Suzuki Step 125 Service Manual
FOREWORD
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This manual con tains an intro ducto ry de scri ption o n
the SUZUKI UY125/S and procedures for its inspection/service and ov erhau l of its main com pon ents.
Other info rm ation co ns ider ed as ge ner ally kno wn is
not included.
Read the GENERAL INFORMATION section to
familiarize yourse lf with t he motorcycl e and its m aintenance. U se this s ection a s well as o ther sectio ns
to use as a guide for proper inspection and service.
This manua l will hel p you kn ow the motor cycle better so that you can assure your customers of fast
and reliable service.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
1
2
3
* This manual has been p repared on the ba sis
of the latest specifications at the time of publication. If modifications have been made since
then, differen ces may exi st betwe en the c ontent of this manual and the actual motorcycle.
* Illustrations i n this manu al 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 wr itten for persons who h ave
enough know ledg e, s kills a nd tools, i nclud in g
special tools, for se rvicing SUZUKI motorcy cles. If you do not ha ve the proper knowledge
and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
!
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Imprope r repair may result in in jury to the
mechanic and may render the motorcycle
unsafe for th e rider and passenger.
FUEL AND LUBRICATION
SYSTEM
CHASSIS
ELECTRICAL SYSTEM
SERVICING INFORMATION
4
5
6
7
© COPYRIGHT THAI SUZUKI MOTOR CO., LTD. 2005
THAI SUZUKI MOTOR CO., LTD.
HOW TO USE THIS MANUAL
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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 secti on easily.
4. The contents are listed on the first page of each section to
help you 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 tor que, lubricating points and locking agent points, are provided.
Example: Front wheel
1 Spacer
2 Dust seal
3 Bearing
4 Front wheel spacer
5 Front wheel
6 Bearing
7 Front brake shoe
8 Dust seal
Speedometer drive
9
gear
0 Front brake camshaft
A Front brake panel
Speedometer driven
B
gear
C Front brake cam lever
D Front axle
A Front axle nut
B Spoke nipple
Front brake cam lever
C
bolt
"
ITEM N·m kgf-m
A 42 4.2
B 4.5 0.45
C 80.8
SYMBOL
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Listed in th e t able b elow ar e th e sy m bols i ndic ating ins truc tions a nd othe r in for matio n ne c essar y for ser vicing. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torqu e control requir ed.
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 SUPER GREASE “A”.
99000-25010
Apply SUZUKI SILICONE GREASE.
99000-25100
Apply SUZUKI MOLY PASTE.
99000-25140
Apply THREAD LOCK SUPER “1360”.
99000-32130
Use fork oil.
99000-99044-10G
Apply or use brake fluid.
Measure in voltage range.
Measure in current range.
Measure in resistance range.
Apply SUZUKI BOND “1215”.
99000-31110
Apply SUZUKI BOND “1207B”.
99000-31140
Apply THREAD LOCK SUPER “1322”.
99000-32110
Apply THREAD LOCK “1342”.
99000-32050
Measure in diode test range.
Measure in continuity test range.
Use special tool.
Indication of service data.
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GENERAL INFO RMATION 1-1
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GENERAL INFORMATION
CONTENTS
WARNING/CAUTION/NOTE.... ............... ............... .............. ............... ......... 1- 2
GENERAL PRECAUTIONS......................................................................... 1- 2
SUZUKI UY125K6/SK6 (’06-MODEL)......................................................... 1- 4
SERIAL NUMBER LOCATION................... .............. ............... ............... ..... 1- 4
FUEL AND OIL RECOMMENDATION ........................................................ 1- 5
FUEL.................... .............. ............... ............... .............. ............... ......... 1- 5
ENGINE OIL .......................................................................................... 1- 5
REDUCTION GEAR OIL ....................................................................... 1- 5
BRAKE FLUID (UY125S).. ............... ............... .............. ............... ......... 1- 5
FRONT FORK OIL................................................................................. 1- 5
BREAK-IN PROCEDURES.......................................................................... 1- 5
SPECIFICATIONS.................... ............... ............... .............. ............... ......... 1- 6
1
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
CODE COUNTRY or AREA EFFECTIVE FRAME NO.
P-14 (UY125)
P-14 (UY125S)
Thailand
Thailand
CF48A-TH
CF48B-TH
!!!!!!
!!!!!!
