Suzuki VL125 User manual

VL125
99500-31150-01E
loc83

GROUP INDEX
1
FOREWORD
This manual contains an introductory description on
the SUZUKI VL125 and procedures for its inspec-
tion/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 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.
!
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 motor-
cycle.
* Illustrations in this manual are used to show
the basic principles of operation and work pro-
cedures. 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 knowl-
edge and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
PERIODIC MAINTENANCE
ENGINE
FUEL AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
Motorcycle Service Department
cCOPYRIGHT SUZUKI MOTOR CORPORATION 1999
SERVICING INFORMATION

HOW TO USE THIS MANUAL
TO LOCATE WHATYOU 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 WORKTO 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
A65 6.5
B23 2.3
C23 2.3
AFront axle
BAxle pinch bolt
CBrake disc bolt

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.
* 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 1-1GENERAL INFORMATION 1-1
GENERAL INFORMATION 1-1GENERAL INFORMATION 1-1
GENERAL INFORMATION 1-1
GENERAL INFORMATION
CONTENTS
WARNING/CAUTION/NOTE ............................................................... 1- 2
GENERAL PRECAUTIONS................................................................ 1- 2
SUZUKIVL125Y (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 INFORMA1-2 GENERAL INFORMA
1-2 GENERAL INFORMA1-2 GENERAL INFORMA
1-2 GENERAL INFORMATIONTION
TIONTION
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 1-3GENERAL INFORMATION 1-3
GENERAL INFORMATION 1-3GENERAL 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. A l -
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 INFORMA1-4 GENERAL INFORMA
1-4 GENERAL INFORMA1-4 GENERAL INFORMA
1-4 GENERAL INFORMATIONTION
TIONTION
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) 1is stamped on the right side of the frame
tube. The engine serial number 2is 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 1-5GENERAL INFORMATION 1-5
GENERAL INFORMATION 1-5GENERAL INFORMATION 1-5
GENERAL INFORMATION 1-5
ENGINE OIL
Use a premium quality 4-stroke motor oil to ensure longer ser-
vice 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 manufac-
turer, 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 recom-
mended.
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 INFORMA1-6 GENERAL INFORMA
1-6 GENERAL INFORMA1-6 GENERAL INFORMA
1-6 GENERAL INFORMATIONTION
TIONTION
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
1Noise label For E-34
2Fuel caution label For E-02
3Tire pressure label
4Warning safety label
5ID plate
6ID plate For E-18
No. 1No. 1
No. 2No. 2
FrontFront