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Burgman UH125
Suzuki Burgman UH125 Service Manual
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ELE
C
TRICA
L
SYST
EM 9-27
COMBINATION METE
R
REMOVAL AND DI
SASS
EMBLY
•
Rem
ove t
he sp
eed
ometer
. (
!
8-
5)
•
Di
sasse
mble the
spee
dom
ete
r, as s
hown.
#
Whe
n disc
onn
ecting
and reco
nnect
ing th
e speed
om
e-
ter co
uple
r, make su
re to tur
n OFF the ig
nition
s
witch,
or e
lectr
onic pa
rt
s may g
et da
maged
.
297
299
Table of Contents
Foreword Group Index
2
Table of Contents
2
Glossary
5
General Information 1
7
Country and Area Code
7
General Precautions
8
Warning/Caution/Note
8
Product View
10
Serial Number Location
10
Suzuki Uh125K7 ('07-Model)
10
Fuel, Oil and Engine Coolant Recommendation
11
Fuel
11
Engine Oil and Final Gear Oil
11
Brake Fluid
11
Front Fork Oil
11
Engine Coolant
12
Break-In Procedures
13
Specifications
14
Dimensions and Dry Mass
14
Engine
14
Drive Train
14
Chassis
14
Electrical
15
Capacities
15
Periodic Maintenance
16
Periodic Maintenance Schedule
17
Periodic Maintenance Chart
17
Lubrication Points
18
Maintenance and Tune-Up Procedures
19
Air Cleaner
19
Cooling Fan Filter
20
Exhaust Pipe Nuts and Muffler Bolts
21
Valve Clearance
21
Spark Plug
22
Fuel Line
23
Engine Oil and Oil Filter
24
Final Gear Box Oil
25
Throttle Cable Play
26
Cooling System
27
Drive V-Belt
29
Brake System
30
Tire
34
Tire Tread Depth
34
Steering
35
Front Fork
35
Rear Suspension
35
Chassis Bolt and Nut
36
Compression Pressure Check
38
Compression Test Procedure
38
Oil Pressure Check
39
Oil Pressure Test Procedure
39
Automatic Clutch Inspection
40
Initial Engagement Inspection
40
Clutch "Lock-Up" Inspection
40
Sds Check
41
Engine
45
Engine Components Removable with the Engine in Place
46
Engine Removal and Remounting
47
Removal
47
Remounting
51
Engine Disassembly
54
Engine Component Inspection and Service
64
Rocker Arm and Shaft
64
Cylinder Head
65
Cylinder Head Distortion
66
Camshaft
72
Cam Chain Tension Adjuster
74
Cam Chain Tensioner
74
Cam Chain Guide
74
Cylinder
75
Piston
75
Conrod and Crankshaft
77
Oil Pump
79
Oil Sump Filter
79
Movable Drive Face Assembly
80
Clutch Shoe/Movable Driven Face
82
Starter Clutch
88
Generator Cover
90
Final Gear Box Cover
92
Final Gear
94
Crankcase
94
Engine Reassembly
100
Fi System Diagnosis
116
Precautions in Servicing
118
Electrical Parts
118
Fuse
119
Switch
119
Ecm/Various Sensors
119
Electrical Circuit Inspection Procedure
121
Using the Multi-Circuit Tester
124
Fi System Technical Features
125
Injection Time (Injection Volume)
125
Compensation of Injection Time (Volume)
126
Injection Stop Control
126
Fi System Parts Location
127
Fi System Wiring Diagram
129
Ecm Terminal
130
Self-Diagnosis Function
131
User Mode
131
Dealer Mode
132
Fail-Safe Function
133
Fi System Troubleshooting
134
Customer Complaint Analysis
134
Visual Inspection
135
Self-Diagnostic Procedures
136
UNDERSTANDING the DTC (Diagnostic Trouble Code)
137
Dtc Indication Chart
138
Self-Diagnosis Reset Procedure
139
Use of Sds Diagnostic Procedures
140
Use of Sds Diagnosis Reset Procedure
141
Show Data When Trouble (Displaing Data at the Time of Dtc)
142
Malfunction Code and Defective Condition
143
12" (P0335) Ckp Sensor Circuit Malfunction
145
13" (P0105-H/L) Iap Sensor Circuit Malfunction
148
14" (P0120-H/L) Tp Sensor Circuit Malfunction
153
15" (P0115-H/L) Ect Sensor Circuit Malfunction
158
23" (P1651-H/L) to Sensor Circuit Malfunction
162
24" (P0351) Ignition System Malfunction
165
32" (P0201) Fuel Injector Circuit Malfunction
166
40" (P0505 or P0506 and P0507) ISC VALVE CIRCUIT MALFUNCTION
168
41" (P0230-H/L) Fp Circuit Malfunction
172
42" (P01650) Ig Switch Circuit Malfunction
174
44" (P0130) Ho2 Sensor (Ho2S) Circuit Malfunction
175
Sensors
178
Ckp Sensor Inspection
178
Ckp Sensor Removal and Installation
178
Iap Sensor Inspection
178
Iap Sensor Removal and Installation
178
Tp Sensor Inspection
178
Tp Sensor Removal and Installation
178
Ect Sensor Inspection
178
Ect Sensor Removal and Installation
178
To Sensor Inspection
179
To Sensor Removal and Installation
179
Ho2 Sensor Inspection
179
Ho2 Sensor Removal and Installation
179
Fuel System and Throttle Body
180
Fuel System and Throttle
180
Fuel System
181
Construction
181
Removal and Disassembly
182
Fuel Tank Reassembly and Installation
184
Fuel Pressure Inspection
185
Fuel Pump Inspection
186
Fuel Discharge Amount Inspection
186
Fuel Mesh Filter Inspection and Cleaning
187
Throttle Body
188
Construction
188
Removal and Disassembly
189
Inspection
191
Reassembly and Installation
192
Exhaust System
193
Cooling and Lubrication System
196
Cooling and Lubrication
196
Engine Coolant
197
