Suzuki Fl125sdwk7 Benutzerhandbuch

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.

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.

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



Handling crates requires two operators.

Be careful not to scratch the motorcycle.

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

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)

OD ID

AE B

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.

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.

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.

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.

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.

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.

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