Suzuki fl125sdwk7 User guide

K7
February ’07 Printed in Japan (TK) 19
99505-01107-01E
FOREWORD
This motorcycle has been designed and produced utilizing Suzuki’s most modern
technology. The finest product, however, cannot perform properly unless it is cor-
rectly assembled and serviced. This set-up manual has been produced to aid you in
properly assembling and servicing this motorcycle.
Please review this set-up manual carefully before performing any work. Take spe-
cial care to properly perform the required assembly and servicing marked by either
a Warning or a Caution. Failure to follow the directions in either of these two (2) cat-
egories could lead to serious problems. #and areas are
denoted to emphasize certain areas and carry the following meanings:
#
Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in motorcycle damage.
This set-up manual is based on a motorcycle of standard specification. Some minor
differences from this manual may be found in other specifications.

1
PREPARATION
WORKSHOP
#
A: Packed motorcycle
B: Working space
SELF PROTECTION
#
UNCRATING THE MOTORCYCLE
Remove the carton.
#
A: Crate
Remove the strap.
Take out the front wheel assembly and component
parts from the crate base.
A: Strap
B: Front wheel assembly
C: Component parts
The workshop where the machine is assembled
should be clean, spacious, and have a level
floor.
The technician should wear protective clothing
such as leather gloves, a long sleeve shirt, eye
protection and safety shoes as shown in the
illustration when handling metal crates.
Metal crates may have sharp edges and may
cause injury.

2
Remove the nut to take off the handlebar holding
bracket and stay.
A: Nut
B: Bracket
C: Stay
D: Protection cover
Remove the bolts

Aused to mount the steel frame on
the crate base.

Lift the steel frame to separate it from the base of the
crate.
#

A: Steel frame
B: Crate base
NOTE:
The brackets, stay and nuts are no longer
needed and these may be discarded.
Remove the protection cover after taking out
the motorcycle.
Don’t remove the bolt

Bof the motorcycle sup-
porting bracket

C.
Handling crates requires two operators.
Be careful not to scratch the motorcycle.

3
LOCATION OF PARTS
Check all the components which have been removed from the crate.
Parts listed above are installed respectively into the positions as follows.
Item Part Name Q’ty Remarks
A
Front fender front 1
Stepped screw 1 6 × 16 mm
Screw 2 6 × 16 mm
Stepped washer 2 OD:16.0 ID:6.5
T:5.0
B Rear view mirror 2 Right and Left
C Front wheel spacer 1
Item Part Name Q’ty Remarks
DSpeedometer drive
gearbox 1
E Front wheel assembly 1
FBattery electrolyte
container 1
G Owner’s manual set 1
OD : Outside diameter (mm)
ID : Inside diameter (mm)
L : Length (mm)
T : Thickness (mm)
TL
OD ID
B
D
AE B
C

4
The photograph shown indicates the parts dismounted
from the motorcycle in addition to the items shown in
the preceding page.
A: Speedometer cable
Before assembling the motorcycle, thoroughly
understand the “Safety Check Out” described on
page 26.
After completion of assembly, carefully check the
motorcycle referring to the “Safety Check Out”,
then deliver the motorcycle to the customer.
F
F
G
G
E
E
C
C
A
A
B
B
D
D

5
ASSEMBLY
Loosen the rear axle nut.
Remove the bolt.
Remove the motorcycle supporting bracket.
A: Bracket
B: Bolt
C: Rear axle nut
Make sure that the washer is placed on the rear axle.
Tighten the axle nut to the specified torque.
"Rear axle nut: 54 N·m (5.4 kgf-m)
A: Washer
B: Rear axle nut
Attach a hoist band onto the handlebar as shown in
the photograph.
A: Hoist band
B: Protection cover
NOTE:
The bracket and bolt are no longer needed and
may be discarded.

6
Remove the crate axle bracket from the crate base.
A: Crate axle bracket
B: Bolt

1. Lift the front of motorcycle by using a hoist.

2. Raise the rear of motorcycle.

3. Take out the motorcycle from the crate base, then
balance the motorcycle.
FRONT FENDER
Remove the bolt of front brake hose guide.
A: Bolt
B: Front brake hose guide
Set the front fender front to the front fender rear.
A: Front fender front
B: Front fender rear
C: Hook
D: Hole
NOTE:
The bracket and bolts are no longer needed and
these may be discarded.

7
Install the front fender front to the front fork lower
bracket.
A: Front fender front
B: 6 × 16 mm stepped screw
C: 6 × 16 mm screw
D: Stepped washer OD:16.0 mm ID:6.5 mm T:5.0 mm
Reinstall the front brake hose guide.
A: Bolt
B: Front brake hose guide
BRAKE DISC
To prevent brake squeaking and pad contamination,
carefully clean the front brake disc plate with alcohol or
other non-petroleum based solvent.
This will remove the rust-preventive coating and dirt.
FRONT WHEEL
Remove the front axle nut.
Remove the front axle from the fork legs.
A: Front axle nut
B: Front axle
C: Rubber spacer
D: Vinyl tube
NOTE:
The rubber spacer and vinyl tube are no longer
needed and these may be discarded.

8
Mount the front wheel assembly properly.
A: Right fork leg
B: Left fork leg
C: Front axle
D: Front axle nut
E: Front wheel spacer
F: Speedometer drive gear box
Remove the supporter from the brake pad of the front
brake caliper.
A: Supporter
Carefully insert the front brake disc plate between the
caliper brake pads.
Attach the front wheel spacer between the front wheel
hub and right fork leg.
A: Pads
B: Disc plate
C: Front wheel spacer
Insert tabs of the speedometer drive gearbox into front
wheel hub grooves.
A: Tabs
B: Grooves
NOTE:
The flange side of the spacer faces the hub.

9
Insert the front axle from the right side of fork leg.
Fix the front wheel assembly to the front fork.

A: Front axle
Align the edge slit of the meter cable with the blade in
the gearbox.
Connect the speedometer cable to the drive gearbox.
Tighten the nut securely.
A: Speedometer cable
B: Speedometer drive gearbox
C: Nut
Before tightening the front axle nut, position the speed-
ometer drive gearbox correctly.

A: Speedometer drive gearbox
B: Left fork leg
Tighten the front axle nut to the specified torque.
"Front axle nut: 42 N·m (4.2 kgf-m)
A: Front axle nut
Never use force to install the front axle.
If it cannot be installed by hand, it is not cor-
rectly aligned.
Align the curved surface of speedometer drive
gearbox to curved surface of left fork leg, with
the clearances equalized as shown in the pho-
tograph.