Suzuki vecstar 125 мануал

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• Page 1
  USE THIS MANUAL WITH: RV125 SERVICE MANUAL (99500-31233-01E) 9 9 5 0 1 — 3 1 1 5 0 — 0 1 E…

• Page 2: Table Of Contents

  ET SENSOR INSPECTION …………… 79 ET SENSOR REMOVAL AND INSTALLATION ……..80 TO SENSOR INSPECTION…………… 80 TO SENSOR REMOVAL AND INSTALLATION……..81 HO2 SENSOR INSPECTION …………..81 HO2 SENSOR REMOVAL AND INSTALLATION ……..81 © COPYRIGHT SUZUKI MOTOR CORPORATION 2006…

• Page 3: Table Of Contents

  2 RV125K7 (’07-MODEL) RV125K7 (’07-MODEL) CONTENTS FUEL SYSTEM ………………..83 FUEL TANK ………………..83 FUEL LEVEL INDICATOR CHECK RELAY ……….85 FUEL FILTER ………………. 86 THROTTLE BODY………………87 WIRING DIAGRAM ……………….. 93 CABLE AND HOSE ROUTING…………….94 SPECIAL TOOLS………………..97 TIGHTENING TORQUE ………………

• Page 4: Abbreviations Used In This Manual

  : Read Only Memory : Fuel Injection, Fuel Injector (Dis- charge pump; DCP) : Society of Automotive Engineers : Fuel Pump : Suzuki Diagnosis System : Fuel Pressure Regulator FP Relay : Fuel Pump Relay TO Sensor : Tip Over Sensor (TOS)

• Page 5: Dimensions And Dry Mass

  ENGINE Type …………..Four-stroke, air-cooled, OHC Number of cylinders ……….1 Bore …………..57.0 mm Stroke…………..48.8 mm Displacement …………125 cm³ Compression ratio……….9.2 : 1 Fuel system…………Fuel injection Air cleaner…………Polyurethane foam element Starter system…………Electric Lubrication system ……….Wet sump Idle speed …………

• Page 6: Chassis

  RV125K7 (’07-MODEL) 5 CHASSIS Front suspension……….Telescopic, coil spring, oil damped Rear suspension ……….Swingarm type, coil spring, oil damped Front suspension stroke……..110 mm Rear wheel travel ……….136 mm Caster…………..26° Trail …………..91 mm Steering angle …………. 45° (right & left) Turning radius ………….

• Page 7: Periodic Maintenance Schedule

  6 RV125K7 (’07-MODEL) 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 kilometers and time for your convenience. NOTE: More frequent servicing may be performed on motorcycles that are used under severe conditions.

• Page 8: Throttle Cable Play

  RV125K7 (’07-MODEL) 7 MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each Peri- odic Maintenance item which differ from those of the RV125K6 (’06-MODEL). For details other than the following items, refer to the RV125 Service Manual. THROTTLE CABLE PLAY Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter.

• Page 9: Fuel Line

  8 RV125K7 (’07-MODEL) FUEL LINE Inspect initially at 1 000 km (5 months) and every 4 000 km (20 months) thereafter. Replace every 4 years. Inspect the fuel hoses for damage and fuel leakage. If any defects are found, replace the fuel hose with a new one.

• Page 10: Sds Check

  RV125K7 (’07-MODEL) 9 SDS CHECK Using SDS, sample the data at the time of new and periodic vehicle inspections. After saving the sampled data in the computer, file them by model and by user. The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition of vehicle functions that has changed with time.

• Page 11
  10 RV125K7 (’07-MODEL) Data at 3 000 r/min under no load Data at the time of racing…
• Page 12
  RV125K7 (’07-MODEL) 11 Data of intake negative pressure during idling (90 °C) Data of manifold absolute pressure operation at the time of starting…
• Page 13
  12 RV125K7 (’07-MODEL) Example of trouble Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in compar- ison by showing them in the graph. Read the change of value by comparing the current data to the past data that have been saved under the same condition, then you may determine how changes have occurred with the pass of time and identify what problem is currently occurring.

• Page 14: Fi System Diagnosis

  RV125K7 (’07-MODEL) 13 FI SYSTEM DIAGNOSIS PRECAUTIONS IN SERVICING When handling the component parts or servicing the FI system, observe the following points for the safety of the system. ELECTRICAL PARTS Connector/Coupler • When connecting a connector, be sure to push it in until a click is felt.