–
–
1-2 GENERAL INFORMATION
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WARNING/CAUTION/NOTE
Please read thi s manua l and follow its instruc tions carefu lly. To em phasize s pecial info rmation, the symb ol
and the words WARNIN G, CA UTION and NOTE have speci al meanings . Pay sp ecial attent ion to the m essages highlighted by these signal words.
!
Indicates a potential hazard that could result in death or injury.
"
Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note , howev er, that the warnings and cauti ons contained in this manual c annot possibly cover all
potential h azards re lating to the servic ing, or lac k of servici ng, of th e motorc ycle. In ad dition to the WARN INGS and C AU TI ONS st ated , you mu s t use goo d judg em ent and bas ic mechanical sa fety p rinc iples . If you
are unsure about how to perform a particular service operation, ask a more experienced mechanic for
advice.
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 fo rced out-
doors.
* When workin g w ith to xic o r flam ma ble m aterial s, m ak e s ure that the area you wo rk in is well-
ventilated and that you follow all of the material manufacturer’s instructions.
* Never use gasoline as a cleaning solven t.
* To avoid getting burned, do not touch the engine, engine oil, radiato r and exhaust system
until they have cooled.
After servicing the fuel, oil, water, exhaust or brake systems, check all lines and fittings related
to the system for leaks.
GENERAL INFO RMATION 1-3
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"
* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-
lent.
* When removin g pa rts th at are t o be reused , k eep t hem a rrang ed in an orderl y man n er so that
they may be reinstalled in the proper order and orientation.
* Be sure to use special tools when instructed.
* Make sure th at 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 recon necting the b attery, conn ect the posi tive cable first and then the negative ca ble,
and replace the terminal cover on the positive terminal.
* When performing service to electrical parts, if the service procedures do not require use of
battery power, disconnect the negative cable from the battery.
* When tightening the cylinder head or case bolts and nuts, tighten the larger sizes first.
Always tighten the bolts and nuts diagonally from the inside toward outside and to the speci-
fied tightening torque.
* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking
nuts, cotter p ins, circlips and certain other pa rts as specified, be sure to repl ace them with
new ones. Als o, before installing these new parts, be sure to remove an y 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 g roove and securely fitted.
* Use a torque wrench to tight en fast eners to t he spec ified torq ue. W ipe off g rease a nd 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 and other fluids: bat-
teries and tires.
* To protect Earth’s natural resources, properly dispose of used motorcycle and parts.
1-4 GENERAL INFORMATION
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SUZUKI UY125K6/SK 6 (’06-M OD EL)
RIGHT SIDE (UY125S)
LEFT SIDE (UY125)
SERIAL NUMBER LOCATION
The frame s erial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the left si de of the steering head pipe. The engine serial number 2 is loc ated on the left s ide of the crankc ase . The se num ber s are
required especially for registering the machine and ordering spare parts.
GENERAL INFO RMATION 1-5
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FUEL AND OIL RECOMMENDATION
FUEL
Gasoline used should be graded 91 octane (Research Method) or higher. Unleaded gasoline is recommended.
ENGINE OIL
Oil quality is a major contributor to your engine’s performance
and life . A lways sele ct g ood q uali ty e ngine o il. Us e o f SF/SG or
SH/SJ in API with MA in JASO.
Suzuki recommends the use of SAE 10W-40 engine oil. If SAE
10W-40 en gine oil is not ava ilable, sele ct an alternat ive acco rding to the right chart.
REDUCTION GEAR OIL
Use a good quality SAE 10W-40 multi-grade motor oil.
BRAKE FLUID (UY125S)
Specificat ion an d classifica tion : DOT 4
!
Since the brake system of this motorcycle is filled with a glyco l-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 se rvicing, which ha s been stored for a lo ng
period.
FRONT FOR K OIL
Use SUZUKI FORK OIL G10 (#10) or an equivalent fork oil.
BREAK-IN PROCEDURES
During m anu facture onl y th e be st po ssibl e mat erials a re used and all ma chined pa rts a re finis hed to a v ery
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. Refer to the following throttle position recommendations.
• Keep to these break-in throttle positions:
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
for short periods of time.
