00
TABLE OF CONTENTS
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Lubrication ................................. 0B-1
Service Data...........................................................0C-1
Engine ......................................................................... 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Emission Control Devices ...................................... 1B-1
Engine Electrical Devices.......................................1C-1
Engine Mechanical.................................................1D-1
Engine Lubrication System .................................... 1E-1
Engine Cooling System.......................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System.......................................................1H-1
Starting System....................................................... 1I-1
Charging System.....................................................1J-1
Exhaust System ..................................................... 1K-1
Suspension................................................................. 2-i
Precautions .............................................................. 2-1
Suspension General Diagnosis.............................. 2A-1
Front Suspension ................................................... 2B-1
Rear Suspension....................................................2C-1
Wheels and Tires ...................................................2D-1
Driveline / Axle............................................................ 3-i
Precautions .............................................................. 3-1 1
Drive Chain / Drive Train / Drive Shaft ...................3A-1
Brakes ......................................................................... 4-i
Precautions .............................................................. 4-1
Brake Control System and Diagnosis ....................4A-1 2
Front Brakes...........................................................4B-1
Rear Brakes ...........................................................4C-1
ABS ........................................................................4E-1
Transmission / Transaxle .......................................... 5-i 3
Precautions .............................................................. 5-1
Manual Transmission .............................................5B-1
Clutch .....................................................................5C-1
Steering ....................................................................... 6-i 4
Precautions .............................................................. 6-1
Steering General Diagnosis ...................................6A-1
Steering / Handlebar ..............................................6B-1
Body and Accessories............................................... 9-i 5
Precautions .............................................................. 9-1
Wiring Systems ......................................................9A-1
Lighting Systems ....................................................9B-1
Combination Meter / Fuel Meter / Horn ..................9C-1
Exterior Parts .........................................................9D-1 6
Body Structure .......................................................9E-1
9
 Table of Contents 00- i

Section 00
00

Precautions
CONTENTS

Precautions ...............................................00-1 Precautions for Electrical Circuit Service ............ 00-2

Precautions........................................................... 00-1 Precautions for Circuit Tester.............................. 00-7
General Precautions ........................................... 00-1 Precautions for SDS-II ........................................ 00-7
00-1 Precautions:

Precautions
Precautions

Precautions
General Precautions • When performing service to electrical
BENM23K10000001 parts, if the service procedures do not
! WARNING require use of battery power, disconnect
the negative (–) cable from the battery.
• Proper service and repair procedures are
• When tightening the cylinder head or case
important for the safety of the service
bolts and nuts, tighten the larger sizes
mechanic and the safety and reliability of
first. Always tighten the bolts and nuts
the motorcycle.
diagonally from the inside toward outside
• When 2 or more persons work together, and to the specified tightening torque.
pay attention to the safety of each other.
• Whenever you remove oil seals, gaskets,
• When it is necessary to run the engine packing, O-rings, locking washers, self-
indoors, make sure that exhaust gas is locking nuts, cotter pins, circlips and
forced outdoors. certain other parts as specified, be sure to
• When working with toxic or flammable replace them with new ones. Also, before
materials, make sure that the area you installing these new parts, be sure to
work in is well ventilated and that you remove any left over material from the
follow all of the material manufacturer’s mating surfaces.
instructions. • Never reuse a circlip. When installing a
• To avoid getting burned, do not touch the new circlip, take care not to expand the
engine, engine oil and exhaust system end gap larger than required to slip the
until they have cooled. circlip over the shaft. After installing a
circlip, always ensure that it is completely
NOTICE seated in its groove and securely fitted.
• Use a torque wrench to tighten fasteners
• Never use gasoline as a cleaning solvent.
to the specified torque. Wipe off grease
• After servicing the fuel, oil, exhaust or and oil if a thread is smeared with them.
brake systems, check all lines and fittings
• After reassembling, check parts for
related to the system for leaks.
tightness and proper operation.
• If parts replacement is necessary, replace
• To protect the environment, do not
the parts with Suzuki Genuine Parts or
unlawfully dispose of used motor oil and
their equivalent.
other fluids: batteries, and tires.
• When removing parts that are to be reused,
• To protect Earth’s natural resources,
keep them arranged in an orderly manner
properly dispose of used motorcycle and
so that they may be reinstalled in the
parts.
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.
 Precautions: 00-2

Precautions for Electrical Circuit Service
BENM23K10000002
When handling the electrical parts or servicing the
electric system, observe the following points for the
safety of the system.
• Inspect each lead wire circuit for poor connection by
shaking it by hand lightly. If any abnormal condition is
found, repair or replace.

Electrical Parts
Connector / Coupler
• Faulty electrical system is often related to poor
electrical contact of connector/coupler. Before
servicing individual electronic part, check electrical
contact of the connector/coupler.
• When connecting a connector, be sure to push it in
until a click is felt.
I310G1000003-02

• When taking measurements at electrical coupler (1)

using a tester probe (2), be sure to insert the probe
from the wire harness side (rear) of the coupler.

I310G1000001-01

• With a lock type coupler, be sure to release the lock 1

when disconnecting, and push it in fully to engage the
lock when connecting.
IF04K1000002-02
• When disconnecting the coupler, be sure to hold the
coupler body and do not pull the lead wires. • When connecting meter probe (2) from the terminal
side of the coupler (1) because it cannot be connected
• Inspect each terminal on the connector/coupler for
from harness side, use extra care not to bend the
looseness or bending.
male terminal of coupler of force its female terminal
• Push in the coupler straightly. An angled or skewed open for connection.
insertion may cause the terminal to be deformed, In case of such coupler as shown connect probe as
possibly resulting in poor electrical contact. shown to avoid opening female terminal.
• Inspect each terminal for corrosion and Never connect probe where male terminal is
contamination. The terminals must be clean and free supposed to fit.
of any foreign material which could impede proper
terminal contact.
• Before refitting the sealed coupler, make sure its seal
rubber is positioned properly. The seal rubber may
possibly come off the position during disconnecting
work and if the coupler is refitted with the seal rubber
improperly positioned, it may result in poor water
sealing.

ID26J1000014-01

• Avoid applying grease or other similar material to

connector/coupler terminals to prevent electric
trouble.

I310G1000002-01
00-3 Precautions:

Clamp ECM / CDI UNIT / ABS Control unit/Hydraulic unit /

• Clamp the wire harness at such positions as indicated Various sensors
in “Wiring Harness Routing Diagram” in Section 9A • Since each component is a high-precision part, great
(Page 9A-11). care should be taken not to apply any severe impacts
• Bend the clamp properly so that the wire harness is during removal and installation.
clamped securely.
• In clamping the wire harness, use care not to allow it
to hang down.
• Do not use wire or any other substitute for the band
type clamp.

[A] [B]

I425A1000006-01

IE02K1000002-01

[A]: Correct clamping [B]: Incorrect clamping

Fuse
• When a fuse is blown, always investigate the cause to
correct it and then replace the fuse.
• Do not use a fuse of different capacity.
• Do not use wire or any other substitute for the fuse.
I649G1000003-02

• Be careful not to touch the electrical terminals of the

electronic parts (ECM / CDI UNIT, etc.). The static
electricity from your body may damage them.

I649G1000001-02

Switch
Never apply grease material to switch contact points to
prevent damage.
I310G1000008-01

• When disconnecting and connecting the coupler,
make sure to turn OFF the ignition switch (1), or
electronic parts may get damaged.
IE39J1000001-01
• Never allow dust or water to contact the ABS control
unit/HU.
I649G1000004-02
• The ABS control unit/HU cannot be disassembled.
Replace the whole unit with a new one.
I649G1000005-02
• Never connect any tester (voltmeter, ohmmeter, or
whatever) to the electronic unit when its coupler is
disconnected. Otherwise, damage to electronic unit
may result.
• Never connect an ohmmeter to the electronic unit with
its coupler connected. If attempted, damage to ECM /
CDI UNIT / ABS control unit/HU or sensor may result.
• Be sure to use a specified voltmeter/ohmmeter.
Otherwise, accurate measurements may not be
obtained and personal injury may result.
Precautions: 00-4
Battery
• Select the same type MF battery when replacing the
battery.
• Battery connection in reverse polarity is strictly
prohibited. Such a wrong connection will damage the
components of the FI system and ABS instantly when
reverse power is applied.
I718H1000004-01
• Removing any battery terminal of a running engine is
strictly prohibited. The moment such removal is made,
damaging counter electromotive force will be applied
to the electronic unit which may result in serious
damage.
I310G1000011-01
• Before measuring voltage at each terminal, check to
make sure that battery voltage is 11 V or higher.
Terminal voltage check with a low battery voltage will
lead to erroneous diagnosis.
I310G1000012-02
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.
00-5 Precautions:

Open circuit check 4) Using continuity inspect or voltage check procedure

Possible causes for the open circuit are as follows. As as described below, inspect the wire harness
the cause can exist in the connector/coupler or terminal, terminals for open circuit and poor connection.
they need to be checked carefully. Locate abnormality, if any.
• Loose connection of connector/coupler
• Poor contact of terminal (due to dirt, corrosion or rust,
poor contact tension, entry of foreign object etc.)
• Wire harness being open.
• Poor terminal-to-wire connection.
When checking system circuits including an electronic
[A] [C]
control unit such as ECM, etc., it is important to perform
careful check, starting with items which are easier to
check. [B]
ID26J1000005-03
1) Disconnect the negative (–) cable from the battery. [A]: Looseness of crimping
2) Check each connector/coupler at both ends of the [B]: Open
circuit being checked for loose connection. Also [C]: Thin wire (A few strands left)
check for condition of the coupler lock if equipped.
Continuity check
1) Measure resistance across coupler [B] (between [A]
[A]
and [C] in the figure).
If no continuity is indicated (infinity or over limit), the
circuit is open between terminals [A] and [C].
[A]
2 [A]
1

[B]
1
IE02K1000004-01

[A]: Check for loose connection 1. Sensor 2. ECM

[C]
3) Using a test male terminal, check the female
terminals of the circuit being checked for contact
tension.
Check each terminal visually for poor contact IE02K1000007-01

(possibly caused by dirt, corrosion, rust, entry of 1. ECM

foreign object, etc.). At the same time, check to
make sure that each terminal is fully inserted in the
coupler and locked.
If contact tension is not enough, rectify the contact to
increase tension or replace. The terminals must be
clean and free of any foreign material which could
impede proper terminal contact.
2) Disconnect the coupler [B] and measure resistance
between couplers [A] and [B-1].
If no continuity is indicated, the circuit is open
between couplers [A] and [B-1]. If continuity is
indicated, there is an open circuit between couplers
[B-2] and [C] or an abnormality in coupler [B-2] or
coupler [C].

[A]
[A]
[B-2]

1
[B]
IE02K1000005-01

[A]: Check contact tension by inserting and removing. [B] [C]

[B]: Check each terminal for bend and proper alignment.
[B-1]

IE02K1000008-01

1. ECM
 Precautions: 00-6

Voltage check Short circuit check (Wire harness to ground)

If voltage is supplied to the circuit being checked, voltage
check can be used as circuit check.
1) With all connectors/couplers connected and voltage
applied to the circuit being checked, measure
voltage between each terminal and body ground.
2) If measurements were taken as shown in the figure
and results were listed in the following, it means that
the circuit is open between terminals [A] and [B].
Voltage between
[A] and body ground: 0 V
[B] and body ground: Approx. 5 V
[C] and body ground: Approx. 5 V
3) Also, if measured values are as listed following, a
resistance (abnormality) exists which causes the
voltage drop in the circuit between terminals [A] and
[B].
Voltage between
[A] and body ground: 3 V – 2 V voltage drop
[B] and body ground: Approx. 5 V
[C] and body ground: Approx. 5 V
[A]
1) Disconnect the negative (–) cable from the battery.
2) 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. Otherwise, diagnosis
will be wrong.
3) Measure resistance between terminal at one end of
circuit ([A] terminal in the figure) and body ground. If
continuity is indicated, there is a short circuit to
ground between terminals [A] and [C].
[A]
[D]
[C]

[E]

[B]
[C]

[A] [C]

IF04K1000003-01

[D]: To other parts [E]: Other parts

4) Disconnect the connector/coupler included in circuit

(coupler [B]) and measure resistance between
[A] [B] [C] terminal [A] and body ground. If continuity is
indicated, the circuit is shorted to the ground
ID26J1000008-05
between terminals [A] and [B].

[A]

[D]

[B]

IF04K1000001-01

[D]: To other parts

00-7 Precautions:

Precautions for Circuit Tester Using Needle Pointed Prove

BENM23K10000003
• Use the Suzuki multi circuit tester set. NOTICE
Special tool • When using the multi circuit tester, do not
(A): 09900–25008 strongly touch the terminal of the ECM
couplers with a needle pointed tester
• The following items are included in the special tool.
probe to prevent the terminal damage or
– Multi circuit tester body terminal bend.
– Tachometer sensor • When connecting the multi circuit tester,
– Test leads use the needle pointed probe to the back
– Peak volt adapter side of the lead wire coupler and connect
the probes of tester to them.
– Case
• Use the needle pointed probe to prevent
– Instruction Manual
the rubber of the water proof coupler from
• Read the instruction manual to use the tester damage.
correctly.
• Be sure to set the tester to the correct testing range. Special tool
• If the voltage and current are not known, make 09900–25009
measurements using the highest range.
Precautions for SDS-II
BENM23K10000004
Symbols
• In some models of the SUZUKI motorcycles, the DTC
Symbol Definition
can be confirmed by using SDS-II.
DC
AC • Read the instruction manual when using SDS-II and
Ω Resistance operate it properly.
Continuity Special tool
Diode (A): 09904–41030

Functions (A)
/ /
Function switch
key switch (6)
Voltage
(1) Select or .
measurement
(2) or (3),
Current
whichever Select or .
measurement
appropriate.
Resistance
(4) —
measurement
Continuity test (5) Select .
B A

Diode test (5) Select .

IH23K5000001-01

(A)
6
3
2 4
5
1

ID26J1000011-01

Section 0
General Information
CONTENTS
General Information ................................ 0A-1
General Description .............................................0A-1
Abbreviations ...................................................... 0A-1
Symbols .............................................................. 0A-2
Wire Color Symbols ............................................ 0A-3
Vehicle Side View ............................................... 0A-3
Vehicle Identification Number ............................. 0A-4
Country and Area Codes .................................... 0A-4
Warning, Caution, and Information Labels
Location ............................................................ 0A-5
Component Location ...........................................0A-6
Electrical Components Location ......................... 0A-6
Maintenance and Lubrication................. 0B-1
Precautions...........................................................0B-1
Precautions for Maintenance .............................. 0B-1
Scheduled Maintenance ......................................0B-1
Periodic Maintenance Schedule Chart................ 0B-1
Repair Instructions ..............................................0B-2
Air Cleaner Element Inspection .......................... 0B-2
Air Cleaner Element Replacement...................... 0B-2
Exhaust Pipe Bolt and Muffler Bolt Inspection .... 0B-2
Valve Clearance Inspection and Adjustment ...... 0B-2
Spark Plug Inspection ......................................... 0B-2
Spark Plug Replacement .................................... 0B-2
Fuel Hose Inspection .......................................... 0B-2
Evaporative Emission Control System
Inspection (If Equipped) .................................... 0B-2
Fuel Hose Replacement ..................................... 0B-2
Engine Oil Replacement ..................................... 0B-2
Engine Oil Filter Replacement ............................ 0B-2
Table of Contents 0- i
0
Throttle Cable Play Inspection and
Adjustment ........................................................0B-2
Pair System Inspection (If Equipped)..................0B-2
Engine Coolant Replacement .............................0B-2
Radiator Hose Inspection....................................0B-2
Clutch Cable Play Inspection and Adjustment ....0B-2
Drive Chain Inspection and Adjustment ..............0B-2
Drive Chain Cleaning and Lubricating.................0B-2
Brake System Inspection ....................................0B-2
Brake Fluid Inspection.........................................0B-3
Brake Fluid Replacement....................................0B-3
Brake Hose Inspection ........................................0B-3
Brake Hose Replacement ...................................0B-3
Tire Inspection.....................................................0B-3
Steering System Inspection ................................0B-3
Front Fork Inspection ..........................................0B-3
Rear Suspension Inspection ...............................0B-3
Chassis Bolt and Nut Inspection .........................0B-3
Lubrication Points................................................0B-6
Special Tools and Equipment .............................0B-6
Recommended Service Material .........................0B-6
Service Data ............................................. 0C-1
Precautions...........................................................0C-1
Precautions for Service Data ..............................0C-1
Specifications .......................................................0C-1
Specifications ......................................................0C-1
Service Data........................................................0C-3
Fasteners Information .......................................0C-10
Special Tools and Equipment ...........................0C-12
Recommended Service Material .......................0C-12
Fuel / Oil / Fluid / Coolant Recommendation ....0C-12
0A-1 General Information:

General Information
General Information

General Description
Abbreviations I:
BENM23K10101001 IAP: Intake Air Pressure
A:
IAT: Intake Air Temperature
AAT: Ambient Air Temperature
I.D.: Inside Diameter
ABDC: After Bottom Dead Center
IG: Ignition
ABS: Anti-lock Brake System
IN.: Intake
AC: Alternating Current
ISC: Idle Speed Control
ACL: Air Cleaner
J:
AKI: Anti-knock index
JASO: Japanese Automobile Standards Organization
AP: Atmospheric Pressure
L:
API: American Petroleum Institute
LCD: Liquid Crystal Display
ATDC: After Top Dead Center
LED: Light Emitting Diode
A/F: Air Fuel Ratio
LH: Left Hand
B:
LO: Low
BBDC: Before Bottom Dead Center
M:
BTDC: Before Top Dead Center
Max: Maximum
B+: Battery Positive Voltage
MIL: Malfunction Indicator Lamp
C:
Min.: Minimum
CDI: Capacitive Discharge Ignition
MTBE: Methyl Tertiary Butyl Ether
CKP: Crankshaft Position
N:
CKT: Circuit
NOx: Nitrogen Oxides
CLP: Clutch Lever Position
O:
CMP: Camshaft Position
O2: Oxygen
CO: Carbon Monoxide
OBD: On-Board Diagnostic System
CPU: Central Processing Unit
OHC: Over Head Camshaft
CVT: Continuously Variable Transmission
O.D.: Outside Diameter
D:
P:
DC: Direct Current
PAIR: Pulsed Secondary Air Injection
DOHC: Double Over Head Camshaft
PCV: Positive Crankcase Ventilation
DRL: Daytime Running Light
PP: Pulley Position
DTC: Diagnostic Trouble code
R:
E:
RH: Right Hand
ECM: Engine Control Module
ROM: Read Only Memory
ECT: Engine Coolant Temperature
RON: Research Octane Number
ET: Engine Temperature
RPM: Engine Speed
EVAP: Evaporative Emission
S:
EX.: Exhaust
SAE: Society of Automotive Engineers
EXCV: Exhaust control valve
SDS: Suzuki Diagnosis System
EXCVA: Exhaust control valve actuator
SRAD: Suzuki Ram Air Direct
F:
STCS: Secondary Throttle Control System
FI: Fuel Injection, Fuel Injector
STD: Standard
FP: Fuel pump
STP: Secondary Throttle Position
FPR: Fuel Pressure Regulator
STV: Secondary Throttle Valve
FTPC: Fuel Tank Pressure Control
STVA: Secondary Throttle Valve Actuator
FWD: Forward
T:
G:
TC: Traction Control
GEN: Generator
TDC: Top Dead Center
GND: Ground
TO: Tip-over
GP: Gear Position
TP: Throttle Position
H:
TPS: Throttle Position Sensor
HC: Hydrocarbons
HI: High
HO2: Heated Oxygen
HU: Hydraulic Unit
 General Information: 0A-2

Symbols
BENM23K10101002
Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The
meaning of each symbol is also included in the table.

NOTE
The table below shows generally used symbols, and includes some symbols not used in this manual.

Symbol Definition
Torque control required.
Data beside it indicate 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.
99000-25011
Apply SUZUKI SUPER GREASE C.
99000-25030
Apply SUZUKI MOLYBDENUM GREASE L.
99000-25280
Apply SUZUKI MOLY PASTE.
99000-25140
Apply SUZUKI SILICONE GREASE.
99000-25100
Apply SUZUKI WATER RESISTANT GREASE EP2.
99000-25350
Apply SUZUKI BOND 1207B.
99000-31140
Apply SUZUKI BOND 1215.
99000-31110
Apply SUZUKI BOND 1216B.
99000-31230
Apply THREAD LOCK CEMENT 1303B.
99000-32030
Apply THREAD LOCK CEMENT 1322D.
99000-32150
Apply THREAD LOCK CEMENT 1342H.
99000-32160
Apply THREAD LOCK CEMENT 1360.
99000-32130
Use SUZUKI SUPER LONG LIFE COOLANT (BLUE).
99000-99032-20X
Use SUZUKI LONG LIFE COOLANT (GREEN).
99000-99032-12X
Apply or use fork oil.
Apply or use brake fluid.
Use special tool.
Do not reuse.
Note on reassembly.
0A-3 General Information:

Wire Color Symbols

BENM23K10101003
Symbol Wire Color Symbol Wire Color
B Black Lg Light green
L Blue O Orange
Br Brown P Pink
Dbr Dark brown R Red
Dg Dark green V Violet
G Green W White
Gr Gray Y Yellow
Sb Sky blue

There are two kinds of colored wire used in this vehicle. One is single-colored wire and the other is dual-colored
(striped) wire.
The single-colored wire uses only one color symbol (i.e. G). The dual-colored wire uses two color symbols (i.e. G/Y).
The first symbol represents the base color of the wire and the second symbol represents the color of the stripe.

ID26J1010224-02

1. G (Base color) 2. Y (Stripe color) 3. G (Base Color)

Vehicle Side View SUZUKI GSX S 125 (M1)

BENM23K10101004
SUZUKI GSX R 125 (M1)

IH23K5010002-01
IH23K5010001-01
 General Information: 0A-4

Vehicle Identification Number

BENM23K10101005
The frame serial number or V.I.N. (Vehicle Identification
Number) is stamped on the right side of the frame down
tube (1). The engine serial number is located on the left
side of the crankcase (2).

IH23K1010003-02

IH23K1010002-03

Country and Area Codes

BENM23K10101006
The following code stand for the applicable country and area.
Code Country or Area
P21 E.U.
P24 Australia
P43 Saudi Arabia
P51 Korea
0A-5 General Information:

Warning, Caution, and Information Labels Location

BENM23K10101007

1 7 2
5

[B]

[A]

[C] 6
3
IL23K3010001-01

[A]: Fuel tank cover 2. Fuel limitation label or gasoline label (If equipped) 6. Information label or UN Noise label (If equipped)
[B]: Fuel tank inlet tray 3. Tire information label 7. Helmet label or Fuel information label (If equipped)
[C]: Swingarm 4. Radiator cap label 8. E24 Noise label (If equipped)
1. General warning label 5. ID Plate, Manufacturer label, or Safety plate (If equipped) 9. Brake fluid label (If equipped)
 General Information: 0A-6

Component Location
Electrical Components Location
BENM23K10103001
GSX R 125 Model

2 14
12 6
1

11

15
7
10
13
8
4

IL23K3010002-01

1. Main switch (keyless start model) 6. ECM 11. Horn

2. Clutch lever position switch 7. Keyless control module 12. EVAP system purge control solenoid valve (if equipped)
3. Cooling fan 8. GP switch 13. PAIR control solenoid valve (if equipped)
4. ECT sensor 9. Speed sensor 14. ABS control unit / Hydraulic unit (if equipped)
5. Regulator/rectifier 10. Generator/CKP sensor 15. Side stand switch (if equipped)
0A-7 General Information:

6 9
3 4 7 16
1
5
8

14 13 11 10

12
17 15

IM23K1010001-01

1. Mode select coupler (6P) & (2P) (with ABS) 7. Fuel pump/fuel level gauge 13. Turn signal relay
2. Cooling fan relay 8. Fuel Injector 14. Rear brake light switch
3. Sub relay 9. Front brake light switch 15. TO sensor
4. Fuse box 10. Ignition coil 16. Front wheel speed sensor (if equipped)
5. Starter relay/Main fuse 11. O2 sensor 17. Rear wheel speed sensor (if equipped)
6. Battery 12. IAP/TP/IAT and ISC sensor
 General Information: 0A-8

GSX S 125 Model

2
13
11 5
1

10

14
9
12
7
4

IL23K3010003-01

1. Ignition switch (Ignition switch model) 6. Regulator/Rectifier 11. EVAP system purge control solenoid valve (if equipped)
2. Clutch lever position switch 7. GP switch 12. PAIR control solenoid valve (if equipped)
3. Cooling fan 8. Speed sensor 13. ABS control unit / Hydraulic unit (if equipped)
4. ECT sensor 9. Generator/CKP sensor 14. Side stand switch (if equipped)
5. ECM 10. Horn
0A-9 General Information:

6
4 7 9
3 16
1
5
8

14 13 11 10

12
17 15

IM23K1010002-01

1. Mode select coupler (6P) & (2P) (with ABS) 7. Fuel pump/fuel level gauge 13. Turn signal relay
2. Cooling fan relay 8. Fuel Injector 14. Rear brake light switch
3. Sub relay 9. Front brake light switch 15. TO sensor
4. Fuse box 10. Ignition coil 16. Front wheel speed sensor (if equipped)
5. Starter relay/Main fuse 11. O2 sensor 17. Rear wheel speed sensor (if equipped)
6. Battery 12. IAP/TP/IAT and ISC sensor
 Maintenance and Lubrication: 0B-1

Maintenance and Lubrication

General Information

Precautions
Precautions for Maintenance
BENM23K10200001
The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work
necessary to keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed
in terms of kilometers, miles and months for your convenience.

NOTE
More frequent servicing may be required on motorcycles that are used under severe conditions.

Scheduled Maintenance
Periodic Maintenance Schedule Chart
BENM23K10205001
NOTE
I = Inspect and clean, adjust, replace or lubricate as necessary.
R = Replace.
T = Tighten.

Interval
months 2 12 24
Item
km 1000 4000 8000
miles 600 2500 5000
— I I
Air cleaner element (I: (Page 0B-2)), R: (Page 0B-2))
Replace every 12000 km (7500 miles).
Exhaust pipe bolt and muffler bolt (T: (Page 0B-2)) T — T
Valve clearance (I: (Page 0B-2)) — — I
Spark plug (I: (Page 0B-2), (R: (Page 0B-2)) — I R
— I I
Fuel hose (I: (Page 0B-2), (R: (Page 0B-2))
Replace every 4 years.
Evaporative emission control system (if equipped) (I: (Page 0B-2)) — — I
Engine oil (R: (Page 0B-2)) R R R
Engine oil filter (R: (Page 0B-2)) R — R
Throttle cable play (I: (Page 0B-2)) I I I
Pair (air supply) system (if equipped) (I: (Page 0B-2)) — I I
“SUZUKI SUPER LONG LIFE COOLANT” Replace every 4 years or 16000 km (10000
(Blue) miles).
Engine coolant (R:
“SUZUKI LONG LIFE COOLANT” (Green)
(Page 0B-2)) Replace every 2 years or 8000 km (5000
or an engine coolant other than “SUZUKI
miles).
SUPER LONG LIFE COOLANT” (Blue)
Radiator hose (I: (Page 0B-2)) — I I
Clutch cable play (I: (Page 0B-2)) I I I
I I I
Drive chain (I: (Page 0B-2), I: (Page 0B-2))
Clean and lubricate every 1000 km (600 miles).
Brake (I: (Page 0B-2)) I I I
— I I
Brake hose (I: (Page 0B-3), R: (Page 0B-3))
Replace every 4 years.
— I I
Brake fluid (I: (Page 0B-3), R: (Page 0B-3))
Replace every 2 years.
Tires (I: (Page 0B-3)) — I I
Steering (I: (Page 0B-3)) I — I
Front forks (I: (Page 0B-3)) — — I
Rear suspension (I: (Page 0B-3)) — — I
Chassis bolts and nuts (T: (Page 0B-3)) T T T
Lubrication (I: (Page 0B-6)) Lubricate every 1000 km (600 miles).
0B-2 Maintenance and Lubrication:

Repair Instructions
Air Cleaner Element Inspection Throttle Cable Play Inspection and Adjustment
BENM23K10206001 BENM23K10206012
Refer to “Air Cleaner Element Inspection” in Section 1D Refer to “Throttle Cable Play On-Vehicle Inspection and
(Page 1D-9). Adjustment” in Section 1D (Page 1D-12).

Air Cleaner Element Replacement Pair System Inspection (If Equipped)

BENM23K10206002 BENM23K10206013
Refer to “Air Cleaner Box Removal and Installation” in Refer to “PAIR System Inspection (If Equipped)” in
Section 1D (Page 1D-9). Section 1B (Page 1B-12)

Exhaust Pipe Bolt and Muffler Bolt Inspection Engine Coolant Replacement
BENM23K10206003 BENM23K10206014
Refer to “Exhaust System Inspection” in Section 1K Refer to “Engine Coolant Replacement” in Section 1F
(Page 1K-4). (Page 1F-5).

Valve Clearance Inspection and Adjustment Radiator Hose Inspection

BENM23K10206004 BENM23K10206015
Refer to “Valve Clearance Inspection and Adjustment” in Refer to “Coolant Hose Inspection” in Section 1F (Page
Section 1D (Page 1D-25). 1F-7).

Spark Plug Inspection Clutch Cable Play Inspection and Adjustment

BENM23K10206005 BENM23K10206016
Refer to “Spark Plug Inspection and Cleaning” in Section Refer to “Clutch Cable Play On-Vehicle Inspection and
1H (Page 1H-6). Adjustment” in Section 5C (Page 5C-2).

Spark Plug Replacement Drive Chain Inspection and Adjustment

BENM23K10206006 BENM23K10206017
Refer to “Spark Plug Removal and Installation” in Refer to “Drive Chain Inspection and Adjustment” in
Section 1H (Page 1H-5). Section 3A (Page 3A-2).

Fuel Hose Inspection Drive Chain Cleaning and Lubricating

BENM23K10206007 BENM23K10206018
Refer to “Fuel Pressure Inspection” in Section 1G (Page Refer to “Drive Chain Cleaning and Lubricating” in
1G-4). Section 3A (Page 3A-4).

Evaporative Emission Control System Brake System Inspection

BENM23K10206019
Inspection (If Equipped) Brake Pad
BENM23K10206008
Refer to “EVAP Control System Inspection (If Equipped)” • Front: (Page 4B-2)
in Section 1B (Page 1B-15) • Rear: (Page 4C-1)

Fuel Hose Replacement Brake Disc

BENM23K10206009
Refer to “Fuel Feed Hose Removal and Installation” in • Front: (Page 4B-8)
Section 1G (Page 1G-5). • Rear: (Page 4C-7)

Engine Oil Replacement Brake Light Switch

BENM23K10206010 Refer to “Rear Brake Light Switch Inspection” in Section
Refer to “Engine Oil Replacement” in Section 1E (Page 4A (Page 4A-9).
1E-5).
Brake Pedal Height
Engine Oil Filter Replacement Refer to “Brake Pedal Height Inspection and
BENM23K10206011
Refer to “Oil Filter Replacement” in Section 1E (Page Adjustment” in Section 4A (Page 4A-12).
1E-6).
 Maintenance and Lubrication: 0B-3

Brake Fluid Inspection Tire Inspection

BENM23K10206020 BENM23K10206024
Refer to “Brake Fluid Level Check” in Section 4A (Page Refer to “Tire Inspection and Cleaning” in Section 2D
4A-10). (Page 2D-12).

Brake Fluid Replacement Steering System Inspection

BENM23K10206021 BENM23K10206025
Refer to “Brake Fluid Replacement” in Section 4A (Page Refer to “Steering On-Vehicle Inspection” in Section 6B
4A-15). (Page 6B-13).

Brake Hose Inspection Front Fork Inspection

BENM23K10206022 BENM23K10206026
Refer to “Brake Hose Inspection” in Section 4A (Page Refer to “Front Fork On-Vehicle Inspection” in Section
4A-10). 2B (Page 2B-2).

Brake Hose Replacement Rear Suspension Inspection

BENM23K10206023 BENM23K10206027
• Front: (Page 4A-17) Refer to “Rear Suspension On-vehicle Inspection” in
Section 2C (Page 2C-2).
• Rear: (Page 4A-18)

Chassis Bolt and Nut Inspection

BENM23K10206028
Check that all chassis bolts and nuts are tightened to their specified torque.
0B-4 Maintenance and Lubrication:

GSX R 125 Model

3, (b)

9, (b) 10, (e)

1, (a)

9, (b)
2, (b)
12, (e)
11, (f)

13, (g)

7, (d) 9, (b)

19, (j)

4, (c) 21, (j)

15, (b) 14, (h)

16, (i)

5, (c)

8, (b)
7, (d)

6, (b)

9, (b)
20, (j)
18, (j)
17, (i)
6, (b)
IH23K5020001-01
 Maintenance and Lubrication: 0B-5

1. Steering stem head nut 12. Rear brake master cylinder bolt (b): 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
2. Handlebar bolt 13. Rear brake master cylinder rod lock-nut (c): 44 Nm (4.4 kgf-m, 31.8 lbf-ft)
3. Front fork upper clamp bolt 14. Rear axle nut (d): 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
4. Front fork lower clamp bolt 15. Rear brake disc bolt (e): 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
5. Front axle nut 16. Rear shock absorber upper mounting bolt (f): 57.5 Nm (5.86 kgf-m, 42.4 lbf-ft)
6. Front brake disc bolt 17. Rear shock absorber lower mounting nut (g): 18 Nm (1.8 kgf-m, 13.5 lbf-ft)
7. Brake air bleeder valve 18. Front wheel speed sensor bolt (if equipped) (h): 65 Nm (6.6 kgf-m, 47.9 lbf-ft)
8. Front brake caliper mounting bolt 19. Rear wheel speed sensor bolt (if equipped) (i): 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
9. Brake hose union bolt 20. Front wheel speed sensor rotor bolt (if equipped) (j): 6.3 Nm (0.64 kgf-m, 4.64 lbf-ft)
10. Front brake master cylinder holder bolt 21. Rear wheel speed sensor rotor bolt (if equipped)
11. Swingarm pivot nut (a): 30 Nm (3.1 kgf-m, 22.5 lbf-ft)

GSX S 125 Model

2, (b)

4, (a)

3, (b) 3, (b)
1, (a)

IH23K5020002-01 IH23K5020003-01

1. Steering stem nut (a): 30 Nm (3.1 kgf-m, 22.5 lbf-ft) 1. Front fork lower clamp bolt (a): 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
2. Handlebar holder clamp bolt (b): 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
3. Front fork upper clamp bolt
0B-6 Maintenance and Lubrication:

Lubrication Points
BENM23K10206029
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated as follows.

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.

5
6
1

7 8
2 3 4 3 9

GSX R125 Model GSX S125 Model

IK23K4020001-01

1. Clutch lever pivot 5. Front brake lever pivot 9. Rear brake pedal pivot
2. Side-stand pivot and spring hook 6. Throttle cable : Apply oil.

3. Pillion footrest pivot 7. Center stand pivot and spring hook (GSX S125) : Apply grease.
4. Drive chain 8. Kick starter lever pivot (GSX S125) : Apply silicone grease.

Special Tools and Equipment

Recommended Service Material
BENM23K10208001
NOTE
Required service material(s) is also described in:
“Lubrication Points” (Page 0B-6)
 Service Data: 0C-1

Service Data
General Information

Precautions
Precautions for Service Data
BENM23K10300001
NOTE
Specifications and service data are subject to change without notice.

