Suzuki FL125SDW User manual

Printed in Japan

K7

DIC120

TOP

BOTTOM (Back: 13mm)

9 9 5 0 0 - 3 1 3 7 1 - 0 1 E

Prepared by

March, 2007

Part No. 99500-31371-01E

Printed in Japan

396

NOTICE

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

messages 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 motorcycle. 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.

GROUP INDEX

GENERAL INFORMATION

1

PERIODIC MAINTENANCE

2

ENGINE

3

FUEL AND LUBRICATION

SYSTEM

4

CHASSIS

5

ELECTRICAL SYSTEM

6

SERVICING INFORMATION

7

FL125SDW

8

FOREWORD

This manual contains an introductory description on

the SUZUKI FL125S/SD/SDW and procedures for

its inspection/service and overhaul of its main com-

ponents.

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

to use 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

or tools, ask your authorized SUZUKI motor-

cycle dealer to help you.

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the

services described in this manual.

Improper repair may result in injury to the

mechanic and may render the motorcycle

unsafe for the rider and passenger.

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, is its exploded view. Work instructions and other service information

such as the tightening torque, lubricating points and locking agent points, are provided.

Example: Front wheel

"

1 Front axle bolt

2 Brake disc

3 Spacer

4

Front wheel bearing

(Right)

5 Spoke nipple

6 Front wheel

7 Front axle spacer

8

Front wheel bearing

(Left)

9 Speedometer gearbox

A Front axle nut

B Brake disc bolt

ITEM N·m kgf-m

A 42 4.2

B 23 2.3

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 or use brake fluid.

Apply oil. Use engine oil unless other-

wise specified.

Measure in voltage range.

Apply molybdenum oil solution.

(Mixture of engine oil and SUZUKI

MOLY PASTE in a ratio of 1:1)

Measure in current range.

Apply SUZUKI SUPER GREASE “A”.

99000-25010

Measure in resistance range.

Apply SUZUKI SILICONE GREASE.

99000-25100

Measure in diode test range.

Apply SUZUKI MOLY PASTE.

99000-25140

Measure in continuity test range.

Apply SUZUKI BOND “1207B”.

99104-31140

Use special tool.

Apply THREAD LOCK SUPER “1322”.

99000-32110

Indication of service data.

Use fork oil.

99000-99001-SS8

1-1 GENERAL INFORMATION

GENERAL INFORMATION

CONTENTS

GENERAL PRECAUTIONS ......................................................................... 1- 2

SUZUKI FL125SK7/SDK7 (’07-MODEL)..................................................... 1- 3

SERIAL NUMBER LOCATION .................................................................... 1- 3

FUEL AND OIL RECOMMENDATION ........................................................ 1- 4

FUEL...................................................................................................... 1- 4

ENGINE OIL .......................................................................................... 1- 4

BRAKE FLUID....................................................................................... 1- 4

FRONT FORK OIL................................................................................. 1- 4

BREAK-IN PROCEDURES.......................................................................... 1- 4

SPECIFICATIONS........................................................................................ 1- 5

COUNTRY AND AREA CODES

The following codes stand for the applicable country(-ies) and area(-s).

CODE COUNTRY or AREA EFFECTIVE FRAME NO.

P-14 (FL125S)

P-14 (FL125SD)

Thailand

BF45A – TH100001 –

BF45B – TH100001 –

GENERAL INFORMATION 1-2

1

6

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 material 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 lines and fittings related to the

system for leaks.

* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-

lents.

* 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 lubricant, bond, 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 do not require use of

battery power, disconnect the negative cable from the battery.

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

Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci-

fied tightening torque.

* 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 other fluids: bat-

teries and tires.

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

1-3 GENERAL INFORMATION

SUZUKI FL125SK7/SDK7 (’07-MODEL)

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number)

1 is stamped on the left side of the steer-

ing 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.

LEFT SIDE (FL125SD)

RIGHT SIDE (FL125SD)

GENERAL INFORMATION 1-4

FUEL AND OIL RECOMMENDATION

FUEL

Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recom-

mended.

ENGINE OIL

Oil quality is a major contributor to your engine’s performance

and life. Always select good quality engine oil. Use oil with API

classification of SF/SG or SH/SJ with JASO classification MA.

SUZUKI recommends the use of SAE 10W-40 engine oil. If SAE

10W-40 engine oil is not available, select an alternative. accord-

ing to the right chart.

BRAKE FLUID

Specification and classification: DOT 4

!

FRONT FORK OIL

Use SUZUKI FORK OIL SS-08 or an equivalent fork oil.

BREAK-IN 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. Refer to the following throttle position recommendations.

• Keep to these break-in throttle positions:

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 full throttle operation

for short periods of time.

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.