• Page 15
  14 RV125K7 (’07-MODEL) • When connecting meter probe from the terminal side of the coupler (where connection from harness side not being possi- ble), use extra care not to force and cause the male terminal to bend or the female terminal to open. Connect the probe as shown to avoid opening of female ter- minal.
• Page 16
  RV125K7 (’07-MODEL) 15 • When disconnecting and connecting the ECM, make sure to turn OFF the ignition switch 1, or electronic parts may get damaged. • Battery connection in reverse polarity is strictly prohibited. INCORRECT Such a wrong connection will damage the components of the FI system instantly when reverse power is applied.
• Page 17
  16 RV125K7 (’07-MODEL) ELECTRICAL CIRCUIT INSPECTION PROCEDURE While there are various methods for electrical circuit inspection, described here is a general method to check for open and short circuit using an ohmmeter and a voltmeter. Open circuit check Possible causes for the open circuits are as follows. As the cause can exist in the connector/coupler or terminal, they need to be checked carefully.
• Page 18
  RV125K7 (’07-MODEL) 17 Continuity check • Measure resistance across coupler B (between A and C in the figure). If no continuity is indicated (infinity or over limit), the circuit is open between terminals A and C. 1 ECM • Disconnect the coupler B and measure resistance between couplers A and B.
• Page 19
  18 RV125K7 (’07-MODEL) Short circuit check (wire harness to ground) • Disconnect the negative cable from the battery. • Disconnect the connectors/couplers at both ends of the circuit to be checked. NOTE: If the circuit to be checked branches to other parts as shown, disconnect all connectors/couplers of those parts.
• Page 20
  RV125K7 (’07-MODEL) 19 USING THE MULTI-CIRCUIT TESTER • Use the Suzuki multi-circuit tester set (09900-25008). • Use well-charged batteries in the tester. • Be sure to set the tester to the correct testing range. Using the tester • Incorrectly connecting the + and — probes may cause the inside of the tester to burnout.

• Page 21: Fi System Technical Features

  20 RV125K7 (’07-MODEL) FI SYSTEM TECHNICAL FEATURES INJECTION TIME (INJECTION VOLUME) The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of intake air pressure, engine speed and throttle opening angle, and various compensations. These compensations are determined according to the signals from various sensors that detect the engine and driving conditions.

• Page 22
  RV125K7 (’07-MODEL) 21 COMPENSATION OF INJECTION TIME (VOLUME) The following different signals are output from the respective sensors for compensation of the fuel injection time (volume). SIGNAL DESCRIPTION ENGINE TEMPERATURE SENSOR When engine temperature is low, injection time (volume) is SIGNAL increased.
• Page 23
  22 RV125K7 (’07-MODEL) FI SYSTEM PARTS LOCATION A ECM D Ignition coil (IG coil) B Tip-over sensor (TOS) E Speedometer C Heated oxygen sensor (HO2S)
• Page 24
  RV125K7 (’07-MODEL) 23 A ECM H Engine temperature sensor (ETS) F Fuel injector I Crankshaft position sensor (CKPS) G ISC valve J Intake air pressure sensor/Throttle position sensor/Intake air temperature sensor (IAPS/TPS/IATS)
• Page 25
  24 RV125K7 (’07-MODEL) FI SYSTEM WIRING DIAGRAM…
• Page 26
  RV125K7 (’07-MODEL) 25 FUEL INJECTOR The system employs fuel injector (Discharge pump; DCP) that causes injection fuel to be pressurized within the pump. The fuel injector pressurizes gravity fed fuel with its plunger and injects the pressurized fuel into the intake pipe.
• Page 27
  26 RV125K7 (’07-MODEL) FUEL CIRCULATION From the fuel tank, fuel enters into the fuel injector through the fuel filter. Vapor generated here returns to the fuel tank. 3-way joint From fuel tank Fuel filter Fuel tank return Fuel injector ECM (Engine Control Module) consists of CPU (Central Pro- cessing Unit), memory (ROM/RAM) and IN/OUT section.
• Page 28
  RV125K7 (’07-MODEL) 27 TO SENSOR TO (Tip-Over) sensor detects the vehicle inclination. When the vehicle tips to more than 65°, a signal is sent to ECM. When this signal continues for more than 4 seconds, ECM interrupts cur- rent to fuel injector and ignition coil. To restart the engine, turn the ignition switch OFF once and then attempt starting in the normal procedure.
• Page 29
  28 RV125K7 (’07-MODEL) CKP SENSOR CKP (Crank position) sensor generates the reference ignition signal and sends it to ECM. ECM calculates and determines the injection and ignition tim- ings on the basis of this signal. HO2 SENSOR HO2 (Heated Oxygen) sensor is made of zirconia element (plat- inum plated) which changes output voltage depending on the oxygen concentration difference between its internal and exter- nal surfaces.