Specifications
Specifications
BENM23K10307001
GSX R 125 Model
Dimensions and curb mass
Item Specification Remark
Overall length 2000 mm (78.74 in) —
Overall width 700 mm (27.56 in) —
Overall height 1070 mm (42.12 in) —
Wheelbase 1300 mm (51.18 in) —
Curb mass 134 kg (295.42 lbs) —
Ground clearance 155 mm (6.1 in) —

GSX S 125 Model

Dimensions and curb mass
Item Specification Remark
Overall length 2000 mm (78.74 in) —
Overall width 745 mm (29.33 in) —
Overall height 1035 mm (40.74 in) —
Wheelbase 1300 mm (51.18 in) —
Curb mass 133 kg (293.21 lbs) —
Ground clearance 165 mm (6.5 in) —

Engine
Item Specification Remark
Type Four-stroke, liquid-cooled, DOHC —
Number of cylinders 1 —
Bore 62.0 mm (2.441 in) —
Stroke 41.2 mm (1.622 in) —
Displacement 124 cm3 (7.6 cu. in) —
Compression ratio 11 : 1 —
Fuel system Fuel injection —
Air cleaner Paper filter —
Starter system Kick (if equipped) and electric —
Lubrication system Wet sump —

Drive train
Item Specification Remark
Clutch Wet multi-plate type —
Transmission 6-speed constant mesh —
Gearshift pattern 1-down, 5-up —
Primary reduction ratio 3.285 (69/21) —
0C-2 Service Data:

Item Specification Remark

Low 2.923 (38/13) —
2nd 1.933 (29/15) —
3rd 1.476 (31/21) —
Gear ratios
4th 1.217 (28/23) —
5th 1.045 (23/22) —
Top 0.925 (25/27) —
Final reduction ratio 3.214 (45/14) —
Drive chain RK 428KLO, 122 links —

Chassis
Item Specification Remark
Front suspension Telescopic, coil spring, oil damped —
Rear suspension Swingarm type, coil spring, oil damped —
Front fork stroke 110 mm (4.33 in) —
Rear wheel travel 115 mm (4.53 in) —
GSX R 125 35° —
Steering angle
GSX S 125 40° —
Trail 93.3 mm (3.7 in) —
Caster 25.5° —
Turning radius 2.3 m (7.5 ft) —
Front brake Disc brake —
Rear brake Disc brake —
Front tire size 90/80-17M/C 46S —
Rear tire size 130/70-17M/C 62S —

Electrical
Item Specification Remark
Ignition type Electronic ignition (Transistorized) —
Spark plug NGK MR8E-9 or DENSO U24EPR-N9 —
Battery 12 V 18 kC (5 Ah)/10 HR —
Generator Single-phase A.C. generator —
Main fuse 20 A —
Sub fuse 10 A —
Fan fuse 10 A —
ABS fuse motor (if equipped) 15 A —
ABS fuse valve (if equipped) 10 A —
Headlight LED —
Position light LED —
Brake light/Tail light 12 V 21/5 W —
Turn signal light 12 V 10 W x 4 —
License plate light LED —
Tachometer light LED —
Speedometer light LED —
Turn signal indicator light LED —
Neutral indicator light LED —
High beam indicator light LED —
Engine RPM indicator light LED —
Keyless indicator light LED —
ABS indicator light (if equipped) LED —

Capacities
Item Specification Remark
Fuel tank 11 L (2.90 US gal, 2.41 Imp gal) —
Oil change 1300 ml (1.37 US qt, 1.14 Imp qt) —
Engine oil With filter change 1400 ml (1.48 US qt, 1.23 Imp qt) —
Overhaul 1500 ml (1.59 US qt, 1.32 Imp qt) —
Engine side 800 ml (0.84 US qt, 0.70 Imp qt) —
Coolant Reservoir tank
250 ml (0.26 US qt, 0.22 Imp qt) —
“F” level
 Service Data: 0C-3

Service Data
BENM23K10307002
Emission Control Devices
Item Specification Standard Limit
EVAP system purge control solenoid valve Battery voltage
—
power supply voltage (if equipped)
EVAP system purge control solenoid valve 20°C (68 °F) 30 - 34 Ω
—
power resistance (if equipped)
PAIR control solenoid valve power supply Battery voltage
—
voltage (if equipped)
PAIR control solenoid valve resistance (if 20°C (68 °F) 18 - 22 Ω
—
equipped)

Engine Electrical Devices

Item Specification Standard Limit
IAP sensor power supply voltage 4.75 – 5.25 V —
IAP sensor output voltage At 1 atm. 3.88 – 4.12 V —
IAT sensor power supply voltage 4.75 – 5.25 V —
IAT sensor resistance 23 °C (73.4 °F) 2.169 – 2.557 Ω —
20 °C (68 °F) 2320 – 2590 Ω
ECT sensor resistance —
80 °C (176 °F) 310 – 326 Ω
TP sensor power supply voltage 4.75 – 5.25 V —
Closed 0.65 – 0.75 V
TP sensor output voltage —
Opened 3.80 – 4.00 V
Idle speed 0.3 – 1.2 V —
O2 sensor output voltage
5000 r/min 0.3 – 1.2 V
CKP sensor peak voltage When cranking 2.0 V —
CKP sensor resistance 20 °C (68 °F) Approx. 230 Ω —
TO sensor power supply voltage 4.5 – 5.5 V —
Normal 0.4 – 1.4 V
TO sensor voltage —
Leaning 65° 3.7 – 4.4 V
TO sensor resistance 1650 – 22300 Ω —
ECM power supply voltage Battery voltage —
Speed sensor power supply voltage Battery voltage —
ISC valve resistance 20 °C (68 °F) Approx. 20 Ω —

Engine Mechanical
Item Specification Standard Limit
Throttle body I.D. No 23K0 —
Throttle body bore size 32 mm (1.26 in) —
2.0 – 4.0 mm (0.079 –
Throttle cable play —
0.16 in)
Idle speed When engine warmed 1700 ± 100 r/min —
900 – 1300 kPa
750 kPa (7.6 kgf/cm2,
Compression pressure (9.2 – 13.2 kgf/cm2,
109 psi)
131 – 188 psi)
34.05 – 34.15 mm
Intake 33.75 mm (1.329 in)
(1.341 – 1.344 in)
Cam height
34.38 – 34.42 mm
Exhaust 34.08 mm (1.342 in)
(1.354 – 1.355 in)
0.032 – 0.066 mm
Intake 0.150 mm (0.059 in)
(0.0013 – 0.0025 in)
Camshaft journal oil clearance
0.032 – 0.066 mm
Exhaust 0.150 mm (0.059 in)
(0.0013 – 0.0025 in)
22.012 – 22.025 mm
Intake
(0.8667 – 0.8671 in)
Camshaft journal holder I.D. —
22.012 – 22.025 mm
Exhaust
(0.8667 – 0.8671 in)
0C-4 Service Data:

Item Specification Standard Limit

21.959 – 21.980 mm
Intake
(0.8646 – 0.8653 in)
Camshaft journal O.D. —
21.959 – 21.980 mm
Exhaust
(0.8646 – 0.8653 in)
Camshaft run out Intake & Exhaust — 0.10 mm (0004 in)
Cam chain pin At arrow “3” 15th pin —
0.10 – 0.20 mm
Intake
When engine (0.0040 – 0.0078 in)
Valve clearance —
cold 0.20 – 0.30 mm
Exhaust
(0.0079 – 0.0118 in)
Intake 24 mm (0.94 in)
Valve diameter —
Exhaust 21 mm (0.83 in)
Valve stem run out Intake & Exhaust — 0.05 mm (0.002 in)
Valve head radial run out Intake & Exhaust — 0.03 mm (0.001 in)
Intake — 0.5 mm (0.02 in)
Valve head thickness
Exhaust — 0.5 mm (0.02 in)
4.475 – 4.490 mm
Intake —
(0.1762 – 0.1767 in)
Valve stem O.D.
4.455 – 4.470 mm
Exhaust —
(0.1754 – 0.1759 in)
0.9 – 1.1 mm (0.036 –
Intake —
0.043 in)
Valve seat width
1.0 – 1.2 mm (0.040 –
Exhaust —
0.047 in)
4.500 – 4.512 mm
Intake —
(0.1772 – 0.1776 in)
Valve guide I.D.
4.500 – 4.512 mm
Exhaust —
(0.1772 – 0.1776 in)
0.010 – 0.037 mm
Intake —
Valve guide to valve stem (0.0004 – 0.0014 in)
clearance 0.030 – 0.057 mm
Exhaust —
(0.0012 – 0.0022 in)
Intake — 41.8 mm (1.65 in)
Valve spring free length
Exhaust — 41.8 mm (1.65 in)
138.7 – 159.5 N (14.2
When Intake – 16.2 kg, 31.2 – 35.8 —
compressed to lbf)
Valve spring pre-load
38.10 mm (1.500 138.7 – 159.5 N (14.2
in) Exhaust – 16.2 kg, 31.2 – 35.8 —
lbf)
Cylinder head distortion — 0.05 mm (0.002 in)
Cylinder distortion — 0.05 mm (0.002 in)
62.000 – 62.015 mm
Cylinder bore No nicks or Scratches
(2.4410 – 2.4415 in)
Measure at 12 mm (0.47 in) from 61.970 – 61.985 mm 61.880 mm (2.4362
Piston diameter
the skirt end. (2.4398 – 2.4403 in) in)
0.025 – 0.035 mm 0.120 mm (0.0047
Piston to cylinder clearance
(0.0010 – 0.0030 in) in)
1st — 0.180 mm (0.0071 in)
Piston ring to groove clearance 0.150 mm (0.0059
2nd —
in)
0.81 – 0.83 mm
1st —
(0.0319 – 0.0327 in)
0.81 – 0.83 mm
Piston ring groove width 2nd —
(0.0319 – 0.0327 in)
1.51 – 1.53 mm
Oil —
(0.0594 – 0.0602 in)
 Service Data: 0C-5

Item Specification Standard Limit

0.77 – 0.79 mm
1st —
(0.0303 – 0.0311 in)
Piston ring thickness
0.77 – 0.79 mm
2nd —
(0.0303 – 0.0311 in)
Approx. 8.5 mm (0.33
1st 7.7 mm (0.30 in)
in)
Piston ring free end gap
Approx. 6.3 mm (0.25
2nd 5.0 mm (0.20 in)
in)
0.06 – 0.18 mm
1st 0.50 mm (0.020 in)
(0.003 – 0.007 in)
Piston ring end gap
0.18 – 0.30 mm
2nd 0.50 mm (0.020 in)
(0.008 – 0.011 in)
15.002 – 15.008 mm 15.030 mm (0.5917
Piston pin bore I.D.
(0.5907 – 0.5908 in) in)
14.995 – 15.000 mm 14.980 mm (0.5898
Piston pin O.D.
(0.5904 – 0.5905 in) in)
15.006 – 15.024 mm 15.040 mm (0.5921
Conrod small end I.D.
(0.5908 – 0.5914 in) in)
Conrod deflection — 3.0 mm (0.11 in)
0.10 – 0.45 mm
Conrod big end side clearance 1.0 mm (0.039 in)
(0.004 – 0.017 in)
16.95 – 17.00 mm
Conrod big end width —
(0.6674 – 0.6692 in)
52.90 – 53.10 mm
Crank web to web width —
(2.083 – 2.090 in)
Crankshaft thrust clearance 0.02 – 0.07 —
mm(0.0008 – 0.0027
in)
Crankshaft run out — 0.080 mm (0.0031 in)
Balancer spring free length — 10.0 mm (0.394 in)

Engine Lubrication System

Item Specification Standard Limit
35 – 65 kPa (0.4 – 0.6
Oil pressure At 60 °C (140 °F), 3000 r/min kg/cm2, 5.08 – 9.42 —
psi)
1300 ml (1.37 US qt,
Oil change
1.14 Imp qt)
1400 ml (1.48 US qt,
Necessary amount of engine oil Oil and filter change —
1.23 Imp qt)
1500 ml (1.59 US qt,
Engine overhaul
1.32 Imp qt)

Engine Cooling System

Item Specification Standard Limit
Approx. 800 ml (0.84
Engine side
US qt, 0.70 Imp, qt)
Engine coolant —
Approx. 250 ml (0.26
Reserve tank side (“F” level)
US qt, 0.22 Imp, qt)
107.9 – 137.3 kPa
Radiator cap valve opening
(1.1 – 1.4 kgf/cm2, —
pressure
15.7 – 19.9 psi)
Cooling fan relay power supply
Battery voltage —
voltage
Approx. 105 °C (221
OFF → ON
°F)
Cooling fan operating temperature —
Approx. 100 °C (212
ON → OFF
°F)
0C-6 Service Data:

Item Specification Standard Limit

Thermostat valve opening 91.5 – 94.5 °C (196.7
—
temperature – 202.1 °F)
3.0 mm (0.12 in) or
Thermostat valve lift 106 °C (222.8 °F) —
more

Fuel System
Item Specification Standard Limit
Fuel injector power supply voltage Battery voltage
Fuel injector resistance 20 °C (68 °F) 11.5 – 12.5 Ω —
56 ml (1.89 US oz,
FP discharge amount Per 10 seconds —
1.97 Imp oz) or more
288 – 300 kPa (2.94 –
Fuel pressure 3.05 kgf/cm2, 41.8 – —
43.5 psi)

Ignition System
Item Specification Standard Limit
NGK MR8E-9 or
Type
DENSO U24EPR-N9
Spark plug —
0.8 – 0.9 mm (0.032 –
Gap
0.035 in)
Spark performance At 1 atm. 8 mm (0.3 in) or more —
Ignition coil primary peak voltage 150 V —
Primary 1.84 – 2.76 Ω
Ignition coil resistance —
Secondary 10.01 – 18.59 kΩ

Starting System
Item Specification Standard Limit
Stater motor brush length 5.0 mm (0.20 in) 3.5 mm (0.14 in)
Starter relay resistance 3–6Ω —
Side-stand switch voltage ON (Side-stand retracted) 0.4 - 0.6 V —
OFF (Side-stand on the ground) 1.4 V or more

Charging System
Item Specification Standard Limit
Battery leakage current 10 mA —
Regulated voltage Charging output At 5000 r/min 14 – 15 V —
Generator coil resistance 20 °C (68 °F) Approx. 0.3 Ω - 2.0 Ω —
When engine
Generator no-load voltage At 5000 r/min 60 V (AC) or more —
cold
Standard charging 0.5 A for 5 to 10 hours
Reaching time —
Fast charging 5 A for 0.5 hour
Generator Max. output At 5000 r/min Approx. 125 W —
FTZ6V-BS or
Type designation
FTZ5L-BS
12 V 18 kC (5 Ah)/10
Battery Capacity —
HR
Standard
At 20 °C (68 °F) 1.32
electrolyte S.G.

Front Suspension
Item Specification Standard Limit
Front fork inner tube O.D. 31 mm (1.2 in) —
Without spring, inner/outer tube
Front fork oil level 122 mm (4.80 in) —
fully compressed
Front fork spring free length 387 mm (15.2 in) 378 mm (14.9 in)
196 ml (6.6 US oz, 6.9
Front fork oil capacity Each leg —
Imp oz)
 Service Data: 0C-7

Rear Suspension
Item Specification Standard Limit
Swingarm pivot shaft run out — 0.3 mm (0.01 in)

Wheels and Tires

Item Specification Standard Limit
Front Axial & Radial — 2.0 mm (0.08 in)
Wheel rim run out
Rear Axial & Radial — 2.0 mm (0.08 in)
Wheel axle run out Front & Rear — 0.25 mm (0.010 in)
90/80-17 M/C 46S,
Front
tubeless
Tire size —
130/70-17 M/C 62S,
Rear
tubeless
Front DUNLOP / D102FAJ
Tire type —
Rear DUNLOP / D102AJ
Recommend Front — 1.6 mm (0.062 in)
Tire tread depth
depth Rear — 1.6 mm (0.062 in)
175 kPa (1.75 kgf/
Front
cm2, 25 psi)
Solo riding —
200 kPa (2.00 kgf/
Rear
cm2, 29 psi)
Cold inflation tire pressure
175 kPa (1.75 kgf/
Front
cm2, 25 psi)
Dual riding —
200 kPa (2.00 kgf/
Rear
cm2, 29 psi)
Front 17 M/C × MT 2.15
Wheel rim size —
Rear 17 M/C × MT 3.50

Drive Chain / Drive Train / Drive Shaft

Item Specification Standard Limit
Type RK 428KLO —
Drive chain
Links 122 Links —
Drive chain 20-pitch length — 255.5 mm (10.06 in)
20 – 30 mm (0.8 – 1.1
Drive chain slack On side-stand position —
in)

Brake Control System and Diagnosis

Item Specification Standard Limit
48.7 – 58.7 mm
Rear brake pedal height —
(1.92– 2.31 in)
Approx. 13 mm (0.51
Front
Master cylinder bore / piston in)
—
diameter Approx. 12.7 mm
Rear
(0.50 in)

Front Brakes
Item Specification Standard Limit
Front brake disc thickness 4.0 mm (0.16 in) 3.5 mm (0.14 in)
Front brake disc run out — 0.30 mm (0.012 in)
Front brake caliper cylinder bore / Approx. 28 mm (1.1
—
piston diameter in)

Rear Brakes
Item Specification Standard Limit
Rear brake disc thickness 4.0 mm (0.16 in) 3.5 mm (0.14 in)
Rear brake disc run out — 0.3 mm (0.012 in)
Rear brake caliper cylinder bore / Approx. 32 mm (1.3
—
piston diameter in)
0C-8 Service Data:

ABS
Item Specification Standard Limit
0.68 - 1.65mm
Front —
Wheel speed sensor - sensor rotor (0.027 - 0.064 in.)
clearance 0.48 - 1.65mm
Rear —
(0.019 - 0.064 in.)

Manual Transmission
Item Specification Standard Limit
0.1 – 0.3 mm (0.004 –
No.1 0.5 mm (0.019 in)
0.011 in)
Gearshift fork to groove clearance
0.1 – 0.3 mm (0.004 –
No.3 0.5 mm (0.019 in)
0.011 in)
5.0 – 5.1 mm (0.197 –
No.1
0.200 in)
Gearshift fork groove width —
5.5 – 5.6 mm (0.217 –
No.3
0.220 in)
4.8 – 4.9 mm (0.189 –
No.1
0.192 in)
Gearshift fork thickness —
5.3 – 5.4 mm (0.209 –
No.3
0.212 in)
50 – 60 mm (2.0 – 2.3
Gearshift lever height —
in)

Clutch
Item Specification Standard Limit
10 – 14 mm (0.4 – 0.5
Clutch lever play —
in)
2.9 – 3.1 mm (0.115 –
Drive plate thickness 2.6 mm (0.103 in)
0.122 in)
11.9 – 12.0 mm (0.469
With groove 11.4 mm (0.449 in)
– 0.472 in)
Drive plate claw width
11.8 – 12.0 mm (0.465
Without groove 11.3 mm (0.445 in)
– 0.472 in)
Driven plate distortion — 0.10 mm (0.004 in)
Clutch spring free length 32.5 mm (1.28 in) 30.9 mm (1.22 in)

Steering / Handlebar
Item Specification Standard Limit
2 – 5 N (0.21 – 0.50
Steering tension initial force —
kgf, 0.50 – 1.12 lbf)

Wiring Systems
Item Specification Standard Limit
MAIN 20 A —
SUB 10 A —
Fuse size
FAN 10 A —
ABS motor (if equipped) 15 A —
ABS valve (if equipped) 10 A —

Lighting Systems
Item Specification Standard Limit
HI LED —
Headlight
LO LED —
Position light LED —
Brake light / Taillight 12 V 21/5 W —
Turn signal light 12 V 10 W x 4 —
License light LED —
 Service Data: 0C-9

Combination Meter / Others

Item Specification Standard Limit
Instrument panel light LED —
MIL LED —
ECT indicator light LED —
ABS indicator light (if equipped) LED —
Turn signal indicator light LED —
Hi beam indicator light LED —
Neutral indicator light LED —
Engine RPM indicator light LED —
0C-10 Service Data:

Fasteners Information Fastener Strength Identification

BENM23K10307003 Most commonly used strength classes of metric
Metric Fasteners fasteners are 4T, 6.8, 7T and 8.8. Strength class is
Most of the fasteners used for this vehicle are JIS- indicated by a number or radial line(s) embossed on the
defined and ISO-defined metric fasteners. When head of each bolt. Some metric nuts have a punched
replacing any fasteners, it is most important that number, 6 or 8 on their end surfaces. Figure shows
replacement fasteners are of the correct diameter, different strength markings.
thread pitch and strength. When replacing metric fasteners, use bolts and nuts of
NOTICE the same strength class as or higher class than the
original bolts and nuts. It is also important to select
Combining male and female fasteners with replacement fasteners of the correct diameter and
different thread pitches will damage both thread pitch. Correct replacement bolts and nuts are
fasteners. available as SUZUKI spare parts.
It is important to note that, even when the Metric bolts and nuts: Strength class numbers or marks
nominal diameter (1) of the threads is the (The larger the number, the greater the strength).
same, JIS-defined and ISO-defined fasteners
may be different in thread pitch (2) or width
across flats (3). Refer to the following table
for these differences.
Before installing a fastener, check it for
correct thread pitch and then, screw it in or
on the mating fastener by hand. If the
fastener is too tight to turn by hand, its
thread pitch may be different from that of the
mating fastener.

JIS-TO-ISO main fasteners comparison table

Nominal diameter
M6 M8 M10 M12 M14
Thread pitch 1.0 1.25 1.25 1.25 1.5
JIS
Width across flats 10 12 14 17 19
Thread pitch 1.0 1.25 1.5 1.5 1.5
ISO
Width across flats 10 13 16 18 21
IE31J1030002-01

1. Nut strength identification

2
IE31J1030001-02

Standard Tightening Torques

Each fastener should be tightened to the torque specified in each section. If no torque description or specification is
provided in the relevant section, refer to the following tightening torque chart for the applicable torque for each
fastener. When a fastener of greater strength than the original one is used, use the torque specified for the original
fastener.
 Service Data: 0C-11

NOTE
• For flanged bolts, flanged nuts and self-locking nuts of the 4T and 7T strength classes, add 10% to
the applicable tightening torques given in the following chart.
• The following chart is applicable only where the fastened parts are made of steel or light alloy.

Tightening torque chart

Thread diameter (Nominal diameter) (mm)
Strength Unit
4 5 6 8 10 12 14 16 18
Fastener of strength class equivalent to Nm 1.5 3.0 5.5 13 29 45 65 105 160
4T kgf-m 0.15 0.31 0.56 1.3 3.0 4.6 6.6 10.7 16.3
lbf-ft 1.5 2.5 4.0 9.5 21.5 33.5 48.0 77.5 118.0

IE31J1030003-01
Fastener of strength class equivalent to Nm 2.4 4.7 8.4 20 42 80 125 193 280
6.8 kgf-m 0.24 0.48 0.86 2.0 4.3 8.2 12.7 19.7 28.6
lbf-ft 2.0 3.5 6.5 15.0 31.0 59.0 92.5 142.5 206.5

IE31J1030004-01
Flanged fastener of strength class Nm 2.4 4.9 8.8 21 44 84 133 203 298
equivalent to 6.8 kgf-m 0.24 0.50 0.90 2.1 4.5 8.6 13.6 20.7 30.4
*: Self-locking nut (6 strength) lbf-ft 2.0 4.0 6.5 15.5 32.5 62.0 98.5 150.0 220.0

IE31J1030005-01
Fastener of strength class equivalent to Nm 2.3 4.5 10 23 50 85 135 210 240
7T kgf-m 0.23 0.46 1.0 2.3 5.1 8.7 13.8 21.4 24.5
lbf-ft 2.0 3.5 7.5 17.0 37.0 63.0 99.5 155.0 177.0

IE31J1030006-01
Fastener of strength class equivalent to Nm 3.1 6.3 11 27 56 105 168 258 373
8.8 (bolt) or 8 (nut) kgf-m 0.32 0.64 1.1 2.8 5.7 10.7 17.1 26.3 38
lbf-ft 2.5 5.0 8.5 20.0 41.5 77.5 124.0 190.5 275.5

IE31J1030007-01
Flanged fastener of strength class Nm 3.2 6.5 12 29 59 113 175 270 395
equivalent to 8.8 (bolt) or 8 (nut) kgf-m 0.33 0.66 1.2 3.0 6.0 11.5 17.8 27.5 40.3
lbf-ft 2.5 5.0 9.0 21.5 43.5 83.5 129.0 199.5 291.5

IE31J1030008-01

Width across flats Thread diameter Unit

Small crown shape bolt
“b” [mm] “a” [mm] Nm kgf-m lbf-ft
7 5 4.5 0.46 3.5
8 6 10 1.0 7.5

ID26J1030004-01

*: Self-locking nut
0C-12 Service Data:

Special Tools and Equipment

Recommended Service Material
BENM23K10308001
Material SUZUKI recommended product or Specification Note
Coolant SUZUKI LONG LIFE COOLANT P/No.: 99000–99032– (Page 0C-12)
(GREEN) 12X
SUZUKI SUPER LONG LIFE P/No.: 99000–99032– (Page 0C-12)
COOLANT (BLUE) 20X
Fork oil SUZUKI FORK OIL SS-8 P/No.: 99000–99001– (Page 0C-13)
SS8

Fuel / Oil / Fluid / Coolant Recommendation ! WARNING

BENM23K10308002
Fuel Since the brake system of this motorcycle is
NOTICE filled with a glycol-based brake fluid by the
manufacturer, do not use or mix different
Do not use leaded gasoline. If it is used, the types of fluid such as silicone-based and
engine and the emission control system will petroleum-based fluid for refilling the
be damaged. system, otherwise serious damage will
result.
Use unleaded gasoline with an octane rating of 91 RON
Do not use any brake fluid taken from old or
or higher.
used or unsealed containers.
Never reuse brake fluid left over from a
Engine Oil
previous servicing, which has been stored
Use engine oils which meet the following requirements.
for a long period.
Engine oil
API service classification SG, SH, SJ or SL
JASO T903 standard MA Engine Coolant
Viscosity SAE 10W-40 Suzuki recommends the use of SUZUKI LONG LIFE
COOLANT or SUZUKI SUPER LONG LIFE COOLANT.
If SAE 10W-40 engine oils are not available, select oils
Coolant 99000–99032–12X (SUZUKI LONG LIFE
of an appropriate viscosity grade according to the
COOLANT (GREEN))
following chart.
Coolant 99000–99032–20X (SUZUKI SUPER LONG
LIFE COOLANT (BLUE))

For SUZUKI LONG LIFE COOLANT

ENGINE OIL
NOTICE
• Use a high quality ethylene glycol base
anti-freeze, mixed with distilled water. Do
not mix an alcohol base anti-freeze and
IF34J1030001-01 different brands of anti-freeze.
Suzuki does not recommend the use of engine oils • Do not put in more than 60% anti-freeze or
which have an “ENERGY CONSERVING” indication in less than 30%. (Refer to Fig. 1 and 2.)
the API service symbol for any of its motorcycles / ATVs.
They can affect the engine life and the clutch The 70:30 mixture of distilled water and ethylene glycol
performance. anti-freeze will provide the optimum corrosion protection
and excellent heat protection, and will protect the cooling
system from freezing at temperatures above –14.5 °C
PI
SERVICE
PI
SERVICE (5.9 °F).
If the vehicle is to be exposed to temperatures below –
SJ

SJ
A

SAE SAE
10W-40 10W-40 14.5 °C (5.9 °F), this mixing ratio should be increased up
EN E

NG

to 50% according to the figure.

VI

GY
R

R
CONSE

IF04K1030002-02

Brake Fluid
Specification and classification: DOT 4
 Service Data: 0C-13

Anti-freeze Proportioning Chart NOTICE

Anti-freeze density Freezing point Mixing of anti-freeze/engine coolant should
30% –14.5 °C (5.9 °F) be limited to 60%. Mixing beyond it would
50% –34.0 °C (–29.2 °F) reduce its efficiency. If the anti-freeze/engine
coolant mixing ratio is below 30%, rust
Fig.1: Engine coolant density-freezing point curve inhabiting performance is greatly reduced.
Be sure to mix it above 50% even though the
(°F) (°C)
atmospheric temperature does not go down
32 0
to the freezing point.
32 –10
–4 –20 For SUZUKI SUPER LONG LIFE COOLANT
Freezing point

–22 –30 NOTICE

–40 –40 • Ethanol or methanol base coolant or water
–58 –50 alone should not be used in cooling
system at any time as damage to cooling
–76 –60
system could occur.
–94 –70 • Do not mix the distilled water, SUZUKI
LONG LIFE COOLANT (coolant color:
20 40 60 80 100 Green) or equivalent.
Density (%)
I310G1160001-02
SUZUKI SUPER LONG LIFE COOLANT will provide the
optimum corrosion protection and excellent heat
Fig.2: Engine coolant density-boiling point curve protection, and will protect the cooling system from
freezing at temperatures above –36 °C (–33 °F).
(°F) (°C)
(kgf/cm²)
302 150 Anti-freeze concentration table
1.5 Anti-freeze density Freezing point
284 140
50% –36 °C (–33 °F)
Gauge pressure
Boiling point

266 130 0.9

0.5 Anti-freeze / Engine coolant

248 120
The engine coolant perform as a corrosion and rust
230 110 0 inhibitor as well as anti-freeze. Therefore, the engine
coolant should be used at all times even though the
212 100
atmospheric temperature in your area does not go down
to freezing point.
0 10 20 30 40 50 60 Suzuki recommends the use of SUZUKI COOLANT
Density (%)
I310G1160002-02
antifreeze/engine coolant. If this is not available, use an
equivalent which is compatible with an aluminum
Water for mixing radiator.
Use distilled water only. Water other than distilled water
can corrode and clog the aluminum radiator. Front Fork Oil
For engine coolant mixture information, refer to “Engine Use SUZUKI FORK OIL SS-8.
Coolant” (Page 0C-12). Fork oil 99000–99001–SS8 (SUZUKI FORK OIL SS-8)
0C-14 Service Data:

Section 1
Engine
CONTENTS
Precautions .................................................1-1
Precautions............................................................. 1-1
Precautions for Engine.......................................... 1-1
Engine General Information and
Diagnosis ................................................. 1A-1
Precautions...........................................................1A-1
Precautions for DTC Trouble Shooting ............... 1A-1
General Description .............................................1A-1
Injection Timing Description ................................ 1A-1
Keyless Start System Description ....................... 1A-2
CAN Communication System Description........... 1A-4
Engine Easy Start System Description ............... 1A-4
Self-Diagnosis Function ...................................... 1A-4
Schematic and Routing Diagram........................1A-8
FI System Wiring Diagram .................................. 1A-8
Keyless Start System Wiring Diagram .............. 1A-10
Component Location .........................................1A-11
FI System Component Location........................ 1A-11
Diagnostic Information and Procedures..........1A-14
Engine Symptom Diagnosis .............................. 1A-14
DTC Check ....................................................... 1A-18
DTC Clearance ................................................. 1A-19
DTC Table......................................................... 1A-20
Fail-Safe Function Table ................................... 1A-21
FI System Troubleshooting ............................... 1A-22
DTC P0335 (C12): CKP Sensor “A” Circuit....... 1A-24
DTC P0105 / P0106 / P0107 (C13): IAP
Sensor Circuit ................................................. 1A-26
DTC P0120 / P0123 (C14): TP Sensor/Switch
“A” Circuit ........................................................ 1A-28
DTC P0115 / P0117 (C15): ECT Sensor
Circuit.............................................................. 1A-30
DTC P0500 (C16): Vehicle Speed Sensor “A” .. 1A-31
DTC P0500 (C16): Front Wheel Speed
Sensor (with ABS) / DTC P2158 (C91): Rear
Wheel Speed Sensor (with ABS) .................... 1A-34
DTC P0110 / P0112 (C21): IAT Sensor 1
Circuit.............................................................. 1A-36
DTC P1700 / P1701 (C23): TO Sensor Circuit
Low/High ......................................................... 1A-38
DTC P0351 (C24): Ignition Coil “A” Primary/
Secondary Circuit............................................ 1A-40
DTC P0201 (C32): Injector Circuit/Open........... 1A-40
Table of Contents 1- i
DTC P0505 (C40): ISC Valve Circuit
Malfunction......................................................1A-41
DTC P0230 (C41): Fuel Pump Circuit Low/
High.................................................................1A-43
DTC P1610 (C42): Ignition Switch Circuit
Malfunction......................................................1A-44
DTC P0130 / P0131 / P0132 (C44): O2
Sensor Circuit Bank 1 Sensor 1 ......................1A-45
DTC P0170 (C45): Fuel Trim Bank 1 ................1A-47
DTC P0418 (C49): PAIR System Control “A”
Circuit (If Equipped) ........................................1A-49
DTC P0480 (C60): Fan 1 Control Circuit ..........1A-52
DTC P0443 / P0449 (C62): EVAP System
Purge Control Valve Circuit (If Equipped) .......1A-54
DTC P0506 / P0507 (C65): ISC System
Malfunction......................................................1A-57
Special Tools and Equipment ...........................1A-59
Special Tool ......................................................1A-59
Emission Control Devices ...................... 1B-1
Precautions...........................................................1B-1
Precautions for Emission Control Devices ..........1B-1
General Description .............................................1B-1
Fuel Injection System Description.......................1B-1
Crankcase Emission Control System
Description ........................................................1B-2
Exhaust Emission Control System
Description (If Equipped)...................................1B-3
Evaporative Emission Control System
Diagram (If Equipped) .......................................1B-4
Schematic and Routing Diagram ........................1B-5
PAIR System Hose Routing Diagram (If
Equipped)..........................................................1B-5
PCV Hose Routing Diagram ...............................1B-6
EVAP Canister Hose Routing Diagram (If
Equipped)..........................................................1B-7
Repair Instructions ............................................1B-11
PAIR Reed Valve Removal and Installation (If
Equipped)........................................................1B-11
PAIR Control Solenoid Valve Removal and
Installation (If Equipped) .................................1B-11
PAIR System Inspection (If Equipped)..............1B-12
Cylinder Head Cover Inspection .......................1B-13
PCV Hose Inspection ........................................1B-13
PCV Hose Removal and Installation .................1B-13
1-ii Table of Contents
EVAP Control System Removal and
Installation (If Equipped) ................................. 1B-13
EVAP Control System Inspection (If
Equipped)........................................................ 1B-15
Specifications.....................................................1B-18
Tightening Torque Specifications......................1B-18
Special Tools and Equipment ...........................1B-18
Special Tool ......................................................1B-18
Engine Electrical Devices ....................... 1C-1
Precautions...........................................................1C-1
Precautions for Engine Electrical Device ............1C-1
Precautions for Replacing Remote Controller.....1C-1
Precautions for Replacing Keyless Control
Unit....................................................................1C-1
Precautions for Remote Controller Disposal .......1C-1
Component Location ...........................................1C-1
Engine Electrical Components Location .............1C-1
Diagnostic Information and Procedures............1C-1
Engine Symptom Diagnosis ................................1C-1
Repair Instructions ..............................................1C-2
ECM Removal and Installation............................1C-2
IAP/TP/IAT Sensor Inspection ............................1C-3
TP Fully Closed Learned Value Reset ................1C-4
ISC Valve Inspection...........................................1C-4
ISC Valve Removal and Installation....................1C-5
ISC Aperture Learned Value Reset.....................1C-6
ECT Sensor Inspection .......................................1C-7
ECT Sensor Removal and Installation ................1C-7
O2 Sensor Inspection..........................................1C-8
O2 Sensor Removal and Installation...................1C-8
Long Term Fuel Trim Reset ................................1C-9
CKP Sensor Inspection .....................................1C-10
CKP Sensor Removal and Installation ..............1C-11
TO Sensor Removal and Installation ................1C-11
TO Sensor Inspection .......................................1C-11
Speed Sensor Removal and Installation ...........1C-12
Speed Sensor Inspection ..................................1C-13
Remote Controller Registration.........................1C-13
Remote Controller Battery Replacement ..........1C-16
Specifications.....................................................1C-17
Tightening Torque Specifications......................1C-17
Special Tools and Equipment ...........................1C-17
Special Tool ......................................................1C-17
Engine Mechanical .................................. 1D-1
Precautions...........................................................1D-1
Precautions for Engine Mechanical.....................1D-1
Schematic and Routing Diagram........................1D-1
Throttle Cable Routing Diagram..........................1D-1
Diagnostic Information and Procedures............1D-5
Compression Pressure Check ............................1D-5
Repair Instructions ..............................................1D-6
Intake System Components ................................1D-6
Air Cleaner Element Removal and Installation ....1D-8
Air Cleaner Element Inspection...........................1D-9
Air Cleaner Box Removal and Installation...........1D-9
Throttle Cable Play On-Vehicle Inspection
and Adjustment ...............................................1D-12
Throttle Cable Removal and Installation ...........1D-13
Throttle Cable Inspection ..................................1D-13
Throttle Body Removal and Installation ............1D-13
Throttle Body Disassembly and Reassembly....1D-15
Throttle Body Inspection and Cleaning .............1D-15
Intake Pipe Removal and Installation................1D-16
Cylinder Head Cover Removal and
Installation .......................................................1D-17
Cylinder Head Cover Inspection .......................1D-18
Cam Chain Tension Adjuster / Camshaft
Housing / Camshaft Removal .........................1D-19
Cam Chain Tension Adjuster / Camshaft
Housing / Camshaft Installation ......................1D-20
Cam Chain Tension Adjuster Inspection ...........1D-23
Camshaft Inspection .........................................1D-23
Valve Clearance Inspection and Adjustment ....1D-25
Camshaft Sprocket Inspection ..........................1D-29
Cylinder Head Assembly / Cam Chain Guide
/ Cylinder Removal and Installation.................1D-29
Cam Chain Guide Inspection ............................1D-33
Cam Chain Tensioner Removal and
Installation .......................................................1D-33
Cam Chain Tensioner Inspection......................1D-33
Cylinder Head Disassembly and Reassembly ..1D-33
Cylinder Head Inspection ..................................1D-34
Valve / Valve Spring Removal and Installation ..1D-34
Valve Inspection................................................1D-36
Valve Spring Inspection ....................................1D-38
Valve Seat Repair .............................................1D-38
Cylinder Inspection............................................1D-39
Piston Removal and Installation ........................1D-39
Piston Ring Removal and Installation ...............1D-40
Piston and Piston Ring Inspection ....................1D-41
Cam Chain Removal and Installation ................1D-43
Balancer Shaft Drive / Driven Gear Removal
and Installation ................................................1D-43
Balancer Shaft Driven Gear Disassembly and
Reassembly ....................................................1D-45
Balancer Shaft Drive / Driven Gear Inspection ..1D-46
Engine Assembly Removal ...............................1D-46
Engine Assembly Installation ............................1D-48
Crankcase Assembly Disassembly ...................1D-50
Crankcase Assembly Reassembly....................1D-52
Conrod / Crankshaft Inspection.........................1D-54
Balancer Shaft Inspection .................................1D-55
Crankcase Bearing / Oil Seal Inspection...........1D-55
Crankcase Bearing Removal and Installation ...1D-56
Crankshaft Thrust Clearance Inspection and
Shim Selection ................................................1D-57
Specifications .....................................................1D-58
Tightening Torque Specifications......................1D-58
Special Tools and Equipment ...........................1D-59
Recommended Service Material .......................1D-59
Special Tool ......................................................1D-59
Engine Lubrication System .................... 1E-1
Precautions...........................................................1E-1
Precautions for Engine Oil ..................................1E-1
Schematic and Routing Diagram ........................1E-2

Engine Lubrication System Chart Diagram ......... 1E-2
Diagnostic Information and Procedures............ 1E-3
Engine Lubrication Symptom Diagnosis ............. 1E-3
Oil Pressure Check ............................................. 1E-3
Repair Instructions .............................................. 1E-5
Engine Oil Inspection .......................................... 1E-5
Engine Oil Replacement ..................................... 1E-5
Oil Filter Replacement ........................................ 1E-6
Oil Sump Filter Removal and Installation ............ 1E-7
Oil Sump Filter Inspection and Cleaning............. 1E-8
Oil Pump / Oil Pump Driven Gear / Oil Pump
Drive Gear Removal and Installation ................ 1E-8
Oil Pump Inspection .......................................... 1E-10
Specifications..................................................... 1E-10
Tightening Torque Specifications...................... 1E-10
Special Tools and Equipment ........................... 1E-10
Special Tool ...................................................... 1E-10
Engine Cooling System ...........................1F-1
Precautions........................................................... 1F-1
Precautions for Engine Cooling System.............. 1F-1
Precautions for Engine Coolant .......................... 1F-1
General Description ............................................. 1F-1
Engine Coolant Description ................................ 1F-1
Schematic and Routing Diagram........................ 1F-1
Cooling Circuit Diagram ...................................... 1F-1
Water Hose Routing Diagram ............................. 1F-2
Diagnostic Information and Procedures............ 1F-4
Engine Cooling Symptom Diagnosis................... 1F-4
Repair Instructions .............................................. 1F-4
Engine Coolant Level Inspection ........................ 1F-4
Engine Coolant Replacement ............................. 1F-5
Engine Cooling System Inspection ..................... 1F-6
Radiator Cap Inspection ..................................... 1F-6
Cooling Fan On-Vehicle Inspection .................... 1F-7
Coolant Hose Inspection ..................................... 1F-7
Ignition System ........................................ 1H-1
Radiator Removal and Installation ...................... 1F-8
Radiator Fan Assembly Removal and
Installation ......................................................... 1F-9
Radiator Inspection and Cleaning ..................... 1F-10
Radiator Reservoir Tank Inspection.................. 1F-11
Radiator Reservoir Tank Removal and
Installation ....................................................... 1F-11
Coolant Hose Removal and Installation ............ 1F-12
Cooling Fan Relay Inspection ........................... 1F-12
Thermostat Removal and Installation................ 1F-13
Thermostat Inspection ...................................... 1F-13
Water Pump Assembly Components ................ 1F-15
Water Pump Removal and Installation.............. 1F-15
Water Pump Disassembly and Reassembly ..... 1F-15
Water Pump Related Parts Inspection .............. 1F-18
Specifications..................................................... 1F-19
Tightening Torque Specifications...................... 1F-19
Special Tools and Equipment ........................... 1F-19
Recommended Service Material ....................... 1F-19
Special Tool ...................................................... 1F-19
Fuel System ............................................. 1G-1
Precautions...........................................................1G-1
Table of Contents 1-iii
Precautions for Fuel System .............................. 1G-1
General Description ............................................ 1G-2
Fuel System Description .................................... 1G-2
Schematic and Routing Diagram ....................... 1G-3
Fuel Tank Water Drain Hose and Fuel Tank
Breather Hose (If Equipped) Routing
Diagram............................................................ 1G-3
Diagnostic Information and Procedures ........... 1G-3
Fuel System Symptom Diagnosis ...................... 1G-3
Repair Instructions ............................................. 1G-4
Fuel Pressure Inspection ................................... 1G-4
Fuel Discharge Amount Inspection .................... 1G-4
Fuel Feed Hose Disconnecting and
Reconnecting ................................................... 1G-5
Fuel Feed Hose Inspection ................................ 1G-5
Fuel Feed Hose Removal and Installation ......... 1G-5
Fuel Tank Construction ...................................... 1G-6
Fuel Tank Cap Removal and Installation ........... 1G-7
Fuel Tank Removal and Installation................... 1G-8
Fuel Pump Components .................................... 1G-9
Fuel Pump On-Vehicle Inspection.................... 1G-10
Fuel Pump Assembly Removal and
Installation ...................................................... 1G-10
Fuel Pump Disassembly and Reassembly....... 1G-11
Fuel Mesh Filter Inspection .............................. 1G-13
Fuel Level Gauge Inspection ........................... 1G-13
Fuel Injector On-Vehicle Inspection ................. 1G-13
Fuel Injector Removal and Installation ............. 1G-14
Fuel Injector Inspection and Cleaning.............. 1G-15
Specifications .................................................... 1G-16
Tightening Torque Specifications..................... 1G-16
Special Tools and Equipment .......................... 1G-16
Recommended Service Material ...................... 1G-16
Special Tool ..................................................... 1G-16
Schematic and Routing Diagram ........................1H-1
Ignition System Diagram .....................................1H-1
Ignition System Components Location................1H-1
Diagnostic Information and Procedures ............1H-2
Ignition System Symptom Diagnosis...................1H-2
No Spark or Poor Spark ......................................1H-2
Repair Instructions ..............................................1H-4
Ignition Coil Construction ....................................1H-4
Keyless Control Unit Construction ......................1H-4
Spark Plug Removal and Installation ..................1H-5
Spark Plug Inspection and Cleaning ...................1H-6
Ignition Coil Removal and Installation .................1H-6
Ignition Coil Inspection ........................................1H-7
Ignition Relay Inspection (Keyless Start
Model) ...............................................................1H-8
Ignition Switch Inspection....................................1H-8
Ignition Switch Removal and Installation.............1H-9
Keyless Control Unit Removal and Installation ..1H-11
Specifications .....................................................1H-12
Tightening Torque Specifications......................1H-12
Special Tools and Equipment ...........................1H-13
Special Tool ......................................................1H-13
1-iv Table of Contents
Starting System ......................................... 1I-1
Schematic and Routing Diagram......................... 1I-1
Starting System Diagram ..................................... 1I-1
Component Location ............................................ 1I-1
Starting System Components Location................ 1I-1
Diagnostic Information and Procedures............. 1I-2
Starting System Symptom Diagnosis................... 1I-2
Starter Motor Will Not Run ................................... 1I-2
Starter Motor Runs But Does Not Crank the
Engine ................................................................ 1I-4
Repair Instructions ............................................... 1I-4
Starter Motor Components................................... 1I-4
Keyless Start System Inspection.......................... 1I-5
Starter Motor Assembly Removal and
Installation .......................................................... 1I-5
Starter Motor Disassembly and Reassembly ....... 1I-6
Starter Motor Inspection....................................... 1I-7
Starter Relay Removal and Installation................ 1I-8
Starter Relay Inspection....................................... 1I-9
Starter Interlock System Parts Inspection ............ 1I-9
Starter Clutch Removal and Installation............. 1I-10
Starter Clutch Inspection.................................... 1I-12
Starter Switch Inspection ................................... 1I-12
Kick Starter Components (If Equipped).............. 1I-13
Kick Starter Lever Removal and Installation ...... 1I-14
Kick Starter Shaft Removal and Installation....... 1I-14
Kick Starter Shaft Oil Seal Removal and
Installation ........................................................ 1I-16
Kick Starter Parts Inspection.............................. 1I-16
Specifications...................................................... 1I-17
Tightening Torque Specifications....................... 1I-17
Special Tools and Equipment ............................ 1I-18
Recommended Service Material ........................ 1I-18
Special Tool ....................................................... 1I-18
Charging System ...................................... 1J-1
Schematic and Routing Diagram ........................ 1J-1
Charging System Diagram .................................. 1J-1
Component Location ........................................... 1J-1
Charging System Components Location............. 1J-1
Diagnostic Information and Procedures ............ 1J-2
Charging System Symptom Diagnosis................ 1J-2
Battery Runs Down Quickly ................................ 1J-3
Repair Instructions .............................................. 1J-4
Battery Current Leakage Inspection.................... 1J-4
Regulated Voltage Inspection ............................. 1J-4
Generator Inspection........................................... 1J-4
Generator Removal............................................. 1J-5
Generator Installation .......................................... 1J-7
Regulator / Rectifier Construction ....................... 1J-9
Regulator / Rectifier Removal and Installation .. 1J-10
Battery Construction.......................................... 1J-11
Battery Charging ............................................... 1J-12
Battery Removal and Installation ...................... 1J-13
Battery Visual Inspection................................... 1J-13
Specifications ..................................................... 1J-14
Tightening Torque Specifications...................... 1J-14
Special Tools and Equipment ........................... 1J-14
Recommended Service Material ....................... 1J-14
Special Tool ...................................................... 1J-14
Exhaust System....................................... 1K-1
Precautions...........................................................1K-1
Precautions for Exhaust System .........................1K-1
Repair Instructions ..............................................1K-1
Exhaust System Components .............................1K-1
Muffler Removal and Installation .........................1K-2
Exhaust System Inspection .................................1K-4
Specifications .......................................................1K-4
Tightening Torque Specifications........................1K-4
 Precautions: 1-1

Precautions
Engine

Precautions
Precautions for Engine
BENM23K11000001
Refer to “General Precautions” in Section 00 (Page 00-1), “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2), “Precautions for Circuit Tester” in Section 00 (Page 00-7), and “Precautions for SDS-II” in Section 00
(Page 00-7).
1A-1 Engine General Information and Diagnosis:

Engine General Information and Diagnosis

Engine

Precautions
Precautions for DTC Trouble Shooting
BENM23K11100001
Refer to “General Precautions” in Section 00 (Page 00-1), “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2), “Precautions for Circuit Tester” in Section 00 (Page 00-7), and “Precautions for SDS-II” in Section 00
(Page 00-7).