1-5 GENERAL INFORMATION

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length.......................................................................... 1 900 mm

Overall width ........................................................................... 715 mm

Overall height.......................................................................... 1 070 mm

Wheelbase .............................................................................. 1 225 mm

Seat height.............................................................................. 760 mm

Ground clearance ................................................................... 125 mm

Dry mass................................................................................. 103 kg ................ FL125S

106 kg ................ FL125SD

ENGINE

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

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

Bore ........................................................................................ 53.5 mm

Stroke...................................................................................... 55.2 mm

Displacement .......................................................................... 124 cm³

Compression ratio................................................................... 9.6 : 1

Carburetor............................................................................... MIKUNI VM18

Air cleaner............................................................................... Paper filter

Starter system......................................................................... Kick ....................... FL125S

Electric and kick .... FL125SD

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

Idle speed ............................................................................... 1 400 ± 100 r/min

DRIVE TRAIN

Clutch...................................................................................... Wet shoe, automatic, centrifugal type

Transmisson ........................................................................... 4 speed

Gearshift pattern ..................................................................... All down

Primary reduction ratio............................................................ 3.409 (75/22)

Final reduction ratio ................................................................ 2.333 (35/15)

Gear ratios, Low ..................................................................... 2.909 (32/11)

2nd ...................................................................... 1.785 (25/14)

3rd....................................................................... 1.294 (22/17)

Top...................................................................... 1.052 (20/19)

Drive chain .............................................................................. D.I.D 428 102 links

GENERAL INFORMATION 1-6

CHASSIS

Front suspension..................................................................... Telescopic, coil spring, oil damped

Rear suspension ..................................................................... Swingarm type, coil spring, oil damped

Front fork stroke ...................................................................... 90 mm

Rear wheel travel .................................................................... 77 mm

Steering angle ......................................................................... 45° (right and left)

Caster...................................................................................... 27°

Trail ......................................................................................... 70 mm

Turning radius ......................................................................... 1.9 m

Front brake.............................................................................. Disc brake

Rear brake .............................................................................. Drum brake

Front tire size .......................................................................... 60/100-17 M/C 33 P

Rear tire size ........................................................................... 70/90-17 M/C 43 P

ELECTRICAL

Ignition type............................................................................. Electronic ignition (CDI)

Ignition timing .......................................................................... 10° B.T.D.C at 1 400 r/min

Spark plug ............................................................................... NGK C6HSA or DENSO U20FS-U

Battery..................................................................................... 12 V 9.0 kC (2.5 Ah)/10 HR ..... FL125S

12V 12.6 kC (3.5 Ah)/10HR ..... FL125SD

Generator ................................................................................ Single-phase A.C. generator

Fuse ........................................................................................ 10 A

Headlight ................................................................................. 12 V 25/25 W × 2

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

License plate light ................................................................... 12 V 5 W

Turn signal light....................................................................... 12 V 10 W

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

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

Turn signal indicator light ........................................................ 12 V 1.7 W × 2

Gear position indicator light..................................................... 12 V 1.7 W

Neutral indicator light .............................................................. 12 V 1.7 W

CAPACITIES

Fuel tank ................................................................................. 4.3 L

Engine oil, oil change ............................................................. 800 ml

with filter change................................................... 900 ml

overhaul ................................................................ 1 000 ml

These specifications are subject to change without notice.

2-1 PERIODIC MAINTENANCE

6

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

EXHAUST PIPE NUT AND MUFFLER MOUNTING BOLT ................. 2- 5

VALVE CLEARANCE ........................................................................... 2- 6

SPARK PLUG ....................................................................................... 2- 9

FUEL LINE ............................................................................................ 2-10

ENGINE OIL AND OIL FILTER ............................................................ 2-11

THROTTLE CABLE PLAY ................................................................... 2-13

IDLE SPEED ......................................................................................... 2-13

PAIR (AIR SUPPLY) SYSTEM ............................................................. 2-13

DRIVE CHAIN ....................................................................................... 2-14

BRAKES ............................................................................................... 2-16

TIRES .................................................................................................... 2-19

STEERING ............................................................................................ 2-21

FRONT FORK ....................................................................................... 2-21

REAR SUSPENSION ........................................................................... 2-21

CHASSIS BOLTS AND NUTS ............................................................. 2-22

COMPRESSION PRESSURE CHECK .......................................................... 2-24

COMPRESSION TEST PROCEDURE ................................................. 2-24

OIL PRESSURE CHECK ............................................................................... 2-25

OIL PRESSURE TEST PROCEDURE ................................................. 2-25

AUTOMATIC CLUTCH INSPECTION ........................................................... 2-26

1. INITIAL ENGAGEMENT INSPECTION ............................................ 2-26

2. CLUTCH “LOCK-UP” INSPECTION ............................................... 2-26

PERIODIC MAINTENANCE 2-2

2

6

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. Mileages are expressed in terms of kilometer

and time for your convenience.

NOTE:

More frequent servicing may be performed on motorcycles that are used under severe conditions.

PERIODIC MAINTENANCE CHART

NOTE:

I = Inspect and adjust, clean, lubricate or replace as necessary.

R = Replace

T = Tighten

Interval

Item

km 1 000 4 000 8 000

months 5 20 40

Air cleaner

—I I

Replace every 12 000 km.

Exhaust pipe nut and muffler mounting bolt T — T

Valve clearance I I I

Spark plug — I R

Fuel line — I I

Engine oil R R R

Engine oil filter R — R

Throttle cable play I I I

Idle speed I I I

PAIR (Air supply) system — I I

Drive chain

III

Clean and lubricate every 1 000 km.

