Suzuki RV125 User manual

99500-31233-01E

GROUP INDEX

GENERAL INFORMATION

1

PERIODIC MAINTENANCE

2

ENGINE

3

FUEL AND LUBRICATION

SYSTEM

4

CHASSIS

5

ELECTRICAL SYSTEM

6

SERVICING INFORMATION

7

RV125K4/K5 (’04, ’05-MODELS)

8

RV125K6 (’06-MODELS)

9

FOREWORD

This manual contains an introductory description on

the SUZUKI RV125 and procedures for its inspec-

tion/service and overhaul of its main components.

Other information considered as generally known is

not included.

Read the GENERAL INFORMATION section to

familiarize yourself with the motorcycle and its main-

tenance. Use this section as well as other sections

as a guide for proper inspection and service.

This manual will help you know the motorcycle bet-

ter so that you can assure your customers of fast

and reliable service.

!

* This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modifications have been made since

then, differences may exist between the con-

tent of this manual and the actual motorcycle.

* Illustrations in this manual are used to show

the basic principles of operation and work

procedures. They may not represent the

actual motorcycle exactly in detail.

* This manual is written for persons who have

enough knowledge, skills and tools, including

special tools, for servicing SUZUKI motorcy-

cles. If you do not have the proper knowledge

and tools, ask your authorized SUZUKI

motorcycle dealer to help you.

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the ser-

vices described in this manual. Improper

repair may result in injury to the mechanic

and may render the motorcycle unsafe for

the rider.

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.

4. The contents are listed on the first page of each section to

help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE

Under the name of each system or unit there is an exploded view which provides work instructions and other

service information (e.g., tightening torque, lubricating points and locking agent points).

Example: Front wheel

Spacer

Bearing

Front axle spacer

Bearing

Brake disc

Speedometer gearbox

Balancer weight

Front axle

Brake disc bolt

Spoke nipple

ITEM N·m kgf-m

65 6.5

23 2.3

4.5 0.45

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servic-

ing. The meaning of each symbol is also included in the table.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Data beside it indicates specified

torque.

Apply THREAD LOCK “1322”.

99000-32110

Indicates service data.

Apply THREAD LOCK “1342”.

99000-32050

Apply oil. Use engine oil unless other-

wise specified.

Apply THREAD LOCK SUPER “1360”.

99000-32130

Apply molybdenum oil solution.

(mixture of engine oil and SUZUKl

MOLY PASTE in a ratio of 1 : 1)

Apply or use brake fluid.

Apply SUZUKI SUPER GREASE “A”.

99000-25010

Measure in voltage range.

Apply SUZUKI SILICONE GREASE.

99000-25100

Measure in resistance range.

Apply SUZUKI MOLY PASTE.

99000-25140

Measure in current range.

Apply THERMO-GREASE.

99000-59029

Measure in diode test range.

Apply SUZUKI BOND “1207B”.

99000-31140

Measure in continuity test range.

Apply SUZUKI BOND “1216B”.

99000-31230

Use special tool.

Apply THREAD LOCK SUPER “1303”.

99000-32030

Use fork oil.

99000-99044-10G

G

1216B

1

GENERAL INFORMATION 1-1

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

INFORMATION LABELS ...............................................................................1- 6

SPECIFICATIONS .........................................................................................1- 7

DIMENSIONS AND DRY MASS ............................................................1- 7

ENGINE ..................................................................................................1- 7

DRIVE TRAIN .........................................................................................1- 7

CHASSIS ................................................................................................1- 8

ELECTRICAL .........................................................................................1- 8

CAPACITIES ..........................................................................................1- 8

COUNTRY AND AREA CODES ....................................................................1- 9

1-2 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.

"

Indicates a potential hazard that could result in motorcycle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all

potential hazards relating to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS

and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are

unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.

GENERAL PRECAUTIONS

!

* Proper service and repair procedures are important for the safety of the service mechanic and

the safety and reliability of the motorcycle.