Radiator and Radiator Hose
198
Inspection
198
Removal
199
Disassembly
200
Reassembly and Installation
200
Cooling Fan
202
Inspection
202
Removal
202
Installation
202
Cooling Fan Thermo-Switch
203
Removal
203
Inspection
203
Installation
203
Engine Coolant Temperature Gauge
204
Removal
204
Inspection
204
Installation
204
Ect Sensor
205
Removal
205
Inspection
205
Installation
206
Thermostat
206
Removal
206
Inspection
206
Installation
207
Water Pump
208
Removal and Disassembly
208
Inspection
210
Reassembly and Installation
210
Lubrication System
213
Oil Pressure
213
Oil Filter
213
Oil Sump Filter
213
Oil Pump
213
Engine Lubrication System Chart
214
Chassis
215
Exterior Parts
217
Fastener
217
Handlebar Covers
218
Front Cover
218
Windscreen
218
Lower Meter Panel
219
Front Leg Shield
220
Lower Leg Shield
221
Side Leg Shield (Lh)
221
Side Leg Shield (Rh)
222
Rear Lower Leg Shield
222
Front Frame Cover
222
Seat
223
Pillion Rider Handles
223
Lower Frame Cover
223
Frame Cover
223
Trunk Box
225
Footboard
226
Front Box
227
Front Wheel
228
Construction
228
Removal
229
Inspection and Disassembly
229
Reassembly and Installation
231
Handlebars
233
Construction
233
Removal
234
Installation
234
Front Fork
236
Construction
236
Removal and Disassembly
237
Inspection
239
Reassembly
240
Steering
243
Construction
243
Removal and Disassembly
244
Inspection and Disassembly
245
Reassembly
246
Rear Wheel
249
Construction
249
Removal
250
Inspection
250
Installation
250
Front Brake
251
Construction
251
Brake Fluid Replacement
252
Brake Pad Replacement
252
Front Brake Caliper Removal and Disassembly
252
Front Brake Caliper Inspection
254
Front Brake Caliper Reassembly
254
Brake Disc Inspection
256
Front Brake Master Cylinder Removal and Disassembly
256
Front Brake Master Cylinder Inspection
257
Front Brake Master Cylinder Reassembly and Installation
258
Rear Brake
260
Construction
260
Rear Brake Caliper Removal and Disassembly
261
Rear Brake Caliper Inspection
262
Rear Brake Caliper Reassembly
262
Rear Brake Master Cylinder Removal and Disassembly
263
Rear Brake Master Cylinder Inspection
263
Rear Brake Master Cylinder Reassembly and Installation
264
Delay Valve Removal
264
Delay Valve Installation
264
Rear Suspension
265
Construction
265
Rear Swingarm Bearing Inspection
266
Rear Swingarm Bearing Removal
266
Rear Swingarm Bearing Installation
266
Rear Shock Absorber Removal
267
Rear Shock Absorber Inspection
267
Rear Shock Absorber Installation
267
Tire and Wheel
268
Tire Removal
268
Inspection
268
Valve Inspection
269
Tire Installation
270
Electrical System
272
Cautions in Servicing
274
Connector
274
Coupler
274
Clamp
274
Fuse
274
Switch
274
Semi-Conductor Equipped Part
275
Battery
275
Connecting the Battery
275
Wiring Procedure
275
Using the Multi-Circuit Tester
276
Location of Electrical Components
277
Charging System
279
Troubleshooting
279
Inspection
281
Starter System
284
Trouble Shooting
284
Starter Motor Removal
285
Starter Motor Disassembly
286
Starter Motor Inspection
287
Starter Motor Reassembly
288
Starter Motor Installation
289
Starter Relay Inspection
290
Side-Stand/Ignition Interlock System Parts Inspection
291
Ignition System
293
Troubleshooting
293
Inspection
295
Combination Meter
298
Removal and Disassembly
298
Inspection
299
Lamps
301
Headlight, Position Light, Brake Light/Taillight, License Plate Light and Turn Signal Light
301
Bulb Replacement
302
Headlight Beam Adjustment
305
Switches
306
Ignition Switch Removal and Installation
306
Inspection
307
Battery
308
Specifications
308
Initial Charging
308
Servicing
310
Recharging Operation
310
Servicing Information
311
Troubleshooting
312
Fi System Malfunction Code and Defective Condition
312
Engine
314
Radiator (Cooling System)
319
Chassis
320
Brakes
321
Electrical
322
Battery
323
Wiring Diagram
324
Wiring Harness, Cable and Hose Routing
325
Wiring Harness Routing
325
Cable Routing
327
Cooling System Hose Routing
328
Brake Hose Routing
329
Engine Electrical Parts Harness Routing
330
Ho2 Sensor Harness Routing
331
Speedometer Cable Routing
332
Throttle Body Hose Routing
333
Drain Hose Routing
334
Seat Molding Installation
335
Exterior Parts Set-Up
336
Drive Belt Cooling Filter and Clutch Cover Gasket Installation
339
Front Box Cushion Installation
340
Side-Stand Installation
341
Center Stand Installation
341
Special Tools
342
Tightening Torque
346
Engine
346
Fi System and Intake Air System
347
Cooling System
347
Brake Disc
347
Tightening Torque Chart
348
Service Data
349
4
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Suzuki Burgman UH125 Specifications
General
Brand
Suzuki
Model
Burgman UH125
Category
Scooter
Language
English
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