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VL125
Suzuki VL125 Service Manual
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ENGINE 3-11
ENGINE DISASSEMBL
Y
ST
AR
TER MO
T
O
R
•
Remo
ve the star
ter motor
.
GEAR POSITION SWITCH
•
Remove the gear position switch.
•
Remove the contacts
1
,
2
and springs
3
,
4
.
SPEED SENSOR
•
Remo
ve the speed sensor
.
CYLINDER HEAD CO
VER
•
Remove the spark plugs. (
9
2-6)
•
Remove the head cover caps.
45
47
Table of Contents
General Information 1
5
Electrical System
2
Fuel and Lubrication System
2
Servicing Information
2
How to Use this Manual
3
Table of Contents
5
General Information
2
Periodic Maintenance
2
Warning/Caution/Note
6
General Precautions
6
Suzuki Vl125Y (2000-Model)
8
Serial Number Location
8
Fuel and Oil Recommendation
9
Fuel
9
Engine Oil
9
Brake Fluid
9
Front Fork Oil
9
Break-In Procedures
9
Cylinder Identification
10
Information Labels
10
Specifications
11
Dimensions and Dry Mass
11
Country and Area Codes
13
Periodic Maintenance
14
Periodic Maintenance Schedule
15
Periodic Maintenance Chart
15
Lubrication Points
16
Maintenance and Tune-Up Procedures
17
Valve Clearance
17
Spark Plug
19
Exhaust Pipe Bolt and Muffler Bolt
20
Air Cleaner
20
Carburetor
22
Idling Adjustment
22
Throttle Cable Play
22
Fuel Hose
23
Clutch
23
Engine Oil and Oil Filter
24
Drive Chain
26
Adjusting
27
Cleaning and Lubricating
27
Brake System
28
Steering
32
Front Fork
32
Rear Suspension
32
Tire
33
Chassis Bolts and Nuts
33
Compression Pressure Check
34
Oil Pressure Check
35
Engine
36
Engine Components Removable with Engine in Place
37
Engine Removal and Reinstallation
38
Engine Removal
38
Engine Reinstallation
43
Engine Disassembly
46
Engine Component Inspection and Service
55
Cylinder Head Cover
55
Camshaft
57
Cam Chain Tension Adjuster
58
Cam Chain Tensioner
58
Cylinder Head
59
Cylinder
68
Piston
69
Piston Ring End Gap
70
Piston Ring Groove Width
70
Piston Ring Thickness
70
Conrod and Crankshaft
72
Generator Cover
73
Starter Clutch
74
Starter Driven Gear
75
Clutch Cover
76
Clutch
77
Primary Driven Gear
78
Oil Pump
78
Transmission
79
Crankcase
81
Engine Reassembly
84
Primary Drive Gear
92
Starter Idle Gear
96
Piston Ring
97
Cam Chain Guide
98
Speed Sensor
104
Starter Motor
105
Fuel and Lubrication System
107
Fuel System
108
Fuel Pump
108
Fuel Tank/Fuel Cock
109
Removal
109
Inspection
110
Reassembly
111
Fuel Pump
111
Carburetor
112
Specifications
112
Air Controle Valve
113
Slow System
114
Main System
115
Accelerator Pump System
116
Removal
117
Disassembly
117
Inspection
120
Carburetor Cleaning
120
Inspection
121
Fuel Level Adjustment
122
Float Height Adjustment
123
Reassembly and Reinstallation
124
Lubrication System
127
Chassis
128
Exterior Parts Removal and Remounting
129
Front Fender
129
Front Seat
129
Rear Seat
129
Luggage Box
129
Frame Cover
130
Rear Fender
132
Front Wheel
134
Removal
134
Inspection and Disassembly
135
Reassembly
137
Remounting
139
Front Brake
140
Brake Fluid Replacement
140
Brake Pad Replacement
140
Caliper Removal and Disassembly
140
Caliper Inspection
141
Caliper Reassembly
141
Caliper Remounting
142
Brake Disc Inspection
143
Master Cylinder Removal and Disassembly
144
Master Cylinder Inspection
145
Master Cylinder Reassembly and Remounting
145
Handlebars
147
Removal
147
Remounting
148
Front Fork
149
Removal and Disassembly
149
Inspection
152
Reassembly and Remounting
153
Front Fork Oil
155
Steering
157
Removal and Disassembly
157
Inspection
158
Reassembly and Remounting
159
Rear Wheel
162
Removal
163
Inspection and Disassembly
164
Reassembly and Remounting
166
Rear Brake
169
Removal and Disassembly
169
Inspection
170
Reassembly and Remounting
170
Rear Shock Absorber
172
Removal
173
Inspection and Disassembly
174
Reassembly and Remounting
175
Electrical System
177
Cautions in Servicing
178
Location of Electrical Components
180
Charging System
182
Description
182
Troubleshooting
183
Inspection
184
Starter System and Side-Stand/Ignition Interlock System
186
Starter System Description
186
Side-Stand/Ignition Interlock System Description
186
Troubleshooting
187
Starter Motor Removal and Disassembly
188
Starter Motor Inspection
188
Starter Motor Reassembly
189
Starter Relay Inspection
190
Side-Stand/Ignition Interlock System Part Inspection
191
Ignition System
193
Description
193
Troubleshooting
194
Inspection
195
Speedometer
199
Removal and Disassembly
199
Speed Sensor Inspection
200
Lamps
201
Headlight and Position Light
201
Brake Light/Taillight
202
Turn Signal Light
202
Switches
203
Ignition Switch Removal
203
Battery
205
Specifications
205
Initial Charging
205
Servicing
206
Recharging Operation
207
Servicing Information
208
Troubleshooting
209
Engine
209
Carburetor
212
Shaft Drive
212
Chassis
213
Brakes
214
Electrical
215
Battery
216
Wiring Diagram (for E-02, 19 / for E-03, 28, 33 / for E-24)
217
Wire Harness, Cable and Hose Routing
220
Wire Harness Routing
220
Cable Routing
223
Fuel Hose Routing
224
Cooling Hose Routing
225
Front Brake Hose Routing
226
Battery Protector
227
Speed Sensor Lead Wire Routing
227
Special Tools
228
Tightening Torque
231
Engine
231
Secondary and Final
232
Chassis
233
Tightening Torque Chart
234
Service Data
235
5
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Suzuki VL125 Specifications
General
Brand
Suzuki
Model
VL125
Category
Motorcycle
Language
English
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