* When 2 or more persons work together, pay attention to the safety of each other.

* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-

doors.

* When working with toxic or flammable materials, make sure that the area you work in is well

ventilated and that you follow all of the manufacturer’s instructions.

* Never use gasoline as a cleaning solvent.

* To avoid getting burned, do not touch the engine, engine oil, radiator and exhaust system

until they have cooled.

* After servicing the fuel, oil, exhaust or brake systems, check all of the lines, and fittings

related to the system for leaks.

GENERAL INFORMATION 1-3

"

* 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.

* Be sure to use special tools when instructed.

* Make sure that all parts used in reassembly are clean. Lubricate them when specified.

* Use the specified lubricants, bonds or sealant.

* When removing the battery, disconnect the negative cable first and then the positive cable.

When reconnecting the battery, connect the positive cable first and then the negative cable,

and replace the terminal cover on the positive terminal.

* When performing service to electrical parts, if the service procedures not require use of bat-

tery power, disconnect the negative battery cable.

* When tightening the cylinder head, case bolts and nuts, tighten the larger sizes first. Always

tighten the bolts and nuts from the inside working out, in a crisscross manner.

* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts,

cotter pins, circlips and certain other parts as specified, be sure to replace them with new

ones. Also, before installing these new parts, be sure to remove any left over material from the

mating surfaces.

* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger

than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is

completely seated in its groove and securely fitted.

* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a

thread is smeared with them.

* After reassembling, check parts for tightness and proper operation.

* To protect the environment, do not unlawfully dispose of used motor oil and all other fluids:

batteries and tires.

* To protect the Earth’s natural resources, properly dispose of used motorcycle and parts.

1-4 GENERAL INFORMATION

SUZUKI RV125K3 (’03-MODEL)

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.

FUEL AND OIL RECOMMENDATION

FUEL

Gasoline used should be graded 91 octane (Research Method) or higher. An unleaded gasoline type is rec-

ommended.

LEFT SIDE

RIGHT SIDE

GENERAL INFORMATION 1-5

ENGINE OIL

Use a premium quality 4-stroke motor oil to ensure longer ser-

vice life of your motorcycle. Use only oils which are rated SF or

SG under the API service classification.

The recommended viscosity is SAE 10W-40. If an SAE 10W-40

motor oil is not available, select an alternative according to the

right chart.

BRAKE FLUID

# Specification and classification: DOT 4

!

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” before subjecting the engine

to maximum stresses. The future performance and reliability of the engine depends on the care and restraint

exercised during its early life. The general rules are as follows:

• Keep to these break-in throttle opening limits:

Initial 800 km: Less than 1/2 throttle

Up to 1 600 km: Less than

3/4

throttle

• Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to throttle full operation.

• Do not maintain constant engine speed for an extended time period during any portion of the break-in. Try

to vary the throttle position.

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manu-

facturer, do not use or mix different types of fluid such as silicone-based and petroleum-based

fluid for refilling the system, otherwise serious damage will result.

Do not use any brake fluid taken from old or used or unsealed containers.

Never re-use brake fluid left over from a previous servicing, which has been stored for a long

period.

1-6 GENERAL INFORMATION

INFORMATION LABELS

NO. LABEL or PLATE NAME

1 Fuel caution label

2 Tire information label

3 Warning safety label

4 Warning rear carrier label

5 ID plate

6 Anti-tamparing label

Head pipe (Right side)

GENERAL INFORMATION 1-7

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 .................................................................... Four-stroke, air-cooled, OHC

Number of cylinders ............................................ 1

Bore..................................................................... 57.0 mm

Stroke .................................................................. 48.8 mm

Displacement ...................................................... 125 cm³

Compression ratio ............................................... 9.2 : 1

Carburetor ........................................................... MIKUNI BS26

Air cleaner ........................................................... Polyurethane foam element

Starter system ..................................................... Electric

Lubrication system .............................................. Wet sump

Idle speed............................................................ 1 500 ± 100 r/min