NOTE
After repairing the trouble, clear the DTC. (Page 1A-19)

General Description
Injection Timing Description
BENM23K11101001
Injection Time (Injection Volume)
The factors to determine the injection time include the basic fuel injection time, which is calculated on the basis of the
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.

Intake Air Pressure Intake air pressure

Sensor (IAP Sensor) signal
Basic
Crankshaft Position Engine speed fuel
Sensor (CKP Sensor) signal injection
time
Throttle Position Throttle opening
Sensor (TP Sensor) signal

Various Various signals Corrective

Sensors variables

Definitive
Fuel injector Injection signal fuel
injection
time

IE12J1110001-02
 Engine General Information and Diagnosis: 1A-2

Compensation of Injection Time (Volume)

The following different signals are outputted from the respective sensors for compensation of the fuel injection time
(volume).
Signal Descriptions
ECT sensor signal When engine coolant temperature is low, injection time (volume) is increased.
Air/fuel ratio is compensated to the theoretical ratio from density of oxygen in
O2 sensor signal exhaust gases. The compensation occurs in such a way that more fuel is
supplied if detected air/fuel ratio is lean and less fuel is supplied if it is rich.
IAT sensor signal When intake air temperature is low, injection time (volume) is increased.
Engine rpm signal At high speed, the injection time (volume) is increased.
Starting signal When starting engine, additional fuel is injected during cranking engine.
During acceleration, the fuel injection time (volume) is increased, in
Acceleration signal / deceleration
accordance with the throttle opening speed and engine rpm. During
signal
deceleration, the fuel injection time (volume) is decreased.

Injection Stop Control

Signal Descriptions
When the motorcycle tips over, the tip-over sensor sends a signal to the
TO sensor signal ECM. Then, the ECM stops the fuel pump, fuel injector and ignition coil
control.
Over-rev. limiter signal The fuel injector stops operation when engine rpm reaches rev. limit rpm.

Keyless Start System Description

BENM23K11101002
• The keyless start system transmits radio waves between the keyless control unit (2) and the remote controller (3) by
means of pushing the request switch built in the ignition switch (1).
• When the multiple IDs held by the keyless control unit (2) are compared with the IDs registered in the remote
controller (3) and all the IDs match, the ignition solenoid is unlocked for 4 seconds to enable the ignition switch (1)
operation.
• Turning the ignition switch (1) ON, and pushing the start switch to start the engine. (all interlocks for engine start are
released)
• After the Ignition switch (1) is turned OFF and then 4 seconds have elapsed, the engine returns to its initial state
(before the request switch was pushed).
• When the remote controller (3) cannot be used due to missing or battery run down, input secret code using the
request switch and the engine can be started.
• Setting the ignition switch (1) to the LOCK position with the handlebars turned fully to left, locks the handlebars.
• Up to 6 remote controller (3) can be added. When 6 remote controllers (3) have been added, no further remote
controller (3) can be registered. If new remote controller wants to be added, the keyless control unit (2) and the
ECM (4) must be replaced at the same time.
• Setting the ignition switch (1) to the “ • ” (ACC) position enables the ignition key (5) removal and installation.
Using the removed ignition key (5) enables the operating the fuel cap (6) and removal of the rear seat (7).
• The remote control features the communication mode for communicating with the motorcycle, and the stop mode
for preventing erroneous operations.
1A-3 Engine General Information and Diagnosis:

P
1 5

10
8 9

IH23K5110009-01

1. Ignition switch / Request switch 5. Ignition key 9. Right turn signal light
2. Keyless control unit 6. Fuel lid 10. LED (Turn signal indicator light)
3. Remote controller 7. Rear seat
4. ECM 8. Left turn signal light
 Engine General Information and Diagnosis: 1A-4

CAN Communication System Description

BENM23K11101003
ECM (1), ABS control unit (if equipped) (2), and combination meter (3) are transmitted / received data through two
communication lines (CAN High (4) and CAN Low (5)) connected through CAN communication. Data obtained by a
specific control module can be shared with every control module.

1 2 3

4 5 4 5 4 5

IH23K4110027-01

Engine Easy Start System Description

BENM23K11101004
The engine easy start system controls the engine start by one-push of the starter switch to operate the starter motor
automatically until the engine starts.

“Push”
IH23K5110010-01

Self-Diagnosis Function
BENM23K11101005
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 LCD (DISPLAY) panel and LED (MIL). To check the function of the individual FI
system devices, the dealer mode is provided. In this check, the special tool is necessary to read the DTC.
1A-5 Engine General Information and Diagnosis:

Warning Function
The ECM warns riders to turn the MIL (1) on or blink it depending on the failure place or its content.
And the ECM turns the MIL off when detecting 3 D/C-correct continuously after detecting the first abnormality.

IH23K5110011-01

Supplementation
• The driving cycle (D/C) means the cycle beginning from turning the ignition switch ON through starting the engine
until turning the ignition switch OFF. The 3 driving cycles are the term repeating 3 times of the above mentioned
cycle.
• The warm up cycle means the cycle of engine warm up operation that the engine coolant temperature reaches
more than 71 °C (159.8 °F) and also rises more than 22.2 °C (72.0 °F) from the one at engine starting.

Diagnostic Coupler Location

Mode select coupler (6P) (1) and (2P) (2) is located under the rear seat. This coupler can use SDS-II tool and OBD
(for Oceania and Europe Model) conversion cable.
Special tool
(A): 09904–41051 (for Oceania and Europe model)
(B): 09930–82760

(B)

(A)

IH23K5110012-01
 Engine General Information and Diagnosis: 1A-6

User Mode
LCD (display)
Malfunction MIL indication (2) Indication mode
indication (1)
“NO” Odometer *1 — —
Odometer (*1) and Each 2 sec. Odometer (*1) and
Engine can start MIL turns ON.
“FI” letters (*2) “FI” is indicated alternately.
“YES”
MIL turns ON and then
Engine cannot start “FI” letters (*3) “FI” is indicated continuously.
blinks.

*1
Current letter display refer to any one of the following: odometer, tripmeter A or tripmeter B.

*2
When one of the signals does not reach the ECM, the fail-safe circuit is activated and fuel injection continues. In this
case, “FI” and odometer (*1) are indicated in the LCD panel and motorcycle is in running condition.

*3
The injection signal is stopped, when the CKP sensor signal, TO sensor signal, ignition signal, injector signal, or
ignition switch signal is not sent to ECM.
In this case, “FI” is indicated in the LCD panel. Motorcycle is not in running condition.

NOTE
The MIL turns ON about 3 seconds after turning the ignition switch ON.

1
IM23K1110009-08
1A-7 Engine General Information and Diagnosis:

Dealer Mode
The defective function is memorized in the ECM. Use the special tool’s coupler to connect to the mode select coupler
(6P).
The memorized malfunction code is displayed on LCD panel. Malfunction means that the ECM does not receive
normal signals from the devices. These affected devices are indicated in code form.
Special tool
(A): 09930–82760

(A)

IG12K1110054-01

IM23K1110010-24

Malfunction LCD (display) indication MIL indication Indication mode

“NO” C00 —
C** code is indicated from small MIL turns OFF.
“YES” For each 2 sec., code is indicated.
to large numbers.

DTC Storage
Two (current and past) DTCs, can be memorized in the ECM.
• Current DTC is cleared when the ignition switch is turned OFF, then it is memorized in ECM as a Past DTC.
• Past DTCs are not cleared even when the ignition switch has been turned OFF or the trouble has been repaired.
 Engine General Information and Diagnosis: 1A-8

Schematic and Routing Diagram

FI System Wiring Diagram
BENM23K11102001

12

Dg T33

1
13
B1
T27 GW

G T20
14
GND VTA VCC R T8 T29 PW

2
WP T11 15
T4 WG

GND PM VCC
16
GB T23 T17 YR M
3 GND DON VCC

Br T34 17
T1 WL
4 BL T6

18
5 BO T9
YW
T13

BBr T21
19 M
6
OW T2 20
T3 R
7 21 22
BY T30 T7 OB 23 24

25
8 SDL-KWP GrR T35 T32 PW

26
T26 YG

27
T15 BY

28 M 29
WR T31

9 SMART KEY
TEST SW
T10 YR

M
T12 Lg

B1
30
T36 Sb
GL T28

T24 BLg
10 BG T14

L T18
T5 BW

T25 BW

11 P T22

IM23K1110011-08

1. CKP sensor 9. Keyless start system (if equipped) 17. Ignition coil 25. Ignition switch signal(if
equipped)
2. IAP/TP/IAT sensor 10. Combination meter 18. Cooling fan relay 26. Starter switch
3. TO sensor 11. Speed sensor 19. Cooling fan motor 27. Starter relay
4. ECT sensor 12. ECM 20. Self-shut off power source 28. Starter motor
5. O2 sensor 13. Fuel injector 21. Kill switch 29. Battery
6. Side stand switch (if equipped) 14. Canister purge solenoid valve (if equipped) 22. Ignition switch 30. ISC Sensor
7. Clutch switch 15. PAIR solenoid valve (if equipped) 23. Regulator/rectifier
8. SDL-KWP (if equipped) 16. Fuel pump 24. Generator
1A-9 Engine General Information and Diagnosis:

Terminal Arrangement of ECM Connector “T”

1 2 3 4 5 6 7 8 9 10 1112
13 14151617 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36

IH23K1110016-01

Terminal No. Circuit Terminal No. Circuit

T1 Ignition coil T19 —
T2 Side stand switch (if equipped) T20 Intake air temperature sensor
T3 Self-shut off power source (if equipped) T21 Sensor ground
T4 PAIR solenoid valve (if equipped) T22 Speed sensor
T5 Control circuit ground T23 Manifold pressure sensor
T6 Water temperature sensor T24 ISC actuator 2B
T7 Battery T25 Power source ground
T8 Sensor power T26 Starter switch
T9 O2 sensor T27 Injector
T10 ISC actuator 1A T28 Meter Communication
T11 Throttle position sensor T29 Canister purge solenoid valve (if equipped)
T12 ISC actuator 1B T30 Clutch switch
T13 Radiator fan relay T31 Test sw/communication line A/smart key
T14 Tachometer T32 Ignition switch
T15 Starter relay T33 Crankshaft position sensor
T16 — T34 Fuel cut sensor
T17 Fuel pump T35 SDL - KWP (ABS model)
T18 Neutral switch T36 ISC actuator 2A
 Engine General Information and Diagnosis: 1A-10

Keyless Start System Wiring Diagram

BENM23K11102002

2
1
O/W T10 T2 W/R 10

11
T9 P [A]
3
O/R T7
[A] 12

B/W T5 13
T11 Bl
5
4
B/R T8

6 If Equipped

T6 V [B]

T12 Bl/G [B]

8
7
9

IH23K4110028-01

[A]: From Terminal 7 3. Sub fuse (10 A) 7. Remote controller 11. Keyless indicator light
[B]: To turn signal light 4. Main fuse (10 A) 8. Receiver 12. Ignition relay
1. Keyless control unit 5. Request switch 9. Antenna 13. Ignition solenoid
2. Ignition switch 6. Battery 10. ECM

Terminal Arrangement of Keyless Control Unit Connector “T”

6 5 4 3 2 1
12 11 10 9 8 7

IH23K1110020-01

Terminal No. Circuit Terminal No. Circuit

T1 — T7 Power source (+B)
T2 Communication line T8 Request switch
T3 — T9 Keyless indicator
T4 — T10 Main switch monitor
T5 Ground T11 Ignition solenoid
T6 Left answer back output (if equipped) T12 Right answer back output (if equipped)
1A-11 Engine General Information and Diagnosis:

Component Location
FI System Component Location
BENM23K11103001
GSX R 125 Model

2
4

3 1

13 5
7

6
11
12

8 9 10

14

IH23K5110003-01

1. ECM 6. ECT sensor 11. Starter motor

2. Combination meter 7. Starter relay 12. O2 sensor
3. FP relay 8. CKP sensor 13. EVAP system purge control solenoid valve (if equipped)
4. Clutch lever position switch 9. GP sensor 14. Side stand switch
5. Fuel pump 10. Speed sensor

1
2 6

8 3
7
11 4
12

10

14 13

IH23K5110004-01
 Engine General Information and Diagnosis: 1A-12

1. ECM 6. Ignition relay 11. ABS control unit (if equipped)

2. TO sensor 7. Fuel injector 12. Pair control solenoid valve (if equipped)
3. Ignition coil 8. Cooling fan relay 13. Front wheel speed sensor (if equipped)
4. IAP/TP/IAT sensor 9. Cooling fan 14. Rear wheel speed sensor (if equipped)
5. Ignition solenoid 10. Keyless control unit

GSX S 125 Model

2 4

3 1

5
7
13

6 11

12 10
8
9
14

IK23K4110005-01

1. ECM 6. ECT sensor 11. Starter motor

2. Combination meter 7. Starter relay 12. O2 sensor
3. FP relay 8. CKP sensor 13. EVAP system purge control solenoid valve (if equipped)
4. Clutch lever position switch 9. GP sensor 14. Side stand switch
5. Fuel pump 10. Speed sensor
1A-13 Engine General Information and Diagnosis:

2
6 3
8 5 9
4

11 10

IH23K5110006-01

1. ECM 5. Fuel injector 9. Pair control solenoid valve (if equipped)

2. TO sensor 6. Cooling fan relay 10. Front wheel speed sensor (if equipped)
3. Ignition coil 7. Cooling fan 11. Rear wheel speed sensor (if equipped)
4. IAP/TP/IAT sensor 8. ABS control unit (if equipped)
 Engine General Information and Diagnosis:
Diagnostic Information and Procedures
Engine Symptom Diagnosis
Condition Possible cause
Engine will not start or is Valve clearance out of adjustment.
hard to start Worn valve guides or poor seating of
(Compression too low) valves.
Mistimed valves.
Excessively worn piston rings.
Worn-down cylinder bore.
Too slow starter motor cranking.
Poor seating of spark plug.
Engine will not start or is Defective spark plug.
hard to start (Plug not Too wide spark plug gap.
sparking) Fouled spark plug.
Wet spark plug.
Defective spark plug cap.
Defective ignition coil.
Defective CKP sensor.
Defective ECM.
Open-circuited wiring connections.
Open or short in high-tension cord.
Engine will not start or is Clogged fuel filter or fuel hose.
hard to start (No fuel
reaching the intake port)
Defective fuel pump.
Defective fuel pressure regulator.
Defective fuel injector.
Defective ECM.
Open-circuited wiring connections.
Engine will not start or is Defective fuel pump.
hard to start (Incorrect Defective fuel pressure regulator.
fuel/air mixture) Defective TP sensor.
Defective CKP sensor.
Defective IAP sensor.
Defective ECM.
Defective ECT sensor.
Defective IAT sensor.
Clogged ISC valve air passage way
1A-14
BENM23K11104001
Correction / Reference Item
Adjust. (Page 1D-25)
Repair or replace. (Page 1D-33)
Adjust. (Page 1D-25)
Replace. (Page 1D-40)
Replace. (Page 1D-29)
Repair or replace.
• Repair: (Page 1I-7)
• Replace: (Page 1I-5)
Retighten. (Page 1H-5)
Replace. (Page 1H-5)
Adjust or replace. (Page 1H-6)
Clean or replace. (Page 1H-6)
Dry or replace. (Page 1H-6)
Replace. (Page 1H-6)
Replace. (Page 1H-6)
Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Replace. (Page 1C-2)
Repair or replace. (Page 9A-3)
Replace. (Page 1H-6)
Clean or replace.
• Fuel filter: (Page 1G-13)
• Fuel hose: (Page 1G-5)
Replace. (Page 1G-10)
Replace. (Page 1G-10)
Replace. (Page 1G-14)
Replace. (Page 1C-2)
Repair and replace. (Page 9A-3)
Replace. (Page 1G-10)
Replace. (Page 1G-10)
Replace. (Page 1D-13)
Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Replace. (Page 1D-13)
Replace. (Page 1C-2)
Replace. (Page 1C-7)
Replace. (Page 1D-13)
Repair or replace. (Page 1D-13)
1A-15 Engine General Information and Diagnosis:

Condition Possible cause Correction / Reference Item

Engine idles poorly Valve clearance out of adjustment. Adjust. (Page 1D-25)
Poor seating of valves. Repair. (Page 1D-38)
Defective valve guides. Replace. (Page 1D-33)
Worn down camshafts and/or camshafts Replace.
surface. • Removal: (Page 1D-19)
• Installation: (Page 1D-20)
Too wide spark plug gap. Adjust or replace. (Page 1H-6)
Defective ignition coil. Replace. (Page 1H-6)
Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Defective ECM. Replace. (Page 1C-2)
Defective TP sensor. Replace. (Page 1D-13)
Defective fuel pump. Replace. (Page 1G-10)
Dirty throttle body. Clean. (Page 1D-15)
Engine stalls often Defective IAP sensor or circuit. Repair or replace. (Page 1D-13)
(Incorrect fuel/air mixture) Clogged fuel filter. Clean or replace. (Page 1G-13)
Defective fuel pump. Replace. (Page 1G-10)
Defective fuel pressure regulator. Replace. (Page 1G-10)
Defective ECT sensor. Replace. (Page 1C-7)
Defective thermostat. Replace. (Page 1F-13)
Defective IAT sensor. Replace. (Page 1D-13)
ISC valve clogged or defective. Clean or Replace. (Page 1C-5)
Engine stalls often (Fuel Defective fuel injector. Replace. (Page 1G-14)
injector improperly No injection signal from ECM. Repair or replace. (Page 1C-2)
operating) Open or short circuited wiring Repair or replace. (Page 9A-3)
connections.
Defective battery or low battery voltage. Replace or recharge. (Page 1J-12)
Engine stalls often Defective ECM. Replace. (Page 1C-2)
(Control circuit or sensor Defective fuel pressure regulator. Replace. (Page 1G-10)
improperly operating) Defective TP sensor. Replace. (Page 1D-13)
Defective IAT sensor. Replace. (Page 1D-13)
Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Defective ECT sensor. Replace. (Page 1C-7)
Defective ISC valve. Replace. (Page 1C-5)
Engine stalls often Fouled spark plug. Clean or replace. (Page 1H-6)
(Engine internal parts Defective CKP sensor. Replace.
improperly operating) • Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Defective ECM. Replace. (Page 1C-2)
Clogged fuel hose. Clean or replace. (Page 1G-5)
Valve clearance out of adjustment. Adjust. (Page 1D-25)
Dirty throttle body. Clean. (Page 1D-15)
Noisy engine (Excessive Too large valve clearance. Adjust. (Page 1D-25)
valve chatter) Weakened or broken valve springs. Replace. (Page 1D-34)
Worn tappet or camshafts surface. Replace.
• Removal: (Page 1D-19)
• Installation: (Page 1D-20)
Worn or burnt camshaft journals. Replace. (Page 1D-33)

Condition
Noisy engine (Noise
seems to come from
piston)
Combustion chamber fouled with
carbon.
Worn piston pin or piston pin bore.
Worn piston rings or ring grooves.
Noisy engine (Noise Stretched cam chain.
seems to come from cam Worn sprockets.
chain)
Noisy engine (Noise
seems to come from
crankshaft)
Noisy engine (Noise
seems to come from
balancer)
Noisy engine (Noise
seems to come from
water pump)
Engine runs poorly in
high speed range
(Defective engine internal/
electrical parts)
Engine runs poorly in
high speed range
(Defective air flow
system)
Engine runs poorly in
high speed range
(Defective control circuit
or sensor)
Engine General Information and Diagnosis:
Possible cause
Worn down piston or cylinder.
Cam chain tension adjuster not working. Repair or replace. (Page 1D-33)
Rattling bearing due to wear.
Worn or burnt big-end bearing.
Worn or burnt crankcase bearings.
Worn or burnt balancer shaft bearings. Replace. (Page 1D-56)
Too much play on pump shaft bearings.
Worn or damaged impeller shaft.
Worn or damaged oil seal.
Contact between pump case and
impeller.
Weakened valve springs.
Worn camshaft.
Valve timing out of adjustment.
Too narrow spark plug gap.
Ignition not advanced sufficiently due to Replace ECM. (Page 1C-2)
poorly working timing advance circuit.
Defective ignition coil.
Defective CKP sensor.
Defective ECM.
Clogged air cleaner element.
Clogged fuel hose, resulting in
inadequate fuel supply to injector.
Defective fuel pump.
Defective TP sensor.
Clogged air cleaner element.
Sucking air from throttle body joint or
intake pipe joint.
Defective ECM.
Defective throttle valve.
Low fuel pressure.
Defective TP sensor.
Defective IAT sensor.
Defective IAP sensor.
Defective CKP sensor.
Defective ECM.
1A-16
Correction / Reference Item
Replace.
• Piston: (Page 1D-39)
• Cylinder: (Page 1D-29)
Clean. (Page 1D-34)
Replace. (Page 1D-39)
Replace. (Page 1D-40)
Replace. (Page 1D-43)
Replace.
• Removal: (Page 1D-19)
• Installation: (Page 1D-20)
Replace. (Page 1D-56)
Replace.
• Disassembly: (Page 1D-50)
• Reassembly: (Page 1D-52)
Replace. (Page 1D-56)
Replace. (Page 1F-15)
Replace. (Page 1F-15)
Replace. (Page 1F-15)
Replace. (Page 1F-15)
Replace. (Page 1D-34)
Replace.
• Removal: (Page 1D-19)
• Installation: (Page 1D-20)
Adjust. (Page 1D-25)
Adjust. (Page 1H-6)
Replace. (Page 1H-6)
Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Replace. (Page 1C-2)
Replace. (Page 1D-9)
Clean and prime.
Replace. (Page 1G-10)
Replace. (Page 1D-13)
Replace. (Page 1D-9)
Retighten or replace.
Replace. (Page 1C-2)
Replace. (Page 1D-13)
Repair or replace.
Replace. (Page 1D-13)
Replace. (Page 1D-13)
Replace. (Page 1D-13)
Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Replace. (Page 1C-2)
1A-17 Engine General Information and Diagnosis:

Condition Possible cause Correction / Reference Item

Engine lacks power Loss of valve clearance. Adjust. (Page 1D-25)
(Defective engine internal/ Weakened valve springs. Replace. (Page 1D-34)
electrical parts) Valve timing out of adjustment. Adjust. (Page 1D-25)
Worn piston rings or cylinder. Replace. (Page 1D-40)
Poor seating of valves. Repair. (Page 1D-38)
Fouled spark plug. Clean or replace. (Page 1H-6)
Incorrect spark plug. Replace. (Page 1H-5)
Clogged fuel injector. Clean or replace. (Page 1G-15)
Clogged air cleaner element. Replace. (Page 1D-9)
Sucking air from throttle body joint or Retighten or replace.
intake pipe joint.
Too much engine oil. Drain out excess oil.
Defective fuel pump. Replace. (Page 1G-10)
Defective ECM. Replace. (Page 1C-2)
Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Defective ignition coil. Replace. (Page 1H-6)
Engine lacks power Low fuel pressure. Repair or replace.
(Defective control circuit Defective TP sensor. Replace. (Page 1D-13)
or sensor) Defective IAT sensor. Replace. (Page 1D-13)
Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Defective IAP sensor. Replace. (Page 1D-13)
Defective ECM. Replace. (Page 1C-2)
Engine overheats Heavy carbon deposit on piston crown. Clean.
(Defective engine internal Not enough oil in the engine. Add oil. (Page 1E-5)
parts) Defective oil pump or clogged oil circuit. Replace or clean. (Page 1E-8)
Use of incorrect engine oil. Replace. (Page 1E-5)
Sucking air from throttle body joint or Retighten or replace.
intake pipe joint.
Defective cooling system. Refer to (Page 1F-4)
Engine overheats (Lean Short-circuited IAP sensor/lead wire. Repair or replace. (Page 1D-13)
fuel/air mixture) Short-circuited IAT sensor/lead wire. Repair or replace. (Page 1D-13)
Sucking air from throttle body joint or Retighten or replace.
intake pipe joint.
Defective fuel injector. Replace. (Page 1G-15)
Defective ECT sensor. Replace. (Page 1C-7)
Engine overheats (Other Ignition timing is too advanced due to Replace.
factors) defective timing advance system (ECT
sensor, CKP sensor or ECM).
Dirty or heavy exhaust Too much engine oil. Drain out excess oil.
smoke Worn piston rings or cylinder. Replace. (Page 1D-40)
Worn valve guides. Replace. (Page 1D-33)
Scored or scuffed cylinder wall. Replace. (Page 1D-29)
Worn valve stems. Replace. (Page 1D-34)
Defective valve stem oil seal. Replace. (Page 1D-34)
Worn oil ring side rails. Replace. (Page 1D-40)
 Engine General Information and Diagnosis: 1A-18

DTC Check 3) Start the engine or crank the engine for more than 4
BENM23K11104002 seconds.
NOTE
4) Turn the special tool’s switch ON.
• Do not disconnect the coupler from ECM,
battery cable from battery, ECM ground
wire from engine or main fuse before
confirming DTC stored in memory. Such
disconnection will erase memorized
information in ECM memory.
• Before checking DTC, read “User mode
and Dealer mode” under “Self-Diagnosis
Function” (Page 1A-4) carefully to have
good understanding as to what functions
are available and how to use it. ID26J1110213-02

• DTC can be checked by using the SDS-II or 5) Check the DTC to determine the malfunction part.
OBD (for Oceania and Europe model). (Page 1A-20)
Refer to the SDS-II or OBD (for Oceania
and Europe model) operation manual for
further details.

Current DTC

NOTE
Current DTC is erased when the ignition
switch is turned OFF.

1) Open the rear seat.

2) Connect the special tool to the mode select coupler IG12K1110009-01
(6P) at the wiring harness.
Special tool Past DTC
(A): 09930–82760 NOTE
Past DTC is not indicated if there is
malfunction in TP sensor.

1) Open the rear seat.

2) Connect the special tool to the mode select coupler
(2P) at the wiring harness.
Special tool
(A) (A): 09930–82760

IM23K1110010-24

(A)

IM23K1110010-24
1A-19 Engine General Information and Diagnosis:
3) Open the throttle grip fully within 3 seconds after
turning ON the special tool’s switch and hold the
throttle grip opened.
(A)
IG12K1110010-01
4) In the state of Step 3), turn the ignition switch ON
and hold the throttle grip as it is for more than 1
second.
5) Check the DTC to determine the malfunction part.
(Page 1A-20)
IG12K1110009-01
DTC Clearance
BENM23K11104003
NOTE
• DTC is memorized in the ECM also when
the lead wire coupler of any sensor is
disconnected. Therefore, when a lead wire
coupler has been disconnected in the
diagnosis, erase the stored Past DTC.
• Clear the DTC using the SDS-II or OBD (for
Oceania and Europe model). Refer to the
SDS-II or OBD (for Oceania and Europe
model) operation manual for further
details.
Current DTC
1) After repairing the trouble, turn OFF the ignition
switch and turn ON again.
2) If the MIL (1) turns OFF, the malfunction is cleared.
1
IM23K1110012-08
3) Disconnect the special tool from the mode select
coupler and install the removed parts.
NOTE
Even though the Current DTC is cleared, Past
DTC (previous malfunction history code) still
remains stored in the ECM. Therefore, erase
the Past DTC memorized in the ECM.
Past DTC
1) Display Past DTC. Refer to “Past DTC” under “DTC
Check” (Page 1A-18).
2) Clear the DTC using the SDS-II or OBD (for Oceania
and Europe model). Refer to the SDS-II or OBD (for
Oceania and Europe model) operation manual for
further details.
 Engine General Information and Diagnosis: 1A-20

DTC Table
BENM23K11104004
DTC DTC name DTC detecting condition
— C00 None —
P0335 C12 (Page The signal does not reach ECM for 1 sec. or more,
CKP Sensor “A” Circuit
1A-24) after receiving the IAP sensor signal.
P0105 C13 (Page IAP Sensor Circuit • The IAP sensor vacuum hose has come off.
P0106 1A-26) • The sensor output voltage is higher than 4.85 V. /
P0107 The sensor output voltage is lower than 0.2 V.
P0120 C14 (Page TP Sensor/Switch “A” Circuit The sensor output voltage is higher than 4.8 V. /
P0123 1A-28) The sensor output voltage is lower than 0.2 V.
P0115 C15 (Page ECT Sensor Circuit The sensor signal voltage is higher than 4.85 V. /
P0117 1A-30) The sensor signal voltage is lower than 0.1 V.
P0500 • The speed sensor signal is not input to ECM
even if engine speed is more than 4000 rpm and
• Vehicle Speed Sensor “A”
C16 (Page throttle valve is open.
1A-31) • Front Wheel Speed Sensor (with
• The ABS control unit / hydraulic unit is not input
ABS)
front wheel speed sensor signal to ECM for more
than 2.5 sec.
P0110 C21 (Page IAT Sensor 1 Circuit The sensor signal voltage is higher than 4.85 V. /
P0112 1A-36) The sensor signal voltage is lower than 0.2 V.
P1700 C23 (Page TO sensor circuit Low/High The sensor signal voltage is higher than 4.7 V. / The
P1701 1A-38) sensor signal voltage is lower than 0.2 V.
P0351 C24 (Page Ignition Coil “A” Primary/Secondary The ignition coil signal is interrupted 8 times or
1A-40) Circuit more continually although CKP signal is detected.
P0201 C32 (Page Faulty fuel injector signal is detected 4 times or
Injector Circuit/Open
1A-40) more.
P0505 C40 (Page ISC system circuit malfunction The circuit voltage of motor drive unusual
1A-41)
P0230 Voltage is applied to fuel pump although fuel pump
C41 (Page
Fuel Pump Circuit Low/High is turned OFF. / No voltage is applied to fuel pump
1A-43)
although fuel pump is turned ON.
P1610 C42 (Page Ignition Switch Signal Circuit Ignition switch signal is not input to the ECM or
1A-44) Keyless Control Module.
P0130 C44 (Page O2 Sensor Circuit Bank 1 Sensor 1 O2 sensor output voltage is not input to ECM during
P0131 1A-45) engine operation and running condition.
P0132
P0170 C45 (Page Fuel Trim Bank 1 The fuel trim correction is out of its threshold value.
1A-47)
P0418 C61 (Page • PAIR System Control “A” Circuit • No voltage is input to ECM even though the PAIR
1A-49) control solenoid valve is OFF.

P2258 • PAIR System Control “A” Circuit • Voltage is input to ECM even though the PAIR
High control solenoid valve is ON.
P0480 C60 (Page Cooling fan relay drive circuit voltage is not applied
Fan 1 Control Circuit
1A-52) to the ECM for 3 sec.
P0443 C62 (if • EVAP System Purge Control EVAP system purge control solenoid valve does not
P0449 equipped) Valve Circuit (if equipped) operate although the command is sent.
(Page 1A- • EVAP System Vent Valve /
54) Solenoid Circuit
P0506 C65 (if ISC System RPM Lower Than Idle speed dropped lower than desired idle speed
equipped) Expected by more than specified range.
P0507 (Page 1A- ISC System RPM Higher Than Idle speed rose higher than desired idle speed by
57) Expected more than specified range.

P2158 C91 (Page Rear wheel speed sensor (with “Rear wheel speed sensor signal is not input to ABS
1A-34) ABS) control/hydraulic unit (with ABS)”
1A-21 Engine General Information and Diagnosis:

Fail-Safe Function Table

BENM23K11104005
FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum
performance necessary even under malfunction condition.
Item Fail-safe mode Starting ability Running ability
CMP sensor When camshaft position signal has failed during running, “NO” “YES”
the ECM determines cylinder before occurrence of such
a failure.
• ECM controls actuators assuming that intake air
pressure is 101.3 kPa (760 mmHg).
IAP sensor • ECM calculates basic fuel injection time from engine “YES” “YES”
speed and TP.
• ECM stops A/F feedback (closed loop) control.
• ECM controls actuators assuming that TP is 105.6°.
TP sensor “YES” “YES”
• ECM stops A/F feedback (closed loop) control.
• ECM controls actuators assuming that ECT is 60 °C
ECT sensor (140 °F). “YES” “YES”
• ECM stops A/F feedback (closed loop) control.
• ECM controls actuators assuming that IAT is 25 °C (77
IAT sensor °F). “YES” “YES”
• ECM stops A/F feedback (closed loop) control.
O2 sensor ECM stops A/F feedback (closed loop) control. “YES” “YES”
TO sensor ECM stops fuel injection, ignition and fuel pump. “NO” “NO”
ISC valve When motor disconnection or lock occurs, power from “YES” “YES”
ECM is shut OFF.
Ignition signal Fuel-cut “YES” “YES”
Gear position signal Gear position signal is fixed the position before “YES” “YES”
occurrence of failure.
Cooling fan relay ECM stops controlling cooling fan relay. “YES” “YES”
PAIR control solenoid ECM stops controlling PAIR control solenoid valve (if “YES” “YES”
valve (if equipped) equipped).
EVAP system purge ECM stops controlling EVAP system purge control
control solenoid valve solenoid valve (if equipped). “YES” “YES”
(if equipped)
Front vehicle speed Front vehicle speed is fixed to 0 km/h (0mile/h) (with
“YES” “YES”
sensor (with ABS) ABS).
Rear vehicle speed Rear vehicle speed is fixed to 0 km/h (0mile/h) (with
“YES” “YES”
sensor (with ABS) ABS)

NOTE
The engine can start and can run even if the signal in the table is not received from each sensor. But,
the engine running condition is not complete, providing only emergency help (by fail-safe circuit). In
this case, it is necessary to bring the motorcycle to the workshop for complete repair.
 Engine General Information and Diagnosis: 1A-22

FI System Troubleshooting
BENM23K11104006
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 following will facilitate collecting information to the point required for proper
analysis and diagnosis.

NOTE
This form is a standard sample. The form should be modified according to conditions and
characteristics of each market.

Example: Customer problem inspection form

User name: Model: VIN:
Date of issue: Date Reg.: Date of problem: Mileage:

MIL condition □ Always ON / □ Sometimes ON / □ Always OFF / □ Good condition

Malfunction display/code User mode: □ No display / □ Malfunction display ( )
(LCD) Dealer mode: □ No code / □ Malfunction code ( )

PROBLEM SYMPTOMS
□ Difficult Starting □ Poor Driveability
□ No cranking □ Hesitation on acceleration
□ No initial combustion □ Back fire / □ After fire
□ No combustion □ Lack of power
□ Poor starting at □ Surging
(□ cold / □ warm / □ always) □ Abnormal knocking
□ Other □ Engine rpm jumps briefly
□ Other

□ Poor Idling □ Engine Stall when

□ Poor fast Idle □ Immediately after start
□ Abnormal idling speed □ Throttle valve is opened
(□ High / □ Low) ( r/min) □ Throttle valve is closed
□ Unstable □ Load is applied
□ Hunting ( r/min to r/min) □ Other
□ Other

□ OTHERS:

MOTORCYCLE/ENVIRONMENTAL CONDITION WHEN PROBLEM OCCURS

Environmental condition
Weather □ Fair / □ Cloudy / □ Rain / □ Snow / □ Always / □ Other
Temperature □ Hot / □ Warm / □ Cool / □ Cold (°C / °F) / □ Always
Frequency □ Always / □ Sometimes (times / day, month) / □ Only once
□ Under certain condition
Road □ Urban / □ Suburb / □ Highway / □ Mountainous (□ Uphill / □ Downhill)
□ Tarmacadam / □ Gravel / □ Other
Motorcycle condition
Engine condition □ Cold / □ Warming up phase / □ Warmed up / □ Always / □ Other at starting
□ Immediately after start / □ Racing without load / □ Engine speed ( r/min)
Motorcycle condition During driving: □ Constant speed / □ Accelerating / □ Decelerating
□ Right hand corner / □ Left hand corner
□ At stop / □ Motorcycle speed when problem occurs ( km/h, mile/h)
□ Other:
1A-23 Engine General Information and Diagnosis:

Visual Inspection
Prior to diagnosis using the mode select switch, SDS-II, or OBD (for Oceania and Europe model) perform the following
visual inspections. The reason for visual inspection is that mechanical failures (such as oil leakage) cannot be
displayed on the screen with the use of mode select switch, SDS-II, or OBD (for Oceania and Europe model).
Inspection item Referring section
Level “Engine Oil Inspection” in Section 1E
Engine oil
Leakage (Page 1E-5)
“Engine Coolant Level Inspection” in
Level
Section 1F (Page 1F-4)
Engine coolant
“Engine Cooling System Inspection” in
Leakage
Section 1F (Page 1F-6)
Level —
Fuel “Fuel Feed Hose Inspection” in
Leakage
Section 1G (Page 1G-5)
Dirt “Air Cleaner Element Inspection” in
Air cleaner element
Clogging Section 1D (Page 1D-9)
“Battery Visual Inspection” in Section
Battery Corrosion of terminal
1J (Page 1J-13)
“Throttle Cable Play On-Vehicle
Throttle cable Play Inspection and Adjustment” in Section
1D (Page 1D-12)
Disconnection —
Vacuum hoses of air intake system Looseness —
Bend —
Fuses Burning —
MIL Operation “Self-Diagnosis Function” (Page 1A-4)
Each indicator light Operation “Combination Meter On-Vehicle
Inspection” in Section 9C (Page 9C-3)
Combination meter Operation “Combination Meter On-Vehicle
Inspection” in Section 9C (Page 9C-3)
Leakage of exhaust gas “Exhaust System Inspection” in
Exhaust system
Noise Section 1K (Page 1K-4)
Disconnection
Harness coupler
Poor contact
 Engine General Information and Diagnosis: 1A-24

DTC P0335 (C12): CKP Sensor “A” Circuit

BENM23K11104007
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
The CKP sensor signal does not reach ECM for 1 sec. • Metal particles or foreign material being stuck on the CKP
or more, after receiving the IAP sensor signal. sensor and rotor tip
• CKP sensor
• CKP sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8).

B Dg T33

2 1

G B/Br T21

IH23K1110009-01

1. CKP sensor 2. Generator 3. ECM

Troubleshooting – Between B/Br wire and ground: infinity

Step 1
CKP sensor signal circuit and ground circuit check
1) Turn the ignition switch OFF.
2) Disconnect the CKP sensor coupler and ECM
coupler.
• CKP sensor: (Page 1C-11)
• ECM: (Page 1C-2) IG12K1110015-01

3) Check for proper terminal connection to the CKP – Between the Dg wire terminal and B/Br wire
sensor coupler and ECM coupler. terminal at CKP sensor coupler: infinity
4) If connections are OK, check the following points.
• Resistance
– Dg wire and B/Br wire: less than 1 Ω

IG12K1110016-01

• Voltage
– Turn the ignition switch ON.
– Dg wire and B/Br wire: approx. 0 V
Is check result OK?

Yes Go to Step 2.

No Repair or replace the defective wire

harness.
T21
T33

IH23K1110017-01

– Between Dg wire and ground: infinity

1A-25 Engine General Information and Diagnosis:

Step 2
CKP sensor resistance check
1) Turn the ignition switch OFF.
2) Check the CKP sensor resistance. Refer to “CKP
Sensor Resistance” under “CKP Sensor
Inspection” in Section 1C (Page 1C-10).
Is check result OK?

Yes Go to Step 3.

No Replace the CKP sensor with a new one.

(Page 1C-10)

Step 3
CKP sensor peak voltage check
1) Connect the ECM coupler.
2) Check the CKP sensor peak voltage with the peak
volt adapter. Refer to “CKP Sensor Peak Voltage”
under “CKP Sensor Inspection” in Section 1C
(Page 1C-10).
Is check result OK?

Yes Go to Step 4.

No Replace the CKP sensor with a new one.

(Page 1C-10)

Step 4
CKP sensor and generator rotor check
1) Turn the ignition switch OFF.
2) Remove the generator cover. Refer to “Generator
Removal” in Section 1J (Page 1J-5).
3) Check that end face of the CKP sensor (1) and
generator rotor teeth (2) are free from any metal
particles and damage.

2
1

IG12K1110017-01

Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-2)

No Clean or replace defective parts.

 Engine General Information and Diagnosis: 1A-26

DTC P0105 / P0106 / P0107 (C13): IAP Sensor Circuit

BENM23K11104008
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
The sensor output voltage is higher than 4.85 V. / The • Vacuum passage between throttle body and IAP sensor
sensor output voltage is lower than 0.2 V. • IAP sensor
• IAP sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8).

1 5

R T8
2 WP T11

3 G/B T23

4 G T20
B/Br T21
IH23K4110029-01

1. IAP/TP/IAT sensor 3. IAP sensor 5. ECM

2. TP sensor 4. IAT sensor

Troubleshooting 6) Measure the voltage between the R wire and B/Br

wire.
Step 1
IAP sensor power supply circuit check IAP sensor power supply voltage
[Standard]: 4.75 – 5.25 V
1) Turn the ignition switch OFF.
2) Remove the following parts.
a) Under cowling: (Page 9D-26)
b) Front box: (Page 9D-29)
c) Right frame cover: (Page 9D-31)
3) Disconnect the IAP/TP/IAT sensor coupler (1).
V
IF42J1110014-01

Is check result OK?