• Page 30: Ecm Terminal

  RV125K7 (’07-MODEL) 29 ECM TERMINAL ECM coupler TERMINAL TERMINAL CIRCUIT CIRCUIT Power ground (E0) Ignition coil ISC valve FI indicator light Fuel injector — Control ground (E1) Sensor ground (E2) Mode select switch Fuel injector + Power source (+B) HO2 sensor heater —…

• Page 31: Self-Diagnosis Function

  30 RV125K7 (’07-MODEL) SELF-DIAGNOSIS FUNCTION The self-diagnosis function is incorporated in the ECM. The function has two modes, “User mode” and “Dealer mode”. The user can only be notified by the FI indicator light. To check the function of the individual FI system devices, the dealer mode is provided.

• Page 32
  RV125K7 (’07-MODEL) 31 DEALER MODE The defective function is memorized in the ECM. Use the special tool’s coupler to connect to the dealer mode coupler. The memorized malfunction code is displayed by the flashing pattern of FI indicator light. Malfunction means that the ECM does not receive normal signal from the devices. These affected devices are indicated in the code form.

• Page 33: Fail-Safe Function

  32 RV125K7 (’07-MODEL) FAIL-SAFE FUNCTION FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a mini- mum performance necessary even under malfunction condition. STARTING RUNNING ITEM FAIL-SAFE MODE ABILITY ABILITY IAP sensor Intake air pressure is fixed to 101 “YES”…

• Page 34: Fi System Troubleshooting

  RV125K7 (’07-MODEL) 33 FI SYSTEM TROUBLESHOOTING CUSTOMER COMPLAINT ANALYSIS Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this purpose, use of such an inspection form such as below will facilitate collecting information required for proper analysis and diagnosis.

