Suzuki VL 125 Intruder Service Repair Manual

VL125 99500-31150-01E loc83

GROUP INDEX 1 FOREWORD This manual contains an introductory description on the SUZUKI VL125 and procedures for its inspection/service and overhaul of its main components. Other information considered as generally known is not included. Read the GENERAL INFORMATION section to fa- miliarize yourself with the motorcycle and its maintenance. 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. ! 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. 2 3 4 5 6 7 GENERAL INFORMATION * This manual has been prepared on the basis of the latest specifications at the time of pub- lication. If modifications have been made since then, differences may exist between the content 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, includ- ing special tools, for servicing SUZUKI mo- torcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you. PERIODIC MAINTENANCE ENGINE FUEL AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM Motorcycle Service Department SERVICING INFORMATION

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 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 Left Right " ITEM N . m kgf . m A 65 6.5 B 23 2.3 C 23 2.3 A Front axle B Axle pinch bolt C Brake disc bolt

SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table. * How to make Molybdenum oil : Pour an engine oil and SUZUKI MOLY PASTE in a ratio of 1:1 by volume into such as oiler, and stir well. SYMBOL DEFINITION SYMBOL DEFINITION Use special tool. Torque control required Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise specified. Apply *Molybdenum oil solution (Mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1:1) Apply SUZUKI MOLY PASTE. 99000-25140 Apply THREAD LOCK SUPER “1303”. 99000-32030 Apply THREAD LOCK SUPER “1360”. 99000-32130 Apply or use brake fluid. Measure in voltage range. Measure in resistance range. Measure in current range. Measure in diode test range. Use fork oil. 99000-99044-10G Measure in continuity test range. Indication of service data. Apply THREAD LOCK “1342”. 99000-32050 Apply SUZUKI SUPER GREASE “A”. 99000-25010 Apply SUZUKI SILICONE GREASE. 99000-25100 # $ % & ’ ( ) * + , - . / 0 1 2 3 " Apply SUZUKI BOND “1215”. 99000-31110 Apply SUZUKI BOND “1216”. 99000-31160 4 5 Apply THERMO GREASE “G”. 99000-25300 6

1 GENERAL INFORMATION 1-1 GENERAL INFORMATION 1-1 GENERAL INFORMATION 1-1 GENERAL INFORMATION 1-1 GENERAL INFORMATION 1-1 GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE ............................................................... 1- 2 GENERAL PRECAUTIONS ................................................................ 1- 2 SUZUKI VL125Y (2000-MODEL) ........................................................ 1- 4 SERIAL NUMBER LOCATION ........................................................... 1- 4 FUEL AND OIL RECOMMENDATION ................................................ 1- 5 FUEL ................................................................................................ 1- 5 ENGINE OIL .................................................................................... 1- 5 BRAKE FLUID ................................................................................. 1- 5 FRONT FORK OIL ........................................................................... 1- 5 BREAK-IN PROCEDURES ................................................................. 1- 5 CYLINDER IDENTIFICATION ............................................................. 1- 6 INFORMATION LABELS .................................................................... 1- 6 SPECIFICATIONS ............................................................................... 1- 7 COUNTRY AND AREA CODES ......................................................... 1- 9

1-2 GENERAL INFORMA 1-2 GENERAL INFORMA 1-2 GENERAL INFORMA 1-2 GENERAL INFORMA 1-2 GENERAL INFORMATION TION TION TION TION 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. 7 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 WARN- INGS 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 ad- vice. 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 outdoors. * 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 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.

GENERAL INFORMATION 1-3 GENERAL INFORMATION 1-3 GENERAL INFORMATION 1-3 GENERAL INFORMATION 1-3 GENERAL INFORMATION 1-3 7 * If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. * 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 not require use of battery power, disconnect the negative cable the battery. * When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first. Al- ways tighten the bolts and nuts diagonally from the inside working out 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, engine coolant and other fluids: batteries, and tires. * To protect Earth’s natural resources, properly dispose of used motorcycle and parts.

1-4 GENERAL INFORMA 1-4 GENERAL INFORMA 1-4 GENERAL INFORMA 1-4 GENERAL INFORMA 1-4 GENERAL INFORMATION TION TION TION TION SUZUKI VL125Y (2000-MODEL) *Difference between photograph and actual motorcycle depends on the markets. SERIAL NUMBER LOCATION The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the frame tube. 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 RIGHT SIDE

GENERAL INFORMATION 1-5 GENERAL INFORMATION 1-5 GENERAL INFORMATION 1-5 GENERAL INFORMATION 1-5 GENERAL INFORMATION 1-5 ENGINE OIL Use a premium quality 4-stroke motor oil to ensure longer service 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 following chart. BRAKE FLUID Specification and classification: DOT 4 ! Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, 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. FRONT FORK OIL Use fork oil #10. FUEL AND OIL RECOMMENDATION FUEL Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recommended. 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. The general rules are as follows. • Keep to these break-in procedures: 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. • Do not maintain constant engine speed for an extended time period during any portion of the break-in. Try to vary the throttle position.

1-6 GENERAL INFORMA 1-6 GENERAL INFORMA 1-6 GENERAL INFORMA 1-6 GENERAL INFORMA 1-6 GENERAL INFORMATION TION TION TION TION CYLINDER IDENTIFICATION The two cylinders of this engine are identified as No. 1 and No. 2 cylinder, as counted from rear to front (as viewed by the rider on the seat). INFORMATION LABELS 1 Noise label For E-34 2 Fuel caution label For E-02 3 Tire pressure label 4 Warning safety label 5 ID plate 6 ID plate For E-18 No. 1 No. 1 No. 2 No. 2 Front Front

Suzuki VL 125 Intruder Service Repair Manual

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