Yes Go to Step 3.

1 No Go to Step 2.

IH23K1110012-03

4) Check for proper terminal connection to the IAP/

TP/IAT sensor coupler.
5) If connections are OK, turn the ignition switch ON.
1A-27 Engine General Information and Diagnosis:

Step 2 – G/B wire terminal and other terminal at IAP/

IAP sensor ground circuit check TP/IAT sensor coupler: infinity
1) Measure the voltage between the R wire and
ground.

V
IF42J1110018-01
IF42J1110015-01
• Voltage
Is voltage same as Step 1? – Turn the ignition switch ON.
Yes Repair or replace the B/Br wire. – G/B wire: approx. 0 V

No Repair or replace the R wire.

Step 3
IAP sensor signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler. (Page 1C-2) V
3) Check for proper terminal connection to the ECM
IF42J1110019-01
coupler.
4) If connections are OK, check the following points. Is check result OK?
• Resistance Yes Go to Step 4.
– G/B wire: less than 1 Ω
No Repair or replace the G/B wire.

Step 4
IAP sensor output voltage at idle speed check
1) Turn the ignition switch OFF.
2) Connect the ECM coupler and IAP/TP/IAT sensor
coupler.
3) Run the engine at idle speed and check the IAP
sensor voltage between the Br wire and B/Br wire.
Refer to “IAP Sensor Output Voltage” under “IAP/
TP/IAT Sensor Inspection” in Section 1C (Page
1C-3).
Is check result OK?
T23
Yes Replace the ECM with a known good one,
IH23K4110032-01 and inspect it again. (Page 1C-2)
– Between G/B wire and ground: infinity
No Replace the throttle body assembly with a
new one. (Page 1D-13)

IF42J1110017-01
 Engine General Information and Diagnosis: 1A-28

DTC P0120 / P0123 (C14): TP Sensor/Switch “A” Circuit

BENM23K11104009
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
The sensor output voltage is higher than 4.8 V. / The • TP sensor
sensor output voltage is lower than 0.2 V. • TP sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8).

1 5

R T8
2 WP T11

3 G/B T23

4 G T20
B/Br T21
IH23K4110031-01

1. IAP/TP/IAT sensor 3. IAP sensor 5. ECM

2. TP sensor 4. IAT sensor

Troubleshooting 6) Measure the voltage between the R wire and B/Br

wire.
Step 1
TP sensor power supply circuit check TP sensor power supply voltage
[Standard]: 4.75 – 5.25 V
1) Turn the ignition switch OFF.
2) Remove the following parts.
a) Under cowling: (Page 9D-26)
b) Front box: (Page 9D-29)
c) Right frame cover: (Page 9D-31)
3) Disconnect the IAP/TP/IAT sensor coupler (1).
V
IF42J1110014-01

Is check result OK?

Yes Go to Step 3.

1 No Go to Step 2.

IH23K1110012-03

4) Check for proper terminal connection to the IAP/

TP/IAT sensor coupler.
5) If connections are OK, turn the ignition switch ON.
1A-29 Engine General Information and Diagnosis:

Step 2 – Between WP wire terminal and other

TP sensor ground circuit check terminal at IAP/TP/IAT sensor coupler:
infinity
1) Measure the voltage between the R wire and
ground.

V
IF42J1110034-01
IF42J1110015-01 • Voltage
Is voltage same as Step 1? – Turn the ignition switch ON.
– WP wire: approx. 0 V
Yes Repair or replace the B/Br wire.

No Repair or replace the R wire.

Step 3
TP sensor signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler. (Page 1C-2) V
3) Check for proper terminal connection to the ECM
IF42J1110035-01
coupler.
4) If connections are OK, check the following points. Is check result OK?
• Resistance Yes Go to Step 4.
– WP wire: less than 1 Ω
No Repair or replace the WP wire.

Step 4
TP sensor output voltage check
1) Turn the ignition switch OFF.
2) Connect the ECM coupler and the IAP/TP/IAT
sensor coupler.
3) Turn the ignition switch ON.
4) Check the TP sensor voltage between the WP
wire and B/Br wire with turning the throttle grip
open and close. Refer to “TP Sensor Output
Voltage” under “IAP/TP/IAT Sensor Inspection” in
T11 Section 1C (Page 1C-3).
Is check result OK?
IH23K4110033-01
Yes Replace the ECM with a known good one,
– Between WP wire and ground: infinity and inspect it again. (Page 1C-2)

No Replace the throttle body assembly with a

new one. (Page 1D-13)

IF42J1110033-01
 Engine General Information and Diagnosis: 1A-30

DTC P0115 / P0117 (C15): ECT Sensor Circuit

BENM23K11104010
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
The sensor signal voltage is higher than 4.85 V. / The • ECT sensor
sensor signal voltage is lower than 0.1 V. • ECT sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8).

2
1

B/L T6

B/Br T21

IH23K4110034-01

1. ECT sensor 2. ECM

Troubleshooting – Between B/L wire and ground: infinity

– Between B/Br wire and ground: infinity
Step 1
ECT sensor signal circuit and ground circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler and ECT sensor
coupler.
• ECM: (Page 1C-2)
• ECT sensor: (Page 1C-7)
3) Check for proper terminal connection to the ECM
coupler and ECT sensor coupler.
4) If connections are OK, check the following points.
IF42J1110029-01
• Resistance
– Between B/L wire terminal and B/Br wire
– B/L wire and B/Br wire: less than 1 Ω terminal: infinity

IF42J1110030-01

T6
T21

IH23K4110036-01
1A-31 Engine General Information and Diagnosis:

• Voltage Step 2
– Turn the ignition switch ON. ECT sensor resistance check
– B/L wire and B/Br wire: approx. 0 V 1) Turn the ignition switch OFF.
2) Check the ECT sensor resistance. (Page 1C-7)
Is check result OK?

Yes Replace the ECM with a known good one,

V and inspect it again. (Page 1C-2)

No Replace the ECT sensor with a new one.

(Page 1C-7)
V
IF42J1110031-01

Is check result OK?

Yes Go to Step 2.

No Repair or replace the defective wire

harness.

DTC P0500 (C16): Vehicle Speed Sensor “A”

BENM23K11104011
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
The speed sensor signal is not input to ECM even if • Metal particles or foreign material being stuck on the speed
engine speed is more than 4000 rpm and throttle valve sensor and drive shaft spline
is open. • Speed sensor
• Speed sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8).

3
2
1

P T22
B/W

IH23K4110035-01

1. Speed sensor 2. ECM 3. Speedometer

 Engine General Information and Diagnosis: 1A-32

Troubleshooting Step 3
Speed sensor signal circuit check
Step 1
Speed sensor power supply circuit check 1) Turn the ignition switch OFF.
1) Turn the ignition switch OFF. 2) Disconnect the ECM coupler. (Page 1C-2)
2) Disconnect the speed sensor coupler. (Page 3) Check for proper terminal connection to the ECM
1C-12) coupler.
3) Check for proper terminal connection to the speed 4) If connections are OK, check the following points.
sensor coupler. • Resistance
4) If connections are OK, turn the ignition switch ON. – P wire: less than 1 Ω
5) Measure the voltage between the R wire and B/W
wire.
Speed sensor power supply voltage
[Standard]: Battery voltage

IG12K1110024-01 T22
Is check result OK?
IH23K4110037-01

Yes Go to Step 3. – Between P wire and ground: infinity

No Go to Step 2.

Step 2
Speed sensor ground circuit check
1) Measure the voltage between the R wire and
ground.

IG12K1110027-02

– Between P wire terminal and other terminal

at speed sensor coupler: infinity

IG12K1110025-01

Is voltage same as Step 1?

Yes Repair or replace the B/W wire.

No Repair or replace the R wire.

If this DTC is detected again, replace the IG12K1110028-01
speedometer and recheck DTC.
1A-33 Engine General Information and Diagnosis:

• Voltage
– Turn the ignition switch ON.
– P wire: approx. 0 V

IG12K1110029-01

Is check result OK?

Yes Go to Step 4.

No Repair or replace the P wire.

Step 4
Speed sensor check
1) Turn the ignition switch OFF.
2) Remove the speed sensor. (Page 1C-12)
3) Check the speed sensor. (Page 1C-13)
Is check result OK?

Yes Go to Step 5.

No Replace the speed sensor. (Page 1C-

12)

Step 5
Driveshaft spline check
1) Remove the engine sprocket cover. Refer to
“Engine Sprocket Removal and Installation” in
Section 3A (Page 3A-4).
2) Check the driveshaft spline for metal particles or
foreign material.

IH23K1110013-01

Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-2)

No Clean or replace defective parts.

 Engine General Information and Diagnosis: 1A-34

DTC P0500 (C16): Front Wheel Speed Sensor (with ABS) / DTC P2158 (C91): Rear Wheel Speed
Sensor (with ABS)
BENM23K11104012
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
C16: Front Wheel Speed Sensor (with ABS) • Front wheel speed sensor circuit
The front wheel speed sensor signal is not input to • ABS control unit / hydraulic unit
ABS Control Unit / Hydraulic Unit
• ECM
C91: Rear Wheel Speed Sensor (with ABS) • Rear wheel speed sensor circuit
The rear wheel speed sensor signal is not input to ABS • ABS control unit / hydraulic unit
Control Unit / Hydraulic Unit.
• ECM

Refer to “FI System Wiring Diagram” (Page 1A-8)

2
1

W/R
B/R
T6 Gr/R T35
W/Y
B/Y

4
IH23K4110010-02

1. ABS control unit / hydraulic unit 3. Front wheel speed sensor

2. ECM 4. Rear wheel speed sensor

Troubleshooting

Step 1
ABS DTC Check
1) Check that DTC is detected in ABS. Refer to “DTC (Diagnostic Trouble Code) Output” in Section 4E (Page 4E-
17).
Is the DTC detected?

Yes Go to troubleshooting for DTC. Refer to “DTC Table” in Section 4E (Page 4E-21).

No Go to step 2.

Step 2
Front / Rear wheel speed sensor signal circuit check (From ABS control unit / hydraulic unit to ECM)
1) Turn the ignition switch OFF.
2) Disconnect the ABS control unit coupler and ECM couplers.
• ABS control unit / hydraulic unit. Refer to “ABS Control Unit / HU Removal and Installation” in Section 4E
(Page 4E-37)
• ECM refer to “ECM Removal and Installation” in Section 1C (Page 1C-2)
3) Check for proper terminal connection to the ABS control unit coupler and ECM couplers.
4) If connections are OK, check the following points.
1A-35 Engine General Information and Diagnosis:

• Resistance
– Gr/R ABS control unit / hydraulic unit wire: less than 1 Ω

T35

IH23K4110011-01

– Gr/R ABS control unit / hydraulic unit wire: infinity

T35

IH23K4110012-01

Is check result OK?

Yes Replace the ECM with a known good one, and inspect again. Refer to “ECM Removal and Installation”
in Section 1C (Page 1C-2)

No Repair or replace the defective wire harness.

 Engine General Information and Diagnosis: 1A-36

DTC P0110 / P0112 (C21): IAT Sensor 1 Circuit

BENM23K11104013
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
The sensor output voltage is higher than 4.85 V. / The • IAT sensor
sensor output voltage is lower than 0.2 V. • IAT sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8).

1 5

R T8
2 WP T11

3 G/B T23

4 G T20
B/Br T21
IH23K4110038-01

1. IAP/TP/IAT sensor 3. IAP sensor 5. ECM

2. TP sensor 4. IAT sensor
1A-37 Engine General Information and Diagnosis:

Troubleshooting – Between G wire terminal and B/Br wire

terminal at IAP/TP/IAT sensor coupler:
Step 1 infinity
IAT sensor signal circuit and ground circuit check
1) Turn the ignition switch OFF.
2) Remove the following parts.
a) Under cowling: (Page 9D-26)
b) Front box: (Page 9D-29)
c) Right frame cover: (Page 9D-31)
3) Disconnect the IAP/TP/IAT sensor coupler (1).
IF42J1110024-01

• Voltage
– Turn the ignition switch ON.
– G wire and B/Br wire: approx. 0 V

IH23K1110012-03

4) Disconnect the ECM coupler. (Page 1C-2) IF42J1110025-02

5) Check for proper terminal connection to the IAP/ Is check result OK?
TP/IAT sensor coupler and ECM coupler.
6) If connections are OK, check the following points. Yes Go to Step 2.
• Resistance No Repair or replace the defective wire
– G wire and B/Br wire: less than 1 Ω harness.

Step 2
IAT sensor resistance check
1) Turn the ignition switch OFF.
2) Check the IAT sensor resistance. Refer to “IAT
Sensor Resistance” under “IAP/TP/IAT Sensor
Inspection” in Section 1C (Page 1C-3).
Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-2)
T20
No Replace the throttle body assembly with a
T21 new one. (Page 1D-13)
IH23K4110039-01

– Between G wire and ground: infinity

– Between B/Br wire and ground: infinity

IF42J1110023-01
 Engine General Information and Diagnosis: 1A-38

DTC P1700 / P1701 (C23): TO Sensor Circuit Low/High

BENM23K11104014
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
The sensor signal voltage is higher than 4.7 V. / The • TO sensor
sensor signal voltage is lower than 0.2 V. • TO sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8).

R T8

Br T34

B/Br T21

IH23K4110040-01

1. TO sensor 2. ECM

Troubleshooting Step 2
TO sensor ground circuit check
Step 1
TO sensor power supply circuit check 1) Measure the voltage between the R wire and
ground.
1) Turn the ignition switch OFF.
2) Disconnect the TO sensor coupler. Refer to
(Page 1C-11)
3) Check for proper terminal connection to the TO
sensor coupler.
4) If connections are OK, turn the ignition switch ON.
V
5) Measure the voltage between the R wire and B/Br
wire. ID26J1110154-02

TO sensor power supply voltage Is voltage same as Step 1?

[Standard]: 4.5 – 5.5 V
Yes Repair or replace the B/Br wire.

No Repair or replace the R wire.

V
ID26J1110153-02

Is check result OK?

Yes Go to Step 3.

No Go to Step 2.
1A-39 Engine General Information and Diagnosis:

Step 3 • Voltage
TO sensor signal circuit check – Turn the ignition switch ON.
1) Turn the ignition switch OFF. – Br wire: approx. 0 V
2) Disconnect the ECM coupler. Refer to (Page
1C-2)
3) Check for proper terminal connection to the ECM
coupler.
4) If connections are OK, check the following points. V
• Resistance
– Br wire: less than 1 Ω ID26J1110158-02

Is check result OK?

Yes Go to Step 4.

No Repair or replace the Br wire.

Step 4
TO sensor output voltage check
1) Turn the ignition switch OFF.
2) Connect the ECM coupler and TO sensor coupler.
3) Check the TO sensor output voltage. Refer to “TO
Sensor Output Voltage” under “TO Sensor
Inspection” in Section 1C (Page 1C-11).
Is check result OK?

T34 Yes Replace the ECM with a known good one,

IH23K4110041-01
and inspect it again. Refer to (Page 1C-
2)
– Between Br wire and ground: infinity
No Replace the TO sensor with a new one.
Refer to (Page 1C-11)

ID26J1110156-03

– Between Br wire terminal and other terminal

at TO sensor coupler: infinity

ID26J1110157-03
 Engine General Information and Diagnosis: 1A-40

DTC P0351 (C24): Ignition Coil “A” Primary/Secondary Circuit

BENM23K11104015
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
The ignition coil signal is interrupted 8 times or more Refer to “No Spark or Poor Spark” in Section 1H (Page
continually although CKP signal is detected. 1H-2).

DTC P0201 (C32): Injector Circuit/Open

BENM23K11104016
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
Faulty fuel injector signal is detected 4 times or more. • Fuel injector
• Fuel injector circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8).

4
5

2
3
1

O/B

G/W T27

IH23K4110042-01

1. Fuel injector 3. Ignition switch 5. Main fuse

2. ECM 4. Regulator/rectifier

Troubleshooting Is check result OK?

Step 1 Yes Go to Step 2.

Fuel injector power supply voltage check
No Repair or replace the O/B wire.
1) Turn the ignition switch OFF.
2) Disconnect the fuel injector coupler. Refer to “Fuel Step 2
Injector Removal and Installation” in Section 1G Fuel injector drive circuit check
(Page 1G-14). 1) Turn the ignition switch OFF.
3) Check for proper terminal connection to the fuel 2) Disconnect the ECM coupler. (Page 1C-2)
injector coupler. 3) Check for proper terminal connection to the ECM
4) If connections are OK, turn the ignition switch ON. coupler.
5) Measure the voltage between the O/B wire and
ground.
Fuel injector power supply voltage
[Standard]: Battery voltage

IF04K1110023-01
1A-41 Engine General Information and Diagnosis:

4) If connections are OK, check the following points. – Between G/W wire terminal and O/B wire
• Resistance terminal at fuel injector coupler: infinity
– G/W wire: less than 1 Ω

IF04K1110032-01

• Voltage
– Turn the ignition switch ON.
– G/W wire: approx. 0 V

T27 IF04K1110033-01

IH23K4110043-01 Is check result OK?

– Between G/W wire and ground: infinity
Yes Go to Step 3.

No Repair or replace the G/W wire.

Step 3
Fuel injector resistance check
IF04K1110031-01 1) Turn the ignition switch OFF.
2) Check the fuel injector resistance. (Page 1G-13)
Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-2)

No Replace the fuel injector with a new one.

(Page 1G-14)

DTC P0505 (C40): ISC Valve Circuit Malfunction

BENM23K11104017
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
The circuit voltage of motor drive is unusual. • ISC valve circuit.
• ECM malfunction.

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8)

1 2

Sb T36

B/Lg T24

Lg T12

Y/R T10
IM23K1110013-08

1. ISC Valve 2. ECM

 Engine General Information and Diagnosis: 1A-42

Troubleshooting

Step 1
ISC Valve circuit open or shorted to ground
1) Turn ignition switch OFF.
2) Disconnect ISC valve coupler. Refer to “ISC Valve Removal and Installation” in Section 1C (Page 1C-5)
3) Check ISC valve coupler.
4) If OK, then check the ISC valve resistance. Measure the ISC valve resistance between terminal A and terminal
B, terminal C and terminal D.
ISC valve resistance
[Standard]: Approx. 20 Ω at 20 °C

IH23K2110004-01

5) If OK, then check the ISC valve continuity.

ISC valve continuity
[Standard]: Infinity
Is check result OK?

Yes Go to step 2.

No Replace ISC valve with a new one.

Step 2
ECM malfunction check
Are the resistance and continuity OK?

Yes • Wire open or shorted to ground

• Intermittent trouble or faulty ECM.
• Recheck each terminal and wire harness for open circuit and poor connection.
• Replace ECM with a known good one, and inspect it again.

No Replace ISC valve with a new one.

1A-43 Engine General Information and Diagnosis:

DTC P0230 (C41): Fuel Pump Circuit Low/High

BENM23K11104018
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
Voltage is applied to fuel pump although fuel pump is • Fuel pump
turned OFF. / No voltage is applied to fuel pump • Fuel pump circuit
although fuel pump is turned ON.
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8).

1 Y/R T17

3 5
O/B Y/B 4 R

IH23K4110046-01

1. Fuel pump 3. Ignition switch 5. Main fuse

2. ECM 4. Regulator/rectifier 6. Battery

Troubleshooting Step 2
Fuel pump drive circuit check
Step 1
Fuel pump power supply voltage check 1) Turn the ignition switch OFF.
1) Turn the ignition switch OFF. 2) Disconnect the ECM coupler. Refer to (Page
1C-2)
2) Disconnect the fuel pump coupler. Refer to “Fuel
Pump Assembly Removal and Installation” in 3) Check for proper terminal connection to the ECM
Section 1G (Page 1G-10). coupler.
3) Check for proper terminal connection to the fuel 4) If connections are OK, check the following points.
pump coupler. • Resistance
4) If connections are OK, turn the ignition switch ON. – Y/R wire: less than 1 Ω
5) Measure the voltage between the O/B wire and
ground.
Fuel pump power supply voltage
[Standard]: Battery voltage

T17
IF42J1110044-01

Is check result OK? IH23K4110048-01

Yes Go to Step 2.

No Repair or replace the O/B wire.

 Engine General Information and Diagnosis: 1A-44

– Between Y/R wire and ground: infinity • Voltage

– Turn the ignition switch ON.
– Y/R wire: approx. 0 V

IF42J1110046-01

– Between Y/R wire terminal and other

terminal at fuel pump coupler: infinity IF42J1110048-01

Is check result OK?

Yes Go to Step 3.

No Repair or replace the Y/R wire.

Step 3
Fuel pump operation check
1) Turn the ignition switch OFF.
IF42J1110047-01
2) Check the fuel pump operation. Refer to (Page
1G-4)
Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. Refer to (Page 1C-
2)

No Replace the fuel pump with a new one.

Refer to (Page 1G-10)

DTC P1610 (C42): Ignition Switch Circuit Malfunction

BENM23K11104019
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
Ignition switch signal is not input to the ECM or Keyless • Ignition switch circuit
Control Unit • ECM or Keyless Control Module

Troubleshooting

NOTE
Refer to “Ignition Switch Inspection” in Section 1H (Page 1H-8)
1A-45 Engine General Information and Diagnosis:

DTC P0130 / P0131 / P0132 (C44): O2 Sensor Circuit Bank 1 Sensor 1

BENM23K11104020
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
O2 sensor output voltage is not input to ECM during • O2 sensor
engine operation and running condition. • O2 sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8).

B B/O T9
BW B/Br T21

IM23K1110007-10

1. O2 sensor 2. ECM

Troubleshooting – Between B/O wire and ground: infinity

Step 1
O2 sensor signal circuit check
1) Turn the ignition switch OFF.
2) Disconnect the O2 sensor coupler and the ECM
coupler.
• O2 sensor: Refer to (Page 1C-8) IG12K1110038-02

• ECM: Refer to (Page 1C-2) • Voltage

3) Check for proper terminal connection to the O2 – Turn the ignition switch ON.
sensor coupler and the ECM coupler. – B/O wire: approx. 0 V
4) If connections are OK, check the following points.
• Resistance
– B/O wire: less than 1 Ω

IG12K1110039-02

Is check result OK?

Yes Go to Step 2.

No Repair or replace the B/O wire.

T9

IH23K4110050-01
 Engine General Information and Diagnosis: 1A-46

Step 2 Step 3
O2 sensor ground circuit check O2 sensor output voltage check
1) Check the following points. 1) Turn the ignition switch OFF.
• Resistance 2) Connect the ECM coupler.
– B/Br wire: less than 1 Ω 3) Warm up the engine enough.
4) Measure the O2 sensor voltage between the B/O
wire terminal and B/Br wire terminal, in idling
condition. Refer to (Page 1C-8)
Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. Refer to (Page 1C-
2)

No Replace the O2 sensor with a new one.

Refer to (Page 1C-8)

T21

IH23K4110053-01

– Between B/Br wire and ground: infinity

IG12K1110041-02

– Between B/Br wire terminal and B/O wire

terminal at O2 sensor coupler: infinity

IG12K1110042-02

• Voltage
– Turn the ignition switch ON.
– B/Br wire: approx. 0 V

IG12K1110043-02

Is check result OK?

Yes Go to Step 3.

No Repair or replace the B/Br wire.

1A-47 Engine General Information and Diagnosis:

DTC P0170 (C45): Fuel Trim Bank 1

BENM23K11104021
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
The fuel trim correction is out of its threshold value. • Fuel system
• Air intake system
• Exhaust system
• Emission control system
• O2 sensor / O2 sensor circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8).

3 4 5
T9 B/O B/Br

B/Br 6
B/O

2
IM23K1110008-10

1. ECM 3. Engine stop switch 5. Main fuse

2. O2 sensor 4. Ignition switch 6. Battery

Troubleshooting

Step 1
Fuel system and emission control system check
1) Check the following points related to fuel and emission control systems.
• Fuel pressure: (Page 1G-4).
• Fuel injector circuit: Refer to “Wiring Diagram” under “DTC P0201 (C32): Injector Circuit/Open” (Page 1A-40).
• Fuel injector: (Page 1G-15).
• IAP sensor: (Page 1C-3).
• PAIR system: (Page 1C-3).
• EVAP control system (if equipped): (Page 1B-15).
• PCV hose: (Page 1B-13).
Is check result OK?

Yes Go to step 2.

No Repair or replace defective parts.

 Engine General Information and Diagnosis: 1A-48

Step 2
Exhaust system and air intake system check
1) Check exhaust system and air intake system for clogging and leakage.
• Exhaust system: (Page 1K-4)
• Air intake system:

IH23K5110014-01

Is check result OK?

Yes Go to step 3.

No Repair or replace defective parts.

Step 3
O2 sensor circuit check
1) Check O2 sensor circuit. Refer to “Step 1” under “DTC P0130 / P0131 / P0132 (C44): O2 Sensor Circuit Bank 1
Sensor 1” (Page 1A-45).
Is check result OK?

Yes Go to step 4.

No Repair or replace defective wire harness.

Step 4
DTC recheck
1) Replace the O2 sensor. (Page 1C-8)
2) Perform “DTC Check” (Page 1A-18) and check DTC.
Is DTC P0170 (C45) still detected?

Yes Replace the ECM with a known good one, and inspect it again. (Page 1C-2)

No End.
1A-49 Engine General Information and Diagnosis:

DTC P0418 (C49): PAIR System Control “A” Circuit (If Equipped)
BENM23K11104022
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
PAIR control solenoid valve does not operate although • PAIR control solenoid valve
the command is sent. • PAIR control solenoid valve circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8).

3 4 5
T4 W/G O/B

IH23K4110013-01

1. ECM 3. Engine stop switch 5. Main fuse

2. PAIR control solenoid valve 4. Ignition switch 6. Battery

Troubleshooting

Step 1
PAIR control solenoid valve power supply voltage check
1) Turn the ignition switch OFF.
2) Disconnect the PAIR control solenoid valve coupler. Refer to “PAIR Control Solenoid Valve Removal and
Installation (If Equipped)” in Section 1B (Page 1B-11)
3) Check for proper terminal connection to the PAIR control solenoid valve coupler.
4) If connections are OK, turn the ignition switch ON.
5) Measure the voltage between the W/G or O/B wire and ground.
PAIR control solenoid valve power supply voltage
[Standard]: Battery voltage

V
IH23K4110014-01

Is check result OK?

Yes Go to step 2.

No Repair or replace the W/G or O/B wire.

 Engine General Information and Diagnosis: 1A-50

Step 2
PAIR control solenoid valve driver circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM couplers. “ECM Removal and Installation” in Section 1C (Page 1C-2)
3) Check for proper terminal connection to the ECM couplers.
4) If connections are OK, check the following points.
• Resistance
– W/G wire: less than 1 Ω

T4

IH23K4110015-01

– Between W/G wire and ground: infinity

IH23K4110016-01

– Between W/G wire terminal and O/B wire terminal at PAIR control solenoid valve coupler: infinity

IH23K4110017-01

• Voltage
– Turn the ignition switch ON.
– W/G wire: approx. 0 V

V
IH23K4110018-01
1A-51 Engine General Information and Diagnosis:

Is check result OK?

Yes Go to Step 3.

No Repair or replace the W/G wire.

Step 3
PAIR control solenoid valve resistance check
1) Turn the ignition switch OFF.
2) Measure the PAIR control solenoid valve resistance. Refer to “PAIR Control Solenoid Valve” under “PAIR
System Inspection (If Equipped)” in Section 1B (Page 1B-12)
PAIR control solenoid valve resistance
Approx. 18 – 22 Ω at 20°C (68°F)
(Terminal - Terminal)

IH23K4110019-01

Is check result OK?

Yes Replace the ECM with a known good one, and inspect it again. Refer to “ECM Removal and Installation”
in Section 1C (Page 1C-2)

No Replace the PAIR control solenoid valve with a new one. Refer to “PAIR Reed Valve Removal and
Installation (If Equipped)” in Section 1B (Page 1B-11)
 Engine General Information and Diagnosis: 1A-52

DTC P0480 (C60): Fan 1 Control Circuit

BENM23K11104023
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
Cooling fan relay drive circuit voltage is not applied to • Cooling fan relay circuit
the ECM for 3 sec. • ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8).

1
7 OB Y/W T13

5 4
6
3

IH23K4110052-01

1. Cooling fan relay 4. Fan fuse 7. To sub relay

2. ECM 5. Main fuse
3. Cooling fan motor 6. Battery

Troubleshooting 4) Check for proper terminal connection to the

cooling fan relay.
Step 1 5) If connections are OK, turn the ignition switch ON.
Cooling fan relay power supply circuit check
6) Measure the voltage between OB wire and
1) Turn the ignition switch OFF. ground.
2) Open the passenger seat.
Cooling fan relay power supply voltage
3) Disconnect the cooling fan relay (1). [Standard]: Battery voltage

IG12K1110046-02

Is check result OK?

IH23K4110009-02 Yes Go to Step 2.

No Repair or replace the OB wire.

1A-53 Engine General Information and Diagnosis:

– Between Y/W wire terminal and other

Step 2
terminal at cooling fan relay coupler: Infinity
Cooling fan relay drive circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM coupler. (Page 1C-2)
3) Disconnect the sub relay (1).

1 IG12K1110050-03

• Voltage
– Turn the ignition switch ON.
– Y/W wire: approx. 0 V

IK23K4110009-01

4) Check for proper terminal connection to the ECM

coupler.
5) If connections are OK, check the following points.
IG12K1110051-02
• Resistance
Is check result OK?
– Y/W wire: less than 1 Ω
Yes Go to Step 3.

No Repair or replace the Y/W wire.

Step 3
Cooling fan relay check
1) Check the cooling fan relay. (Page 1F-12)
Is check result OK?

Yes Replace the ECM with a known good one,

and inspect it again. (Page 1C-2)

No Replace the cooling fan relay with a new

one.

T13

IH23K4110054-01

– Between Y/W wire and ground: infinity

IG12K1110049-04
 Engine General Information and Diagnosis: 1A-54

DTC P0443 / P0449 (C62): EVAP System Purge Control Valve Circuit (If Equipped)
BENM23K11104024
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
EVAP system purge control solenoid valve does not • EVAP system purge control solenoid valve
operate although the command is sent. • EVAP system purge control solenoid valve circuit
• ECM

Wiring Diagram
Refer to “FI System Wiring Diagram” (Page 1A-8)

3 4 5
T29 P/W O/B

IH23K4110020-01

1. ECM 3. Engine stop switch 5. Main fuse

2. PAIR control solenoid valve 4. Ignition switch 6. Battery

Troubleshooting

Step 1
EVAP system purge control solenoid valve power supply voltage check
1) Turn the ignition switch OFF.
2) Disconnect the EVAP system purge control solenoid valve coupler. Refer to “EVAP Control System Removal
and Installation (If Equipped)” in Section 1B (Page 1B-13)
3) Check for proper terminal connection to the EVAP system purge control solenoid valve coupler.
4) If connections are OK, turn the ignition switch ON.
5) Measure the voltage between the P/W or O/B wire and ground.
EVAP system purge control solenoid valve power supply voltage (If equipped)
[Standard]: Battery voltage

V
IH23K4110021-01

Is check result OK?

Yes Go to Step 2.

No Repair or replace the P/W or O/B wire.

1A-55 Engine General Information and Diagnosis:

Step 2
EVAP system purge control solenoid valve driver circuit check
1) Turn the ignition switch OFF.
2) Disconnect the ECM couplers. Refer to “ECM Removal and Installation” in Section 1C (Page 1C-2)
3) Check for proper terminal connection to the ECM couplers.
4) If connections are OK, check the following points.
• Resistance
– P/W wire: less than 1 Ω

T29

IH23K4110022-01

– Between P/W wire and ground: infinity

IH23K4110023-01

– Between G wire terminal and W/R wire terminal at EVAP system purge control solenoid valve coupler:
infinity

IH23K4110024-01
 Engine General Information and Diagnosis: 1A-56

• Voltage
– Turn the ignition switch ON.
– G wire: approx. 0 V.

V
IH23K4110025-01

Is check result OK?

Yes Go to Step 3.

No Repair or replace the P/W wire.

Step 3
EVAP system purge control solenoid valve resistance check
1) Turn the ignition switch OFF.
2) Measure the EVAP system purge control solenoid valve resistance. Refer to “EVAP System Purge Control
Solenoid Valve” under “EVAP Control System Removal and Installation (If Equipped)” in Section 1B (Page 1B-
13)
EVAP system purge control solenoid valve resistance
Approx. 20 – 24 Ω at 20°C (68°F)
(Terminal - Terminal)

IH23K4110026-01

Is check result OK?

Yes Replace the ECM with a known good one, and inspect it again. Refer to “ECM Removal and Installation”
in Section 1C (Page 1C-2).

No Replace the EVAP system purge control solenoid valve with a new one. Refer to “EVAP Control System
Removal and Installation (If Equipped)” in Section 1B (Page 1B-13).
1A-57 Engine General Information and Diagnosis:

DTC P0506 / P0507 (C65): ISC System Malfunction

BENM23K11104025
DTC Detecting Condition and Trouble Area
DTC detecting condition Trouble area
Idle speed rose higher than or dropped lower than • Air passage clogged.
desired idle speed by more than specified range. • ISC valve is fixed.
• ISC malfunction.
• Air leakage.

Troubleshooting

NOTICE
• Be careful not to disconnect the ISC valve coupler at least 5 seconds after ignition switch is turned
to OFF. If the ECM coupler is disconnected within 5 seconds after ignition switch is turned to OFF,
there is a possibility of an unusual value being written in the ECM and causing an error of ISC valve
operation.
• When using the multi-circuit tester, do not strongly touch the terminal of the ECM coupler with a
needle pointed tester probe to prevent terminal damage.

NOTE
After repairing the trouble, clear the DTC using SDS-II or OBD. Refer to (Page 1A-19)

Step 1
Engine combustion check
1) Run the engine at idle speed.
2) By spraying water to exhaust pipe, check evaporation from them to make sure for equal combustion from
cylinder.

IK23K4110001-02

Is check result OK?

Yes Go to step 2.

No Repair or replace defective part.

 Engine General Information and Diagnosis: 1A-58

Step 2
ISC valve initial check
1) Turn the ignition or main switch OFF.
2) Remove the ISC valve. Refer to (Page 1C-5)
3) Connect the ISC valve coupler (1).

IK23K4110006-01

4) Turn the ignition switch ON and then OFF again.

5) While performing above step 4), check that the ISC valve moves from fully open position to fully closed position.

IK23K4110007-01

6) Execute ISC Valve Preset and Opening Initialization. Refer to (Page 1C-6)
Is check result OK?

Yes Go to step 3.

No Replace the ISC valve with a new one. Refer to (Page 1C-5)
1A-59 Engine General Information and Diagnosis:

Step 3
Air intake system check
1) Check air intake system for clogging and leakage.

IK23K4110008-01

Is check result OK?

Yes Go to step 4.

No Repair or replace defective parts.

Step 4
Engine mechanical systems check
1) Check the following points related to engine mechanical system.
• Engine compression. Refer to (Page 1D-5)
• Fuel pressure. Refer to (Page 1G-4)
Is check result OK?

Yes Replace the ECM with a known good one, and inspect it again. Refer to (Page 1C-2)

No Repair or replace defective parts.

Special Tools and Equipment

Special Tool
BENM23K11108001
09904–41051 09930–82760
Conversion cable Mode selection switch
(Page 1A-5) (Page 1A-5) /
(Page 1A-7) /
(Page 1A-18) /
(Page 1A-18)
 Emission Control Devices: 1B-1

Emission Control Devices

Engine

Precautions
Precautions for Emission Control Devices
BENM23K11200001
Refer to “General Precautions” in Section 00 (Page 00-1).

General Description
Fuel Injection System Description
BENM23K11201001
GSX 125 motorcycles are equipped with a fuel injection system for emission level control. This fuel injection system is
precision designed, manufactured and adjusted to comply with the applicable emission limits. With varying engine
conditions, all of the fuel injection volumes are precisely controlled by the programmed injection maps in the ECM to
reduce CO, NOx and HC. Adjusting, interfering with, improper replacement, or resetting of any of the fuel injection
components may adversely affect injection performance and cause the motorcycle to exceed the exhaust emission
level limits.

3 1

5 2

4
5

[A]
[B]
[C]
IH23K4120002-02

[A]: Before-pressurized fuel 1. Fuel tank 4. Fuel mesh filter

[B]: Pressurized fuel 2. Fuel pump 5. Fuel feed hose
[C]: Relieved fuel 3. Fuel pressure regulator 6. Fuel injector
1B-2 Emission Control Devices:

Crankcase Emission Control System Description

BENM23K11201002
The engine is equipped with a PCV system. Blow-by gas in the engine is constantly drawn into the crankcase, which is
returned to the combustion chamber through the PCV (breather) hose (1), air cleaner (2) and throttle body (3).

[A]

[B]

[C]
[D]

IH23K4120003-02

[A]: Fresh air [B]: Fuel/Air mixture [C]: Blow-by gas [D]: Exhaust gas
 Emission Control Devices: 1B-3

Exhaust Emission Control System Description (If Equipped)

BENM23K11201003
The exhaust emission control system is composed of the PAIR system, O2 sensor, three-way catalyst system and ISC
system. The fresh air is drawn into the exhaust ports through the PAIR control solenoid valve and PAIR reed valve.
The PAIR control solenoid valve is operated by the ECM, which is controlled according to the signals from TP, ECT,
IAT, IAP and CKP sensors. ISC valve adjusts the bypass air volume of the throttle body to control engine idling speed
with various sensor signals by varying engine running conditions and the idling control contributes to reduce exhaust
emission level.

1
6

2
5
4

[A]
[B]

IH23K4120004-03

[A]: Fresh air 3. Air cleaner box 7. Three-way catalyst

[B]: Exhaust gas 4. Fuel injector 8. O2 sensor
1. PAIR control solenoid valve 5. ISC valve
2. PAIR reed valve 6. ECM
1B-4 Emission Control Devices:

Evaporative Emission Control System Diagram (If Equipped)

BENM23K11201004

[A] 15 [B]

[B] 13 [A] 8
[B] 13

3
4 14
8
10
13

[A]

1
9

11

2 [C]
12
[D]
[E]
IH23K4120005-03

[A]: GSX R 125 Model 3. Fuel shut-off valve 10. Fuel feed hose
[B]: GSX S 125 Model 4. Check valve 11. EVAP system purge control solenoid valve
[C]: Fuel 5. Fuel tank 12. Purge hose No.2
[D]: HC vapor 6. Fuel pump 13. Fuel tank breather hose
[E]: Fresh air 7. Purge hose No.1 14. Check valve drain hose
1. Throttle body 8. Surge hose 15. Fuel shut-off valve (fuel tank cap side)
2. Intake pipe 9. EVAP canister
 Emission Control Devices: 1B-5

Schematic and Routing Diagram

PAIR System Hose Routing Diagram (If Equipped)
BENM23K11202001

12

11

[D]

5 [C] 7
4 3
8
9

[A]
(a) (a)

4 6

2
10

FWD

7
5
[B]
3
[E] 2
1

13

IH23K4120006-02
1B-6 Emission Control Devices:

[A]: Hold the PAIR control solenoid valve bracket against the frame. 6. Frame cover plate
[B]: Route the hose so that the hose protector is in touch with the cylinder head. 7. PCV hose
[C]: Create clearance between the PAIR cleaner hose and throttle body pulley. 8. PAIR valve hose
[D]: Face the match mark leftward. 9. PAIR reed valve
[E]: Face the match mark forward. 10. Clamp
: Face the clamp end upward.
1. PAIR control solenoid valve 11. Clamp
: Face the clamp end leftward.
2. PAIR control solenoid valve bracket 12. Clamp
: Face the clamp end rightward.
3. PAIR cleaner hose 13. Clamp
: Face the clamp end downward.
4. Throttle cable : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
5. Clamp
: Clamp the PAIR cleaner hose.
: Fix the hose directly below the frame cover plate.