• Page 35
  34 RV125K7 (’07-MODEL) MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS Environmental condition Weather Fair Cloudy Rain Snow Always Other Temperature Warm Cool Cold ( °C) Always Frequency Always Sometimes ( times/ day, month) Only once Under certain condition Road Urban Suburb Highway Mountainous ( Uphill Downhill)
• Page 36
  RV125K7 (’07-MODEL) 35 SELF-DIAGNOSTIC PROCEDURES NOTE: * Do not disconnect the coupler from ECM, battery cable from battery, ECM ground wire from engine or main fuse before confirming the DTC (Diagnostic Trouble Code) stored in mem- ory. Such disconnection will erase the memorized information in ECM memory.
• Page 37
  36 RV125K7 (’07-MODEL) UNDERSTANDING THE DTC (Diagnostic Trouble Code) A two-digit DTC is shown through the flashing pattern of the FI indicator light. The DTCs are displayed from a smaller number to a larger number in that order. When all the applicable DTCs have been displayed, the displaying of the DTCs repeat from the first one again.
• Page 38
  RV125K7 (’07-MODEL) 37 DTC INDICATION CHART FLASHING PATTERN DTC No. MALFUNCTION PART REMARKS None CKP sensor (Page 44) Pick up coil signal IAP sensor (Page 47) TP sensor (Page 52) ET sensor (Page 57) IAT sensor (Page 61) TO sensor (Page 65) Ignition coil (Page 68) Fuel injector (Page 69) ISC valve (Page 71)
• Page 39
  38 RV125K7 (’07-MODEL) C40 code has no first digit display. For this reason, the interval A between the displays as shown below is longer than the others. 4.0 sec. 1.0 sec. SELF-DIAGNOSIS RESET PROCEDURE • After repairing the trouble, turn OFF the ignition switch and turn ON again.
• Page 40
  RV125K7 (’07-MODEL) 39 USE OF SDS DIAGNOSTIC PROCEDURES NOTE: * Do not disconnect the coupler from ECM, battery cable from battery, ECM ground wire from engine or main fuse before confirming the DTC (Diagnostic Trouble Code) stored in mem- ory. Such disconnection will erase the memorized information in ECM memory.
• Page 41
  40 RV125K7 (’07-MODEL) USE OF SDS DIAGNOSIS RESET PROCEDURE • After repairing the trouble, turn OFF the ignition switch and turn ON again. • Click the DTC inspection button 1. • Check the DTC. • The previous malfunction history code (Past DTC) still remains stored in the ECM.
• Page 42
  RV125K7 (’07-MODEL) 41 SHOW DATA WHEN TROUBLE DISPLAING DATA AT THE TIME OF DTC) ECM stores the engine and driving conditions (in the form of data as shown in the figure) at the moment of the detection of a malfunction in its memory. This data is called “Show data when trouble”. Therefore, it is possible to know engine and driving conditions (e.g., whether the engine was warm or not, where the motorcycle was running or stopped) when a malfunction was detected by checking the show data when trouble.
• Page 43
  42 RV125K7 (’07-MODEL) DTC TABLE AND DEFECTIVE CONDITION DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM NO FAULT ––––––––––– ––––––––––– CKP sensor The CKP sensor signal does not reach CKP sensor wiring and mechan- ECM for 4 sec. or more, after receiving ical parts the IAP sensor signal.
• Page 44
  RV125K7 (’07-MODEL) 43 DETECTED DTC No. DETECTED FAILURE CONDITION CHECK FOR ITEM TO sensor The sensor voltage should be the fol- TO sensor, lead wire/coupler lowing for 2 sec. and more, after igni- connection tion switch is turned ON. 0.2 V sensor voltage <…
• Page 45
  44 RV125K7 (’07-MODEL) “12” (P0335) CKP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The CKP sensor signal does not reach ECM for 4 • Metal particles or foreign material being stuck on sec. or more, after receiving the IAP sensor signal. the CKP sensor and rotor tip •…
• Page 46
  RV125K7 (’07-MODEL) 45 5) If OK, then check the continuity between each terminal and ground.  CKP sensor continuity: ∞ Ω (Infinity) (G – Ground) (Bl – Ground)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to step 2.
• Page 47
  46 RV125K7 (’07-MODEL) Is the voltage OK? ECM coupler (Harness side) • Bl or B/Br wire open or shorted to ground. • Loose or poor contacts on the CKP sensor cou- pler or ECM coupler (terminal P or 4). • If wire and connection are OK, intermittent trou- ble or faulty ECM.
• Page 48
  RV125K7 (’07-MODEL) 47 “13” (P0105-H/L) IAP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE IAP sensor voltage is not within the fol- • Clogged vacuum passage between throttle body lowing range. and IAP sensor. 0.2 V Sensor voltage < 4.5 V •…
• Page 49
  48 RV125K7 (’07-MODEL) 3) Disconnect the IAP sensor coupler. 4) Turn the ignition switch ON. 5) Measure the voltage at the R wire and ground. 6) If OK, then measure the voltage at the R wire and B/Br wire.  IAP sensor input voltage: 4.5 – 5.5 V (+ R –…
• Page 50
  RV125K7 (’07-MODEL) 49 5) Disconnect the ECM coupler. 6) Check the continuity between G/B wire C and terminal N. 7) If OK, then check the continuity between B/Br wire B and ter- minal 4.  IAP sensor lead wire continuity: Continuity () …
• Page 51
  50 RV125K7 (’07-MODEL) 6) Disconnect the ECM coupler. 7) Check the continuity between R wire A and terminal 9. Also, check the continuity between G/B wire C and terminal  IAP sensor lead wire continuity: Continuity ()  09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set …
• Page 52
  RV125K7 (’07-MODEL) 51 Step 2 1) Connect the IAP sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Start the engine at idle speed and measure the IAP sensor output voltage (between G/B and B/Br wires). …
• Page 53
  52 RV125K7 (’07-MODEL) “14” (P0120-H/L) TP SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • TP sensor maladjusted range. • TP sensor circuit open or short Difference between actual throttle open- • TP sensor malfunction ing and opening calculated by ECM is •…
• Page 54
  RV125K7 (’07-MODEL) 53 3) Disconnect the TP sensor coupler. 4) Turn the ignition switch ON. 5) Measure the voltage at the R wire and ground. 6) If OK, then measure the voltage at the R wire and B/Br wire.  TP sensor input voltage: 4.5 – 5.5 V (+ R –…
• Page 55
  54 RV125K7 (’07-MODEL) 5) Disconnect the ECM coupler. 6) Check the continuity between P wire A and terminal M. 7) Also, check the continuity between B/Br wire C and terminal  TP sensor lead wire continuity: Continuity ()  09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set …
• Page 56
  RV125K7 (’07-MODEL) 55 6) Disconnect the ECM coupler. 7) Check the continuity between P wire A and terminal M. Also, check the continuity between R wire B and terminal 9.  TP sensor lead wire continuity: Continuity ()  09900-25008: Multi-circuit tester set 09900-25009: Needle pointed probe set …