1-6 GENERAL INFORMATION
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SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length.......................................................................... 1 859 mm
Overall width........................................................................... 654 mm
Overall height .......................................................................... 1 046 mm
Wheelba se.............................................................................. 1 244 mm
Ground clearance ................................................................... 145 mm
Dry mass................................................................................. 94.2 kg .......... UY125
95.5 kg .......... UY125S
ENGINE
Type........................................................................................ Four stroke, forced air-cooled, OHC
Number of cylinders................................................................ 1
Bore ............................................ ............................................ 53.5 mm
Stroke...................................................................................... 55.2 mm
Displacement........................ .................................................. 124 cm³
Compression ratio................................................................... 9.6 : 1
Carburetor............................................................................... MIKUNI BS26
Air cleaner.......... ....... ............ ...... ....... ...... ...... ...... ...... ....... ...... Paper element
Starter system......................................................................... Electric and kick
Lubrication system...................... ....... ...... ...... ...... ...... ....... ...... Wet su mp
Idle speed............................................................................... 1 600 ± 100 rpm
TRANSMISSION
Clutch...................................................................................... Dry shoe, automatic, centrifugal type
Reductio n ratio........................................................................ Variable change (2.700 – 0.825)
Final reduction ratio ................................................................ 9.264 (49/17 × 45/14)
Drive system........................................................................... V-be lt drive
CHASSIS
Front suspension .................................................................... Teles copic, coil spring, oil damped
Rear suspension.................................................. ................... Swingarm type, coil spring, oil damped
Front fork stroke...................................................................... 85 mm
Rear wheel travel................................................. ................... 80 mm
Steering angle......................................................................... 45° (right and left)
Caster ..................................................................................... 25.6°
Trail......................................................................................... 100 mm
Turning radius......................................................................... 1.9 m
Front brake................................................................. ............. Drum brake.......... UY125
Disc brake............ UY125S
Rear brake .............................................................................. Drum brake
Front tire size.......................................................................... 70/90-14 M/C (34 P), tube type
Rear tire size........................................................................... 80/90-14 M/C (40 P), tube type
GENERAL INFO RMATION 1-7
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ELECTRICAL
Ignition t ype............................................................................. Electronic ignition (CDI)
Ignition t iming.......................................................................... 10° B.T.D.C.at 1 600 rpm
Spark plug ............. .................................................................. NGK CR6HSA or DENSO U20FSR-U
Battery..................................................................................... 12 V 12.6 k C (3.5 Ah)/10 HR
Generator................................................................................ Single-phase A.C. generator
Fuse ......... ....... ...... ...... ...... ....... ...... ...... ............ ....... ...... ...... .... 10 A
Headlight........................................ ......................................... 12 V 30/30 W
Turn signal light.................................... ................................... 12 V 10 W
Brake light/T aillight............................... ...... ...... ....... ...... ...... .... 12 V 18/5 W
Speedometer light................................................................... 12 V 3.4 W
High beam indicator light......................................................... 12 V 1.7 W
Turn signal indicator light ........................................................ 12 V 1.7 W
CAPACITIES
Fuel tank ................................................................................. 3.7 L
Engine oil, oil change ............................................................. 950 ml
with filter change................................................... 1 050 ml
overhaul................................................................ 1 100 ml
Reductio n gear oil, oil change................................................ 100 ml
overhaul .................................................. 110 ml
These specifications are subject to change without notice.