PCV Hose Routing Diagram

BENM23K11202002

[A]

IH23K4120009-01

[A]: Face the clamp end upward. 1. PCV hose

 Emission Control Devices: 1B-7

EVAP Canister Hose Routing Diagram (If Equipped)

BENM23K11202003

[E]
5
9
[A]
7
(b)
9 1
11
9
(a) [B] 2
9 [A]
3 2

1 8
9
[C] 15
[F] 4
4 9
6
10
9 (a)
13
12 7 [D]

14
9

IH23K4120007-03
1B-8 Emission Control Devices:

[A]: Fit the EVAP canister cushion to the bracket until the pawls on the bracket come out. 7. EVAP canister drain hose
[B]: Face the match mark leftward. 8. Fuel tank breather hose (GSX S 125 Model)
[C]: Align the projection on the EVAP canister with the projection on the cushion. 9. Clamp
: Fix each clamp in the position 8 – 10 mm (0.32
– 0.39 in) from the hose end.
[D]: Prevent the purge hose No. 2 from contacting the PAIR control solenoid valve bracket. 10. Clamp (GSX S 125 Model)
[E]: To fuel tank (GSX R 125 Model) 11. EVAP system purge control solenoid valve
[F]: To 3-way joint (GSX S 125 Model) 12. Fuel shut-off valve (GSX S 125 Model)
1. EVAP canister 13. EVAP canister bracket
2. EVAP canister cushion 14. Intake pipe No.1
3. Purge hose No. 1 15. Throttle cable clamp
: Clamp the purge hose No. 2.
4. Purge hose No. 2 : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
5. Surge hose (GSX R 125 Model) : 6.7 Nm (0.68 kgf-m, 4.95 lbf-ft)
6. Surge hose (GSX S 125 Model)
 Emission Control Devices: 1B-9

GSX S 125 Model

FWD FWD
[C] 12 13
1 4

[H]
5

2 3
[B] 4 7 8
6
[A] [P]
6

[E] [F]
FWD
[D] [D] [I]
[D] 8 7
4 8
10 11

[G]

14 8
12

13
[J]
[K]
FWD
8 4
14 13
12 16
[L]
15 13
FWD
[M]

8
[N]

12 13 [N]
8 FWD
16 15

14
FWD

[O]
“a”
“a”
[O]
IH23K4120008-02
1B-10 Emission Control Devices:

[A]: Face the clamp end leftward. 2. Surge hose

[B]: Face the clamp end forward. 3. Fuel shut-off valve
[C]: Face the clamp end rightward. 4. Fuel tank breather hose
[D]: Face the clamp end upward. 5. 3-way joint
[E]: Black side 6. Check valve
[F]: Gray side 7. Check valve cushion No.1
[G]: After installing the fuel tank, make sure the fuel tank breather hose and check valve drain 8. Check valve drain hose
hose are fitted in the check valve cushion No.1.
[H]: Face the white mark on each hose forward. 9. Check valve cushion No.2
[I]: Face the slits of the check valve cushion No.1 upward. 10. Check valve bracket
[J]: To fuel tank 11. Air cleaner box
[K]: Fit each hose to the tank nipple fully. 12. EVAP canister drain hose
[L]: Pass the fuel tank water drain hose through the guide on the frame. 13. Fuel tank water drain hose
[M]: Pass the drain hoses between two bridges on the frame. 14. Frame
[N]: Pass the drain hoses behind the swingarm pivot pipe. 15. Swingarm
[O]: Pass the drain hoses in front of the frame bridge and inside of the crankcase plate. 16. Engine assembly
[P]: Wrap the check valve with the check valve cushion No.2 by sticking. “a”: 0 – 20 mm (0 – 0.78 in)
1. EVAP canister
 Emission Control Devices: 1B-11

Repair Instructions
PAIR Reed Valve Removal and Installation (If PAIR Control Solenoid Valve Removal and
Equipped) Installation (If Equipped)
BENM23K11206001 BENM23K11206002
Removal Removal
1) Remove the right front frame cover. (Page 9D-31) 1) Remove the front frame covers. (Page 9D-31)
2) Remove the PAIR reed valve cover (1). 2) Disconnect the PAIR control solenoid valve coupler
(1).

1
1

IH23K4120010-01

3) Remove the PAIR reed valve (1). IH23K4120013-01

3) Remove the PAIR control solenoid valve bracket (1).

IH23K4120011-01

IH23K4120014-01
Installation 4) Disconnect the PAIR cleaner hose (1) and PAIR
Install the PAIR reed valve in the reverse order of valve hose (2) from PAIR control solenoid valve.
removal. Pay attention to the following point:
• Tighten the PAIR reed valve cover bolts (1) to the
specified torque.
Tightening torque
PAIR reed valve cover bolt (a): 10 N·m (1.0 kgf-m,
7.3 lbf-ft)

1, (a)
1

IH23K4120015-01

IH23K4120012-01
1B-12 Emission Control Devices:

Installation PAIR Reed Valve

Install the PAIR control solenoid valve in the reverse Refer to “PAIR Reed Valve Removal and Installation (If
order of removal. Pay attention to the following points: Equipped)” (Page 1B-11).
• Connect the PAIR hoses properly. Refer to “PAIR Inspect the reed valve for carbon deposit.
System Hose Routing Diagram (If Equipped)” (Page If carbon deposit is found on the reed valve, replace the
1B-5). PAIR reed valve with a new one.
• Hold the PAIR control solenoid valve bracket (1)
against the frame and tighten the bolt (2) to the
specified torque.
Tightening torque
PAIR control solenoid valve bracket bolt (a): 10
N·m (1.0 kgf-m, 7.3 lbf-ft)

2, (a)

IH23K4120018-01

PAIR Control Solenoid Valve

Refer to “PAIR Control Solenoid Valve Removal and
1
Installation (If Equipped)” (Page 1B-11).
1) Check that air flows through the air inlet port to the
air outlet ports. If air does not flow out, replace the
IH23K4120016-01 PAIR control solenoid valve with a new one.

PAIR System Inspection (If Equipped)

BENM23K11206003
PAIR Hose
1) Remove the front frame covers. (Page 9D-31)
2) Inspect the PAIR hoses (1) for wear or damage. If it
is worn or damaged, replace the PAIR hose with a
new one. Refer to “PAIR System Hose Routing
Diagram (If Equipped)” (Page 1B-5).

IH23K4120019-01

2) Connect the 12 V battery to the PAIR control

solenoid valve terminals and check the air flow. If air
1 does not flow out, the solenoid valve is in normal
condition.

IH23K4120017-01

3) Install the removed parts.

IH23K4120020-01
 Emission Control Devices: 1B-13

3) Check the resistance between the terminals of the PCV Hose Removal and Installation
PAIR control solenoid valve. BENM23K11206006
Removal
PAIR solenoid valve resistance (If equipped) 1) Remove the left front frame cover. (Page 9D-31)
20 °C (68 °F) [Standard]: 18 – 22 Ω
2) Remove the PCV hose (1).

IH23K4120021-01
IH23K4120022-01

Cylinder Head Cover Inspection Installation

BENM23K11206004
Refer to “Cylinder Head Cover Removal and Installation” 1) Install the PCV hose. Refer to “PCV Hose Routing
in Section 1D (Page 1D-17). Diagram” (Page 1B-6).
Inspect the cylinder head cover in the carbon deposit. If 2) Install the removed parts.
the carbon deposit is found in the cylinder head cover,
remove the carbon.
EVAP Control System Removal and Installation
(If Equipped)
PCV Hose Inspection BENM23K11206007
BENM23K11206005 Hose
1) Remove the left front frame cover. (Page 9D-31) Refer to “EVAP Canister Hose Routing Diagram (If
2) Inspect the PCV hose (1) for wear and damage. Equipped)” (Page 1B-7).
If it is worn or damaged, replace the PCV hose with
a new one. Refer to “PCV Hose Routing Diagram” Removal
(Page 1B-6). 1) Remove the fuel tank. (Page 1G-8)
3) Check that the PCV hose is securely connected. 2) Remove the EVAP hoses.

Installation
1) Install the EVAP hoses.
2) Install the removed parts.

EVAP Canister
1 Removal
1) Remove the fuel tank. (Page 1G-8)
2) Disconnect the surge hose (1) and purge hose No. 1
(2).
IH23K4120022-01

4) Install the removed parts.

2

IH23K4120023-01
1B-14 Emission Control Devices:

3) Disconnect the EVAP canister drain hose (1). 4) Disconnect the purge hose No. 1 (1) and No. 2 (2)
4) Remove the EVAP canister (2). from the EVAP system purge control solenoid valve
(3).

3 2

1 1

IH23K4120024-01
IH23K4120027-01

Installation 5) Remove the EVAP system purge control solenoid

Install the EVAP canister in the reverse order of removal. valve brackets (1).
Pay attention to the following point:
• Connect the hoses properly. Refer to “EVAP Canister
Hose Routing Diagram (If Equipped)” (Page 1B-7).

EVAP System Purge Control Solenoid Valve

Removal
1) Remove the fuel tank. (Page 1G-8)
2) Disconnect the EVAP system purge control solenoid
valve coupler (1).
1

IH23K4120028-01

Installation
1 Install the EVAP system purge control solenoid valve in
the reverse order of removal. Pay attention to the
following points:
• Tighten the EVAP system purge control solenoid valve
nut (1) and bracket bolt (2) to the specified torque.
Tightening torque
IH23K4120025-01 EVAP system purge control solenoid valve nut
3) Remove the EVAP system purge control solenoid (a): 6 N·m (0.61 kgf-m, 4.42 lbf-ft)
valve bracket bolt (1). EVAP system purge control solenoid valve
bracket bolt (b): 10 N·m (1.0 kgf-m, 7.3 lbf-ft)

1, (a)
2, (b)

IH23K4120026-01
IH23K4120029-01

• Connect the hoses properly. Refer to “EVAP Canister

Hose Routing Diagram (If Equipped)” (Page 1B-7).
 Emission Control Devices: 1B-15

Fuel Shut-off Valve (GSX S 125 Model) Installation

Removal Install the check valve in the reverse order of removal.
1) Remove the fuel tank. (Page 1G-8) Pay attention to the following points:
2) Remove the fuel shut-off valve (1) from the EVAP • Connect black side (1) of the check valve to the fuel
canister bracket. tank breather hose (2).

IH23K4120033-01
IH23K4120030-01

3) Disconnect the surge hose (1) and fuel tank breather • Connect the hoses properly. Refer to “EVAP Canister
hose (2) from the fuel shut-off valve. Hose Routing Diagram (If Equipped)” (Page 1B-7).

EVAP Control System Inspection (If Equipped)

2 BENM23K11206008
Refer to “EVAP Control System Removal and Installation
(If Equipped)” (Page 1B-13).

Hose
Inspect the hoses for wear or damage. If it is worn or
damage, replace the hose with a new one.
1
EVAP Canister
1) Inspect the EVAP canister for damage to the body.
IH23K4120031-01 If any defect is found, replace the EVAP canister (1)
with a new one.
Installation
Install the fuel shut-off valve in the reverse order of
removal. Pay attention to the following point:
• Connect the hoses properly. Refer to “EVAP Canister 1
Hose Routing Diagram (If Equipped)” (Page 1B-7).

Check Valve (GSX S 125 Model)

Removal
1) Remove the fuel tank. (Page 1G-8)
2) Remove the check valve (1) from the check valve
cushion No.1 (2) and disconnect the fuel tank
breather hose (3) and check valve drain hose (4). IH23K4120034-01

1
2
IH23K4120032-01
1B-16 Emission Control Devices:

2) Blow air (2.0 kPa, 0.02 kgf/cm2, 0.29 psi) (2) into the 3) Check the resistance between the terminals of the
tank port (1) and check that air comes out from the EVAP system purge control solenoid valve (1). If the
purge port (3), air port (4) and drain port (5). resistance is not within the standard range, replace
If any defect is found, replace the EVAP canister with the EVAP system purge control solenoid valve with a
a new one. new one.
EVAP system purge control solenoid valve
resistance (If equipped)
3 20 °C (68 °F) [Standard]: 30 – 34 Ω
4

2 1

IH23K4120035-01

EVAP System Purge Control Solenoid Valve

1) Check that no air flows through both of the air inlet IH23K4120037-01
and outlet ports. If air flows out, replace the EVAP
system purge control solenoid valve with a new one. Fuel Shut-off Valve
GSX S 125 model

! WARNING
Gasoline and gasoline vapor is toxic. A small
amount of fuel remains in the fuel shut-off
valve when checking it. Do not swallow the
fuel when blowing the fuel shut-off valve.

1) When air is blown into the fuel shut-off valve with its
side (1) positioned upward, the air can pass through
to the canister side.
IH23K4120038-01

2) Connect the 12 V battery to the terminals of the

EVAP system purge control solenoid valve (1) and
check the air flow. If air flows out, the solenoid valve
is in normal condition.

1
1

IH23K4120039-01

2) When air is blown into the fuel shut-off valve with its
side (1) positioned sideways, the air cannot pass
through to the canister side. If the fuel shut-off valve
operates otherwise, it must be replaced.
IH23K4120036-01

1
IH23K4120040-01
 Emission Control Devices: 1B-17

GSX R 125 model
Refer to “Fuel Tank Construction” in Section 1G (Page
1G-6).
1) Hold the fuel tank cap so that the fuel tank cap
breather hole (1) is aligned with and closely contacts
the packing breather port (2) and the fuel tank cap
upper surface (3) is located lower than the fuel tank
cap ring upper surface (4).
3) Keep the step 1), connect the vacuum pump gauge
to the breather port (1) with the fuel tank cap turned
upside down, and give negative pressure to check
that air cannot pass through.
If any defect is found, replace the fuel tank cap with a
new one.
Special tool
(A): 09917–47011

(A)
1

IH23K4120041-01
IH23K4120043-01
2) Keep the step 1), connect the vacuum pump gauge
to the breather port (1) with the fuel tank cap turned Check valve (GSX S 125 Model)
upright, and give positive pressure to check that air Check the check valve if air can pass through smoothly
can pass through. when blown from the gray color side (1) and not from the
Special tool other side. Should any abnormal condition be found,
(A): 09917–47011 replace the valve with a new one.

(A)

IH23K4120044-02

IH23K4120042-01
1B-18 Emission Control Devices:

Specifications
Tightening Torque Specifications
BENM23K11207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
PAIR reed valve cover bolt 10 1.0 7.3 (Page 1B-11)
PAIR control solenoid valve bracket bolt 10 1.0 7.3 (Page 1B-12)
EVAP system purge control solenoid valve nut 6 0.61 4.42 (Page 1B-14)
EVAP system purge control solenoid valve (Page 1B-14)
10 1.0 7.3
bracket bolt

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“PAIR System Hose Routing Diagram (If Equipped)” (Page 1B-5)
“EVAP Canister Hose Routing Diagram (If Equipped)” (Page 1B-7)
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Special Tool
BENM23K11208001
09917–47011
Vacuum pump gauge set
(Page 1B-17) /
(Page 1B-17)
 Engine Electrical Devices: 1C-1

Engine Electrical Devices

Engine

Precautions
Precautions for Engine Electrical Device
BENM23K11300001
Refer to “General Precautions” in Section 00 (Page 00-1), “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2), “Precautions for Circuit Tester” in Section 00 (Page 00-7), and “Precautions for SDS-II” in Section 00
(Page 00-7).

Precautions for Replacing Remote Controller

BENM23K11300002
Remote controller incorporates the secret code. Therefore, register the secret code when remote controller is replaced
or added. (Page 1C-13)

Precautions for Replacing Keyless Control Unit

BENM23K11300003
When the Keyless Control Unit is to be replaced, at the same time, replace the ECM. If not replaced at the same time,
the ECM and Keyless Control Unit ID Numbers cannot be compared, thus the engine will not start.

Precautions for Remote Controller Disposal

BENM23K11300004
• To prevent theft, break remote controller before disposing of it.
• Dispose of the used battery properly according to applicable rules or regulations. Do not dispose of lithium batteries
with ordinary household trash.

Component Location
Engine Electrical Components Location
BENM23K11303001
Refer to “Electrical Components Location” in Section 0A (Page 0A-6).

Diagnostic Information and Procedures

Engine Symptom Diagnosis
BENM23K11304001
Refer to “Engine Symptom Diagnosis” in Section 1A (Page 1A-14).
1C-2 Engine Electrical Devices:

Repair Instructions
ECM Removal and Installation Installation
BENM23K11306001 Install the ECM in reverse order of removal.
Removal
Pay attention to the following point:
1) Disconnect the battery (–) lead wire (1). Refer to
• Connect ECM coupler to ECM as follows:
“Battery Removal and Installation” in Section 1J
(Page 1J-13). a. Insert ECM coupler (1) to ECM (2) until it stops.
2) Remove the battery cover(2). 2

1
1

IG12K1130002-01

b. Turn the lock lever (1) to lock ECM coupler

securely.
IH23K4130004-01

3) Disconnect the ECM connector as follows: 1

a) Push the lock claw (1) in arrow direction “1”.
b) Turn the lock lever (2) in arrow direction “2” until
it stops. Then, disconnect the connector from the
ECM.

IG12K1130003-02

c. Check that lock lever (1) is in locked position.

IH23K1130003-02

4) Remove the ECM.

IG12K1130004-01
 Engine Electrical Devices: 1C-3

IAP/TP/IAT Sensor Inspection TP Sensor

BENM23K11306002
NOTICE 1) Check that the throttle cable play is within the
specification. (Page 1D-12)
Do not remove IAP/TP/IAT sensor (1) and ISC
2) Check the IAP/TP/IAT sensor power supply voltage.
sensor (2) from throttle body. It is available
(Page 1A-28)
only as a throttle body assembly.
3) Turn the ignition switch OFF.
NOTE 4) Insert the needle pointed probes to the lead wire
The IAP sensor, TP sensor, and IAT sensor coupler and turn the ignition switch ON.
are combined into one and installed in the 5) Measure the voltage between the WP wire and B/Br
throttle body. wire by turning the throttle grip open and close. If the
voltage is not within the specified value, replace the
throttle body assembly. (Page 1D-13)
2 TP sensor output voltage
Closed [Standard]: 0.65 – 0.75 V
1 Opened [Standard]: 3.80 – 4.00 V

G
R
1 W/P 2
G/B
B/Br

IH23K1130004-01
IH23K4130010-01
IAP Sensor 1. IAP/TP/IAT sensor 2. ECM
1) Check the IAP/TP/IAT sensor power supply voltage.
(Page 1A-26) IAT Sensor Resistance
2) Turn the ignition switch OFF. 1) Disconnect the IAP/TP/IAT sensor coupler (1).
3) Insert the needle pointed probes to the lead wire
coupler.
4) Start the engine and at idle speed, measure the IAP
sensor output voltage between the G/B wire and B/ 1
Br wire. If the voltage is not within the specified
value, replace the throttle body assembly. (Page
1D-13)
IAP sensor output voltage
At 1 atm. [Standard]: 3.88 – 4.12 V

G
R
1 W/P 2
IH23K1130019-01
G/B
B/Br

IH23K4130009-01

1. IAP/TP/IAT sensor 2. ECM

1C-4 Engine Electrical Devices:

2) Measure the IAT sensor resistance between the 3) Turn the special tools switch ON.
terminals of the IAP/TP/IAT sensor. If the resistance
is out of the specified value, replace the throttle body
assembly. (Page 1D-13)
IAT sensor resistance
23 °C (73.4 °F) [Standard]: 2.169 – 2.557 Ω

ID26J1110213-02

4) Turn the ignition switch ON.

5) After the MIL (1) turns OFF, open the throttle grip
fully.

NOTE
IF42J1130009-01
When the ignition switch is turned ON, MIL is
lit for 3 seconds and thereafter remains unlit.
TP Fully Closed Learned Value Reset
BENM23K11306003
When replacing the throttle body assembly or IAP/TP/
IAT sensor with a new one, reset the TP fully closed
1
learned value in the following procedures:
1) Open the passenger seat.
2) Connect the special tool to the mode select coupler
(2P) at the wiring harness.
Special tool
(A): 09930–82760 IM23K1110012-08

6) Then, MIL turns ON for 2 seconds automatically.

NOTE
• The learned value of throttle valve closing
is set at preset position.
• TP fully closed learned value can be set
using SDS-II or OBD (for Oceania and
Europe model). Refer to the SDS-II or OBD
(A)
(for Oceania and Europe model) operation
manual for further details.

ISC Valve Inspection

BENM23K11306004
1) Disconnect the ISC sensor coupler (1).
IM23K1110010-24

IH23K1130020-03
 Engine Electrical Devices: 1C-5

2) Measure the resistance between the B/G wire 2) Remove the ISC valve (1).
terminal (1) and B/Lg wire terminal (2), and between
the Lbl wire terminal (3) and Y/R wire terminal (4). If
the resistance is out of the specified value, replace
the ISC valve. (Page 1D-13) (1)

(1)

(2)
(3)

(4)
IH23K1130022-01

3) Remove the spring (1) and O-ring (2).

IH23K1130021-01 (2)
ISC valve resistance
20 °C (68 °F) [Standard]: Approx. 20 Ω
(1)
ISC Valve Removal and Installation
BENM23K11306005
Refer to “Air Cleaner Box Removal and Installation” in
Section 1D (Page 1D-9).

Removal

NOTICE
Be careful not to disconnect the ISC valve
IH23K1130026-01
coupler at least 5 second after ignition switch
turned to OFF. If the ECM coupler or ISC
Installation
valve coupler is disconnected within 5
second after ignition switch is turned to OFF, 1) Apply a thin coat of engine oil to the new O-ring (1)
there is a possibility of an unusual valve and install it.
position being written in ECM and causing an
error of ISC valve operation. (1)

1) Disconnect ISC valve coupler (1).

IH23K1130027-01

IH23K1130020-03
1C-6 Engine Electrical Devices:

2) Install the ISC valve (1) to the throttle body and ISC Aperture Learned Value Reset
tighten the ISC valve mounting screw (2). BENM23K11306006
When replacing the throttle body assembly with a new
one or adjusting the throttle valve synchronization, reset
the ISC aperture learned value in the following
(1) (2) procedures:
1) Remove the rear seat.
2) Set up the SDS-II or OBD (for Oceania and Europe
model) referring to the SDS-II or OBD (for Oceania
and Europe model) operation manual for further
details.
3) Turn the ignition switch ON.
4) Click the “Active control”.
5) Click the “ISC aperture learned value reset”.

IH23K1130028-01

3) Connect the ISC valve coupler (1).

IH23K1130020-03

4) After installing the removed parts, reset ISC aperture

learned value.
IH23K5130002-01
NOTICE 6) Click the “Reset” button to clear the ISC aperture
Do not blow ISC valve with compressed air. learned value.
Do not clean ISC valve with high pressure
cleaner or carburetor cleaner.

Use dry cloth for clean the ISC valve (1).

NOTICE
Please keep ISC valve length as per
specification after removal.

ISC valve length has change position or not

in specification can possibility of an unusual
valve position being written in ECM and
causing an error of ISC valve operation.

IH23K5130003-01
 Engine Electrical Devices: 1C-7

NOTE
The learned value of the ISC system is set at
Preset position.
2

IG12K1130009-02

3. Heater

IH23K5130004-01

7) Close the SDS-II tool and turn the ignition switch
OFF.
NOTE
The throttle valve opening initialization is
automatically started after the ignition switch
is turned OFF position.
ECT Sensor Removal and Installation
BENM23K11306008
Removal
1) Drain engine coolant. Refer to “Engine Coolant
Replacement” in Section 1F (Page 1F-5).
2) Disconnect the ECT sensor coupler (1) and remove
the ECT sensor (2).

NOTICE
ECT Sensor Inspection Take special care when handling the ECT
BENM23K11306007
Refer to “ECT Sensor Removal and Installation” (Page sensor. It may cause damage if it gets an
1C-7). excessive impact.
Measure the resistance between terminals of the ECT
sensor (1) depending on coolant temperature as shown
in the following graph. If measured resistance does not
change as specified, replace ECT sensor with a new
one. 1

NOTICE
2
• Handle the ECT sensor carefully as it will
easily be broken if it receives excessive
shock or forces.
• Keep the ECT sensor and thermometer (2)
away from the heater’s water container.

ECT sensor resistance

20 °C (68 °F) [Standard]: 2320 – 2590 Ω
IK23K4130001-02
80 °C (176 °F) [Standard]: 310 – 326 Ω

2320 - 2590

310 - 326
20 80
68 176
IG12K1130008-01
1C-8 Engine Electrical Devices:

Installation 4) Measure the O2 sensor output voltage between the

Install ECT sensor in reverse order of removal. B/O wire and B/Br wire, at idle.
Pay attention to the following point:
O2 sensor output voltage
• Install a new gasket (1) and tighten ECT sensor (2) to Idle speed [Standard]: 0.3 – 1.2 V
specified torque. 5000 r/min: 0.3 – 1.2 V
Tightening torque
ECT sensor (a): 18 N·m (1.83 kgf-m, 13.2 lbf-ft)

1 2, (a)

IG12K1130013-02

5) If OK, then pinch the PAIR hose (1) with a proper

hose clamp (2).
6) Measure the HO2 sensor output voltage while
holding the engine speed at 5000 r/min.
IK23K4130002-01
7) If the O2 sensor output voltage is not within standard
range, replace O2 sensor with a new one. (Page
O2 Sensor Inspection 1C-8)
BENM23K11306009
1) Remove right front fairing. (Page 9D-22) 8) Install the removed parts.
2) Start the engine and warm up the engine enough.
3) Disconnect the O2 sensor lead wire coupler (1).
O2 Sensor Removal and Installation
BENM23K11306010
! WARNING
1
Do not remove the O2 sensor while it is hot.

NOTICE
• Be careful not to expose the O2 sensor to
excessive shock.
• Do not use an impact wrench when
removing or installing the O2 sensor.
• Be careful not to twist or damage the
sensor lead wire.

IH23K4130002-01
 Engine Electrical Devices: 1C-9

Removal 3) Turn the ignition switch ON.

1) Remove right front fairing. Refer to (Page 9D-22) 4) Click the “Active Control”.
2) Disconnect O2 sensor lead wire coupler (1) and 5) Click the “Long term fuel trim reset”.
harness clamp (2).
3) Remove O2 sensor (3).

IH23K4130003-02

Installation
Install O2 sensor in reverse order of removal.
Pay attention to the following points:
• Apply nickel based anti seize to thread part of O2
sensor.
• Tighten O2 sensor to specified torque. IH23K5130005-01

6) Click the “Reset” button to clear the long term fuel

Tightening torque
trim (O2 sensor feedback learned value).
O2 sensor (a): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)

(a)

IH23K1130011-01

• Route the O2 sensor lead wire. Refer to “Wiring

Harness Routing Diagram” in Section 9A (Page 9A-
11).
• Reset the long term fuel trim.
IH23K5130006-01
Long Term Fuel Trim Reset
BENM23K11306011
When replacing the HO2 sensor with a new one, reset
the long term fuel trim in the following procedures:
1) Remove the rear seat.
2) Set up the SDS-II or OBD (for Oceania and Europe
model) tool referring to the SDS-II or OBD (for
Oceania and Europe model) operation manual for
further details.
1C-10 Engine Electrical Devices:

NOTE 3) Disconnect CKP sensor lead wire coupler (1).

The learned value of the long term fuel trim
(HO2 sensor feedback learned value) is set at
preset position.

IH23K5130007-01

7) Close the SDS-II or OBD (for Oceania and Europe

model) and turn the ignition switch OFF.
IK23K4130003-01
NOTE
4) Connect multi circuit tester with peak voltage adapter
The long term fuel trim (HO2 sensor feedback (1) as follows.
learned value) initialization is automatically
started after the ignition switch is turned OFF CKP sensor – circuit tester connection
position. (+) Probe (–) Probe
CKP sensor (2) G lead wire B lead wire

CKP Sensor Inspection

BENM23K11306012
CKP Sensor Peak Voltage 2
G
1
NOTE B
Be sure that all couplers are connected
IG12K1130018-01
properly and the battery used is in fully-
5) Measure CKP sensor peak voltage using the
charged condition.
following procedures:
1) Remove following parts. a) Turn the ignition switch ON.
a) Under cowling: refer to (Page 9D-26) b) Grasp the front or rear brake lever.
b) Front box: Refer to (Page 9D-29) c) Press the starter switch and allow the engine to
2) Disconnect injector coupler (1) to stop the fuel crank for a few seconds, and then measure the
injection. CKP sensor peak voltage.
6) Repeat c) procedure several times and measure the
highest peak voltage.
If the voltage is lower than standard range, inspect
for coupler connection and metal particles or foreign
material being stuck on CKP sensor and generator
rotor.
If the peak voltage is within the standard range,
1
check the continuity between the CKP sensor lead
wire coupler and ECM coupler.
CKP sensor peak voltage
When cranking [Standard]: 2.0 V
7) After measuring CKP sensor peak voltage, connect
CKP sensor lead wire coupler and injector coupler.
IH23K1130012-01 8) Install the removed parts.
 Engine Electrical Devices: 1C-11

CKP Sensor Resistance TO Sensor Removal and Installation

BENM23K11306014
1) Remove the right under cowling. (Page 9D-26) Removal
2) Disconnect the CKP sensor lead wire coupler (1). 1) Remove the fuel tank. Refer to (Page 1G-8)
2) Disconnect the coupler (1) and remove the TO
sensor (2).

1
2
1

IK23K4130004-01

3) Measure the resistance between the lead wire and

ground. If the resistance is not within the standard IH23K1130014-01
range, replace the CKP sensor with a new one.
Refer to “Generator Removal” in Section 1J (Page Installation
1J-5). Install TO sensor in reverse order of removal.
CKP sensor resistance Pay attention to the following point:
20 °C (68 °F) [Standard]: Approx. 230 Ω • When installing the TO sensor, bring the “UPPER”
letters (1) upward.

G
B

IG12K1130019-01 1
4) After measuring the CKP sensor resistance, connect
the CKP sensor coupler.
5) Install the removed parts.

CKP Sensor Removal and Installation

BENM23K11306013
Refer to “Generator Removal” in Section 1J (Page 1J-5).

IK23K4130005-01

TO Sensor Inspection
BENM23K11306015
Refer to “TO Sensor Removal and Installation” (Page
1C-11).

TO Sensor Output Voltage

1) Check TO sensor power supply voltage and circuit.
2) Turn the ignition switch OFF and connect the ECM
coupler.
3) Dismount the TO sensor from its bracket and
connect the TO sensor coupler.
4) Insert the needle point probes to the lead wire
coupler.
5) Turn the ignition switch ON, measure the TO sensor
output voltage between the Br wire and B/Br wire.
1C-12 Engine Electrical Devices:

If the voltage is not within the specified value, Speed Sensor Removal and Installation
replace the TO sensor. (Page 1C-11) BENM23K11306016
Removal
TO sensor output voltage 1) Remove speed sensor (1), and then disconnect the
Normal [Standard]: 0.4 – 1.4 V speed sensor coupler (2).
Leaning 65° [Standard]: 3.7 – 4.4 V

[A]
1

V
2

IK23K4130006-01
IH23K1130017-01

[B] Installation
Install speed sensor in reverse order of removal.
Pay attention to following point:
• Tighten the speed sensor bolt to the specified torque.
Tightening torque
“a” Speed sensor bolt (a): 4.5 N·m (0.46 kgf-m, 3.35
lbf-ft)

V
IK23K4130007-01

[A]: When sensor is horizontal (normal) level.

[B]: When sensor is leaned 65° “a” or more, left and
right, from horizontal level.

6) After finishing the TO sensor inspection, install (a)

removed parts.

TO Sensor Resistance
1) Measure the resistance between R wire terminal (1)
and B/Br wire terminal (2). If the resistance is out of IH23K1130018-01
the specified value, replace the TO sensor.
TO sensor resistance
[Standard]: 1650 – 22300 Ω

2 1

IF04K1130039-02
 Engine Electrical Devices: 1C-13

Speed Sensor Inspection If the voltage reading does not change, replace the
BENM23K11306017 speed sensor with a new one.
Refer to “Speed Sensor Removal and Installation” (Page
1C-12). NOTE
1) Connect a 12 V battery, 10 kΩ resistor and multi While testing, the highest voltage reading
circuit tester to the speed sensor (1) as shown in the should be the same as the battery voltage (12
figure. V).

10 kΩ 12 V

IG12K1130026-02
ID26J1110254-01
2) Move a screwdriver back and forth across the pickup
surface of the speed sensor. The voltage readings
should cycle as follows (0 V → 12 V or 12 V → 0 V).

Remote Controller Registration

BENM23K11306018
NOTICE
• Up to 6 remote controllers can be registered. Once 6 remote controllers have been registered, no
further unit can be added.
• In order to register any additional remote controller after 6 units have been registered, it is
necessary to replace the Keyless Control Unit and ECM at the same time.
• By using the secret code written in the EM-ID card, up to 6 secret codes can be stored in the keyless
control unit.
• Secret codes can be changed to any 4-digit figure as the user likes. However, once any of the secret
codes is changed, for the remote controllers already added, and remote controllers that have been
registered additionally, the secret codes written on the inside of such remote controllers, will be
rendered invalid.
• If the keyless control unit or ECM is replaced, register all of the remote controllers.
• If all of remote controllers are lost, the secret code stored in the keyless control unit can be used to
register remote controllers.

Check the Number of Registered Remote Controllers

1) Place all the registered remote controllers outside the operating range.
2) Push the request switch until the keyless indicator light is turned on.
3) When the keyless indicator light is turned on momentarily, release the request switch.
4) Within 3 seconds, push the request switch until the keyless indicator light is turned on.
5) When the keyless indicator light is turned on momentarily, release the request switch.
6) Within 3 seconds, push the request switch until the keyless indicator light is turned on.
7) After the keyless indicator light is turned on for 3 seconds, it blinks once.
8) Push the request switch the number of times corresponding to the 1st digit in the secret code.
9) 5 seconds later, after the keyless indicator light is turned on for 2 seconds and then blinks 2 times.
10) Push the request switch the number of times corresponding to the 2nd digit in the secret code.
11) 5 seconds later, after the keyless indicator light is turned on for 2 seconds and then blinks 3 times.
12) Push the request switch the number of times corresponding to the 3rd digit in the secret code.
13) 5 seconds later, after the keyless indicator light is turned on for 2 seconds and then blinks 4 times.
14) Push the request switch the number of times corresponding to the 4th digit in the secret code.
1C-14 Engine Electrical Devices:

15) 5 seconds later, the keyless indicator light is turned on for 2 seconds, the hazard light blinks 2 times, and then the
keyless indicator light blinks again.
16) Push the request switch until the keyless indicator light goes off temporarily and then is turned on again.
17) The keyless indicator quickly blinks the number of times corresponding to the number of the registered remote
controllers, and then is turned OFF for 1 second. This blinking repeats for 10 seconds.

Check the number of registered remote controllers procedure (In case of secret code 2341)

ON
1
OFF
[A] [A] [A] [B] [C]

ON
2
OFF
[D] [D] [D] [D] [D] [E]

ON
3
OFF
IH23K1130029-02

[A]: About 5 seconds [D]: 2 seconds 2. Keyless indicator light

[B]: Input the secret code [E]: Blinks the number of times remote controllers 3. Hazard light
registered
[C]: About 3 seconds 1. Request switch

Remote Controller Secret Code Confirmation

1) Set the remote controller already registered to the communication mode and place them within the operating
range.
2) Push the request switch until the keyless indicator light goes off temporarily and then is turned on again.
3) The keyless indicator blinks the secret code stored in the keyless control unit.

Remote control secret code confirmation procedure (In case of secret code 2341)
ON
1
OFF
[A]

ON
2
OFF
[B]
IH23K1130030-02

[A]: About 5 seconds 1. Request switch

[B]: Blink the secret code 2. Keyless indicator light

Remote Controller Secret Code Change

1) Set the remote controller to the communication mode and place them in the operating range.
2) Push the request switch until the keyless indicator light goes off temporarily and then is turned on again.
3) The keyless indicator blinks the secret code stored in the keyless control unit.
4) Immediately after the secret code blinks, press the request switch.
5) When the keyless indicator light is turned on, release the request switch.
6) Within 5 seconds after the keyless indicator light is turned on for 10 seconds and then blinks once, push the
request switch the number of times corresponding to the value of the 1st digit in the new secret code.
7) The keyless indicator blinks the number of times corresponding to the 1st digit in the new secret code, and then is
turned on for 3 seconds.
8) Within 5 seconds after the keyless indicator blinks 2 times, push the request switch the number of times
corresponding to the 2nd digit in the new secret code.
 Engine Electrical Devices: 1C-15

9) The keyless indicator blinks the number of times corresponding to the 2nd digit in the new secret code, and then is
turned on for 3 seconds.
10) Within 5 seconds after the keyless indicator blinks 3 times, push the request switch the number of times
corresponding to the 3rd digit in the new secret code.
11) The keyless indicator blinks the number of times corresponding to the 3rd digit in the new secret code, and then is
turned on for 3 seconds.
12) Within 5 seconds after the keyless indicator blinks 4 times, push the request switch the number of times
corresponding to the 4th digit in the new secret code.
13) The keyless indicator blinks the number of times corresponding to the 4th digit in the new secret code, and then
turn on for 3 seconds.
14) The keyless indicator light is turned on for 10 seconds, the hazard light blinks 2 times, and the secret code change
operation is completed.

Secret code change procedure (In case of secret code 2341 to 3412)

ON
1
OFF [B]
[A] [C]

ON
2
OFF
[D] [E] [B] [B] [B] [B] [E]

ON
3
OFF
IH23K1130031-02

[A]: About 5 seconds [D]: Blink the current secret code 2. Keyless indicator light
[B]: 3 seconds [E]: 10 seconds 3. Hazard light
[C]: Input the new secret code 1. Request switch

Remote Controller Registration

1) Place all the registered remote controllers outside the operating range.
2) Push the request switch until the keyless indicator light is turned on.
3) When the keyless indicator light is turned on momentarily, release the request switch.
4) Within 3 seconds, push the request switch until the keyless indicator light is turned on.
5) When the keyless indicator light is turned on momentarily, release the request switch.
6) Within 3 seconds, push the request switch until the keyless indicator light is turned on.
7) After the keyless indicator light is turned on for 3 seconds, it blinks once.
8) Push the request switch the number of times corresponding to the 1st digit in the secret code.
9) 5 seconds later, after the keyless indicator light is turned on for 2 seconds and then blinks 2 times.
10) Push the request switch the number of times corresponding to the 2nd digit in the secret code.
11) 5 seconds later, after the keyless indicator light is turned on for 2 seconds and then blinks 3 times.
12) Push the request switch the number of times corresponding to the 3rd digit in the secret code.
13) 5 seconds later, after the keyless indicator light is turned on for 2 seconds and then blinks 4 times.
14) Push the request switch the number of times corresponding to the 4th digit in the secret code.
15) 5 seconds later, the keyless indicator light is turned on for 2 seconds, the hazard light blinks 2 times, and then the
keyless indicator light is turned on again.
16) Within 10 seconds, push the request switch until the keyless indicator light is turned on.
17) The keyless indicator light blinks the number of times corresponding to the number of the currently registered
remote controller. (Maximum of 10 seconds)
18) When the remote controller to be registered is placed within operating range and the switch is pushed briefly, the
keyless indicator light is turned on, and remote controller registration completes.
1C-16 Engine Electrical Devices:

Remote controller registration procedure (In case of secret code 2341)

ON
1
OFF
[A] [A] [A] [B] [C]

ON
2
OFF
[D] [D] [D] [D] [D] [E]

ON
3
OFF

ON
4
OFF
IH23K1130032-02

[A]: About 5 seconds [D]: 2 seconds 2. Keyless indicator light

[B]: Input the secret code [E]: Completed registration 3. Hazard light
[C]: About 3 seconds 1. Request switch 4. Remote controller switch

Remote Controller Battery Replacement 2) Remove battery (2) from the lower case (1).
BENM23K11306019
NOTICE
3
When replacing battery of remote controller,
2
the controller could be damaged affected by
static electricity.
Protect the controller from static damage
discharging the static electricity built up in
your body by touching metal before replacing
the battery.
1
1) Remove upper case from lower case using a flat-
IH23K1130034-01
bladed screwdriver rag as shown in figure.
3. Upper case

1 3) Place battery (lithium disc-type CR 2032) (1) so its

“+” terminal faces “+” mark of the lower case (2).

IH23K1130033-01 1
1. Shop rag

IH23K1130035-01
 Engine Electrical Devices: 1C-17

4) Fit the upper case to lower case securely.
NOTE
• Insert the battery all the way into the lower
case.
• Do not touch any electrical components of
the remote controller.
• Be careful not to get any oil or foreign
material on the remote controller or
battery.
• Do not replace the battery with wet hands.
• Dispose of the used battery properly
according to applicable rules or
regulations. Do not dispose of lithium
batteries with ordinary household trash.

Specifications
Tightening Torque Specifications
BENM23K11307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
ECT sensor 18 1.83 13.2 (Page 1C-8)
O2 sensor 25 2.5 18.5 (Page 1C-9)
Speed sensor bolt 4.5 0.46 3.35 (Page 1C-12)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Special Tool
BENM23K11308001
09930–82760
Mode selection switch
(Page 1C-4)
1D-1 Engine Mechanical:

Engine Mechanical
Engine

Precautions
Precautions for Engine Mechanical
BENM23K11400001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2).

NOTE
Identify the position of each removed part. Organize the parts in their respective groups (e.g., intake,
exhaust) so that they can be reinstalled in their original positions.

Schematic and Routing Diagram

Throttle Cable Routing Diagram
BENM23K11402001
GSX R 125 Model

1
[B]

[A]

4 2
1

[B]

[C]

IH23K1140063-01

[A]: Pass the clutch cable behind the clutch cable guide. 2. Clutch cable
[B]: Pass the clutch cable into the cable guide. 3. Clutch cable guide
[C]: Pass the throttle cable into the cable guide. 4. Clutch cable stopper
1. Throttle cable
 Engine Mechanical: 1D-2

(a)

2 5
[A] 2

“a”
[C]

1
4

3
2

[D]

IH23K1140064-01
1D-3 Engine Mechanical:

[A]: Pass the clutch cable through the left side of the frame 3. Throttle cable clamp
head pipe, and the throttle cable through the right side : Attach the clamp at the rearmost part of the frame (horizontal part) as shown in the
of the frame head pipe. figure. Face the clamp lock downward. Point the clamp tip to the right.
[B]: Install the throttle cable with the thread portion fully 4. Frame (horizontal part)
screwed-in.
[C]: Connect the throttle cable end to this hole. 5. Throttle body assembly
[D]: Pass the clutch cable over the throttle cable. “a”: Max. 1.5 mm (0.059 in)
1. Clutch cable : 4.5 Nm (0.46 kgf-m, 3.35 lbf-ft)
2. Throttle cable

GSX S 125 Model

[C]

5 [B]

[B]

2
1
1
3

[A]

[B]

[C]

IH23K2140001-01

[A]: Pass the throttle cable behind the brake hose. 2. Clutch cable
[B]: Pass the clutch cable into the cable guide. 3. Clutch cable guide
[C]: Pass the throttle cable into the cable guide. 4. Clutch cable stopper
1. Throttle cable 5. Frame
 Engine Mechanical: 1D-4

[B], (a)

5
2
[A] 2

“a”
[C]

3
2

[D]

IH23K2140002-01
1D-5 Engine Mechanical:

[A]: Pass the clutch cable through the left side of the frame 3. Throttle cable clamp
head pipe, and the throttle cable through the right side : Attach the clamp at the rearmost part of the frame (horizontal part) as shown in the
of the frame head pipe. figure. Face the clamp lock downward. Point the clamp tip to the right.
[B]: Install the throttle cable with the thread portion fully 4. Frame (horizontal part)
screwed-in.
[C]: Connect the throttle cable end to this hole. 5. Throttle body assembly
[D]: Pass the clutch cable under the throttle cable. Throttle “a”: Max. 1.5 mm (0.059 in)
and clutch cables must past through left side of
harness.
1. Clutch cable : 4.5 Nm (0.46 kgf-m, 3.35 lbf-ft)
2. Throttle cable

Diagnostic Information and Procedures

Compression Pressure Check 4) Disconnect the fuel injector coupler. (Page 1G-14)
BENM23K11404001
The compression pressure reading of a cylinder is a 5) Keep the throttle grip in the fully-opened position.
good indicator of its internal condition. GSX R 125 Model
The decision to overhaul the cylinder is often based on
the results of a compression test. Periodic maintenance
records kept at your dealership should include
compression readings for each maintenance service.