• Page 57
  56 RV125K7 (’07-MODEL) Step 2 1) Connect the TP sensor coupler. 2) Turn the ignition switch ON. 3) Measure the TP sensor output voltage (between + P and — B/Br) by turning the throttle grip.  TP sensor output voltage Throttle valve is closed: Approx.
• Page 58
  RV125K7 (’07-MODEL) 57 “15” (P0115-H/L) ET SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • ET sensor circuit open or short range. • ET sensor malfunction 0.1 V Sensor voltage < 4.7 V • ECM malfunction P0115 Sensor voltage is higher than specified •…
• Page 59
  58 RV125K7 (’07-MODEL) Step 1 (When indicating P0115-H:) 1) Turn the ignition switch OFF. 2) Check the ET sensor coupler 1 for loose or poor contacts. If OK, then check the ET sensor lead wire continuity. 3) Disconnect the ET sensor coupler and ECM coupler. 4) Check the continuity between O wire A and terminal K.
• Page 60
  RV125K7 (’07-MODEL) 59 Step 1 (When indicating P0115-L:) 1) Turn the ignition switch OFF. 2) Check the ET sensor coupler 1 for loose or poor contacts. If OK, then measure the output voltage. 3) Disconnect the ET sensor coupler. 4) Check the continuity between O wire A and ground. If the sound is not heard from the tester, the circuit condition is OK.
• Page 61
  60 RV125K7 (’07-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Disconnect the ET sensor coupler. 3) Measure the ET sensor resistance between B wires.  ET sensor resistance: Approx. 5 – 13 kΩ at 20 – 40 °C (B –…
• Page 62
  RV125K7 (’07-MODEL) 61 “21” (P0110-H/L) IAT SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE Output voltage is not within the following • IAT sensor circuit open or short. (P0110) range. • IAT sensor malfunction. Sensor voltage 4.6 V • ECM malfunction. P0110 Sensor voltage is higher than specified •…
• Page 63
  62 RV125K7 (’07-MODEL) 4) Measure the voltage between Dg wire terminal and ground. 5) Also, measure the voltage between Dg wire terminal and B/Br wire terminal.  IAT sensor input voltage: 4.5 – 5.5 V (+ R – — Ground) (+ R –…
• Page 64
  RV125K7 (’07-MODEL) 63 Step 1 (When indicating P0110-L:) 1) Turn the ignition switch OFF. 2) Check the IAT sensor coupler for loose or poor contacts. If OK, then check the IAT sensor lead wire continuity. 3) Disconnect the IAT sensor coupler. 4) Check the continuity between Dg wire and ground.
• Page 65
  64 RV125K7 (’07-MODEL) Step 2 1) Turn the ignition switch OFF. 2) Measure the IAT sensor resistance.  IAT sensor resistance: Approx. 2.56 kΩ at 20 °C Approx. 1.20 kΩ at 40 °C (Terminal – Terminal)  09900-25008: Multi-circuit tester set …
• Page 66
  RV125K7 (’07-MODEL) 65 “23” (P1651-H/L) TO SENSOR CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE The sensor voltage should be the follow- • TO sensor circuit open or short ing for 2 sec. and more, after ignition • TO sensor malfunction switch is turned ON. •…
• Page 67
  66 RV125K7 (’07-MODEL) Step 1 (When indicating P1651-H:) 1) Turn the ignition switch OFF. 2) Remove the right frame cover. 3) Check the TO sensor coupler 1 for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
• Page 68
  RV125K7 (’07-MODEL) 67 Step 1 (When indicating P1651-L:) 1) Turn the ignition switch OFF. 2) Remove the right frame cover. 3) Check the TO sensor coupler 1 for loose or poor contacts. If OK, then check the TO sensor lead wire continuity. 4) Disconnect the TO sensor coupler.
• Page 69
  68 RV125K7 (’07-MODEL) Step 2 1) Connect the TO sensor coupler and ECM coupler. 2) Insert the needle pointed probes to the lead wire coupler. 3) Turn the ignition switch ON. 4) Measure the voltage between Br/W and B/Br wires. …
• Page 70
  RV125K7 (’07-MODEL) 69 “32” (P0201) FUEL INJECTOR CIRCUIT MALFUNCTION NOTE: When the ignition switch is turned to ON position, the fuel injec- tor starts to operate approx. 2 sec. as purge operation (initial operation) DETECTED CONDITION POSSIBLE CAUSE When the fuel injector current in each detection is •…
• Page 71
  70 RV125K7 (’07-MODEL) 5) If OK, then check the continuity between each terminal and ground.  Fuel injector continuity: ∞ Ω (Infinity) (Terminal – Ground)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.
• Page 72
  RV125K7 (’07-MODEL) 71 “40” (P0505) ISC VALVE CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE When the ISC operation voltage • ISC valve circuit open or shorted to ground remains at 1.0 V or lower continuously (P0505) • ISC valve malfunction for 2 sec. or longer. •…
• Page 73
  72 RV125K7 (’07-MODEL) 5) If OK, then check the continuity between each terminal and ground.  ISC valve continuity: ∞ Ω (Infinity) (Terminal – Ground)  09900-25008: Multi-circuit tester set  Tester knob indication: Resistance (Ω) Are the resistance and continuity OK? Go to Step 2.
• Page 74
  RV125K7 (’07-MODEL) 73 ACTIVE CONTROL INSPECTION (ISC RPM CONTROL) Check 1 1) Set up the SDS tool. (Refer to the SDS operation manual for further details.) 2) Check that the engine is running. 3) Make sure that the engine temperature on data monitor is indicated 80 °C or more.
• Page 75
  74 RV125K7 (’07-MODEL) Check 3 1) Click the button 1 and increase the “Spec” 2 to 1 300 rpm slowly. 2) Check that the “Desired idle speed” 3 is nearly equal to the “Spec” 2. Also, check that the air volume 4 of the ISC duty increases Check 4 1) Increase the “Spec”…
• Page 76
  RV125K7 (’07-MODEL) 75 “44” (P0130/P0135) HO2 SENSOR (HO2S) CIRCUIT MALFUNCTION DETECTED CONDITION POSSIBLE CAUSE HO2 sensor output voltage is not input • HO2 sensor circuit open or shorted to ground. (P0130) to ECM during engine operation and • Fuel system malfunction. running condition.
• Page 77
  76 RV125K7 (’07-MODEL) 7) Disconnect the ECM coupler. Check the continuity between W/G wire A and terminal C. 9) Also, check the continuity between B/Br wire B and terminal 4.  When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a needle pointed tester probe to prevent the terminal damage or terminal bend.
• Page 78
  RV125K7 (’07-MODEL) 77 Is the voltage OK? ECM coupler (Harness side) • W/G wire or B/Br wire open or shorted to ground, or poor C or 4 connection. • If wire and connection are OK, intermittent trou- ble or faulty ECM. •…
• Page 79
  78 RV125K7 (’07-MODEL) Step 2 (When indicating 44/P0135:) 1) Connect the HO2 sensor coupler. 2) Insert the needle pointed probes to the HO2 sensor coupler. 3) Turn the ignition switch ON and measure the heater voltage between W wire (harness side) and ground. 4) If the tester voltage indicates the battery voltage, it is good condition.

