.

The pressure should be as shown.

COLD INFLATION TIRE PRESSURE

HEADLIGHT BEAM ADJUSTMENT

The headlight beam can be adjusted vertically if nec-

essary.

To adjust the beam vertically:

Loosen the headlight fitting bolts and move the head-

light up or down as required.

Tighten the bolts.

A: Bolt

SOLO RIDING DUAL RIDING

FRONT

175 kPa

1.75 kgf/cm

25 psi

175 kPa

1.75 kgf/cm

25 psi

REAR

200 kPa

2.00 kgf/cm

29 psi

280 kPa

2.80 kgf/cm

41 psi

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Suzuki fl125sdwk7 Setup Manual

Suzuki fl125sdwk7 Setup Manual

Suzuki fl125sdwk7 Setup Manual

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