NOTE
• Before checking the engine for
compression pressure, make sure that the
cylinder head bolts are tightened to the
specified torque and the valve clearances
are properly adjusted.
• Make sure that the battery is in fully-
charged condition.
IH23K1140017-01
1) Warm up the engine.
2) Remove the spark plug. Refer to (Page 1H-5) GSX S 125 Model
3) Install the compression gauge and adapter in the
spark plug hole. Make sure that the connection is
tight.
Special tool
(A): 09915–64512
(B): 09913–10750

(A)

IH23K2140003-01

(B)

IH23K1140016-01
 Engine Mechanical: 1D-6

6) Press the starter switch and crank the engine for a • Excessively worn cylinder walls
few seconds. Record the maximum gauge reading • Worn piston or piston rings
as the cylinder compression.
• Piston rings stuck in grooves
Compression pressure • Poor valve seating
[Standard]: 900 – 1300 kPa (9.2 – 13.2 kgf/cm2,
• Ruptured or otherwise defective cylinder head
131 – 188 psi)
gasket
[Limit]: 750 kPa (7.6 kgf/cm2, 109 psi)
7) After checking the compression pressure, install the
If compression pressure is less than the service limit, removed parts.
any of the following reasons can be the cause:

Repair Instructions
Intake System Components
BENM23K11406001
1D-7 Engine Mechanical:

[A]
[E]

16

FWD

15
[C]
[D] FWD

(a)

[B]

13
(a)
2
1
(a)
4
3

14
5

7
6

8
(b) 16
9
15
[A] 8
[G] [F]
7 (c)
10 LH RH

12 LH RH
11 8 (c)

IH23K4140001-01
 Engine Mechanical: 1D-8

[A]: View [A] 3. Fuel hose joint 12. Intake pipe insulator
[B]: Insert the fuel feed hose joint securely into the fuel 4. Fuel injector O-ring 13. Air cleaner assembly
hose joint until a click is heard.
[C]: Align protrusion on the throttle body with cutaway in the 5. Fuel injector 14. Drain plug
intake pipe No.2.
[D]: Align protrusion on the intake pipe No.1 with cutaway in 6. Fuel injector insulator 15. PCV hose
the intake pipe No.2.
[E]: Face the protrusion on the intake pipe insulator toward 7. Throttle body clamp 16. PAIR system air hose (if equipped)
the upper right.
[F]: Throttle body clamp 8. Intake pipe clamp : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
[G]: Intake pipe clamp 9. Intake pipe No.2 : 1.0 Nm → 6.5 Nm (0.10 kgf-m → 0.66 kgf-m,
0.75 lbf-ft → 4.80 lbf-ft)
1. Throttle body assembly 10. Intake pipe No.1 : 1.5 Nm (0.15 kgf-m, 1.10 lbf-ft)
2. Fuel injector cover 11. O-ring

Air Cleaner Element Removal and Installation 4) Remove air cleaner cover (1).
BENM23K11406002
Removal
1) Open front seat. Refer to (Page 9D-20)
2) Remove fuel tank. Refer to (Page 1G-8)

IH23K1140039-02

5) Remove the air cleaner element (1).

IH23K1140040-03

3) Remove sub relay and cooling fan relay holder (1)

and motor starter fuse (2).

IK23K4140002-01

Installation
Install the air cleaner element in the reverse order of
IH23K1140038-03
removal.
1D-9 Engine Mechanical:

Air Cleaner Element Inspection Air Cleaner Box Removal and Installation
BENM23K11406003 BENM23K11406004
Refer to “Air Cleaner Element Removal and Installation” Removal
(Page 1D-8) 1) Remove the following parts.
1) Inspect the air cleaner element for clogging. If it is a) Front seat. Refer to (Page 9D-20)
clogged with dirt, replace it with a new one.
b) Frame cover: Refer to (Page 9D-31)
NOTICE c) Fuel tank. Refer to (Page 1G-8)
• Do not blow the air cleaner element with
compressed air.
• If driving under dusty conditions, clean the
air cleaner element more frequently. Make
sure that the air cleaner is in good
condition at all times. Life of the engine
depends largely on this component.

IH23K1140040-03

2) Remove rear fender rear. Refer to (Page 9D-32)

3) Remove rear fender front. Refer to (Page 9D-33)
4) Loosen the air cleaner outlet tube clamp screw (1).

IK23K4140001-01

2) Remove the drain plug (1) and drain water from the
air cleaner box.

IH23K1140042-02
1

IH23K1140022-01

3) Install the removed parts.

 Engine Mechanical: 1D-10

5) Disconnect the IAP/TP/IAT and ISC sensor coupler 8) Remove regulator/rectifier plate (1).
(1).

IH23K2140004-01
IK23K4140012-01
9) Remove regulator/rectifier bolt and then remove
6) Remove sub relay and cooling fan relay holder (1)
regulator/rectifier coupler (1).
and motor starter fuse (2).

IH23K1140038-03 IH23K2140005-01
7) Remove turn signal relay (1) and TO sensor (2). 10) Remove rear wheel (1) and chain case (2). Refer to
(Page 2D-7)

IH23K1140045-02
1

IK23K4140003-01

11) Remove air cleaner box bolt.

1D-11 Engine Mechanical:

IH23K1140044-03

IH23K1140050-02

Installation
Install the air cleaner box in the reverse order of
removal. Pay attention to the following points:
• Connect the PCV hose. Refer to “PCV Hose Routing
Diagram” in Section 1B (Page 1B-6).
• Connect the pair hose. Refer to “Intake System
Components” (Page 1D-6)
• Position the air cleaner outlet tube clamp and tighten
the air cleaner outlet tube clamp screw (1) to the
specified torque. Refer to “Intake System
Components” (Page 1D-6).
IH23K1140046-03

12) Disconnect the PCV hose (1) and PAIR system air Tightening torque
hose (2). Air cleaner outlet tube clamp screw (a): 1.5 N·m (
0.15 kgf-m, 1.10 lbf-ft)

1, (a)

2
1
IG12K1140015-01

IH23K4140003-01 • Tighten the air cleaner box bolts (1) to specified

13) Remove the air cleaner box (1) to the bottom torque.
through rear swingarm side. Tightening torque
Air cleaner box bolt (a): 10 N·m (1.0 kgf-m, 7.3 lbf-
ft)
 Engine Mechanical: 1D-12

Throttle Cable Play On-Vehicle Inspection and

Adjustment
BENM23K11406005
Inspection
Turn the throttle grip slowly and inspect the throttle cable
play “a” at the periphery of the grip.
1, (a)
Throttle cable play
[Standard]: 2.0 – 4.0 mm (0.079 – 0.16 in)

IH23K1140051-02

“a”

1, (a)

IH23K1140023-02

Adjustment
1) Move the rubber boot (1).
2) Loosen the lock-nut (2) of the throttle cable.
3) Turn the adjuster (3) in or out until the throttle cable
IH23K1140052-02 play (at the throttle grip) is within the specification.
Throttle cable play
[Standard]: 2.0 – 4.0 mm (0.079 – 0.16 in)
4) Tighten the lock-nut while holding the adjuster.

! WARNING
After the adjustment is completed, check that
handlebar movement does not raise the
engine idle speed and the throttle grip
returns smoothly and automatically.

1 2

IH23K1140053-02

5) Install the rubber boot.

1D-13 Engine Mechanical:

Throttle Cable Removal and Installation Installation

BENM23K11406006 Install the throttle cable in reverse order of removal. Pay
Removal attention to the following points:
1) Disconnect the throttle cable from right handle • Install the throttle cable as shown in the throttle cable
switch. Refer to “Handlebar Removal and routing diagram. Refer to “Throttle Cable Routing
Installation” in Section 6B (Page 6B-4). Diagram” (Page 1D-1).
2) Remove the clamp (1). • Connect the EVAP system purge control solenoid
valve coupler (if equipped).
• After installing, check the throttle cable play and
1
proper operation. (Page 1D-12)

Throttle Cable Inspection

BENM23K11406007
Check that the throttle cable moves smoothly from full
close to full open, and in reverse direction. If it does not
move smoothly, lubricate the throttle cable.

Throttle Body Removal and Installation

BENM23K11406008
Removal
1) Remove the air cleaner box. (Page 1D-9)
IK23K4140004-01 2) Disconnect the throttle cable from throttle body.
3) Disconnect the EVAP system purge control solenoid (Page 1D-13)
valve (if equipped) (1). 3) Remove EVAP canister (1). Refer to “EVAP Control
System Removal and Installation (If Equipped)” in
Section 1B (Page 1B-13).

1
1

IH23K4140004-01

4) Loosen the lock-nut (1) and disconnect the throttle

cable from throttle body.
IH23K4140008-01

IK23K4140005-01
 Engine Mechanical: 1D-14

4) Remove ABS control unit / hydraulic unit (1). Refer Installation

to “ABS Control Unit / HU Removal and Installation” Install the throttle body in reverse order of removal.
in Section 4E (Page 4E-37). Pay attention to the following points:
• Align protrusion (1) on the throttle body with cutaway
in the intake pipe No.2.
1

IH23K4140009-01

5) Disconnect the IAP/TP/IAT sensor coupler (1) and

ISC sensor coupler (2).

2
1

1
IG12K1140020-01

• Tighten the throttle body clamp screw to the specified

torque.
Tightening torque
Throttle body clamp screw (a): 1.5 N·m (0.15 kgf-
m, 1.10 lbf-ft)

IH23K1140026-02

6) Loosen the throttle body clamp screw (1), and then

remove throttle body (2).

2 (a)

IK23K4140006-01
1 • Install EVAP canister, check that hose installation and
routing is proper. Refer to “EVAP Canister Hose
Routing Diagram (If Equipped)” in Section 1B (Page
IK23K4140007-01
1B-7) and “EVAP Control System Removal and
Installation (If Equipped)” in Section 1B (Page 1B-13).
1D-15 Engine Mechanical:

• Install ABS control unit / hydraulic unit, check that Throttle Body Inspection and Cleaning
piping installation is proper. Refer to “ABS Control BENM23K11406010

Unit / HU Removal and Installation” in Section 4E Refer to “Throttle Body Removal and Installation” (Page
(Page 4E-37). 1D-13).
• After installing, check throttle cable play and proper Inspection
operation. (Page 1D-12) Check following items for any defects or clogging.
Replace the damaged part or throttle body, if necessary.
Throttle Body Disassembly and Reassembly • O-ring
BENM23K11406009
NOTE • Throttle valve
• Never remove the throttle valve (1). • ISC valve house
• Purge house (if equipped).

Cleaning
• Plug the sensor hole(s) in the main bore with tape or
the like.
• Clean the main bore, throttle valve and passage(s)
using a cotton swab moistened with a carburetor
cleaning chemical.
1
• Clean ISC valve using a cotton swab moistened with a
carburetor cleaning chemical.

IK23K4140008-01 NOTICE
• Never remove or turn the screw (1) and • Some carburetor cleaning chemicals are
lock nut (2). very corrosive. Always follow the chemical
manufacturer’s instructions for proper
use, handling and storage.
• Do not dip the throttle body in a carburetor
cleaning chemical or do not spray the
cleaning chemical directly to the throttle
1 valve. Cleaning chemical will penetrate
into electronic parts resulting in cause of
2
malfunction.
• Do not use wire to clean passages. Wire
may damage them.
IK23K4140009-01
• If the throttle valve is molybdenum-coated,
avoid applying cleaning chemical to the
• Never remove the IAP/TP/IAT sensor (1).
coated surfaces. Cleaning chemical
The IAP/TP/IAT sensor is available only as
loosens the coating, so the air-tightness of
the throttle body assembly.
the throttle valve would be impaired.
• When you reassembly ISC valve (2), make
• Do not apply any cleaning chemical to
sure that ISC valve length not less than the
parts made of rubber and plastic materials.
specification.
Cleaning chemical may damage these
parts.
2 • Do not clean ISC valve direct with cleaning
chemical or carburetor cleaning.
• Do not blow ISC valve with compressed
air.

IK23K4140010-01
 Engine Mechanical: 1D-16

Intake Pipe Removal and Installation • Install the intake pipe No.1 as follows.
BENM23K11406011
Removal a. Install a new O-ring (1) to the insulator (2).
1) Remove the canister purge hose (1). b. Face the protrusion (3) of insulator to thermostat
(4).

1
4

2
IG12K1140029-01

c. Install a new O-ring to the intake pipe.

IH23K4140010-01
d. Tighten the intake pipe No.1 mounting bolts to 1.0
2) Remove the throttle body. (Page 1D-13) Nm (0.10 kgf-m, 0.75 lbf-ft).
3) Loosen the intake pipe No.2 clamp screw (1) and e. Retighten them to 6.5 Nm (0.66 kgf-m, 4.80 lbf-ft).
then remove the intake pipe No.2 (2).
Tightening torque
Intake pipe mounting bolt (a): 1.0 Nm → 6.5
Nm (0.10 kgf-m → 0.66 kgf-m, 0.75 lbf-ft →
2 4.80 lbf-ft)

(a)

1
IG12K1140027-01

4) Disconnect the fuel feed hose from fuel injector.

Refer to (Page 1G-5)
5) Remove the intake pipe No.1 (1) and intake pipe IG12K1140030-01
insulator (2).
• Align protrusion (1) on the intake pipe No.1 with
cutaway in the intake pipe No.2.
• Tighten the intake pipe No.2 clamp screw to the
specified torque.
2 Tightening torque
Intake pipe No.2 clamp screw (a): 1.5 N·m (0.15
kgf-m, 1.10 lbf-ft)

IG12K1140028-01 1

Installation
Install the intake pipe in reverse order of removal. Pay (a)
attention to the following points:

IH23K1140033-01

• Install the canister purge hose.

1D-17 Engine Mechanical:

Cylinder Head Cover Removal and Installation 5) Remove the cylinder head cover (2) and its gasket.
BENM23K11406012
Removal
1) Remove the following parts.
2
a) Under cowling: (Page 9D-26) 1
b) Front box: (Page 9D-29)
2) Disconnect the spark plug cap (1).
3) Disconnect PAIR solenoid valve coupler (1) and then
remove PAIR solenoid valve (2). Refer to “PAIR
Control Solenoid Valve Removal and Installation (If
Equipped)” in Section 1B (Page 1B-11).
IG12K1140032-01

2 1
Installation
Install the cylinder head cover in the reverse order of
removal. Pay attention to the following points:
• Install a new gasket (1) to the cylinder head cover.
• Apply sealant to the “A” of the gasket as shown.
“A”: Sealant 99000–31140 (SUZUKI BOND 1207B)

IH23K4140011-01
“A”
4) Remove the PAIR reed valve (1). Refer to “PAIR
Reed Valve Removal and Installation (If Equipped)”
in Section 1B (Page 1B-11).

1 IG12K1140033-02

• Set new gaskets (1) to the cylinder head cover bolt

and coat the both sides of the gasket with engine oil.

IH23K4140012-01

IG12K1140034-01
 Engine Mechanical: 1D-18

• Tighten the cylinder head cover bolts as follows. f. Fit PAIR solenoid valve bracket stopper (2) to the
a. Tighten the cylinder head cover bolt (1) until its frame.
gasket comes in contact with the cylinder head g. Tighten the PAIR control solenoid valve bracket
cover. bolt (1) to the specified torque.
b. Tighten the cylinder head cover bolt (2) until its Tightening torque
gasket comes in contact with the cylinder head PAIR control solenoid valve bracket bolt (a):
cover. 10 N·m (1.0 kgf-m, 7.3 lbf-ft)
c. Tighten the cylinder head cover bolt (2) to the
specified torque.
1, (a)
d. Tighten the cylinder head cover bolt (1) to the
specified torque.
Tightening torque
Cylinder head cover bolt (a): 12 N·m (1.2 kgf-
m, 9.0 lbf-ft)
2
2, (a)

IH23K4140014-01
1, (a) h. Connect PAIR solenoid valve coupler (1).

1
IG12K1140035-02

e. Tighten the PAIR reed valve cover bolt (1) to the

specified torque.
Tightening torque
PAIR reed valve cover bolt (a): 10 N·m (1.0
kgf-m, 7.3 lbf-ft)

1, (a)

IH23K4140015-01

Cylinder Head Cover Inspection

BENM23K11406013
1) Remove cylinder head cover. (Page 1D-17)
2) Clean and check the gasket grooves and PAIR reed
valve mating surfaces of the cylinder head cover. If
there is anything unusual, replace the cylinder head
cover with a new one.
IH23K4140013-01
1D-19 Engine Mechanical:

Cam Chain Tension Adjuster / Camshaft
Housing / Camshaft Removal
BENM23K11406014
1) Remove the cylinder head cover. (Page 1D-17)
2) Remove the spark plug. Refer to (Page 1H-5)
3) Remove the valve timing inspection plug (1) and
generator cover plug (2).
5) Remove the cam chain tension adjuster cap bolt (1)
and the cam chain tension adjuster bolt (2) and then
remove the cam chain tension adjuster assembly (3)
gasket.
! CAUTION
The cam chain tension adjuster cap bolt is
spring loaded. Be careful when removing it.

2 1
2

IH23K1140035-02

4) Turn the crankshaft to bring the “TDC” line (1) on the

generator rotor to the index mark (2) on the
generator cover and also to bring both camshafts
(EX and IN) to the positions “A” as shown in the
figure. IH23K1140054-02

6) Remove the camshaft housing (1) and cam chain

guide No.2 (2).
2

2
1

IH23K1140034-03
1
“A”

IG12K1140039-01

EX. IN. 7) Remove the dowel pins (1).

8) Remove the intake camshaft (2) and exhaust
I822H1020023-01
camshaft (3).

2 1
3

IG12K1140040-01
 Engine Mechanical: 1D-20

9) Remove the cam sprockets (1). 2) Apply a small quantity of molybdenum oil solution to
the cam faces.

NOTE
Identify the camshafts according to the
following embosses letters.
Intake camshaft (1): [A]
Exhaust camshaft (2): [B]

“A”: Assembly lubrication (Molybdenum oil

solution)
1

IG12K1140041-02

Cam Chain Tension Adjuster / Camshaft

Housing / Camshaft Installation
BENM23K11406015 [A] [B]
1) Apply thread lock to the cam sprocket bolts and
tighten them to the specified torque. 1
“A” 2
“A”: Thread lock cement 99000–32030 (THREAD
LOCK CEMENT 1303B)
Tightening torque IG12K1140043-03

Cam sprocket bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf- [A]: IN [B]: EX
ft)
3) Apply engine oil to the camshaft journals.
4) Turn the crankshaft to align the “TDC” line (1) on the
generator rotor with the index mark (2) on the
generator cover while keeping the cam chain pulled
upward.

2
“A”, (a)

IG12K1140042-03
1

IH23K1140034-03
1D-21 Engine Mechanical:

5) Pull the cam chain lightly.

6) Turn the exhaust camshaft so that the arrow is aligned with the gasket surface of the cylinder head.
(The exhaust camshaft sprocket has an arrow marked “1” (1).)
7) Engage the cam chain with the exhaust camshaft sprocket.

NOTE
Before installing the camshaft, check that the tappets are installed correctly.

8) The other arrow marked “2” (2) should now be pointing straight up. Starting from the roller pin that is directly above
the arrow marked “2”, count out 15 roller pins (from the exhaust camshaft side going towards the intake camshaft
side).
9) Engage the 15th roller pin on the cam chain with the arrow marked “3” (3) on the intake camshaft sprocket.

NOTE
The cam chain should now be on all three sprockets. Be careful not to move the crankshaft until the
camshaft journal holders and cam chain tension adjuster are secured.

[A] [B]

3
2 1 2 3 13 14 15

IG12K1140044-03

[A]: Exhaust cam [B]: Intake cam

10) Install the dowel pins (1). 12) Have the camshaft journal holder seated evenly by
tightening the camshaft journal holder bolts lightly, in
the ascending order of numbers.

NOTICE
Damage to cylinder head or camshaft journal
holder thrust surfaces may result if the
camshaft journal holder is not drawn down
evenly.

NOTE
1
• The ascending order of numbers are
IG12K1140045-01 indicated on the camshaft journal holder.
11) Install the camshaft journal holder (1), washers (2) • The camshaft journal holder bolts at cam
and cam chain guide No.2 (3). chain guide No.2 are shorter than other
NOTE ones.

The washers are installed between the

camshaft journal holder and cam chain guide
No.2.
 Engine Mechanical: 1D-22

13) Tighten the camshaft journal holder bolts in 15) Fit a new gasket (1).
ascending order of numbers to the specified torque.

NOTICE
The camshaft journal holder bolts are made
of a special material and much superior in
strength, compared with other types of high
strength bolts.
Take special care not to use other types of
1
bolts.

Tightening torque
Camshaft journal holder bolt (a): 10 N·m (1.0
IG12K1140049-01
kgf-m, 7.3 lbf-ft)
16) Install the cam chain tension adjuster (1) with “UP”
mark (2) faced to the top of cylinder head.
Tightening torque
3
Cam chain tension adjuster bolt (a): 10 N·m (1.0
kgf-m, 7.3 lbf-ft)
2
(a)

2 (a)
1

IG12K1140046-01

(a) 1

IG12K1140050-01

17) Install the spring (1).

18) Install a new gasket (2) and cam chain tension
adjuster plug (3).

NOTE
Click sound is heard when extending the
push rod.

IG12K1140047-01
1
14) Push the stopper (1) and retract the push rod (2). 3

1
IG12K1140051-01

IG12K1140048-02
1D-23 Engine Mechanical:

19) Tighten the cam chain tension adjuster plug to the 23) Install new O-rings to valve timing inspection plug (1)
specified torque. and generator cover plug (2), and then tighten each
plug to the specified torque.
NOTICE
Tightening torque
After installing the cam chain tension
Valve timing inspection plug (a): 2.3 N·m (0.23
adjuster, check to be sure that the adjuster
kgf-m, 2.0 lbf-ft)
works properly by checking cam chain slack.
Generator cover plug (b): 10,5 N·m (1.07 kgf-m,
Tightening torque 7.75 lbf-ft)
Cam chain tension adjuster plug (a): 8.0 N·m (
0.82 kgf-m, 5.90 lbf-ft)
1, (a)

2, (b)
(a)

IH23K1140037-01

24) Install the spark plug. Refer to (Page 1H-5)

IH23K1140036-01 25) Install the cylinder head cover. (Page 1D-17)
20) Rotate the crankshaft (some turns) and recheck the
valve timing. Cam Chain Tension Adjuster Inspection
BENM23K11406016
NOTICE Refer to “Cam Chain Tension Adjuster / Camshaft
Housing / Camshaft Removal” (Page 1D-19) and “Cam
Make sure that the adjuster works properly
Chain Tension Adjuster / Camshaft Housing / Camshaft
by checking that there is no slack at point
Installation” (Page 1D-20).
[A].
Unlock the ratchet (1), and move the push rod (2) in
place to see if it slides smoothly. If any stickiness is
[A] noted or ratchet mechanism is faulty, replace the cam
chain tension adjuster assembly with a new one.

2 IN 3
1
EX
EX

12K

1
3

2
IN

12K
1

2
IG12K1140053-02

21) Inspect the valve clearance. (Page 1D-25)

22) Apply engine oil to the thread part of the generator
cover plug hole. IG12K1140055-02

Camshaft Inspection
BENM23K11406017
Refer to “Cam Chain Tension Adjuster / Camshaft
Housing / Camshaft Removal” (Page 1D-19) and “Cam
Chain Tension Adjuster / Camshaft Housing / Camshaft
Installation” (Page 1D-20).
 Engine Mechanical: 1D-24

Camshaft Identification Camshaft Journal Wear

The camshafts can be identified by the embossed letter. Inspect the camshaft journal wear using the following
procedures:
1) Determine whether or not each journal is worn down
to the limit by measuring the oil clearance with the
camshaft installed in place.
2) Use the plastigauge to read the clearance at the
widest portion, which is specified as follows:
Special tool
(A): 09900–22301
[A] [B]
(B): 09900–22302

IG12K1140056-02

[A]: IN (Intake camshaft) [B]: EX (Exhaust camshaft)

Cam Wear
Check the camshaft for wear or damage.
Measure the cam height “a” with a micrometer.
Replace a camshaft if the cams are worn to the service
(A), (B)
limit.
Special tool
09900–20202 IG12K1140058-01

Cam height 3) Install camshaft journal holder and tighten the

Intake [Limit]: 33.75 mm (1.329 in) camshaft journal holder bolts in ascending order of
Exhaust [Limit]: 34.08 mm (1.342 in) numbers to the specified torque. Refer to “Cam
Chain Tension Adjuster / Camshaft Housing /
Camshaft Installation” (Page 1D-20).

NOTE
“a”
Do not rotate the camshafts with the
plastigauge in place.
I649G1140199-03
4) Remove the camshaft journal holders and measure
the width of the compressed plastigauge using the
Camshaft Runout
envelope scale.
Measure the runout using the dial gauge. Replace the
camshaft if the runout exceeds the limit. 5) This measurement should be taken at the widest
part of the compressed plastigauge.
Special tool
(A): 09900–20607 Camshaft journal oil clearance
(B): 09900–20701 Intake [Limit]: 0.150 mm (0.059 in)
(C): 09900–21304 Exhaust [Limit]: 0.150 mm (0.059 in)

Camshaft runout
Intake & Exhaust [Limit]: 0.10 mm (0.004 in)

(B)
(A)

IG12K1140059-01

(C)
IG12K1140057-01
1D-25 Engine Mechanical:

6) If the camshaft journal oil clearance exceeds the Valve Clearance Inspection and Adjustment
limit, measure the inside diameter of the camshaft BENM23K11406018

journal holder and the outside diameter of the Inspection

camshaft journal. Replace the camshaft or the Valve clearance adjustment must be checked and
cylinder head depending upon which one exceeds adjusted, a) at the time of periodic inspection, b) when
the specification. the valve mechanism is serviced, and c) when the
camshafts are removed for servicing.
Special tool
(A): 09900–20602 NOTE
(B): 09900–22403 • The cam must be at position “A”, when
(C): 09912–66310 checking or adjusting the valve clearance.
Camshaft journal holder I.D. Clearance readings should not be taken
Intake [Standard]: 22.012 – 22.025 mm (0.8667 – with the cam in any other position than this
0.8671 in) position.
Exhaust [Standard]: 22.012 – 22.025 mm (0.8667 • The clearance specification is for COLD
– 0.8671 in) state.
Camshaft journal O.D. • To turn the crankshaft for valve clearance
Intake [Standard]: 21.959 – 21.980 mm (0.8646 – checking, be sure to use a wrench, and
0.8653 in) rotate in the normal running direction.
Exhaust [Standard]: 21.959 – 21.980 mm (0.8646
– 0.8653 in) “A”

EX. IN.

(B) (A) I822H1020023-01

1) Remove the valve timing inspection plug (1) and

generator cover plug (2).

1
IG12K1140060-01

IH23K1140035-02

(C)

IG12K1140061-01
 Engine Mechanical: 1D-26

2) Turn the crankshaft to bring the “TDC” line (1) on the
generator rotor to the index mark (2) on the
generator cover and also to bring the both camshafts
(EX and IN) to the positions “A” as shown in the
figure.).
2
Adjustment
The clearance is adjusted by replacing the existing
tappet shim with a thicker or thinner shim.
1) Remove the intake or exhaust camshaft. (Page
1D-19)
2) Remove the tappet (1) and shim (2) by fingers or
magnetic hand.

1
1 2

IH23K1140034-03

“A”

IG12K1140063-01

EX. IN. 3) Check the figures printed on the shim. These figures
indicate the thickness of the shim, as illustrated.
I822H1020023-01

3) Measure the valve clearance inserting a thickness

gauge between the cam (1) and tappet (2).
If the clearance is out of specification, adjust the
clearance. 1.70 mm

Special tool I837H1020014-01

(A): 09900–20803 4) Select a replacement shim that will provide a
Valve clearance clearance within the specified range. For the
When engine cold purpose of this adjustment, a total of 21 sizes of
Intake [Standard]: 0.10 – 0.20 mm (0.0040 – tappet shim are available ranging from 1.20 to 2.20
0.0078 in) mm in steps of 0.05 mm.
Exhaust [Standard]: 0.20 – 0.30 mm (0.0079 – 5) Fit the selected shim (1) to the valve stem end, with
0.0118 in) numbers toward tappet. Be sure to check shim size
with micrometer to ensure its size.

NOTE
(A)
• Be sure to apply engine oil to tappet shim
1 top and bottom faces.
• When seating the tappet shim, be sure the
figure printed surface faces the tappet.

2 1

IG12K1140062-01

IF04K1140319-02
 TAPPET SHIM SELECTION TABLE [INTAKE]
TAPPET SHIM NO. (12892-05C00-XXX)

TAPPET SHIM SET (12800-05830)

SUFFIX 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
1D-27 Engine Mechanical:

NO.
MEASURED
VALVE PRESENT
CLEARANCE SHIM SIZE
(mm) (mm) 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20

0.00-0.04 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10
0.05-0.09 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15
0.10-0.20 SPECIFIED CLEARANCE/NO ADJUSTMENT REQUIRED
0.21-0.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.20
0.26-0.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.31-0.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.36-0.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.41-0.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.46-0.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
INTAKE SIDE

0.51-0.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.56-0.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.61-0.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.66-0.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.71-0.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.76-0.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.81-0.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.86-0.90 1.95 2.00 2.05 2.10 2.15 2.20
0.91-0.95 2.00 2.05 2.10 2.15 2.20
0.96-1.00 2.05 2.10 2.15 2.20 HOW TO USE THIS CHART:
1.01-1.05 2.10 2.15 2.20 I. Measure valve clearance. “ENGINE IS COLD”
1.06-1.10 2.15 2.20
II. Measure present shim size.
III. Match clearance in vertical column with present shim size in horizontal
1.11-1.15 2.20
column.
EXAMPLE
Valve clearance is 0.23 mm
Present shim size 1.70 mm
Shim size to be used 1.80 mm

IB08J1020010-03
 TAPPET SHIM SELECTION TABLE [EXHAUST]
TAPPET SHIM NO. (12892-05C00-XXX)

TAPPET SHIM SET (12800-05830)

SUFFIX 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
NO.
MEASURED
VALVE PRESENT
CLEARANCE SHIM SIZE
(mm) (mm) 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20

0.05-0.09 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05
0.10-0.14 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10
0.15-0.19 1.20 1.25 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15
0.20-0.30 SPECIFIED CLEARANCE/NO ADJUSTMENT REQUIRED
0.31-0.35 1.30 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20 2.20
0.36-0.40 1.35 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.41-0.45 1.40 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.46-0.50 1.45 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.51-0.55 1.50 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.56-0.60 1.55 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
EXHAUST SIDE

0.61-0.65 1.60 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.66-0.70 1.65 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.71-0.75 1.70 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.76-0.80 1.75 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.81-0.85 1.80 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.86-0.90 1.85 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.91-0.95 1.90 1.95 2.00 2.05 2.10 2.15 2.20
0.96-1.00 1.95 2.00 2.05 2.10 2.15 2.20
1.01-1.05 2.00 2.05 2.10 2.15 2.20 HOW TO USE THIS CHART:
1.06-1.10 2.05 2.10 2.15 2.20 I. Measure valve clearance. “ENGINE IS COLD”
1.11-1.15 2.10 2.15 2.20
II. Measure present shim size.
III. Match clearance in vertical column with present shim size in horizontal
1.16-1.20 2.15 2.20
column.
1.21-1.25 2.20
EXAMPLE
Valve clearance is 0.33 mm
Engine Mechanical:

Present shim size 1.70 mm

Shim size to be used 1.80 mm

IB08J1020012-03
1D-28
1D-29 Engine Mechanical:

6) Install the camshafts and cam chain tension adjuster. 2) Remove the water bypass hose (1).
(Page 1D-20)
7) Rotate the engine so that the tappet is depressed
fully. This will squeeze out oil trapped between the
shim and the tappet that could cause an incorrect
measurement. Then check the clearance again to
1
confirm that it is within the specified range.
8) After finishing the tappet clearance adjustment,
check that the engine starts smoothly and is free
from any abnormal noise.

Camshaft Sprocket Inspection

BENM23K11406019
Refer to “Cam Chain Tension Adjuster / Camshaft
Housing / Camshaft Removal” (Page 1D-19) and “Cam
IH23K1140055-03
Chain Tension Adjuster / Camshaft Housing / Camshaft
Installation” (Page 1D-20). 3) Remove the engine mounting bolts (1) and bolt (2).
Check the camshaft sprocket teeth for wear or damage. 4) Remove the cylinder head nuts (3).
If any defects are found, replace the camshaft sprocket
and cam chain as a set. (Page 1D-43)

1
3 1

IG12K1140073-01 IH23K1140056-02

5) Remove the cylinder head bolts (1) and washers.

Cylinder Head Assembly / Cam Chain Guide /
Cylinder Removal and Installation NOTE
BENM23K11406020
Be sure to loosen the cylinder head bolts
Refer to “Cam Chain Tension Adjuster / Camshaft
(M8) evenly and in a crisscross pattern.
Housing / Camshaft Removal” (Page 1D-19) and “Cam
Chain Tension Adjuster / Camshaft Housing / Camshaft 6) Remove the cylinder head (2) assembly.
Installation” (Page 1D-20).

Removal 1

1) Remove the following parts.

• Muffler: (Page 1K-2) 2
• Intake pipe: (Page 1D-16)
• Radiator: (Page 1F-8)
• Intake and exhaust camshafts: (Page 1D-25)

1
IG12K1140076-02
 Engine Mechanical: 1D-30

7) Remove the cylinder head gasket (1), dowel pins (2) Installation
and chain guide No.1 (3). 1) Thoroughly wipe off oil from the fitting surface of the
8) Disconnect the ECT sensor coupler (4). crankcase.
2) Coat sealant lightly to the mating surfaces at the
parting line between the right and left crankcases as
2
1 shown.
“A”: Sealant 99000–31110 (SUZUKI BOND 1215)

“A”
IG12K1140075-02

9) Remove the cylinder nuts (1) and then remove the

cylinder (2). “A”

2
IG12K1140078-02

3) Install the dowel pins (1) and new cylinder gasket

(2).

IG12K1140070-02

10) Remove the cylinder gasket (1) and dowel pins (2).
1

IG12K1140079-02

4) Position the gaps of the three rings and side rails as

1 shown.

EX.

1 120° 2
2

IG12K1140071-02
120° 120°

IN.
3
ID26J1140121-05

1. 2nd ring and lower side rail

2. Upper side rail
3. 1st ring and spacer
1D-31 Engine Mechanical:

5) Apply molybdenum oil to the sliding surface of the 8) Install the dowel pins (2) and new cylinder head
piston (1), piston rings (2) and cylinder wall. gasket (3).
“A”: Assembly lubrication (Molybdenum oil 9) Connect the ECT sensor coupler (4).
solution)

2
1
2, “A”
1, “A”
IG12K1140083-02

IG12K1140080-04 10) Place the cylinder head assembly on the cylinder.

6) Hold the piston rings in proper positions, and insert NOTE
the piston into the cylinder (1). (Page 1D-40)
When installing the cylinder head, keep the
NOTE cam chain taut.
• When inserting the piston into the cylinder, 11) Apply engine oil to the both side of the cylinder head
take care not to bend the piston rings. bolt washers (1) before installing.
• When installing the cylinder, keep the cam
chain (2) taut. NOTE
The rounded side of the washer should be
positioned upside.

1
IG12K1140167-01

1 12) Tighten the cylinder head bolts (1) according to the

following procedure:
2
a) Tighten cylinder head bolts to 17 Nm (1.7 kgf-m,
12.5 lbf-ft) in diagonally.
IG12K1140081-02
b) Retighten them to 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
7) Install the cam chain guide No.1 (1). in the same manner as in Step a).
NOTE Tightening torque
There is a guide holder at the bottom of the Cylinder head bolt (a): 17 Nm → 25 Nm (1.7 kgf-
cam chain guide cast in the crankcase. Be m → 2.5 kgf-m, 12.5 lbf-ft → 18.5 lbf-ft)
sure that the cam chain guide is inserted to
the holder properly. 1, (a)

1, (a)
IG12K1140125-02

IG12K1140082-02
 Engine Mechanical: 1D-32

13) Tighten the cylinder nuts (1) and cylinder head nuts
(2) to the specified torque.
Tightening torque 2, (b)
Cylinder nut (a): 10 N·m (1.0 kgf-m, 7.3 lbf-ft)
Cylinder head nut (b): 10 N·m (1.0 kgf-m, 7.3 lbf-
ft)

2, (b) 1, (a)
1, (a)

IL23K3140002-01

1, (a)
! WARNING
Do not reuse cylinder head front engine
IG12K1140084-02
mounting bolts (1).
14) Install spacer (1) to the cylinder head front engine
mounting. Replace with the new one.

! CAUTION
1
Make sure that screw side and tightening
1 surface of the bolt and nut free from
moisture/oil.

16) Apply engine oil to a new gasket and tighten bolt (1)
to the specified torque.
Tightening torque
Bolt (a): 10 N·m (1.0 kgf-m, 7.3 lbf-ft)

IL23K3140001-01
1, (a)
15) Install cylinder head front engine mounting bolts (1)
and cylinder head rear engine mounting bolt (2) and
then tighten to the specified torque.
Tightening torque
Front engine mounting bolt (a): 75 N·m (7.5 kgf-
m, 55.3 lbf-ft)
Rear engine mounting nut (b): 31 N·m (3.1 kgf-
IG12K1140086-03
m, 22,8 lbf-ft)
17) Install the removed parts.
1D-33 Engine Mechanical:

Cam Chain Guide Inspection

BENM23K11406021
Refer to “Cam Chain Tension Adjuster / Camshaft
Housing / Camshaft Removal” (Page 1D-19) and
“Cylinder Head Assembly / Cam Chain Guide / Cylinder (a)
Removal and Installation” (Page 1D-29).
Check the contacting surface of the cam chain guides. If
it is worn or damaged, replace it with a new one.

IG12K1140089-02

Cam Chain Tensioner Inspection

BENM23K11406023
Refer to “Cam Chain Tensioner Removal and
1
Installation” (Page 1D-33).
Check the contacting surface of the cam chain tensioner.
If it is worn or damaged, replace it with a new one.
IG12K1140087-03

1. Cam chain guide No.1 2. Cam chain guide No.2

Cam Chain Tensioner Removal and Installation

BENM23K11406022
Removal
1) Remove the cylinder. (Page 1D-29)
2) Remove the generator rotor. (Page 1J-5)
3) Remove the cam chain tensioner (1) and washer (2).

IG12K1140090-02

Cylinder Head Disassembly and Reassembly

1 BENM23K11406024
Refer to “Cylinder Head Assembly / Cam Chain Guide /
2 Cylinder Removal and Installation” (Page 1D-29).

Disassembly
1) Remove the thermostat cover and thermostat.
(Page 1F-13)
IG12K1140088-02
2) Remove the bolt (1) and gasket (2).
Installation
Install the cam chain tensioner in the reverse order of
removal. Pay attention to the following point:
• Tighten the cam chain tensioner bolt to the specified
torque.
Tightening torque
Cam chain tensioner bolt (a): 10 N·m (1.0 kgf-m,
7.3 lbf-ft) 1

2
IG12K1140091-03

3) Remove the stud bolts (1).

 Engine Mechanical: 1D-34

Cylinder Head Inspection

BENM23K11406025
Refer to “Cylinder Head Assembly / Cam Chain Guide /
Cylinder Removal and Installation” (Page 1D-29).
1) Decarbonize the combustion chamber.
2) Check the gasket surface of the cylinder head for
distortion with a straightedge and thickness gauge,
taking a clearance reading at several places as
1 indicated. If the largest reading at any position of the
straightedge exceeds the limit, replace the cylinder
head.
IG12K1140092-02 Special tool
4) Remove the valves and valve springs. (Page 1D- 09900–20803
34)
Cylinder head distortion
[Limit]: 0.05 mm (0.002 in)
Reassembly
1) Install the valves and valve springs. (Page 1D-34)
2) Install the stud bolts (1).

1
IG12K1140094-02

Valve / Valve Spring Removal and Installation

IG12K1140092-02 BENM23K11406026
Refer to “Cylinder Head Assembly / Cam Chain Guide /
3) Install a new gasket (1) to the bolt (2), and then
Cylinder Removal and Installation” (Page 1D-29).
tighten the bolt.
NOTICE
Identify the position of each removed part.
Organize the parts so that they can be
reinstalled in their original positions.

Removal
1) Remove the tappet (1) and shim (2) by fingers or
2 magnetic hand.