DRIVE TRAIN

Clutch .................................................................. Wet multi-plate type

Transmission....................................................... 6-speed constant mesh

Gearshift pattern ............................................... 1-down, 5-up

Primary reduction ratio ........................................ 3.470 (59/17)

Gear ratios, Low ................................................. 3.000 (33/11)

2nd .................................................. 1.857 (26/14)

3rd ................................................... 1.368 (26/19)

4th ................................................... 1.095 (23/21)

5th ................................................... 0.923 (24/26)

Top .................................................. 0.833 (20/24)

Final reduction ratio............................................. 3.400 (51/15)

Drive chain .......................................................... DID 428, 134 links

1-8 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

Rear tire size........................................................180/80-14 M/C 78P, tube type

ELECTRICAL

lgnition type..........................................................Electronic ignition (Transistorized)

lgnition timing .......................................................13° B.T.D.C. at 1 500 r/min

Spark plug............................................................NGK: CR8E or DENSO: U24ESR-N

Battery..................................................................12 V 21.6 kC (6 Ah)/10 HR

Generator.............................................................Three-phase A.C. generator

Fuse .....................................................................20 A

Headlight..............................................................12 V 60/55 W

Brake light/Taillight...............................................12V 21/5 W

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

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

Turn signal light....................................................12 V 21W

Speedometer light................................................12 V 1.7 W

Neutral indicator light ...........................................12 V 3.4 W

High beam indicator light .....................................12 V 1.7 W

Turn signal indicator light .....................................12 V 3.4 W

CAPACITIES

Fuel tank, including reserve ................................. 7.5 L

Reserve ............................................... 1.8 L

Engine oil, oil change ........................................... 850 ml

with filter change ................................ 950 ml

overhaul..............................................1 200 ml

Front fork (each leg)............................................. 230 ml

These specifications are subject to change without notice.

GENERAL INFORMATION 1-9

COUNTRY AND AREA CODES

The following codes stand for the applicable countries and areas.

CODE COUNTRY OR AREA

E-02

E-19

U. K.

EU

2

6

PERIODIC MAINTENANCE 2-1

CONTENTS

PERIODIC MAINTENANCE

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

ENGINE OIL AND OIL FILTER ..............................................................2-10

DRIVE CHAIN .........................................................................................2-11

BRAKES .................................................................................................2-13

STEERING ..............................................................................................2-17

TIRE AND WHEEL .................................................................................2-18

EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLTS ............2-19

FRONT FORK ........................................................................................2-19

REAR SUSPENSION .............................................................................2-19

CHASSIS BOLTS AND NUTS ...............................................................2-20

COMPRESSION PRESSURE CHECK ............................................................2-22

COMPRESSION TEST PROCEDURE ...................................................2-22

OIL PRESSURE CHECK .................................................................................2-23

OIL PRESSURE TEST PROCEDURE ...................................................2-23

2-2 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

NOTE:

I=Inspect and clean, adjust, replace or lubricate as necessary; C=Clean; R=Replace; T=Tighten

Interval

Item

km 1 000 4 000 8 000

months 5 20 40

Air cleaner element — I I

Exhaust pipe bolts and muffler mounting

bolts

TTT

Valve clearance I I I

Spark plug — I R

Fuel line

III

Replace every 4 years.

Engine oil filter R — R

Engine oil R R R

Throttle cable I I I

Idle speed I I I

Clutch I I I

Drive chain

III

Clean and lubricate every 1 000 km.

Brakes I I I

Brake hose

—I I

Replace every 4 years.

Brake fluid

—I I

Replace every 2 years.

Tires and wheels — I I

Steering I — I

Front forks — — I

Rear suspension — — I

Chassis nuts and bolts T T T

PERIODIC MAINTENANCE 2-3

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.

NOTE:

* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.

* Lubricate exposed parts which are subject to rust, with a rust preventative spray especially whenever the

motorcycle has been operated under wet or rainy condition.