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PERIODIC MAINTENANCE 2-1
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PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE SCHEDULE ................ ... .......................... ......... 2- 2
PERIODIC MAINTENANCE CHART .......... .......................... .............. .. 2- 2
LUBRICATION POINTS ....... ............... .............. ............... ............... ..... 2- 3
MAINTENANCE AND TUNE-UP PROCEDURES ......................................... 2- 4
AIR CLEANER ...................................................................................... 2- 4
EXHAUST PIPE BOLT AND MUFFLER MOUNTING NUT ................. 2- 5
COOLING FAN FILTER ....................................................................... 2- 5
VALVE CLEARANCE ........................................................................... 2- 6
SPARK PLUG ..... .............. ............... ............... .............. ............... ......... 2- 7
FUEL LINE ............................................................................................ 2- 8
ENGINE OIL AND OIL FILTER ............................................................ 2- 8
ENGINE IDLE SPEED .......................................................................... 2-10
THROTTLE CABLE PLAY ................................................................... 2-10
DRIVE BELT ......................................................................................... 2-11
REDUCTION GEAR BOX OIL .............................................................. 2-11
BRAKE ................................................................................................. 2-12
BRAKE HOSE AND BRAKE FLUID (UY125S) ................................... 2-13
TIRE AND WHEELS .......................................... ............... ............... ..... 2-15
STEERING ............................................................................................ 2 -17
FRONT FORK ....................................................................................... 2-17
REAR SUSPENSION ........................................................................... 2-17
CHASSIS BOLTS AND NUTS .............................. .......................... ..... 2-18
COMPRESSION PRESSURE CHECK ........................... .......................... ..... 2-20
COMPRESSION TEST PROCEDURE ............................. .................... 2-20
OIL PRESSURE CHECK ...................... ............... ............... .............. ............. 2-21
OIL PRESSURE TEST PROCEDURE ................................................. 2-21
AUTOMATIC CLUTCH INSPECTION ............................ ............... .............. .. 2-22
1. INITIAL ENGAGEMENT INSPECTION ............................................ 2-22
2. CLUTCH “LOCK-UP” INSPECTION ............................................... 2-22
2
6
2-2 PERIODIC MAINTENANCE
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PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the motorcycle operating at peak performance and economy. Mileages are expressed in terms of kilometer
and time for your convenience.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Interval
Item
Air cleaner
Exhaust pipe bolt and muffler bolt T — T
Cooling fan filter Clean every 3 000 km.
Valve clearance I I I
Spark plug — I R
Fuel line
Engine oil R R R
Engine oil filter R — R
Idle rpm I I I
Throttle cable play I I I
Drive belt — I I
Final reduction gear box oil — — I
Brake I I I
Brake hose (UY125S)
Brake fluid (UY125S)
Tire and wheels — I I
Steering I — I
Front fork — — I
Rear suspension — — I
Chassis bolt and nut T T T
km 1 000 4 000 8 000
months 5 20 40
—I I
Replace every 12 000 km.
—I I
Replace every four years.
—I I
Replace every four years.
—I I
Replace every two years.
NOTE:
I = Inspect and adjust, clean, lubricate or replace as necessary
R = Replace
T = Tighten
PERIODIC MAINTENANCE 2-3
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LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
Rear brake
lever holder
Footrest pivot
Speedometer
cable
Center stand pivot
and spring hook
Side-stand pivot
and spring hook
Throttle cable
Front brake
lever holder
Speedometer
gearbox
NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
* Lubricate exposed parts which are subject to rust, with a rust preventative spray whenever the motorcycle
has been operated under wet or rainy conditions.
2-4 PERIODIC MAINTENANCE
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MAINTENANCE AND TUNE-UP
PROCEDURES
This section describes the servicing procedures for each item of
the Periodic Maintenance requirements.
AIR CLEANER
Inspect every 4 000 km (20 m ont hs) and rep lac e every
12 000 km thereafter.
• Place the motorcycle on the side stand.
• Remove the frame cover (left and right). (!5-10)
• Remove the hook 1.
• Remove the air cl eaner element bo x cap 2 b y removing th e
screws.
• Remove the air cleaner element 3.
• Inspect the air cleaner element for clogging.
If the a ir cleaner eleme nt is clo gge d wi th dust, r eplace th e a ir
cleaner element with a new one.
"
Do not blow the a ir cleaner el ement with com pressed
air.
NOTE:
If driving u nder dusty conditions, replace the air cleaner element
more frequently. Make sure that the air cleaner is in good condition at all times. The l ife of the e ngine depends largely on thi s
component.
• Install a new air cleaner element in the reverse order of
removal.
• Remove the drain plug from the air cl eaner box to allow any
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water to drain out.
EXHAUST PIPE BOLT AND MUFFLER
MOUNTING NUT
Tighten initially at 1 000 km (5 m onths) and every
8 000 km (40 months) thereafter.
• Tighten th e exhaust pipe bolts 1 and muffler mounting bolts
2.
PERIODIC MAINTENANCE 2-5
COOLING FAN FILTER
Clean every 3 000 km.
• Remove the cooling fan cover 1.
• Remove the holder 2 and cooling fan filter 3.
• Clean th e fa n f ilter in the s am e man ner o f th e a ir cl ea ner el ement.
• Reinstall the cleaned or new filter in the reverse order of
removal.
"
Do not apply engine oil to the filter after cleaning it.