1
IG12K1140093-02 1
2

IG12K1140063-01
1D-35 Engine Mechanical:

2) Using the special tools, compress the valve spring Installation

and remove the two cotter halves (1) from the valve 1) Install the valve spring seat (1).
stem.
2) Apply molybdenum oil solution to a new oil seal (2),
Special tool and press-fit it into position.
(A): 09916–14510
“A”: Assembly lubrication (Molybdenum oil
(B): 09916–14530
solution)
(C): 09919–28610
09916–84511

1 1

2, “A”

(C)
(B)
(A) IG12K1140098-03

IG12K1140095-03
3) Insert the valve, with its stem coated with
molybdenum oil solution all around and along the full
3) Remove the valve spring retainer (1) and valve
stem length without any break.
spring (2).
4) Pull out the valve (3) from the combustion chamber NOTICE
side. When inserting the valve, take care not to
damage the lip of the oil seal.
3
“A”: Assembly lubrication (Molybdenum oil
2 solution)

IG12K1140096-03
“A”
5) Remove the oil seal (1) and spring seat (2). ID26J1140087-02

4) Install the valve spring with the small-pitch portion

(1) facing cylinder head.

4
2

3 2

1 1

ID26J1140274-03
IG12K1140097-02
2. Large-pitch portion 4. Paint
6) Remove the other valves in the same manner as 3. Upward
described previously.
5) Put on the valve spring retainer (1), and using the
special tools, press down the spring, fit the cotter
halves (2) to the stem end, and release the lifter to
allow the cotter halves to wedge in between retainer
and stem.
 Engine Mechanical: 1D-36

NOTICE NOTE
• Be sure to restore each spring and valve to When seating the tappet shim, be sure the
their original positions. figure printed surface faces the tappet.
• Be careful not to damage the valve and
valve stem when handling it.
• Compressing of the valve spring must be 2
restricted to the extent only necessary to 1
prevent the spring from fatigue.

Special tool
(A): 09916–14510
(B): 09916–14530
(C): 09919–28610
09916–84511
IG12K1140100-02

2
1
Valve Inspection
BENM23K11406027
Refer to “Valve / Valve Spring Removal and Installation”
(Page 1D-34)

Valve Stem Runout

Support the valve using V-blocks, and check its runout
(C) using the dial gauge as shown in the figure. If the runout
(B)
(A) exceeds the service limit, replace the valve.
IG12K1140099-03 Special tool
6) Be sure that the rounded lip (1) of the cotter (3) fits (A): 09900–20607
snugly into the groove (2) in the stem end. (B): 09900–20701
(C): 09900–21304
2 1 Valve stem runout
Intake & Exhaust [Limit]: 0.05 mm (0.002 in)

(A)
3

(B)

IE12J1140082-01

7) Apply engine oil to the stem ends and tappet shims

(1).
8) Apply engine oil to the tappets (2).
9) Install the tappet shims and the tappets to their (C)
ID26J1140091-01
original positions.
Valve Head Radial Runout
Place the dial gauge at a right angle to the valve head
face and measure the valve head radial runout. If it
measures more than the service limit, replace the valve.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09900–21304
Valve head radial runout
Intake & Exhaust [Limit]: 0.03 mm (0.001 in)
1D-37 Engine Mechanical:

(A)

(B)

(C)
(A)
ID26J1140092-01
ID26J1140094-01

Valve Face Wear

Visually inspect each valve face for wear. Replace any Valve Seat Width
valve with an abnormally worn face. The thickness of the 1) Visually check for valve seat width on each valve
valve face decreases as the face wears. Measure the face. If the valve face has worn abnormally, replace
valve head “a”. If it is out of specification replace the the valve.
valve with a new one. 2) Coat the valve seat with a red lead (Prussian Blue)
Special tool and set the valve in place.
09900–20102 3) Rotate the valve with light pressure.
Valve head thickness Special tool
Intake [Limit]: 0.5 mm (0.02 in) (A): 09916–10911
Exhaust [Limit]: 0.5 mm (0.02 in)
(A)

“a”

IF34J1140162-01

IG12K1140101-02
Valve Stem Wear
Measure the valve stem O.D. using the micrometer. 4) Check that the transferred red lead (Blue) on the
If the valve stem is worn down to the limit, as measured valve face is uniform all around and in center of the
with a micrometer, replace the valve. valve face.
If the seat width “a” measured exceeds the standard
Special tool value, or seat width is not uniform reface the seat
(A): 09912–66310 using the seat cutter. (Page 1D-38)
Valve stem O.D. Valve seat width
Intake [Standard]: 4.475 – 4.490 mm (0.1762 – 0.1767 Intake [Standard]: 0.9 – 1.1 mm (0.036 – 0.043 in)
in) Exhaust [Standard]: 1.0 – 1.2 mm (0.040 – 0.047
Exhaust [Standard]: 4.455 – 4.470 mm (0.1754 – in)
0.1759 in)

“a”

IF34J1140163-02
 Engine Mechanical: 1D-38

Valve Seat Sealing Condition

1) Clean and assemble the cylinder head and valve
components.
2) Fill the intake and exhaust ports with gasoline to
check for leaks. If any leaks occur, inspect the valve
seat and face for burrs or other things that could
prevent the valve from sealing. (Page 1D-38)

ID26J1140263-01

Valve Seat Repair

BENM23K11406029
Refer to “Valve / Valve Spring Removal and Installation”
(Page 1D-34)
The valve seats (1) for intake and exhaust valves are
machined to two or three different angles. The seat
contact surface is cut at 45°.
IG12K1140126-01
NOTICE
Valve Spring Inspection • The valve seat contact area must be
BENM23K11406028
Refer to “Valve / Valve Spring Removal and Installation” inspected after each cut.
(Page 1D-34) • Do not use lapping compound after the
The force of the coil spring keeps the valve seat tight. final cut is made. The finished valve seat
Weakened spring results in reduced engine power should have a velvety smooth finish but
output and often accounts for the chattering noise not a highly polished or shiny finish. This
coming from the valve mechanism. will provide a soft surface for the final
Check the valve springs for proper strength by seating of the valve which will occur
measuring its free length and also by the force required during the first few seconds of engine
to compress it. If the spring length is less than the operation.
service limit or if the force required to compress the
spring does not fall within the range specified, replace NOTE
spring as a set.
After servicing the valve seats, be sure to
Special tool check the valve clearance after the cylinder
(A): 09900–20102 head has been installed. (Page 1D-25)
Valve spring free length
Intake & Exhaust [Limit]: 41.8 mm (1.65 in) 60° 45° 30° 45°
15°
Valve spring pre-load
When compressed to 38.10 mm (1.500 in)
Intake & Exhaust [Standard]: 138.7 – 159.5 N (14.2 –
16.2 kg, 31.2 – 35.8 lbf)
1 1

IN. EX.
(A) IG12K1140102-01

Intake Exhaust
Seat angle 30°/45°/60° 15°/45°
0.9 – 1.1 mm 1.0 – 1.2 mm
Seat width
(0.035 – 0.043 in) (0.040 – 0.047 in)
Valve 24 mm 21 mm
ID26J1140098-01 diameter (0.94 in) (0.83 in)
Valve guide 4.500 – 4.512 mm
←
I.D. (0.1772 – 0.1776 in)
1D-39 Engine Mechanical:

Cylinder Inspection Piston Removal and Installation

BENM23K11406030 BENM23K11406031
Refer to “Cylinder Head Assembly / Cam Chain Guide / Refer to “Cylinder Head Assembly / Cam Chain Guide /
Cylinder Removal and Installation” (Page 1D-29). Cylinder Removal and Installation” (Page 1D-29).

Cylinder Distortion Removal

Check the gasket surface of the cylinder for distortion 1) Place a clean rag over the cylinder base so as not to
with a straightedge and thickness gauge, taking a drop the piston pin circlip (1) into the crankcase.
clearance reading at several places as indicated. If the
2) Remove the piston pin circlip.
largest reading at any position of the straightedge
exceeds the limit, replace the cylinder. 3) Draw out the piston pin (2) and remove the piston
(3).
Special tool
09900–20803
2 3
Cylinder distortion
[Limit]: 0.05 mm (0.002 in)

IG12K1140105-02

Installation
1) When installing the piston pin, apply molybdenum oil
IG12K1140103-02 solution onto the piston pin.

Cylinder Bore NOTE

Check the cylinder wall for any scratches, nicks or other When installing the piston, the indent (1) on
damage. Measure the cylinder bore diameter at six the piston head must be faced to exhaust
places. side.
Special tool “A”: Assembly lubrication (Molybdenum oil
09900–20530 solution)
Cylinder bore
[Standard]: 62.000 – 62.015 mm (2.4410 – 2.4415 in)

“A”

IG12K1140104-02
IH23K5140001-01
 Engine Mechanical: 1D-40

2) Place a clean rag over the cylinder base so as not to Installation

drop the piston pin circlip (1) into the crankcase.
3) Install a new piston pin circlip.
NOTE
End gap of the circlip should not be aligned
with the cutaway (2) in the piston pin bore.
NOTE
• When installing the piston ring, be careful
not to damage the piston.
• Do not expand the piston ring excessively
since it is apt to be broken down.

1) Install the piston rings in the order of the oil ring, 2nd
ring and 1st ring.
a) The first member to go into the oil ring groove is
a spacer (1).
After placing the spacer, fit the two side rails (2).

2 2

1 1

2
IH23K5140002-01

Piston Ring Removal and Installation IE39J1140163-02

BENM23K11406032
Refer to “Piston Removal and Installation” (Page 1D-39).
NOTICE
Removal When installing the spacer, be careful not to
allow its two ends to overlap in the groove.
1) Carefully spread the ring opening with your thumbs
and then push up the opposite side of the 1st ring to
remove it.
[A]
NOTE
Do not expand the piston ring excessively to
avoid breaking the ring.

[B]
IF34J1140094-02

[A]: Incorrect [B]: Correct

I831G1140178-01

2) Remove the 2nd ring and oil ring in the same

procedure.
1D-41 Engine Mechanical:

b) Install the 2nd ring (1) and 1st ring (2) to piston. Piston and Piston Ring Inspection
BENM23K11406033
NOTE Refer to “Piston Ring Removal and Installation” (Page
1D-40).
• 1st ring and 2nd ring differ in shape.
• Face the side with the stamped mark Piston Diameter
upward when assembling. Measure the piston diameter using the micrometer at 12
mm (0.47 in) “a” from the skirt end. If the piston diameter
is less than the service limit, replace the piston.
2
Special tool
(A): 09900–20203
Piston diameter
[Limit]: 61.880 mm (2.4362 in)

IG12K1140108-02
“a”
2) Position the gaps of the three rings and side rails as
IE12J1140101-01
shown. Before inserting piston into the cylinder,
check that the gaps are so located.

EX.

1 120° 2

(A)
120° 120°
IE12J1140102-01
IN.
3 Piston to Cylinder Clearance
ID26J1140121-05
Subtract the piston diameter from the cylinder bore
1. 2nd ring and lower side rail diameter. If the piston to cylinder clearance exceeds the
2. Upper side rail service limit, replace both the cylinder and the piston.
3. 1st ring and spacer
Piston to cylinder clearance
[Limit]: 0.120 mm (0.0047 in)
 Engine Mechanical: 1D-42

Piston Ring to Groove Clearance Piston Ring Free End Gap and Piston Ring End Gap
Measure the side clearances of the 1st and 2nd piston Measure the piston ring free end gap using vernier
rings using the thickness gauge. If any of the clearances calipers. Next, fit the piston ring squarely into the
exceed the limit, replace both the piston and piston cylinder and measure the piston ring end gap using the
rings. thickness gauge. If any of the measurements exceed the
service limit, replace the piston ring with a new one.
Special tool
(A): 09900–20803 Special tool
(B): 09912–66310 (A): 09900–20102
(B): 09900–20803
Piston ring to groove clearance
1st [Limit]: 0.180 mm (0.0071 in) Piston ring free end gap
2nd [Limit]: 0.150 mm (0.0059 in) 1st [Limit]: 7.7 mm (0.30 in)
2nd [Limit]: 5.0 mm (0.20 in)
Piston ring groove width
1st [Standard]: 0.81 – 0.83 mm (0.0319 – 0.0327 in) Piston ring end gap
2nd [Standard]: 0.81 – 0.83 mm (0.0319 – 0.0327 in) 1st [Limit]: 0.50 mm (0.020 in)
Oil [Standard]: 1.51 – 1.53 mm (0.0594 – 0.0602 in) 2nd [Limit]: 0.50 mm (0.020 in)
Piston ring thickness
1st [Standard]: 0.77 – 0.79 mm (0.0303 – 0.0311 in)
2nd [Standard]: 0.77 – 0.79 mm (0.0303 – 0.0311 in)

(A)

(A)
ID26J1140126-02

(B)
IG12K1140109-02

(A)
(A)
(B)

IG12K1140110-02

ID26J1140125-01
1D-43 Engine Mechanical:

Piston Pin Bore Cam Chain Removal and Installation

Measure the piston pin bore inside diameter using the BENM23K11406034

small bore gauge. If measurement is out of specification, Removal

replace the piston. 1) Remove the cam chain tensioner. (Page 1D-33)
2) Remove the cam chain (1).
Special tool
(A): 09900–20602
(B): 09900–22401 1
Piston pin bore I.D.
[Limit]: 15.030 mm (0.5917 in)

(A)
(B)

IG12K1140111-02

ID26J1140128-01 Installation
Install the cam chain in the reverse order of removal.
Piston Pin
Measure the piston pin outside diameter at three Balancer Shaft Drive / Driven Gear Removal and
positions using the micrometer. If any of the Installation
measurements are out of specification, replace the BENM23K11406035
piston pin. Removal
1) Remove the following parts.
Special tool
(A): 09912–66310 • Clutch component parts: (Page 5C-6)
• Oil pump component parts: (Page 1E-8)
Piston pin O.D.
[Limit]: 14.980 mm (0.5898 in) 2) Remove the primary drive gear (1), key (2) and
balancer shaft drive gear (3).

3
2
(A)
1

ID26J1140129-01

IG12K1140112-02

3) Install the suitable shaft (1) in order to fix the

balancer shaft.

“a”
IG12K1140113-02

“a”: 12.5 – 13.5 mm (0.50 – 0.53 in)

 Engine Mechanical: 1D-44

4) Check that the balancer shaft is fixed. Installation

Install the balancer shaft drive gear and driven gear in
the reverse order of removal. Pay attention to the
following points:
• Align the punch marks (1) on the balancer shaft drive
gear (2) and balancer shaft driven gear (3).

IG12K1140114-02

5) Remove the balancer shaft driven gear nut (1) and

washer (2).
2
3
IG12K1140118-02
2
• Hold the balancer shaft and tighten the balancer shaft
driven gear nut (1) to the specified torque.
1 Tightening torque
Balancer shaft driven gear nut (a): 50 N·m (5.1
kgf-m, 37.0 lbf-ft)

1, (a)
IG12K1140115-02

6) Remove the balancer driven gear (1).

IG12K1140119-02

• Make sure combination color of primary drive gear

installed with primary driven gear is correct. (Page
5C-14)

IG12K1140116-02 ! WARNING
7) Remove the key (1), spacer (2) and washer (3).
Primary drive gear and primary driven gear
are installed with combination color.

Failure to installation the gear will increase

1
the noise or abnormal friction.

IG12K1140117-02
1D-45 Engine Mechanical:

Balancer Shaft Driven Gear Disassembly and 2) Face the punch mark (1) of the balancer shaft driven
Reassembly gear inner race upward.
BENM23K11406036
3) Facing the sharp edge side of the snap ring (2)
Refer to “Balancer Shaft Drive / Driven Gear Removal
outward, fit it to the balancer shaft driven gear inner
and Installation” (Page 1D-43).
race (3). Position the opening (4) of the snap ring in
the center of the rib portion as shown in the figure.
Disassembly
4) Install the washer (5) and wave washer (6).
1) Remove the following parts from the balancer shaft
driven gear.
• Inner race (1)
• Snap rings (2) 1
6
3
• Balancer shaft driven gear (3)
• Dampers (4)
• Springs (5)
2
• Wave washer (6)
5
• Washer (7) 4
• Pin (8)
IG12K1140122-05
Special tool
09900–06107 5) Face the punch mark (1) of the balancer shaft driven
gear (2) upward, install it to the balancer shaft driven
gear inner race (3).
4
1

3 2
2
5
5

8 8 2
1
3

4
IG12K1140127-02

6 7 6) Align the cutaway (1) of the balancer shaft driven

IM23K1140001-02
Reassembly
1) Apply engine oil to the sliding surfaces of the
balancer shaft driven gear (1) and inner race (2).
gear inner race with the punch mark (2) of the
balancer shaft driven gear as shown in the figure and
install springs (3) and dampers (4).
NOTE
Make sure to install the pin (5) securely.

4
1 1
2

2 5

3
3
IG12K1140121-03

IM23K1140002-02
 Engine Mechanical: 1D-46

7) Facing the sharp edge side of the snap ring (1) 11) Remove the clutch cable from the clutch release
outward, fit it to the balancer shaft driven gear inner arm. Refer to “Clutch Cable Removal and
race. Position the opening (2) of the snap ring in the Installation” in Section 5C (Page 5C-3).
center of the rib portion as shown in the figure. 12) Disconnect the spark plug cap (1).

2
IG12K1140129-02 IG12K1140131-02

13) Disconnect the PAIR solenoid valve coupler (1),

Balancer Shaft Drive / Driven Gear Inspection PAIR valve hose (2) and (3).
BENM23K11406037
Refer to “Balancer Shaft Drive / Driven Gear Removal
and Installation” (Page 1D-43).
Inspect the balancer shaft drive gear (1) and driven gear
(2) for wear or damage. If any defects are found, replace (1)

them with new ones.

(2)
(3)

1 2

IH23K4140007-02

IG12K1140130-01

Engine Assembly Removal

BENM23K11406038
1) Disconnect the battery (–) lead wire. Refer to
“Battery Removal and Installation” in Section 1J
(Page 1J-13).
2) Drain engine oil. (Page 1E-5)
3) Remove the frame cover (Page 9D-22).
4) Drain engine coolant. Refer to “Engine Coolant
Replacement” in Section 1F (Page 1F-5).
5) Remove the muffler. (Page 1K-2)
6) Remove the EVAP Control System. Refer to “EVAP
Control System Removal and Installation (If
Equipped)” in Section 1B (Page 1B-13).
7) Remove the intake pipe. (Page 1D-16)
8) Remove the radiator. (Page 1F-8)
9) Remove the engine sprocket. (Page 3A-4)
10) Remove the GP switch from crankcase. Refer to “GP
Switch Removal and Installation” in Section 5B
(Page 5B-11).
1D-47 Engine Mechanical:

14) Remove PAIR control solenoid valve (1). Refer to 17) Support the engine using a jack (1).
“PAIR Control Solenoid Valve Removal and
Installation (If Equipped)” in Section 1B (Page 1B-
11).

IH23K4140016-01

15) Remove PAIR reed valve (1). Refer to “PAIR Reed

Valve Removal and Installation (If Equipped)” in IK23K4140011-01

Section 1B (Page 1B-11). 18) Remove the cylinder head front engine mounting
bolts (1) and cylinder head rear engine mounting (2).

1
1

IH23K4140006-01
16) Disconnect the stop lamp switch lead wire coupler
(1), generator lead wire coupler (2), gear position
sensor lead wire coupler (3), and ECT sensor
coupler (4).
IH23K5140007-01
19) Remove the engine mounting nuts (1) and bolts (2)
(crankcase lower side).
20) Gradually lower the engine. Then, remove the
engine assembly from the frame.

2 2
3 1
1

2 1

IH23K5140008-01
IH23K1140057-02
 Engine Mechanical: 1D-48

Engine Assembly Installation

BENM23K11406039
Install the engine assembly in the reverse order of removal. Pay attention to the following points:
• Install the engine assembly using a jack.

NOTICE
Be careful not to catch the wiring harness and hoses between the frame and the engine.

• Insert the engine mounting bolts (crankcase) (1) from left side, and install their new nuts (2).
• Install spacer (3) for cylinder head front engine mounting.
• Install new cylinder head front engine mounting bolts (4).

! WARNING
Do not reuse cylinder head front engine mounting bolts (4).

Replace with the new one.

! CAUTION
The screw side and the tightening surface of the bolt and the nut must be free from moisture / oil.

• Insert the cylinder head rear engine mounting nut (5).

• Tighten each bolts and nuts to the specified torque as shown.
Tightening torque
Rear upper/lower crankcase engine mounting nut (a): 75 N·m (7.5 kgf-m, 55.3 lbf-ft)
Cylinder head front engine mounting bolt (a): 75 N·m (7.5 kgf-m, 55.3 lbf-ft)
Cylinder head rear engine mounting nut (b): 31 N·m (3.1 kgf-m, 22.8 lbf-ft)

LH RH

2 (a) 5 (b)

1 4 (a)

“a”
2 (a)

1
2 (a)

“a”
3 3
4 (a)
4 (a) 4 (a)

(b) 5

“b”
IL23K3140003-02

1. Engine mounting bolt (crankcase side) 5. Cylinder head rear engine mounting nut : 31 Nm (3.1 kgf-m, 22.8 lbf-ft)
2. Engine mounting nut (crankcase side) “a”: 140 mm (5.51 in) : Do not reuse.
3. Spacer “b”: 35 mm (1.38 in)
4. Cylinder head front engine mounting bolts : 75 Nm (7.5 kgf-m, 55.3 lbf-ft)

• Install the EVAP control system (if equipped). (Page 1B-13)

1D-49 Engine Mechanical:

• Check the PAIR system hose. (Page 1B-12)

• Route the side-stand switch wiring harness (if equipped). (Page 9A-11)
• Connect PAIR control solenoid valve coupler. (Page 1B-11)
• Check the wiring harness routing. (Page 9A-11)
• After finishing the engine installation, check the following items.
– Drive chain slack: (Page 3A-2)
– Gearshift lever height: (Page 5B-13)
– Throttle cable play: (Page 1D-12)
– Clutch cable play: (Page 5C-2)
– Engine oil leakage: (Page 1E-5)
– Engine coolant leakage: (Page 1F-6)
– Fuel leakage: (Page 1G-5)
 Engine Mechanical: 1D-50

Crankcase Assembly Disassembly
BENM23K11406040
1) Remove the engine assembly. (Page 1D-46)
2) Remove the piston. (Page 1D-39)
3) Remove the starter motor assembly. (Page 1I-5)
4) Remove under cowling brace (1) and reservoir
bracket (2).
GSX R 125 Model
5) Remove the clutch cover. Refer to “Clutch Removal”
in Section 5C (Page 5C-6).
6) Remove the generator cover. Refer to “Generator
Removal” in Section 1J (Page 1J-5).
7) Remove the right side parts as follows.
• Oil pump (1) and oil pump drive gear (2): (Page
1E-8)
• Clutch (3): (Page 5C-6)
• Balancer shaft driven gear (4), balancer shaft
drive gear (5) and primary drive gear (6): (Page
1D-43)
• Gearshift shaft (7) and gearshift cam (8): (Page
5B-14)

5
3
2

IH23K1140065-01 4

GSX S 125 Model

7 6

8 1
2
IH23K1140061-02

8) Remove the left side parts as follows.

• Generator rotor (1): (Page 1J-5)
• Starter idle gear (2) and starter clutch gear (3):
(Page 1I-10)
• Oil sump filter (4)
• Cam chain tensioner (5): (Page 1D-33)
• Cam chain (6): (Page 1D-43)
IH23K2140007-01

5 2

1
4
IG12K1140166-01
1D-51 Engine Mechanical:

9) Remove the crankcase bolts (1) from left side. 12) Remove the crank balancer shaft (1) and shim (2).

NOTE
Loosen the crankcase bolts diagonally.
1

IG12K1140140-01

13) Remove the transmission component parts. (Page

5B-3)
14) Remove the crankshaft assembly (1) with the special
IG12K1140137-02
tool.
10) Turn over the crankcase and remove the right
crankcase (1) with the special tool. Special tool
(A): 09920–13120
NOTE
• Fit the crankcase separating tool, so that
the tool arms are in parallel with the side of
(A)
crankcase.
• The crankshaft and transmission
components should remain in the left
crankcase half. 1

Special tool
(A): 09920–13120

IG12K1140141-01

15) Remove the crankcase bearings. (Page 1D-56)

(A)

IG12K1140138-01

11) Remove the dowel pins (1).

IG12K1140139-01
 Engine Mechanical: 1D-52

Crankcase Assembly Reassembly 3) Install the transmission component parts. (Page

BENM23K11406041 5B-3)
1) Install the crankcase bearings. (Page 1D-56) 4) Install the crank balancer shaft (1) and shim (2).
2) Install the crankshaft assembly into the left
crankcase using the special tools.

NOTICE
1
• Do not hit the crankshaft with a plastic
mallet or the like to install it into the 2
crankcase.
• Make sure that the direction of conrod is
turned toward the cylinder hole.

NOTE
When installing the crankshaft into the IG12K1140140-01

crankcase, insert the attachments ø35 mm (1)
of the bearing installation set and crankshaft
installer attachment (2) between the
crankcase bearing inner race and crankshaft
installer.
5) Clean the mating surfaces of the left and right
crankcase halves.
6) Install the dowel pins (1) into the left crankcase.

Special tool
(A): 09910–32812
(B): 09913–70210
(C): 09910–32860 1

1
(A)

IG12K1140139-01

2, (C)

1, (B)
IG12K1140168-01

(A)

2, (C)

1, (B)

IG12K1140142-01
1D-53 Engine Mechanical:

7) Apply engine oil to each running and sliding part. 11) After the crankcase bolts have been tightened,
8) Apply sealant to the mating surface of the right check if the crankshaft (1), driveshaft (2) and
crankcase. countershaft (3) rotate smoothly.
Right side
NOTE
• Make surfaces free from moisture, oil, dust
and other foreign materials.
• Spread on surfaces thinly to form an even
layer, and assemble the crankcases within
few minutes.
• Take extreme care not to apply any sealant
3
to the oil hole, oil groove and bearing.
1
• Apply to distorted surfaces as it forms a
comparatively thick film.
IG12K1140145-01
“A”: Sealant 99000–31110 (SUZUKI BOND 1215)
Left side

1 2
“A”

IG12K1140146-01

12) Install the removed parts.

IG12K1140143-02

9) Assemble the right and left crankcase halves. ! WARNING

10) Tighten the crankcase bolts (L75) (1) and (L40) (2) a
Primary drive gear and primary driven gear
little at a time to equalize the pressure.
are installed with combination color.
Tightening torque Make sure combination color of primary drive
Crankcase bolt (a): 10 N·m (1.0 kgf-m, 7.3 lbf-ft) gear installed with primary driven gear is
correct. Refer to (Page 5C-14)
1, (a) 2, (a)
Failure to installation the gear will increase
the noise or abnormal friction.

IG12K1140144-01
 Engine Mechanical: 1D-54

Conrod / Crankshaft Inspection Conrod Deflection

BENM23K11406042 Wear on the big end of the conrod can be estimated by
Refer to “Crankcase Assembly Disassembly” (Page 1D- checking the movement of the small end. This method
50) and “Crankcase Assembly Reassembly” (Page 1D- can also check the extent of wear on the parts of the
52). conrod big end.
If the deflection exceeds the service limit, replace the
Conrod Small End I.D. crankshaft assembly.
Measure the conrod small end inside diameter with a
pair of dial calipers. • Move the small end sideways while holding the big
If the conrod small end inside diameter exceeds the end immovable in thrust direction.
service limit, replace the crankshaft assembly. • Measure the amount of deflection.
Special tool • Turn the conrod and see if it moves smoothly without
(A): 09900–20605 play and noise.

Conrod small end I.D. Special tool

[Limit]: 15.040 mm (0.5921 in) (A): 09900–20607
(B): 09900–20701
(C): 09900–21304
Conrod deflection
[Limit]: 3.0 mm (0.11 in)

(A)

(A)

(B)

IF34J1140164-01

Conrod Big End Side Clearance

Push the big end of the conrod to one side and measure
the side clearance using a thickness gauge. If the
clearance exceeds the service limit, replace crankshaft
assembly.
(C)
Special tool IF34J1140165-01
(A): 09900–20803
Conrod big end side clearance
[Limit]: 1.0 mm (0.039 in)

(A)

IG12K1140147-01
1D-55 Engine Mechanical:

Crankshaft Runout Balancer Shaft Inspection

With the right and left crank journals supported with V- BENM23K11406043

blocks, turn the crankshaft slowly. At this time, measure
the crankshaft end runout using a dial gauge. If the
runout exceeds the service limit, replace the crankshaft
assembly.
NOTE
Set the V-blocks so that the crankshaft
becomes horizontal.
Refer to “Crankcase Assembly Disassembly” (Page 1D-
50) and “Crankcase Assembly Reassembly” (Page 1D-
52).
Inspect the balancer shaft for wear or damage. If any
wear or damage is found, replace the balancer shaft with
a new one.

Special tool
(A): 09900–20607
09900–20701
09900–21304
Crankshaft runout
[Limit]: 0.080 mm (0.0031 in)

IG12K1140149-01
(A) (A)
Crankcase Bearing / Oil Seal Inspection
BENM23K11406044
Refer to “Crankcase Assembly Disassembly” (Page 1D-
50) and “Crankcase Assembly Reassembly” (Page 1D-
52).
1) Inspect the play “a” of the bearings by hand while it
is in the crankcase or installed in the crankshaft.
IG12K1140171-01 Rotate the inner race or outer race by hand to
inspect for abnormal noise and smooth rotation.
Width Between Crankshaft Webs Replace the bearings if there is anything unusual.
Measure the width “a” between crankshaft webs. If the (Page 1D-56)
width is out of specification, replace the crankshaft
assembly. “a”
Crank web to web width
“a”
[Standard]: 52.90 – 53.10 mm (2.083 – 2.090 in)

ID26J1140287-03

Right case

“a”
IG12K1140148-02

IG12K1140151-01
 Engine Mechanical: 1D-56

Left case Right crankcase

1) Remove the crankshaft bearing (1) and balancer
shaft bearing (2) with the special tool.
Special tool
(A): 09913–70210

(A) (A)

IG12K1140152-01

2) Inspect oil seal lip (1) for wear or damage. If any

defects are found, replace the oil seal with a new 2
1
one. (Page 5B-8)

IG12K1140155-01

2) Remove the driveshaft bearing, countershaft bearing

1
and gearshift cam bearing. (Page 5B-8)

Installation
Left crankcase
1) Install a new crankshaft bearing (1) and a new
balancer shaft bearing (2) using the special tool.
Special tool
(A): 09913–70210
IG12K1140153-01

Crankcase Bearing Removal and Installation (A) (A)

BENM23K11406045
Refer to “Crankcase Assembly Disassembly” (Page 1D-
50) and “Crankcase Assembly Reassembly” (Page 1D-
52).

Removal
Left crankcase 2
1
1) Remove the crankshaft bearing (1) and balancer
shaft bearing (2) with the special tools.
IG12K1140156-01
Special tool
2) Install the driveshaft bearing and countershaft
(A): 09913–70210
bearing. (Page 5B-8)
(B): 09921–20240

(A) (B)

1
2

IG12K1140154-01

2) Remove the driveshaft bearing and countershaft

bearing. (Page 5B-8)
1D-57 Engine Mechanical:

Right crankcase 4) Put the plastigage (special tool) about 10 mm (0.39

1) Install a new crankshaft bearing (1) and a new in) on the shim as shown.
balancer shaft bearing (2) using the special tool. Special tool
Special tool (A): 09900–22301
(A): 09913–70210

(A) (A)

1
(A)

2
IG12K1140159-01

IG12K1140157-01 5) Install the right crankcase and tighten the bolts (L75)
2) Install the driveshaft bearing, countershaft bearing (1) and (L40) (2) to the specified torque.
and gearshift cam bearing. (Page 5B-8)
NOTE
Do not apply sealant to the mating surfaces
Crankshaft Thrust Clearance Inspection and
in this stage.
Shim Selection
BENM23K11406046
Refer to “Crankcase Assembly Disassembly” (Page 1D- Tightening torque
50) and “Crankcase Assembly Reassembly” (Page 1D- Crankcase bolt (a): 10 N·m (1.0 kgf-m, 7.3 lbf-ft)
52).
1, (a) 2, (a)
Inspection
1) Install the crankshaft into the left crankcase.
2) Clean and degrease the contact surfaces of the
crankshaft, shim and inner race of the right
crankshaft bearing.
3) Install the removed shim (1) onto the crankshaft (2).

1
IG12K1140160-01

6) Separate the crankcase into 2 parts, left and right.

7) Measure the width of compressed plastigage with
2 the envelope scale.
Crankshaft thrust clearance
[Standard]: 0.02 – 0.07 mm (0.0008 – 0.0027 in)

IG12K1140158-01

IG12K1140161-01

8) If the thrust clearance is out of standard value, select

an appropriate shim.
 Engine Mechanical: 1D-58

Selection
1) Remove the thrust shim and measure its thickness using the micrometer.
Special tool
(A): 09912–66310
(B): 09900–20702

(A)

(B)

ID26J1140236-01

2) Select a suitable shim from the following table.

Crankshaft thrust clearance (measured value) +
Part No. Thrust shim thickness
shim thickness (measured value)
0.60 – 0.65 mm (0.024 – 0.026 in) 12228-12K00-0A0 0.58 – 0.62 mm (0.023 – 0.024 in)
0.65 – 0.70 mm (0.026 – 0.028 in) 12228-12K00-0B0 0.63 – 0.67 mm (0.025 – 0.026 in)
0.70 – 0.75 mm (0.028 – 0.030 in) 12228-12K00-0C0 0.68 – 0.72 mm (0.027 – 0.028 in)
0.75 – 0.80 mm (0.030 – 0.031 in) 12228-12K00-0D0 0.73 – 0.77 mm (0.029 – 0.030 in)
0.80 – 0.85 mm (0.031 – 0.033 in) 12228-12K00-0E0 0.78 – 0.82 mm (0.031 – 0.032 in)
0.85 – 0.90 mm (0.033 – 0.035 in) 12228-12K00-0F0 0.83 – 0.87 mm (0.033 – 0.034 in)
0.90 – 0.95 mm (0.035 – 0.037 in) 12228-12K00-0G0 0.88 – 0.92 mm (0.035 – 0.036 in)
0.95 – 1.00 mm (0.037 – 0.039 in) 12228-12K00-0H0 0.93 – 0.97 mm (0.037 – 0.038 in)
1.00 – 1.05 mm (0.039 – 0.041 in) 12228-12K00-0J0 0.98 – 1.02 mm (0.039 – 0.040 in)
1.05 – 1.10 mm (0.041 – 0.043 in) 12228-12K00-0K0 1.03 – 1.07 mm (0.041 – 0.042 in)
1.10 – 1.15 mm (0.043 – 0.045 in) 12228-12K00-0L0 1.08 – 1.12 mm (0.043 – 0.044 in)
1.15 – 1.20 mm (0.045 – 0.047 in) 12228-12K00-0M0 1.13 – 1.17 mm (0.044 – 0.046 in)
1.20 – 1.25 mm (0.047 – 0.049 in) 12228-12K00-0N0 1.18 – 1.22 mm (0.046 – 0.048 in)
1.25 – 1.30 mm (0.049 – 0.051 in) 12228-12K00-0P0 1.23 – 1.27 mm (0.048 – 0.050 in)
1.30 – 1.35 mm (0.051 – 0.053 in) 12228-12K00-0R0 1.28 – 1.32 mm (0.050 – 0.052 in)
1.35 – 1.40 mm (0.053 – 0.055 in) 12228-12K00-0S0 1.33 – 1.37 mm (0.052 – 0.054 in)
1.40 – 1.45 mm (0.055 – 0.057 in) 12228-12K00-0T0 1.38 – 1.42 mm (0.054 – 0.056 in)

Specifications
Tightening Torque Specifications
BENM23K11407001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Air cleaner outlet tube clamp screw 1.5 0.15 1.10 (Page 1D-11)
Air cleaner box bolt 10 1.0 7.3 (Page 1D-11)
Throttle body clamp screw 1.5 0.15 1.10 (Page 1D-14)
Intake pipe mounting bolt 1.0 Nm → 6.5 Nm (0.10 kgf-m → 0.66 kgf- (Page 1D-16)
m, 0.75 lbf-ft → 4.80 lbf-ft)
Intake pipe No.2 clamp screw 1.5 0.15 1.10 (Page 1D-16)
Cylinder head cover bolt 12 1.2 9.0 (Page 1D-18)
PAIR reed valve cover bolt 10 1.0 7.3 (Page 1D-18)
PAIR control solenoid valve bracket bolt 10 1.0 7.3 (Page 1D-18)
Cam sprocket bolt 11 1.1 8.5 (Page 1D-20)
Camshaft journal holder bolt 10 1.0 7.3 (Page 1D-22)
Cam chain tension adjuster bolt 10 1.0 7.3 (Page 1D-22)
Cam chain tension adjuster plug 8.0 0.82 5.90 (Page 1D-23)
Valve timing inspection plug 2.3 0.23 2.0 (Page 1D-23)
1D-59 Engine Mechanical:

Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Generator cover plug 10,5 1.07 7.75 (Page 1D-23)
Cylinder head bolt 17 Nm → 25 Nm (1.7 kgf-m → 2.5 kgf-m, (Page 1D-31)
12.5 lbf-ft → 18.5 lbf-ft)
Cylinder nut 10 1.0 7.3 (Page 1D-32)
Cylinder head nut 10 1.0 7.3 (Page 1D-32)
Front engine mounting bolt 75 7.5 55.3 (Page 1D-32)
Rear engine mounting nut 31 3.1 22,8 (Page 1D-32)
Bolt 10 1.0 7.3 (Page 1D-32)
Cam chain tensioner bolt 10 1.0 7.3 (Page 1D-33)
Balancer shaft driven gear nut 50 5.1 37.0 (Page 1D-44)
Rear upper/lower crankcase engine mounting (Page 1D-48)
75 7.5 55.3
nut
Cylinder head front engine mounting bolt 75 7.5 55.3 (Page 1D-48)
Cylinder head rear engine mounting nut 31 3.1 22.8 (Page 1D-48)
Crankcase bolt (Page 1D-53) /
10 1.0 7.3
(Page 1D-57)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Throttle Cable Routing Diagram” (Page 1D-1)
“Intake System Components” (Page 1D-6)
“Engine Assembly Installation” (Page 1D-48)
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Recommended Service Material
Material
Assembly lubrication
Sealant
Thread lock cement
BENM23K11408001
SUZUKI recommended product or Specification Note
Molybdenum oil solution — (Page 1D-20) / (Page
1D-31) / (Page 1D-35) /
(Page 1D-35) / (Page
1D-39)
SUZUKI BOND 1215 P/No.: 99000–31110 (Page 1D-30) / (Page
1D-53)
SUZUKI BOND 1207B P/No.: 99000–31140 (Page 1D-17)
THREAD LOCK CEMENT 1303B P/No.: 99000–32030 (Page 1D-20)

Special Tool
BENM23K11408002
09900–06107 09900–20102
Snap ring pliers (External) Vernier calipers (200 mm)
(Page 1D-45) (Page 1D-37) /
(Page 1D-38) /
(Page 1D-42)

09900–20202 09900–20203
Micrometer (25 - 50 mm) Micrometer (50 - 75 mm)
(Page 1D-24) (Page 1D-41)
 Engine Mechanical: 1D-60

09900–20530 09900–20602
Cylinder gauge set Dial gauge (1 x 0.001 mm)
(Page 1D-39) (Page 1D-25) /
(Page 1D-43)

09900–20605 09900–20607
Dial calipers (10 - 34 mm) Dial gauge (10 x 0.01 mm)
(Page 1D-54) (Page 1D-24) /
(Page 1D-36) /
(Page 1D-36) /
(Page 1D-54) /
(Page 1D-55)
09900–20701 09900–20702
Dial gauge chuck Micrometer fixture
(Page 1D-24) / (Page 1D-58)
(Page 1D-36) /
(Page 1D-36) /
(Page 1D-54) /
(Page 1D-55)
09900–20803 09900–21304
Thickness gauge V blocks
(Page 1D-26) / (Page 1D-24) /
(Page 1D-34) / (Page 1D-36) /
(Page 1D-39) / (Page 1D-36) /
(Page 1D-42) / (Page 1D-54) /
(Page 1D-42) / (Page 1D-55)
(Page 1D-54)
09900–22301 09900–22302
Plastigage (0.025 - 0.076 Plastigage (0.051 - 0.152
mm) mm)
(Page 1D-24) / (Page 1D-24)
(Page 1D-57)

09900–22401 09900–22403
Small bore gauge (10 - 18 Small bore gauge (18 - 35
mm) mm)
(Page 1D-43) (Page 1D-25)

09910–32812 09910–32860
Crankshaft installer Crankshaft installer spacer
(20 mm)
1. Main unit 2. Attachment (Page 1D-52)
(Page 1D-52)
1D-61 Engine Mechanical:

09912–66310 09913–10750
Micrometer (0 - 25 mm) Compression gauge adapter
(Page 1D-25) / (Page 1D-5)
(Page 1D-37) /
(Page 1D-42) /
(Page 1D-43) /
(Page 1D-58)
09913–70210 09915–64512
Bearing installer set Compression gauge set
(2500 kPa)
(Page 1D-52) / 1. Gauge 2. Hose (Adapter)
(Page 1D-56) / (Page 1D-5)
(Page 1D-56) /
(Page 1D-56) /
(Page 1D-57)
09916–10911 09916–14510
Valve lapper set Valve lifter
(Page 1D-37) 1. Main unit 2. Attachment
(Page 1D-35) /
(Page 1D-36)

09916–14530 09916–84511
Valve lifter attachment Tweezers
(Page 1D-35) / (Page 1D-35) /
(Page 1D-36) (Page 1D-36)

09919–28610 09920–13120
Sleeve protector Crankcase separator
(Page 1D-35) / 1. Main unit 2. Bolt 3.
(Page 1D-36) Attachment
(Page 1D-51) /
(Page 1D-51)

09921–20240
Bearing remover set
(Page 1D-56)
 Engine Lubrication System: 1E-1

Engine Lubrication System

Engine

Precautions
Precautions for Engine Oil
BENM23K11500001
Refer to “Fuel / Oil / Fluid / Coolant Recommendation” in Section 0C (Page 0C-12).
1E-2 Engine Lubrication System:

Schematic and Routing Diagram

Engine Lubrication System Chart Diagram
BENM23K11502001

CAMSHAFT JOURNAL
HOLDER

INTAKE CAMSHAFT INTAKE CAMSHAFT

JOURNAL(FRONT) JOURNAL(REAR)
CYLINDER WALL CONROD SMALL END

INTAKE CAM FACES

CAM CHAIN
AND TAPPET CYLINDER HEAD CONROD BIG END BEARING

EXHAUST CAMSHAFT EXHAUST CAMSHAFT

JOURNAL(FRONT) JOURNAL(REAR)
CRANKSHAFT

EXHAUST CAM FACES

CAM CHAIN PISTON
AND TAPPET
CYLINDER COOLING JET

PISTON

COUNTERSHAFT
LEFT SIDE BEARING
OIL FILTER

DRIVESHAFT LEFT
SIDE BEARING
COUNTERSHAFT BY-PASS
AND GEARS

OIL PUMP

DRIVESHAFT
AND GEARS CLUTCH PLATES

OIL SUMP
FILTER

IG12K1150001-03
 Engine Lubrication System: 1E-3

Diagnostic Information and Procedures

Engine Lubrication Symptom Diagnosis
BENM23K11504001

Condition Possible cause Correction / Reference Item

Engine overheats Insufficient amount of engine oil. Check level and add. (Page 1E-5)
Defective oil pump. Replace. (Page 1E-8)
Clogged oil circuit. Clean.
Incorrect engine oil. Change. (Page 1E-5)
Exhaust smoke is dirty or Excessive amount of engine oil. Check level and drain. (Page 1E-5)
thick
Engine lacks power Excessive amount of engine oil. Check level and drain. (Page 1E-5)

Oil Pressure Check GSX S 125 Model

BENM23K11504002
Check the engine oil pressure periodically. This will give
a good indication of the condition of the moving parts.