• Page 80: Ckp Sensor Inspection

  RV125K7 (’07-MODEL) 79 SENSORS CKP SENSOR INSPECTION The crankshaft position sensor is installed in the generator cover. (Page 44) CKP SENSOR REMOVAL AND INSTALLATION • Remove the generator cover. (RV125K3 3-14) • Install the generator cover in the reverse order of removal. IAP/TP/IAT SENSOR INSPECTION The intake air pressure sensor/throttle position sensor/intake air temperature sensor are combined into one and installed in the…

• Page 81: To Sensor Inspection

  80 RV125K7 (’07-MODEL) • If the ET sensor ohmic value does not change in the propor- tion indicated, replace it with a new one.  Engine temperature sensor specification Temperature Resistance 20 °C Approx. 13.0 kΩ 40 °C Approx. 6.2 kΩ 80 °C Approx.

• Page 82: To Sensor Removal And Installation

  RV125K7 (’07-MODEL) 81 TO SENSOR REMOVAL AND INSTALLATION • Remove the right frame cover. (RV125K3 5-3) • Remove the rear fender bolts. • Remove the TO sensor. • Install the TO sensor in the reverse order of removal. NOTE: When installing the TO sensor, the arrow mark A must be pointed upward.

• Page 83
  82 RV125K7 (’07-MODEL) • Remove the HO2 sensor 2.  Do not remove the HO2 sensor while it is hot.  * Be careful not to expose the HO2 sensor to exces- sive shock. * Do not use an impact wrench while removing or installing the HO2 sensor.

• Page 84: Fuel System

  RV125K7 (’07-MODEL) 83 FUEL SYSTEM FUEL TANK REMOVAL  * Drain out fuel before removing the fuel tank. * Do not drain fuel while engine is hot.  Gasoline is highly flammable and explosive. Keep heat, spark and flame away. •…

• Page 85
  84 RV125K7 (’07-MODEL) • Remove the inlet tube filter 4. • Remove the fuel level switch 5. INSPECTION Inlet tube filter • Inspect the inlet tube filter for clogging or any damage. • If necessary, clean the inlet tube filter using compressed air. Fuel level switch •…

• Page 86: Fuel Level Indicator Check Relay

  RV125K7 (’07-MODEL) 85 INSTALLATION Installation is in the reverse order of removal. Pay attention to the following point:  Gasoline is very explosive. Extreme care must be taken. The gaskets (1 and 2) must be replaced with new ones to prevent fuel leakage. FUEL LEVEL INDICATOR CHECK RELAY REMOVAL AND INSTALLATION Fuel level indicator check relay is located behind the ECM.