2-6 PERIODIC MAINTENANCE
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VALVE CLEARANCE
Inspect initially at 1 000 km (5 months) and every
4 000 km (20 month s) thereafter.
REMOVAL
• Remove the frame front cover. (!5-8)
• Remove the spark plug. (!2-7)
• Disconnect the breather hoses 1 and remove the head cover
2.
INSPECTION
The valve clearance specification is s ame for both valves. Valve
clearance adjustment must be checked and adjust ed, 1) at the
time of periodic inspection, 2) when the valve mechanism is serviced, and 3) wh en the camshaft is distur bed by removin g it for
servicing.
NOTE:
* The piston must be at (TDC) on the compression stroke in
order to check the valve clearance or to adjust valve clear-
ance.
* The clearance specification is for COLD state.
* To turn the crankshaft for clearance checking, rotate in the nor-
mal running direction. The spark plug should be removed.
• Turn crankshaft to brin g the “TD C” mark A on the cooling fan
to the index mark B on the crankcase.
• Insert a thickness gau ge betw ee n the valve stem end and the
adjusting screw on the rocker arm.
If the clear ance is out of specifi cation, bring i t into the spe cified range.
# Valve clearance (when cold):
IN.: 0.04 – 0.07 mm
EX.: 0.10 – 0.15 mm
$ 09900-20803: Thickness gauge
09917-13210: Valve adjusting driver
Adjuster
Lock-nut
• After finishing the valve clearance adjustment, reinstall the fol-
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lowing items.
* Cylinder head cover (!3-11)
* Spark plug and plug cap (!2-7)
* Frame front cover (!5-8)
SPARK PLUG
Inspect at 4 000 km (20 months) and replace every
8 000 km (40 months) thereafter.
REMOVAL
• Remove the frame front cover. (!5-8)
• Disconnect the spark plug cap and remove the spark plug.
PERIODIC MAINTENANCE 2-7
$ 09930-10121: Spark plug socket wrench set
Standard
NGK CR6HSA
DENSO U20FSR-U
CARBON DEPOSIT
Check to see the carbon deposit on the plug.
If the carbon is deposite d, remove it with a spark plug cle aner
machine or carefully using a tool with a pointed end.
SPARK PLUG GAP
Measure th e plug gap with a thickness gauge if it is correct. If
not, adjust it to the following gap.
# Spark plug gap:
Standard: 0.6 – 0.7 mm
$ 09900-20803: Thickness gauge
ELECTRODE’S CONDITION
Check to see the worn or burnt condition of the electrodes. If it is
extremely worn or burnt, r eplace the plug . And als o repl ace the
plug if it has a broken insulator, damage d thread, etc.
"
Confirm the thread s ize and reac h when re placing the
plug. If the r eac h is too s hort , carb on wil l be depo sit ed
on the screw portion of the plug hole and engine damage may result.
0.6 – 0.7 mm
2-8 PERIODIC MAINTENANCE
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INSTALLATION
"
Before using a spark plug wren ch, carefully turn the
spark plug by finger into the threads of the cylinder
head to prevent damage the aluminum threads.
• Install the spa rk pl ug to the cylinde r hea d by finge r tight, and
then tighten it to the specified torque.
% Spark plug: 11 N·m (1.1 kgf-m)
$ 09930-10121: Spark plug wrench set
FUEL LINE
Inspect every 4 000 km (20 months) thereafter.
Replace every 4 years.
Inspect the fuel hoses for damage and fuel leakage. If any
defects a re found, the fuel hoses must be replaced.
ENGINE OIL AND OIL FILTER
ENGINE OIL REPL ACEMENT
Replace initially at 1 000 km (5 months) and every
4 000 km (20 months) thereafter.
• Ke ep the motorcycle upright.
• Place an oil pan bel ow the engine. Drain oil by rem oving the
engine oil drain plug 1.
• Remove the oil filler cap 2.
• Tighten the engine oil drain plug 1 to the specified torque.
Pour new oil through the oil filler hole. When performing an oil
change (without oil filter replacement), the engine will hold
about 950 ml of oil. Us e an eng ine oil tha t meets AP I service
classifications SF or SG and that has a viscosity rating of SAE
10W-40.
% Engine oil drain plug 1: 18 N·m (1.8 kgf-m)
• Make sure that the engine is cooled.
• Place the motorcycle on level ground and hold it vertically.