Brake I I I

Brake hose

—I I

Replace every 4 years.

Brake fluid

—I I

Replace every 2 years.

Tires — I I

Steering I — I

Front fork — — I

Rear suspension — — I

Chassis bolts and nuts T T T

2-3 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.

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 whenever the motorcycle

has been operated under wet or rainy conditions.

Speedometer

cable

Center stand pivot

and spring hook

Speedometer

gearbox

Side-stand pivot

and spring hook

Kick starter lever Rear brake pedal

Throttle cable

Front brake

lever holder

PERIODIC MAINTENANCE 2-4

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each item of

the Periodic Maintenance requirements.

AIR CLEANER

If the air cleaner element is clogged with dust, intake resistance

will be increased, with a resultant decrease in power output and

increase in fuel consumption. Check and clean the air cleaner

element in the following manner.

• Place the motorcycle on the center stand.

• Remove the air cleaner element box cover

1.

• Using compressed air, blow the dust from the cleaner ele-

ment.

#

• Reinstall the cleaned or new air cleaner element in the

reverse order of removal.

#

Inspect every 4 000 km (20 months) and replace every

12 000 km.

Always apply compressed air to the inside of the air

cleaner element. If compressed air is applied to the

outside, dirt will be forced into the pores of the air

cleaner element, restricting air flow through the air

cleaner element.

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

ment must be replaced.

* If driving under dusty conditions, clean the air

cleaner element more frequently. The surest way to

accelerate engine wear is to operate the engine with-

out the element 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 compo-

nent.

2-5 PERIODIC MAINTENANCE

• Remove the drain plug

2 from the air cleaner box to allow

any water to drain out.

EXHAUST PIPE NUT AND MUFFLER

MOUNTING BOLT

• Tighten the exhaust pipe nuts

1, muffler mounting bolts 2

and muffler connecting bolt

3.

" Exhaust pipe nut: 23 N·m (2.3 kgf-m)

Muffler mounting bolt: 23 N·m (2.3 kgf-m)

Muffler connecting bolt: 23 N·m (2.3 kgf-m)

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

8 000 km (40 months) thereafter.

PERIODIC MAINTENANCE 2-6

VALVE CLEARANCE

REMOVAL

• Remove the leg shields, left and right. ($5-6)

• Disconnect the spark plug cap

1 and remove the spark plug

2.

• Remove the valve inspection caps

3.

• Remove the valve timing inspection plug

4 and generator

cover plug

5.

• Remove the camshaft sprocket cover

6.

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

4 000 km (20 months) thereafter.

2-7 PERIODIC MAINTENANCE

INSPECTION AND ADJUSTMENT

The valve clearance specification is same for both valves. The

valve clearance adjustment must be checked and adjusted, 1) at

the time of periodic inspection, 2) when the valve mechanism is

serviced, and 3) when the camshaft is removed for servicing.

NOTE:

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

to check the valve clearance or to adjust the valve clearance.

* The valve clearance specification is for COLD state.

* To turn the generator rotor for clearance checking, rotate in the

normal running direction. The spark plug should be removed.

• Rotate the generator until the line

A on the crankshaft is at

the center of the hole in the generator cover.

• Align the mark

B on the camshaft sprocket with the concave

line

C of the cylinder head.

PERIODIC MAINTENANCE 2-8

• 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 value.

% Valve clearance (when cold):

Standard: IN.: 0.03 – 0.08 mm

EX.: 0.08 – 0.13 mm

& 09900-20803: Thickness gauge

09917-14910: Valve clearance adjusting driver

" Valve clearance adjuster lock-nut: 10 N·m (1.0 kgf-m)

• After finishing the valve clearance adjustment, reinstall the fol-

lowing items.

* Camshaft sprocket cover. ($3-80)

* Valve timing inspection plug. ($3-80)

* Generator cover plug. ($3-80)

* Spark plug and spark plug cap. ($2-9)

* Left and right leg shields. ($5-6)

Adjusting screw

Lock-nut

2-9 PERIODIC MAINTENANCE

SPARK PLUG

REMOVAL

• Disconnect the spark plug cap

1 and remove the spark plug

2.

& 09930-10121: Spark plug socket wrench set

CARBON DEPOSIT

Check the carbon deposit on the spark plug.

If carbon is deposited, remove it with a spark plug cleaner

machine or carefully using a tool with a pointed end.

SPARK PLUG GAP

Measure the plug gap with a thickness gauge if it is correct. If

not, adjust it to the following gap.

% Spark plug gap:

Standard: 0.6 – 0.7 mm

& 09900-20803: Thickness gauge

ELECTRODE’S CONDITION

Check the condition of the electrode. If it is extremely worn or

burnt, replace the plug. And also replace the plug if it has a bro-

ken insulator, damaged thread, etc.

#

Inspect at 4 000 km (20 months).

Replace every 8 000 km (40 months).

Standard

NGK C6HSA

DENSO U20FS-U

Confirm the thread size and reach when replacing the

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

on the screw portion of the plug hole and engine dam-

age may result.

0.6 – 0.7 mm

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