• Page 87: Fuel Filter

  86 RV125K7 (’07-MODEL) FUEL FILTER REMOVAL  * Drain out fuel before removing the fuel filter. * Do not drain fuel while engine is hot.  Gasoline is highly flammable and explosive. Keep heat, spark and flame away. • Remove the right frame cover. (RV125K3 5-3) •…

• Page 88: Throttle Body

  RV125K7 (’07-MODEL) 87 THROTTLE BODY CONSTRUCTION  1 Return pipe 5 Cushion seal 2 Upper cushion 6 ISC valve ITEM N·m kgf-m 3 O-ring 7 Throttle body 4 Fuel injector A ISC valve screw…

• Page 89
  88 RV125K7 (’07-MODEL) REMOVAL AND DISASSEMBLY  * Drain out fuel before removing the throttle body. * Do not drain fuel while engine is hot. * The throttle body is assembled precisely in factory. Do not disassemble it other than shown in this man- ual.
• Page 90
  RV125K7 (’07-MODEL) 89 • Loosen the air cleaner outlet tube clamp screw. • Remove the intake pipe nuts. • Move the air cleaner box backward and remove the throttle body.  Do not snap the throttle valve from full open to full close after disconnecting the throttle cables.
• Page 91
  90 RV125K7 (’07-MODEL) • Remove the return pipe A, bracket B and upper cushion C. • Remove the O-ring D and cushion seal E. • Remove the ISC valve F.  Never remove the IAP/TP/IAT sensor G from the throt- tle body.
• Page 92
  RV125K7 (’07-MODEL) 91  Avoid removing the adjustetr I and throttle stop screw J. INSPECTION Check following items for any damage or clogging. * O-ring * Throttle valve * Injector cushion seal ISC valve • Remove the O-ring. • Visually inspect the ISC valve for wear, damage or carbon deposit, replace it with a new one if necessary.
• Page 93
  92 RV125K7 (’07-MODEL) • Install the injector as shown.  22.5˚ 22.5˚ Never turn the injector while pushing it. • Install the O-rings 2 and 3.  Replace the O-rings with new ones. • Install the insulator. NOTE: Set the insulator so the O-ring faces to the engine side and tab A upward.

• Page 94: Wiring Diagram

  RV125K7 (’07-MODEL) 93 WIRING DIAGRAM…

• Page 95: Cable Routing

  94 RV125K7 (’07-MODEL) CABLE AND HOSE ROUTING CABLE ROUTING 0 mm 0 mm 1 Throttle cable No.1 *4 Set the clamp as shown. Pass the throttle cables in front of 2 Throttle cable No.2 the brake hose. *5 Clamp the harness only. 3 Wiring harness Pass the throttle cables above Set the upper end of clutch cable…

• Page 96
  RV125K7 (’07-MODEL) 95 HOSE ROUTING UPPER UPPER 45˚ 45˚ 22.5˚ 30˚ – 35˚ Assemble the hoses, union and clamps in the 1 Throttle body insulator proper direction as shown. 2 Air cleaner outlet tube clamp *2 Yellow marking 3 Fuel hose 3-way union *3 White marking 4 Fuel filter *4 Red marking…

• Page 97: Fuel Tank Installation

  96 RV125K7 (’07-MODEL) FUEL TANK INSTALLATION 4.4 N . m (0.44 kgf-m) 1 Frame *1 Align the recess of cushion with the positioning plate. 2 Cushion *2 Cut the clamp so the end 10 mm remains. 3 Fuel tank joint…

• Page 98: Special Tools

  RV125K7 (’07-MODEL) 97 SPECIAL TOOLS 09900-25008 09900-25009 Multi-circuit tester Needle pointed 09904-41010 09930-82720 99565-01010-009 probe set SDS set tool Mode select switch CD-ROM Ver. 9 NOTE: When order the special tool, please confirm whether it is available or not. TIGHTENING TORQUE ITEM N·m kgf-m…

• Page 99: Service Data

  98 RV125K7 (’07-MODEL) SERVICE DATA VALVE + GUIDE Unit: mm ITEM STANDARD LIMIT Valve diam. 25.5 — 22.5 — Valve clearance (when cold) 0.03 – 0.08 — 0.13 – 0.18 — Valve guide to valve stem 0.010 – 0.037 — clearance 0.030 –…

• Page 100: Oil Pump

  RV125K7 (’07-MODEL) 99 CYLINDER + PISTON + PISTON RING Unit: mm ITEM STANDARD LIMIT Compression pressure 1 100 – 1 500 kPa 800 kPa (11 – 15 kgf/cm (8.0 kgf/cm Piston-to-cylinder clearance 0.040 – 0.050 0.120 Cylinder bore 57.000 – 57.015 57.090 Piston diam.