• Install the oil filler cap 2.
• Start the engine and allow it to run for a few minu tes at idling
speed.
• Turn off the en gine and wait minute, then check the oil level
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by removing the filler cap 2. If the level is below mark “L”,
add oil to “F” level. (off the center stand, do not screw the filler
cap.)
If the level is above mark “F”, drain oil to “F” level.
OIL FILTER REPLACEMENT
Replace initially at 1 000 km (5 months) and every
8 000 km (40 months) thereafter.
• Drain engine oil as described in the engine oil replacement
procedure.
• Remove the oil filter cap 1 and oil filter 2.
• Replace the oil filter with a new one.
PERIODIC MAINTENANCE 2-9
F
L
• Install the spring 3 correctly.
• Apply engine oil lightly to the O-rings 4 and 5.
• Install the oil filter cap and tighten the bolts securely.
% Oil filter ca p bolt: 10 N·m (1.0 kgf-m)
NOTE:
* Before instal ling the new oil filter a nd oil filte r cap, make sure
that the spring 3 and new O-rings 4, 5 are installed correctly.
* The arrow mark A on the oil filter cap should be positione d
down.
* Fit the clamp to the bolt B.
• Add new engine oil and c heck the oil level as described in the
engine oil replacement procedure.
# Oil viscosity and classification:
10W-40 (SAE)/SF or SG (API)
# NECESSARY AMOUNT OF ENGIN E OIL
Oil change : 950 ml
Oil and filter change : 1 050 ml
Engine overhaul : 1 100 ml
"
Make sure t hat the o il filter i s install ed prop erly. If th e
filter is installed improperly, serious engine damage
may result.
OIL SUMP FILTER CLEANING (!3-19 and -57)
2-10 PERIODIC MAINTENANCE
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ENGINE IDLE SPEED
Inspect initially at 1 000 km (5 months) and every
4 000 km (20 month s) thereafter.
NOTE:
Make this adjustment when the engine is hot.
• Connect an electric tachometer.
• Start up the en gine and set its sp eed at anywhere between
1 500 and 1 700 rpm by turning throttle stop screw.
Engine idle speed: 1 600 ± 100 rpm
$ 09900-26006: Tachometer
THROTTLE CABLE PLAY
Inspect initially at 1 000 km (5 months) and every
4 000 km (20 month s) thereafter.
Adjust the throttle cable play A with the following proced ure s.
• Loosen the l ock-nut 1 of the throttle cable.
• Turn the adjus ter 2 in or out until the throttle cable play A
should b e 2.0 – 4.0 mm at the throttle grip.
• Tighten the lock-nut 1 while holding the adjuster 2.
Throttle cable play A: 2.0 – 4.0 mm
&
After the a djustmen t is co mpleted , chec k that h andlebar movement does not raise the engine idle speed
and that the throttle grip returns smoothly and automatically.
NOTE:
Major adjus tment can be made by the carburetor side adjuster.
DRIVE BELT
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Inspect every 4 000 km (20 months) thereafter.
• Keep the motorcycle upright.
• Remove the clutch cover. (!3-10)
• Check the c on tact sur face f or cr ack or othe r d ama ge. If crack
or other damage exists, replace the b elt with a new one.
"
If grease or oil is p rese nt on the surfa ce, d ec reas e the
belt thoroughly.
• Install the clutch cover. (!3-72)
NOTE:
Drain water from the clutch cover by removing the drain bolt A.
PERIODIC MAINTENANCE 2-11
REDUCTION GEAR BOX OIL
Inspect every 8 000 km (40 months) thereafter.
• Keep the motorcycle upright.
• Place an oil pan bel ow the ge ar case , and drain oil by r emo ving the oil drain plug 1 and fil ler cap 2.
• Tighten the drain plug 1, and pour fresh oil through the o il
filler.
Oil viscosity and classific ation: SAE 10 W-40 with SF or SG
NECESSARY AMOUNT OF REDUCTION GEAR OIL
Oil change: 100 ml
Overhaul: 110 ml
2-12 PERIODIC MAINTENANCE
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BRAKE
Inspect initially at 1 000 km (5 months) and every
4 000 km (20 month s) thereafter.
BRAKE LEVER PLAY
• Adjust the brake lever play by turning the adjusting nut 1 so
that the play A is 15 – 25 mm as shown.