Clutch lever holder

Brake lever holder

and throttle cable

Drive chain

Side-stand pivot

and spring hook

Brake pedal pivot

2-4 PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each item in the Periodic Maintenance chart.

AIR CLEANER

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. Clean the air cleaner element in

the following manner:

• Remove the left frame cover. (!5-3)

• Remove the air cleaner cover

1.

• Remove the air cleaner element

2.

• Fill a container with a non-flammable cleaning solvent.

• Immerse the air cleaner element in the cleaning solvent and

wash it.

• Squeeze the cleaning solvent out of the washed element by

pressing it between the palms of both hands: do not twist or

wring the element or it will develop tears.

• Immerse the element in motor oil and squeeze the oil out of

the element leaving it slightly wet with oil.

"

A Non-flammable cleaning solvent

B Motor oil SAE 30 or SAE 10W-40

Inspect every 4 000 km (20 months).

Inspect the air cleaner element for tears. A torn ele-

ment must be replaced.

PERIODIC MAINTENANCE 2-5

• Remove the drain plug

1 to allow any water to drain out.

• Reinstall the cleaned air cleaner element in the reverse order

of removal.

"

VALVE CLEARANCE

REMOVAL

• Remove the seat. (!5-3)

• Remove the fuel tank. (!4-2)

• Remove the spark plug. (!2-7)

• Remove the valve inspection caps

1.

• Remove the valve timing inspection plug

2 and generator

cover plug

3.

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.

If driving under dusty conditions, clean the air cleaner

element more frequently. The surest way to accelerate

engine wear is to operate the engine without the ele-

ment or to use a torn element. Make sure that the air

cleaner is in good condition at all times. The life of the

engine depends largely on this component!

Inspect initially at 1 000 km (5 months) and every

4 000 km (20 months) thereafter.

2-6 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.

NOTE:

* The piston must be at (TDC) on the compression stroke in

order to check the valve clearance or to adjust valve clear-

ance.

* The clearance specification is for COLD state.

* To turn the crankshaft for clearance checking, rotate in the nor-

mal running direction. The spark plug should be removed.

• Turn crankshaft to bring the “TDC” line

A on the rotor to the

index mark

B on the generator cover.

• Insert a thickness gauge between the valve stem end and the

adjusting screw on the rocker arm.

If the clearance is out of specification, bring it into the speci-

fied range.

# 09900-20803: Thickness gauge

09917-13210: Valve clearance adjusting driver

$ Valve clearance (when cold):

IN.: 0.08 – 0.13 mm

EX.: 0.13 – 0.18 mm

Adjuster

Lock nut

PERIODIC MAINTENANCE 2-7

SPARK PLUG

• Disconnect the spark plug cap and remove the spark plug.

# 09930-10121: Spark plug wrench set

"

• Carbon deposits on the spark plug will prevent good sparking

and may cause the engine to misfire. Be sure to clean the car-

bon deposits off periodically.

• If the center electrode is fairly worn down, the spark plug

should be replaced and the spark plug gap set to the specifi-

cation using a thickness gauge.

# 09900-20803: Thickness gauge

$ Spark plug gap: 0.7 – 0.8 mm

• Check the spark plug for burns. If any abnormalities are

found, replace the spark plug.

"

• Tighten the spark plug to the specified torque using the spe-

cial tool.

% Spark plug: 18 N·m (1.8 kgf-m)

# 09930-10121: Spark plug wrench set

Inspect every 4 000 km (20 months).

Replace every 8 000 km (40 months).

STD Cold type Hot type

NGK CR8E CR7E CR9E

DENSO U24ESR-N U22ESR-N U27ESR-N

Confirm the thread size and reach when replacing the

spark plug. If the reach is too short, carbon will be

deposited on the screw portion of the plug hole and

engine damage may result.

Before using a spark plug wrench, carefully turn the

spark plug by finger into the threads of the cylinder

head to prevent damage.

0.7 – 0.8 mm

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Suzuki RV125 User manual

Suzuki RV125 User manual

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