• Page 101
  100 RV125K7 (’07-MODEL) DRIVE TRAIN + DRIVE CHAIN Unit: mm (Except ratio) ITEM STANDARD LIMIT Primary reduction ratio 3.470 (59/17) — Final reduction ratio 3.500 (49/14) — Gear ratios 3.000 (33/11) — 1.857 (26/14) — 1.368 (26/19) — 1.095 (23/21) —…
• Page 102
  RV125K7 (’07-MODEL) 101 * FI SENSORS ITEM SPECIFICATION NOTE 172 – 288 Ω CKP sensor resistance + G – — BI CKP sensor peak voltage 2.0 V (When cranking) and more IAP sensor input voltage 4.5 – 5.5 V + G/B – — B/Br IAP sensor output voltage Approx.
• Page 103
  102 RV125K7 (’07-MODEL) ELECTRICAL ITEM SPECIFICATION NOTE Spark plug DENSO: U24ESR-N Type NGK: CR8E 0.7 – 0.8 mm Spark performance Over 8 mm at 1 atm. 1.6 – 2.7 Ω + tap – — tap Ignition coil resistance Primary Plug cap – Secondary 18 –…

• Page 104: Tire Pressure

  Front fork stroke — Front fork spring free length 382.9 Front fork oil level — Front fork oil type SUZUKI FORK OIL #10 or an equivalent fork oil — Front fork oil capacity (each leg) 230 ml — Rear wheel travel —…

• Page 105
  104 RV125K7 (’07-MODEL) FUEL + OIL ITEM SPECIFICATION NOTE Fuel type Gasoline used should be graded 91 octane or higher. An unleaded gasoline type is recom- mended. Fuel tank capacity 6.5 L Engine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MA Engine oil capacity Change 850 ml…
• Page 106
  Prepared by September, 2006 Part No. 99501-31150-01E Printed in Japan…
• Page 107
  Printed in Japan…

i.k. » 06 мар 2009 22:46

делал я как-то этот аппарат. Движек там очень похож на китайские 4-х тактники, так что мануал на него нафиг не нужен.

Жаб » 07 мар 2009 01:03

Если что -пиши письма — есть мотор.

Присоединиться можно. Взрослым сформированным адекватным лицам.

liviuuuu » 07 мар 2009 13:33

I.K с чего ты взял што там китайский мотор??? я китайцев рву на моем скутере как семочек! и темболее он у меня побегал 42000 КМ и не жалуюсь!

liviuuuu » 07 мар 2009 15:16

так че вапще невозможно найти??

KRAX » 07 мар 2009 15:18

ахаха ты хотя бы понимаешь что значит «очень похож»? Тебе никто не слова не сказал, что это китай и т.д.

liviuuuu » 07 мар 2009 15:21

плин я здесь вапще не просил никого сказать какой мотор там стоит! Я просто хочу мануал к ним! просто в Молдове всего 1 такой скутер и он окозался моим =)

liviuuuu » 07 мар 2009 15:23

кстати вещь офигеная да еще и 125 кубиков =) непонемаю почему никто не покупает такие? Наверно в цене дело=) сорри за оффтоп……

DEN 79 » 07 мар 2009 16:43

Посмотри на сайте «легион-автодата» там есть книга по ремонту скутеров 50-250сс в ней есть и твой движок AN 125. Хороша или нет не могу сказать только что сам заказал.

liviuuuu » 07 мар 2009 22:39

А конкретнее??? просто там не могу найти , да и темболее там помоуму заказать надо !

DEN 79 » 08 мар 2009 02:51

Жаб » 08 мар 2009 03:52

Щас я те выпишу весь мануал сразу.

1. Следи за уровнем масла и вовремя его меняй. (не забывай промывать при смене масла помногу раз в бензине масляный фильтр, если не найдешь подходящий новый).

Масло — только 10w-40 БЕЗ ПРИСАДОК. Херню польскую не лей.

2. 1 раз в 5 тысяч км регулируй клапана. Впуск — 7-10, выпуск — 10-13.

Регулируется в вмт в такте сжатия при обоих полностью закрытых клапанах.

3. Хотя бы раз в месяц обслуживай воздушный фильтр.

ВСЕ ОСТАЛЬНОЕ делать в сервисе.

Присоединиться можно. Взрослым сформированным адекватным лицам.

liviuuuu » 08 мар 2009 13:00

Плин мне не надо его покупать мне нужно просто скачать! зачеем платные сыдки даете? Лучше говорите что нету и ВСЁ!