# Brake lever play A: 15 – 25 mm
FRONT BRAKE PADS (UY125S)
The extent o f brake pad wear can be checke d by obse rving the
grooved limit line A on the brake pad . When t he wear ex ceeds
the grooved limit line, replace the pads with new ones.
(!5-25)
"
Replace the brake pads as a set, otherwise braking
performance will be adversely affected.
BRAKE SHOW WEAR
This motorcycle is equipped with the brake lining wear limit indicator on the brake.
To check wear of the brake lining, perform the following steps:
• First, check if the brake system is properly adjusted.
• While operating the brake, check to see tha t the tip of indic ator 1 is within the range 2 on the brake panel.
• If the tip of indicator 1 is beyond the ran ge, the brake shoe
assembly should be replaced with a new set of shoe.
(!5-13 and -49)
BRAKE HOSE AND BRAKE FLUID (UY125S)
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Inspect every 4 000 km (20 months).
Replace hoses every 4 years. Replace fluid every 2
years.
BRAKE HOSE
Check the brake hose for leakage, cracks, wear and damage. If
any damages are found, replace the brake hose with a new one.
PERIODIC MAINTENANCE 2-13
BRAKE FLUID LEVEL CHECK
• Keep the motorcycle upright and place the handlebars
straight.
• Check the brake flu id level relativ e to the low er limit li nes on
the front brake fluid reservoirs.
• When the level is below the lower limit line, replenish with
brake fluid that meets the following specification.
' Specification and classification: DOT 4
&
* The brake sys tem of this motorcyc le is filled with a
glycol-based brake fluid. Do not use or mix different
types of fluid such as silicone-based and petroleum-based fluids. Do not use any brake fluid taken
from old, used or unsealed containers. Never re-use
brake fluid left over from the last servicing or stored
for a long period of time.
* Brake fluid, if it leaks, will int erfere with safe runn ing
and immediately discolor painted surfaces. Check
the brake ho ses and h ose joi nts for crac ks and f luid
leakage before riding.
2-14 PERIODIC MAINTENANCE
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FRONT BRAKE FLUID REPLACEMENT
• Remove the handlebar cover . (!5-5)
• Place the motorcycle on a level surface and keep the handlebar st ra ig h t.
• Remove the front master cylinder reservoir cap and diaphragm.
• Suck up the old brake fluid as much as possible.
• Fill the reservoir with new brake fluid.
' Specification and classification: DOT 4
• Connect a clear hose 1 to the air bleeder valve and insert the
other end of the hose into a receptacle.
• Loosen the a ir bleeder valve and pump the brake lever unt il
the old brake fluid is compl etely out of the brake system.
• Close the air bleeder valve and disconnect the clear hose. Fill
the reservoir with new brake fluid to the upper end of the
inspection window.
% Air bleeder valve: 7.5 N·m (0.75 kgf-m)
AIR BLEEDING FOR THE FRONT BRAKE FLUID CIRCUIT
Air trapped in the fluid circuit acts like a cushion to absorb a
large proport ion of the pressu re developed by the master cylinder and thus inte rferes with the full brak ing performance of th e
brake calipe r. The presence of air is indicated b y “sponginess”
of the brake lever and also by lack of brak ing for ce. Con s iderin g
the dange r to whic h such trapped a ir exp oses the m achine and
rider, it is es sential that , after remou nting the br ake and resto ring the brake system to the normal condition, the brake fluid circuit be purged of air in the following manner:
• Fill up the master cylinder reservoir to the “UPPER” line.
Place the reservoir cap to prevent entry of dirt.
• Connect a clear hos e 1 to the air bleeder valv e, and insert
the free end of the pipe into a receptacle.
• Front brake: Bleed the air from the air bleeder valve.
• Squeeze an d release the brake lever sever al times in rapid
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succession and squeeze the lever fully without releasing it.
Loosen the bleeder valve by turning it a quar ter of a turn so
that the brake fluid runs into the receptac le; this will remove
the tension o f the brake l ever causing it to touch th e handlebar grip. Th en, close th e valve, pu mp and s queeze the lever,
and open the valve.
Repeat this pr ocess unti l the fluid flow ing into the recepta cle no
longer contains air bubbles.
NOTE:
Replenish the brake fluid in the reservoir as necessary while
bleeding the brake system. Make sure that there is alw ays some
fluid visible in the reservoir.
• Close the bleeder valve, and disconnect the clear hos e.
% Air bleeder valve: 7.5 N·m (0.75 kgf-m)
Fill the reservoir with brake fluid to the “UPPER” line.
PERIODIC MAINTENANCE 2-15
"
Handle brake fluid with care: the fluid reacts chemically with paint, plastics, rubber materials and so on.
TIRE AND WHEELS
TIRE TREAD CONDITION
Inspect every 4 000 km (20 months).
Operating the motorcycle with excessively worn tires will
decrease riding stability and consequently invite a dangerous
situation. It is highly recommended to replace a tire when the
remaining depth of the tire tread reaches the following specification.
$ 09900-20805: Tire depth gauge
# Tire tread depth:
Service Limit: FRONT:1.6 mm
R EAR: 1.6 mm
2-16 PERIODIC MAINTENANCE
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TIRE PRESSURE
If the tire pressure is too high or too low, steering will be
adversely aff ected and tire we ar will incre ase. Therefore , maintain the correct tire pressure for good ro adability and a longer
tire life. Co ld inflation tire pressure is as follows.
COLD INFLATION
TIRE PRESSURE
kPa kgf/cm
2
FRONT 175 1.75
REAR 225 2.25
"
The standard tire fitted on this motorcycle is a 70/
90-14M/C 34 P for the front and a 80/90-14M/C 4 0P for
the rear. The use of tires other than those specified
may cause instability. It is highly r ecommended to use
the specified tires.
WHEEL
Make sure that the wheel runout (axial and radial) does not
exceed the service limit when checked as shown. An excessive
amount of runout is usually due to worn or loose wheel bearings
and can be corrected by replacing the bearings. If bearing
replacement fails to reduce the runout, replace the wheel.
# Wheel runout
Service Limit (axial and radial): 2.0 mm
SPOKE NIPPLES
Make sure t hat the nippl es are tight . If necess ary, tighten them
with a spoke nipple wrench.
% Spoke nipple: 4.5 N·m (0.45 kgf-m)
$ 09940-60113: Spoke nipple wrench
STEERING
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Inspect initially at 1 000 km (5 months) and every
8 000 km (40 month s) thereafter.
The steerin g should be adjusted pr operly for smooth tu rning of
handlebars and safe operation. Overtight steering prevents
smooth turning of the handlebars and too loose steering will
cause poor stability. Check that there is no play in the front fork.
Support th e mo torc ycle so that the fr on t wh eel i s off the gr oun d.
With the whee l fa cing st raigh t ahe ad, grasp the low er fork tu bes
near the axle and pull forward. If play is found, readjust the
steering. (!5-46)
FRONT FOR K
Inspect every 8 000 km (40 months).
Inspect the front forks for oil leakage, scoring or scratches on
the outer surface of the inner tubes. Replace any defective
parts, if necessary. (!5-34)
PERIODIC MAINTENANCE 2-17
REAR SUSPENSION
Inspect every 8 000 km (40 months).
Inspect the rear shock absorber for oil leakage and mounting
rubbers including engine mounting for wear and damage.
Replace any defective parts, if necessary. (!5-53)
2-18 PERIODIC MAINTENANCE
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CHASSIS BOLTS AND NUTS
Tighten in itially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter.
Check that all chassis bolts and nuts are tightened to their specified torque. (Refer to page 2-19 for the locations of the following bolts and nuts on the motorcycle.)
ITEM N·m kgf-m
1 Handlebar clamp bolt 60 6.0
2 Steering stem lock-nut 90 9.0
3 Front fork clamp bolt 28 2.8
4 Front fork cap bolt 33 3.3
5 Front axle nut 42 4.2
6 Engine mounting nut 85 8.5
7 Rear axle nut 120 12.0
8 Front brake caliper mounting bolt (UY 125 S) 25 2.5
9 Front brake hose union bolt (UY125S) 23 2.3
0 Front brake disc bolt (UY125S) 23 2.3
A Air breeder valve (UY125S) 7.5 0.75
B Front brake master cylinder bolt (UY125S) 10 1.0
C Rear shock absorber mounting nut (Upper & Lower) 29 2.9
D Front brake cam lever nut (UY125) 8 0.8
E Rear brake cam lever nut 11 1.1
F Spoke nipple 4.5 0.45
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