NOTE
1
Before checking the oil pressure, check the
following:
• Oil level: (Page 1E-5)
• Oil leaks (If leak is found, repair it.)
• Oil quality (If oil is discolored or
deteriorated, replace it.)

1) Remove the oil gallery plug (M6) (1).

GSX R 125 Model
IH23K2150001-01

2) Install the oil pressure gauge and attachment into

1 the oil gallery.
Special tool
(A): 09915–74511
(B): 09940–40211

(B) (A)

IK23K4150001-01

IH23K1150007-02
1E-4 Engine Lubrication System:

3) Warm up the engine as follows: 6) Install a new gasket to the oil gallery plug (M6) (1).
Summer: 10 min. at 2000 r/min 7) Install the oil gallery plug (M6) and tighten it to the
Winter: 20 min. at 2000 r/min specified torque.
4) After warm up, increase the engine speed to 3000 r/
Tightening torque
min and read the oil pressure gauge.
Oil gallery plug (M6) (a): 10 N·m (1.0 kgf-m, 7.3
If the oil pressure is lower or higher than the
lbf-ft)
specification, the following causes may be
considered.
GSX R 125 Model
Oil pressure
At 60 °C (140 °F), 3000 r/min
[Standard]: 35 – 65 kPa (0.4 – 0.6 kgf/cm2, 5.08 – 1, (a)
9.42 psi)
High oil pressure Low oil pressure
• Engine oil viscosity is • Clogged oil filter
too high • Oil leakage from the oil
• Clogged oil passage passage
• Combination of the • Damaged O-ring
above items • Defective oil pump
• Combination of the
above items

5) Stop the engine and remove the oil pressure gauge IH23K1150002-01
and attachment.
GSX S 125 Model
! WARNING
To avoid the risk of being burned, remove the
oil pressure gauge when the oil has cooled.

1, (a)

IH23K2150002-01

8) Check the engine oil level. (Page 1E-5)

 Engine Lubrication System: 1E-5

Repair Instructions
Engine Oil Inspection Engine Oil Replacement
BENM23K11506001 BENM23K11506002
Engine Oil Leakage Inspection 1) Keep the motorcycle upright with the center stand.
Visually check the cylinder, crankcase, etc. for oil
2) Place an oil pan below the engine and remove the oil
leakage.
filler cap (1).
Engine Oil Level Inspection 3) Drain engine oil by removing the oil drain plug (2).
1) Keep the motorcycle upright. NOTE
2) Start the engine and allow it to run for three minutes Warming up of the engine will facilitate
at idling speed. draining of the engine oil due to reduced
3) Turn off the engine and wait about three minutes, viscosity.
then check the oil level through the inspection
window. If the level is below mark “L”, add oil to “F”
level. If the level is above mark “F”, drain oil to “F”
level.

IH23K1150004-01

4) Install a new gasket washer to the oil drain plug (1).

5) Tighten the oil drain plug to the specified torque.
IH23K1150003-01
Tightening torque
Oil drain plug (a): 17,5 N·m (1.78 kgf-m, 12.9 lbf-
ft)

1, (a)

IH23K1150005-01
1E-6 Engine Lubrication System:

6) Pour new oil through the oil filler hole. Oil Filter Replacement
BENM23K11506003
Necessary amount of engine oil 1) Drain engine oil. (Page 1E-5)
Oil change [Standard]: 1300 ml (1.37 US qt, 1.14
2) Remove the oil filter cap (1) and oil filter (2).
Imp qt)
Oil and filter change [Standard]: 1400 ml (1.48 US
qt, 1.23 Imp qt)
Engine overhaul [Standard]: 1500 ml (1.59 US qt,
1.32 Imp qt)
2
GSX R 125 Model
1

IG12K1150009-01

3) Replace the oil filter O-ring (1) with a new one and
apply engine oil to it.

IH23K1150008-02

GSX S 125 Model 1

IG12K1150010-01

4) Fix the spring (1) to the oil filter cap firmly.

5) Replace the oil filter cap O-ring (2) with a new one
and apply engine oil to it.

IH23K2150003-01

7) Install the oil filler cap.

2
8) Check the engine oil level. (Page 1E-5)

IG12K1150011-01
 Engine Lubrication System: 1E-7

6) Position the oil filter (1) so that the valve (2) comes Installation
outside. 1) Install the oil sump filter (1).

NOTICE
• The tab (2) of the oil sump filter should be
positioned upward.
• The lip (3) of the oil sump filter should be
positioned downward.
1 2 • The shorter side of the oil sump filter
should be positioned inside.

IG12K1150012-01

7) Install the oil filter cap (1) and tighten the bolts (2) to 2
the specified torque.
Tightening torque
Oil filter cap bolt (a): 10 N·m (1.0 kgf-m, 7.3 lbf-
ft) 1

2, (a)
3

IG12K1150015-03

IK23K4150002-01 “a”
8) Add new engine oil. (Page 1E-5)
9) Check the engine oil level. (Page 1E-5)

Oil Sump Filter Removal and Installation

BENM23K11506004
Removal
1) Remove the generator cover and gasket. (Page
1J-5)
2) Remove the oil sump filter (1). IG12K1150016-01

“a”: Shorter side

2) Install the generator cover. (Page 1J-7)

IG12K1150014-01
1E-8 Engine Lubrication System:

Oil Sump Filter Inspection and Cleaning 3) Remove the pin (1), oil pump (2) and dowel pins (3).
BENM23K11506005
Refer to “Oil Sump Filter Removal and Installation”
(Page 1E-7).
If the oil sump filter is clogged with sediment or rust,
clean the oil sump filter using compressed air.
1
NOTE
When the oil sump filter is excessively
dirtied, replace it with a new one.

2 3

IG12K1150019-01

4) Remove the generator cover. Refer to “Generator

Removal” in Section 1J (Page 1J-5).
5) Hold the generator rotor (1) with the special tool and
remove the oil pump drive gear nut (2).

NOTE
This oil pump drive gear nut has left-hand
threads.
IG12K1150017-01
Special tool
Oil Pump / Oil Pump Driven Gear / Oil Pump (A): 09930–44521
Drive Gear Removal and Installation
BENM23K11506006
Removal 1

NOTICE 2
Do not attempt to disassemble the oil pump
assembly. The oil pump is available only as
an assembly.

1) Remove the clutch cover and gasket. Refer to

“Clutch Removal” in Section 5C (Page 5C-6).
(A)
2) Remove the dowel pin (1), O-ring (2), E-ring (3) and IG12K1150020-01
oil pump driven gear (4).
6) Remove the conical spring washer (1), washer (2)
and oil pump drive gear (3).

2
1
4 3 1

IG12K1150021-01
IK23K4150003-01
 Engine Lubrication System: 1E-9

7) Remove the key (1). • Hold the generator rotor (1) with the special tool and
tighten the oil pump drive gear nut (2) to the specified
torque.
Special tool
1
(A): 09930–44521
Tightening torque
Primary drive gear nut (a): 70 N·m (7.1 kgf-m,
52.0 lbf-ft)

IG12K1150027-02

Installation
Install the oil pump in the reverse order of removal. Pay
attention to the following points:
• Apply engine oil to the contacting surface and thread 2, (a)
part of oil pump drive gear nut.
• Install the key (1), oil pump drive gear (2), washer (3), (A)
IG12K1150023-01
conical spring washer (4) and oil pump drive gear nut
(5). • Tighten the oil pump mounting bolts to the specified
torque.
NOTE
Tightening torque
• The conical curve side of spring washer Oil pump mounting bolt (a): 10 N·m (1.0 kgf-m,
faces outside. 7.3 lbf-ft)
• The primary drive gear nut has left-hand
threads.

1 (a)

IG12K1150024-01

• When installing a new E-ring (1), pay attention to its

direction. Fit it to the side where the thrust direction
IG12K1150027-02 (2) is as shown in the illustration.

2
1

3 3 1

4
5 4

2 3 4 5

IG12K1150022-02
IF34J1150023-01

3. Oil pump driven gear 4. Sharp edge

1E-10 Engine Lubrication System:

• Apply engine oil to a new O-ring (1) and install it.
Oil Pump Inspection
BENM23K11506007
Refer to “Oil Pump / Oil Pump Driven Gear / Oil Pump
Drive Gear Removal and Installation” (Page 1E-8).
Rotate the oil pump by hand and check that it moves
smoothly. If it does not move smoothly, replace the oil
pump assembly.

IK23K4150004-01

IG12K1150026-01

Specifications
Tightening Torque Specifications
BENM23K11507001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Oil gallery plug (M6) 10 1.0 7.3 (Page 1E-4)
Oil drain plug 17,5 1.78 12.9 (Page 1E-5)
Oil filter cap bolt 10 1.0 7.3 (Page 1E-7)
Primary drive gear nut 70 7.1 52.0 (Page 1E-9)
Oil pump mounting bolt 10 1.0 7.3 (Page 1E-9)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Special Tool
BENM23K11508001
09915–74511 09930–44521
Oil pressure gauge set (600 Rotor holder
kPa)
1. Gauge 2. Hose (Page 1E-8) /
(Page 1E-3) (Page 1E-9)

09940–40211
Fuel pressure gauge
adapter
Discontinued
(Page 1E-3)
 Engine Cooling System: 1F-1

Engine Cooling System

Engine

Precautions
Precautions for Engine Cooling System
BENM23K11600001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2).

! WARNING

• You can be injured by boiling fluid or steam if you open the radiator cap when the engine is hot.
After the engine cools, wrap a thick cloth around cap and carefully remove the cap by turning it a
quarter turn to allow pressure to escape and then turn the cap all the way off.
• The engine must be cool before servicing the cooling system.
• Coolant is harmful:
– If it comes in contact with skin or eyes, flush with water.
– If swallowed accidentally, do not induce vomiting and call physician immediately.
– Keep it away from children.

Precautions for Engine Coolant

BENM23K11600002
Refer to “Fuel / Oil / Fluid / Coolant Recommendation” in Section 0C (Page 0C-12).

General Description
Engine Coolant Description
BENM23K11601001
Refer to “Fuel / Oil / Fluid / Coolant Recommendation” in Section 0C (Page 0C-12).

Schematic and Routing Diagram

Cooling Circuit Diagram
BENM23K11602001

RESERVOIR THERMOSTAT
TANK CYLINDER HEAD

CYLINDER ECT SENSOR

CRANKCASE

RADIATOR

WATER
PUMP

IG12K1160001-01
1F-2 Engine Cooling System:

Water Hose Routing Diagram

BENM23K11602002

“a” [A]

[B] [C]
7 4

[D]
8
7

[K]
[L]
[I]

1 [F]
(a) [G]
[E] 2

(a)
[H]

[J]

IM23K1160001-01

[A]: Keep clearance between the clamp and match mark. [L]: Pass the reservoir tank inlet hose pass the inside of flame
[B]: Insert the hose to the stopper. 1. Radiator cap
[C]: The match mark position on the bulge. 2. Reservoir tank overflow hose
[D]: Clamp end should face downward. 3. Reservoir tank
: Bring the reservoir tank filler neck into contact with the frame.
[E]: Clamp end should face downward. 4. Radiator inlet hose
: Face the yellow mark (7) left side and face the white mark (8) backward.
[F]: Pass reservoir tank inlet hose pass the inside of flame 5. Radiator lower cushion
[G]: Pass the reservoir tank inlet hose over the high-tension cord. 6. Match mark
[H]: Insert the reservoir tank inlet hose until it stops at the bulge on the 7. Yellow mark
radiator cap nipple as shown in the figure.
[I]: Keep a clearance of more than 5 mm (0.20 in) between the frame 8. White mark
and the radiator.
[J]: Face the radiator cap letter as shown in the figure. “a”: 2 – 6 mm (0.08 – 0.23 in)
[K]: Clamp the reservoir tank overflow hose, reservoir tank inlet hose : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
and wiring harness. Do not deform the hoses.
 Engine Cooling System: 1F-3

[G]
1 [E]

(b)

(a)
[B]
3 “a”
[F]
13

14 (b) 6 7 7 6 (b)

8 14
13
4
[C]
(b)
10 9
1
14

[A] (a)

5
[D]

11

IH23K1160041-01

[A]: Clamp end should face backward. 3. Thermostat cover 12. Reservoir tank
[B]: Clamp end should face right side. 4. Thermostat 13. White mark
: Face the thermostat leak hole upward.
[C]: Clamp end should face left side. 5. Water pump drain bolt gasket 14. Yellow mark
[D]: Clamp end should face forward. 6. Radiator spacer 15. Radiator outlet hose
[E]: Pass the reservoir tank overflow hose between reservoir tank 7. Radiator cushion “a”: 65 – 75°
and bracket
[F]: Pass the reservoir tank overflow hose between reservoir tank 8. Radiator : 3.3 Nm (0.34 kgf-m, 2.45
and hook lbf-ft)
[G]: Face the bending point of each hose as shown in the figure. 9. Radiator lower bracket : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
1. Reservoir tank cap: Set cap mark to the nipple direction 10. Radiator outlet hose : Do not reuse.
: Face the yellow mark (13) and white
mark (14) right side.
2. Wiring harness 11. Water bypass hose
1F-4 Engine Cooling System:

Diagnostic Information and Procedures

Engine Cooling Symptom Diagnosis
BENM23K11604001

Condition Possible cause Correction / Reference Item

Engine overheats
Engine over cools
Not enough engine coolant. Add engine coolant. (Page 1F-4)
Radiator core clogged with dirt or scale. Clean. (Page 1F-10)
Faulty cooling fan. Repair or replace. (Page 1F-9)
Defective cooling fan relay, or open-or- Repair or replace. (Page 1F-12)
short circuited.
Clogged water passage. Clean.
Air trapped in the cooling circuit. Bleed air.
Defective water pump. Replace. (Page 1F-15)
Use of incorrect engine coolant. Replace. (Page 1F-5)
Defective thermostat. Replace. (Page 1F-13)
Defective ECT sensor. Replace. (Page 1C-7)
Defective ECM. Replace. (Page 1C-2)
Defective cooling fan relay, or open-or- Repair or replace. (Page 1F-12)
short circuited.
Extremely cold weather. Put on radiator cover.
Defective thermostat. Replace. (Page 1F-13)
Defective ECT sensor. Replace. (Page 1C-7)
Defective ECM. Replace. (Page 1C-2)

Repair Instructions
Engine Coolant Level Inspection 4) Install the reservoir tank cap by aligning the match
BENM23K11606001 mark (1) and reservoir tank overflow hose (2).
1) Keep the motorcycle upright.
2) Remove the following parts.
a) GSX R150
Front fairing. (Page 9D-22)
b) GSX S150
Fuel tank side cover assembly (Page 9D-25)
and Under cowling assembly. (Page 9D-26) 2
3) Check the engine coolant level by observing the full
(1) and lower (2) lines on the engine coolant
reservoir tank. If the level is below the lower line,
1
remove the reservoir tank cap and add engine
coolant to the bottom of full line from the engine
coolant reservoir tank filler.

IH23K1160042-02

1 5) Install under cowling. (Page 9D-26)

IH23K1160001-01
 Engine Cooling System: 1F-5

Engine Coolant Replacement 7) Tighten the water pump drain bolt to the specified
BENM23K11606002 torque.
Refer to “Engine Coolant Description” (Page 1F-1).
1) Remove the following parts. Tightening torque
Water pump drain bolt (a): 10 N·m (1.0 kgf-m, 7.3
a) GSX R150
lbf-ft)
Front fairing. (Page 9D-22)
b) GSX S150
Fuel tank side cover assembly (Page 9D-25)
and Under cowling assembly. (Page 9D-26)
2) Disconnect the reservoir tank inlet hose (1) and drain
engine coolant in reservoir tank.
3) Remove the radiator cap (2).

1
1, (a)
2
IK23K4160004-01

8) Connect the reservoir tank inlet hose.

9) Pour the specified engine coolant up to the radiator
inlet.
Engine coolant
Engine side [Standard]: Approx. 800 ml (0.84 US
qt, 0.70 Imp, qt)
IK23K4160001-01
Reservoir tank side [Standard]: “F” level. 250 ml
4) Remove the water pump drain bolt (1) and drain
(0.26 US qt, 0.22 Imp, qt)
engine coolant.

1
IK23K4160002-01
IK23K4160003-01
10) Install the radiator cap.
5) Flush the radiator with fresh water if necessary.
11) Slowly swing the motorcycle, right and left, to bleed
6) Install a new gasket washer to the water pump drain the air trapped in the cooling circuit.
bolt (1).
12) Remove the radiator cap.
13) Add engine coolant up to the radiator inlet.
14) Start up the engine and bleed air from the radiator
inlet completely.
15) Add engine coolant up to the radiator inlet.
16) Repeat the 15), 16) procedures until no air bleeds
from the radiator inlet.
17) Install the radiator cap securely. Refer to “Water
Hose Routing Diagram” (Page 1F-2).
1F-6 Engine Cooling System:

18) After warming up and cooling down the engine Radiator Cap Inspection
several times, add the engine coolant up to the full BENM23K11606004

level of the reservoir. Refer to “Engine Cooling System Inspection” (Page 1F-
6).
19) Install the removed parts.
1) Drain the engine coolant in reservoir tank. Refer to
“Engine Coolant Replacement” (Page 1F-5).
Engine Cooling System Inspection
BENM23K11606003 2) Remove the radiator cap (1).
1) Drain the engine coolant in reservoir tank. Refer to
“Engine Coolant Replacement” (Page 1F-5).
2) Remove the radiator cap (1) and connect the special
tool to the filler.
3) Pressurize the cooling system with approx. 135 kPa
(1.4 kgf/cm2, 20 psi) of pressure, and then check if it
holds the pressure for 10 seconds.

NOTICE
Do not exceed the radiator cap release 1
pressure, or the radiator cap and
subsequently the radiator, can be damaged.

Special tool
(A): 09918–78211 IK23K4160006-01

(B): 09918–78220 3) Attach the radiator cap (1) to the special tool as
shown in the figure.
4) Slowly apply pressure to the radiator cap.
If the radiator cap does not hold the pressure for at
least 10 seconds, replace it with a new one.
Special tool
(A): 09918–78211
(B): 09918–78220
Radiator cap valve opening pressure
[Standard]: 107.9 – 137.3 kPa (1.1 – 1.4 kgf/cm2,
1
15.7 – 19.9 psi)

1
(B)

IK23K4160005-01

(A)

(B)

(A) ID26J1160007-04

ID26J1160006-05

4) Install the removed parts. Refer to “Water Hose

Routing Diagram” (Page 1F-2).
 Engine Cooling System: 1F-7

Cooling Fan On-Vehicle Inspection Coolant Hose Inspection

BENM23K11606005 BENM23K11606006
1) Remove the following parts. 1) Remove the following parts.
a) GSX R150 a) GSX R150
Front fairing. (Page 9D-22) Front fairing. (Page 9D-22)
b) GSX S150 b) GSX S150
Fuel tank side cover assembly (Page 9D-25) Fuel tank side cover assembly (Page 9D-25)
and Under cowling assembly. (Page 9D-26) and Under cowling assembly. (Page 9D-26)
2) Disconnect the cooling fan motor coupler (1). 2) Check the radiator hoses for crack, damage or
engine coolant leakage. If any defect is found,
replace the radiator hose with a new one.
3) Any leakage from the connecting section (1) should
be corrected by proper tightening. (Page 1F-2)

1
1

IK23K4160007-01

3) Test the cooling fan motor (3) for load current with an
ammeter (2) connected as shown in the figure.
If the fan motor does not turn, replace the cooling fan IH23K4160001-02
assembly with a new one. (Page 1F-8)

NOTE
• When carrying out this test, it is not
necessary to remove the cooling fan.
• Make sure that the battery (1) is capable of
supplying the motor with 12 V.
• With the motor running at full speed, the
ammeter should indicate an amperage not
1
higher than 1.3 A. 1

Cooling fan operating temperature

(OFF→ON) [Standard]: Approx. 105 °C (221 °F)
(ON→OFF) [Standard]: Approx. 100 °C (212 °F)
IK23K4160008-01

3 2

ID26J1160029-01

4) After finishing the cooling fan inspection, install the

removed parts.
1F-8 Engine Cooling System:

Radiator Removal and Installation

BENM23K11606007
Removal
1) Remove the following parts. 1
a) GSX R150
Front fairing. (Page 9D-22)
b) GSX S150
Fuel tank side cover assembly (Page 9D-25)
and Under cowling assembly. (Page 9D-26)
2) Drain engine coolant. (Page 1F-5)
3) Disconnect the radiator fan coupler (1) and clamp
(2).

IH23K4160003-02

6) Remove the radiator lower bracket (1).

1 1

IK23K4160009-01

4) Disconnect the radiator outlet hose (1) and reservoir

tank inlet hose (2).
IK23K4160010-01

7) Remove the radiator (1).

1 1

IH23K4160002-02

5) Disconnect the radiator inlet hose (1). IK23K4160011-01

8) Remove the radiator fan assembly.

 Engine Cooling System: 1F-9

Installation
Install the radiator in the reverse order of removal. Pay
attention to the following points:
• Tighten the radiator fan assembly mounting bolts,
2
radiator mounting bolts and radiator lower bracket bolt
to the specified torque. (Page 1F-9)
• Fit PAIR solenoid valve bracket stopper (2) to the
frame.
• Tighten the PAIR solenoid valve bracket bolt (1) to the
specified torque. 1

Tightening torque
PAIR solenoid valve bracket bolt (a): 10 N·m (1.0
kgf-m, 7.3 lbf-ft)
IK23K4160012-01

1, (a) 3) Remove PAIR control solenoid valve assembly (1) (If

Equipped). Refer to “PAIR Control Solenoid Valve
Removal and Installation (If Equipped)” in Section 1B
(Page 1B-11).

1
2

IH23K4140014-01

• Connect the radiator hoses securely. Refer to “Water

Hose Routing Diagram” (Page 1F-2).
• Pour engine coolant. Refer to “Engine Coolant
Replacement” (Page 1F-5).
IH23K4160005-01

Radiator Fan Assembly Removal and 4) Remove the radiator lower bracket (1).
Installation
BENM23K11606008
Removal
1) Remove the following parts.
a) GSX R150
Front fairing. (Page 9D-22)
b) GSX S150
1
Fuel tank side cover assembly (Page 9D-25)
and Under cowling assembly. (Page 9D-26)
2) Disconnect the radiator fan coupler (1) and clamp
(2).

IK23K4160013-01

5) Loosen the radiator bolts (1).

1F-10 Engine Cooling System:

Tightening torque
Radiator mounting bolt (a): 10 N·m (1.0 kgf-m, 7.3
lbf-ft)

1, (a) 1, (a)
1

2, “A”, (b)

IK23K4160014-01

6) Remove the radiator fan assembly (1).

IK23K4160015-01

• Tighten the radiator lower bracket bolt (1) to the

specified torque.
Tightening torque
1 Radiator lower bracket bolt (a): 10 N·m (1.0 kgf-
m, 7.3 lbf-ft)

IG12K1160018-01

Installation
Install the radiator fan motor in the reverse order of
removal. Pay attention to the following points: 1, (a)
• Tighten the radiator fan assembly mounting bolts (1)
to the specified torque.
Tightening torque
Radiator fan assembly mounting bolt (a): 8.35
N·m (0.85 kgf-m, 6.15 lbf-ft)
IK23K4160016-01

Radiator Inspection and Cleaning

BENM23K11606009
Inspection
1) Remove the following parts.
1, (a) a) GSX R150
Front fairing. (Page 9D-22)
b) GSX S150
Fuel tank side cover assembly (Page 9D-25)
and Under cowling assembly. (Page 9D-26)
IG12K1160019-01
2) Inspect the radiator for coolant leaks. If any defects
• Install EVAP canister assembly.
are found, replace the radiator with a new one.
• Install PAIR solenoid valve assembly.
3) If the fins are bent or dented, repair them by carefully
• Tighten the radiator mounting bolts (1) to the specified straightening them with the blade of a small
torque. screwdriver.
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
 Engine Cooling System: 1F-11

Radiator Reservoir Tank Inspection

BENM23K11606010
1) Remove the following parts.
a) GSX R150
Front fairing. (Page 9D-22)
b) GSX S150
Under cowling assembly. (Page 9D-26)
2) Inspect the radiator reservoir tank (1) coolant leaks.
If any defects are found, replace the radiator
reservoir tank with a new one.

IK23K4160017-01

4) Install the removed parts.

1

Cleaning
1) Remove the following parts.
a) GSX R150
Front fairing. (Page 9D-22)
b) GSX S150
Fuel tank side cover assembly. (Page 9D-25)
2) Blow out any foreign matter that is stuck in the
IK23K4160018-01
radiator fins using compressed air.
3) Install the removed parts.
NOTICE
• Do not bend the fins when using Radiator Reservoir Tank Removal and
compressed air. Installation
BENM23K11606011
• Apply compressed air from the engine Removal
side. If compressed air is applied from the 1) Remove the following parts.
other side, dirt will be forced into the pores
a) GSX R150
of radiator.
Front fairing. (Page 9D-22)
b) GSX S150
Under cowling assembly. (Page 9D-26)
2) Remove the reservoir tank bolt (1) and reservoir tank
(2).
3) Disconnect the reservoir tank inlet hose (3) and drain
engine coolant.
4) Disconnect the reservoir tank overflow hose (4).

1
2
IK23K4160019-01

IH23K1160043-02
1F-12 Engine Cooling System:

Installation Tightening torque

Install radiator reservoir tank in the reverse order of Radiator hose clamp screw (a): 3.3 N·m (0.34 kgf-
removal. Pay attention to the following points: m, 2.45 lbf-ft)
• Apply thread lock to the reservoir tank bolt (1) and
tighten it (1) to the specified torque.
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
Tightening torque
Reservoir tank bolt (a): 10 N·m (1.0 kgf-m, 7.3 lbf-
ft)

(a) (a)

1 2
IK23K4160020-01

Cooling Fan Relay Inspection

BENM23K11606013
1) Open front seat. (Page 9D-20)
2) Disconnect the battery (–) lead wire (1) and remove
the cooling fan relay (2).

IH23K1160031-01
1
• Fill the reservoir tank to the upper level (1). (Page
1F-4)

1
2

IH23K4160004-02

3) First check the insulation between (3) and (4)

terminals with a circuit tester. Then apply 12 V to (1)
and (2) terminals, (+) to (1) and (–) to (2), and check
the continuity between (3) and (4).
IH23K1160032-01 If there is no continuity, replace it with a new one.

Coolant Hose Removal and Installation

BENM23K11606012

Removal
1) Drain engine coolant. (Page 1F-5) 1
2) Remove the water hose. (Page 1F-2)

Installation
Install the coolant hose in the reverse order of removal. 2
4
Pay attention to the following points: 3
• Connect the water hoses securely. Refer to “Water IE31J1160038-01

Hose Routing Diagram” (Page 1F-2). 4) Install the removed parts.

• Tighten the radiator hose clamp screws to the
specified torque.
 Engine Cooling System: 1F-13

Thermostat Removal and Installation • Install the thermostat cover (1) and tighten the bolts
BENM23K11606014 (2) to the specified torque.
Removal
1) Drain engine coolant. (Page 1F-5) Tightening torque
Thermostat cover bolt (a): 10 N·m (1.0 kgf-m, 7.3
2) Place a rag under the thermostat cover (1) and then
lbf-ft)
remove the thermostat cover.

2, (a)
1
1

IK23K4160024-01
IK23K4160021-01
• Pour engine coolant and bleed air from the cooling
3) Remove the thermostat (1).
system. Refer to “Engine Coolant Replacement”
(Page 1F-5).

Thermostat Inspection
BENM23K11606015
1) Inspect the thermostat pellet for signs of cracking.
2) Test the thermostat at the bench for control action.

NOTE
1
• Do not contact the thermostat (1) and the
column thermometer (2) with a pan.
• As the thermostat operating response to
water temperature change is gradual, do
not raise water temperature too quickly.
IK23K4160022-01 • The thermostat with its valve open even
slightly under normal temperature must be
Installation replaced.
Install the thermostat in the reverse order of removal.
Pay attention to the following points: 3) Immerse the thermostat in the water contained in a
• Install the thermostat (1) to thermostat cover. beaker and note that the immersed thermostat is in
suspension.

IK23K4160023-01
1F-14 Engine Cooling System:

4) Heat the water by placing the beaker on a heater (3)

and observe the rising temperature on a
thermometer.

ID26J1160035-04

4. String

5) Read the thermometer just when opening the

thermostat. If this reading, which is the temperature
level at which the thermostat valve begins to open, is
out of the standard value, replace the thermostat
with a new one.
Thermostat valve opening temperature
[Standard]: 91.5 – 94.5 °C (196.7 – 202.1 °F)
6) Keep on heating the water to raise its temperature.
7) Just when the water temperature reaches specified
value, the thermostat valve should have been lifted
by at least 3 mm (0.11 in) “a”. A thermostat failing to
satisfy either of the two requirements (start-to-open
temperature and valve lift) must be replaced.
Thermostat valve lift
At 106 °C (222.8 °F) [Standard]: 3.0 mm (0.11 in)
or more

“a”

I944H1160022-01
 Engine Cooling System: 1F-15

Water Pump Assembly Components

BENM23K11606016

(a) 10 (a)

9 8

3
5

1
IG12K1160036-04

1. Water pump driven gear 6. Impeller/water pump shaft : Apply grease to the O-ring.
2. E-ring 7. O-ring : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
: For installation, refer to “Water Pump Removal and Installation”
(Page 1F-15).
3. Pin 8. Water pump case : Do not reuse.
4. Bearing 9. Water pump drain bolt gasket
5. Water pump shaft oil seal : Apply engine oil.

Water Pump Removal and Installation Water Pump Disassembly and Reassembly
BENM23K11606017 BENM23K11606018
Removal Refer to “Water Pump Removal and Installation” (Page
1) Remove the clutch cover. (Page 5C-6) 1F-15).

NOTE Disassembly
Water pump (1) is built in the clutch cover. 1) Remove the E-ring (1) and water pump driven gear
(2).

1
2

IG12K1160037-01
IG12K1160038-01

Installation
Install the water pump in the reverse order of removal.
1F-16 Engine Cooling System:

2) Remove the pin (1) and E-ring (2). 5) Remove the water pump bearings (1) using
hydraulic press (2) and suitable tools (3).

3
2

2
3
1

1
3
IG12K1160039-01 3
3) Remove the water pump case (1). IG12K1160042-01

6) Remove the oil seal (1) using hydraulic press (2) and
suitable tools (3).

3
2
1

3
IG12K1160040-02

4) Remove the impeller/water pump shaft (1). 3

IG12K1160043-01

7) Remove the O-ring (1).

1

IG12K1160041-01

IG12K1160059-01
 Engine Cooling System: 1F-17

Reassembly
1) Install a new oil seal (1) with the special tool.

NOTE
Face the flat side “A” of the oil seal to the
impeller seal side.

Special tool
(A): 09913–70210

IG12K1160049-01
“A”
4) Apply engine oil to the impeller/water pump shaft (1)
and install it to the clutch cover.

IG12K1160045-01

(A)

“a”
IG12K1160048-02

5) Install a new E-ring (1) as shown in the illustration.

1
1

IG12K1160046-02 1
“a”: Max. 1.0 mm (0.04 in)

2) Apply engine oil to the oil seal lip.

3) Install new water pump bearings (1) one by one
using hydraulic press (2) and suitable tool (3).
Special tool IG12K1160050-01
(A): 09913–50121 6) Install the pin (1) and water pump driven gear (2).

2 2

(A)

1
1

3
IG12K1160047-01 IG12K1160051-01
1F-18 Engine Cooling System:

7) Install a new E-ring (1) as shown in the illustration.
1 1
Water Pump Related Parts Inspection
BENM23K11606019
Refer to “Water Pump Disassembly and Reassembly”
(Page 1F-15).
Oil Seal
Visually inspect the oil seal (1) for damage, with
particular attention given to the lip.
Replace the oil seal that shows indications of leakage.

IG12K1160052-02 1
8) Apply grease to a new O-ring (1).
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)
9) Install the O-ring to the water pump case.

IG12K1160054-01
“A” 1
Impeller/Water Pump Shaft
Visually inspect the impeller (1) and its shaft for damage.
Replace the impeller/water pump shaft if necessary.

1
IG12K1160044-03

10) Install a new gasket washer (1) and tighten the water
pump case bolts (2) to the specified torque.

NOTE
Gasket washer is installed near the triangle
mark (3). IG12K1160055-02

Tightening torque Water Pump Bearing

Water pump case bolt (a): 10 N·m (1.0 kgf-m, 7.3 Rotate the inner race by hand to inspect for abnormal
lbf-ft) noise and smooth rotation.
Replace the bearings if there is anything unusual.

2, (a)

IG12K1160053-02

IG12K1160056-01
 Engine Cooling System: 1F-19

Specifications
Tightening Torque Specifications
BENM23K11607001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Water pump drain bolt 10 1.0 7.3 (Page 1F-5)
PAIR solenoid valve bracket bolt 10 1.0 7.3 (Page 1F-9)
Radiator fan assembly mounting bolt 8.35 0.85 6.15 (Page 1F-10)
Radiator mounting bolt 10 1.0 7.3 (Page 1F-10)
Radiator lower bracket bolt 10 1.0 7.3 (Page 1F-10)
Reservoir tank bolt 10 1.0 7.3 (Page 1F-12)
Radiator hose clamp screw 3.3 0.34 2.45 (Page 1F-12)
Thermostat cover bolt 10 1.0 7.3 (Page 1F-13)
Water pump case bolt 10 1.0 7.3 (Page 1F-18)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Water Hose Routing Diagram” (Page 1F-2)
“Water Pump Assembly Components” (Page 1F-15)
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Recommended Service Material
BENM23K11608001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 1F-18)
Thread lock cement THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 1F-10) / (Page
1F-12)

NOTE
Required service material(s) is also described in:
“Water Pump Assembly Components” (Page 1F-15)

Special Tool
BENM23K11608002
09913–50121 09913–70210
Oil seal remover Bearing installer set
(Page 1F-17) (Page 1F-17)

09918–78211 09918–78220
Radiator cap tester kit Radiator cap tester adapter
(Page 1F-6) / (Page 1F-6) /
(Page 1F-6) (Page 1F-6)
1G-1 Fuel System:

Fuel System
Engine

Precautions
Precautions for Fuel System
BENM23K11700001
! WARNING

• Keep away from fire or spark.

• During disassembling, use care to minimize spillage of gasoline.
• Spilled gasoline should be wiped off immediately.
• Work in a well-ventilated area.

NOTICE
• To prevent the fuel system (fuel tank, fuel hose, etc.) from contamination with foreign particles, blind
all openings.
• After removing the throttle body, tape the cylinder intake section to prevent foreign particles from
entering.
 Fuel System: 1G-2

General Description
Fuel System Description
BENM23K11701001
Fuel System
The fuel delivery system consists of the fuel tank (1), fuel pump (2) (including fuel pressure regulator (7) and fuel mesh
filter (3)), fuel feed hose (4) and fuel injector (5). There is no fuel return hose. The fuel in the fuel tank is pumped up by
the fuel pump and pressurized fuel flows into the injector installed on the intake pipe (6). Fuel pressure is regulated by
the fuel pressure regulator. As the fuel pressure applied to the fuel injector is always kept at the specified level and the
fuel is injected into the intake pipe in conic dispersion when injector opens according to the injection signal from the
ECM.
The fuel relieved by the fuel pressure regulator flows back to the fuel tank.

7 1

4 2

3
4

[A]
6
[B]
[C]
IM23K1170003-01

[A]: Before-pressurized fuel [B]: Pressurized fuel [C]: Relieved fuel

1G-3 Fuel System:

Schematic and Routing Diagram

Fuel Tank Water Drain Hose and Fuel Tank Breather Hose (If Equipped) Routing Diagram
BENM23K11702001

5 3
4

9
To Fuel Tank

8 [F] [G]
6
2
1
1
[E]

[D]

[B]
[C]

[A]

IH23K4170001-01

[A]: Drain hose must be passed in front of frame bridge tube lower 2. Tank & breather valve hose (if equipped)
[B]: Drain hose must be passed inside of RR swingarm pipe R 3. Fuel tank breather valve (if equipped)
[C]: Drain hose must be passed inside of “crank case plate lower and in front of frame bridge tube lower 4. breather valve cushion (if equipped)
[D]: Drain hose must be passed backward of RR swingarm pivot pipe 5. EVAP hose clamp (if equipped)
[E]: Drain hose must be passed between 2 bridges of frame comp. 6. EVAP canister assembly (if equipped)
[F]: Insert hose all the way into the nipple of fuel tank 7. Canister surge hose (if equipped)
[G]: Set white mark of hose outward 8. Canister drain hose (if equipped)
1. Fuel tank water drain hose 9. Frame

Diagnostic Information and Procedures

Fuel System Symptom Diagnosis
BENM23K11704001
Refer to “Engine Symptom Diagnosis” in Section 1A (Page 1A-14).
 Fuel System: 1G-4

Repair Instructions
Fuel Pressure Inspection If the fuel pressure is higher than the specification,
BENM23K11706001 check for the followings:
Refer to “Front Fairing Assembly Removal and
Installation” in Section 9D (Page 9D-22). and “Frame • Fuel pump
Cover Removal and Installation” in Section 9D (Page • Pressure regulator
9D-31) Fuel pressure
1) Disconnect the fuel feed hose (1) from the fuel hose Approx. 300 kPa (3.05 kgf/cm2, 43.5 psi)
joint. (Page 1G-5)
4) Remove the special tools.

! WARNING
Before removing the special tools, turn the
ignition switch OFF and release the fuel
pressure slowly.

5) After finishing the fuel pressure inspection, reinstall

1
the removed parts.

Fuel Discharge Amount Inspection

BENM23K11706002
Refer to “Fuel Tank Cover Removal and Installation” in
Section 9D (Page 9D-27).
1) Lift and support the fuel tank with a wooden block or
IH23K1170001-04
the like.
2) Install the special tools between the fuel feed hose
and fuel hose joint. 2) Disconnect the fuel feed hose (1) from the fuel hose
joint. (Page 1G-5)
Special tool
(A): 09940–40211
(B): 09940–40220
(C): 09915–74511

1
(A)
(C)

(B)

IH23K1170001-04

3) Place the measuring cylinder (1) and insert the fuel

feed hose end (2) into the measuring cylinder.
IH23K1170002-02

3) Turn the ignition switch ON and check for fuel

pressure.
If the fuel pressure is lower than the specification,
check for the followings:
• Fuel hose leakage
• Clogged fuel mesh filter
• Pressure regulator 2 1
• Fuel pump

IG34J1172005-01
1G-5 Fuel System:

4) Disconnect the fuel pump coupler (1). Fuel Feed Hose Disconnecting and
Reconnecting
BENM23K11706003
Disconnecting
1) Place a rag over the fuel feed hose.
2) While pushing the retainer (1), disconnect the fuel
feed hose joint (2) from the fuel pipe.

1
1 2

IF40J1170035-01
IH23K4170003-02

5) Connect proper lead wires to the fuel pump. Reconnecting

Apply 12 V to fuel pump (1) (between W wire
1) Insert the fuel feed hose joint (1) securely until a click
terminal (2) and P wire terminal (3)) for 10 seconds
is heard.
and measure the amount of fuel discharged.
If the discharge amount is out of the specification,
the following cause may be considered.
Possible cause Correction 1
Clogged fuel mesh filter Replace
Defective fuel pump Replace

Battery (+) terminal – Terminal (2) IF40J1170036-01

Battery (–) terminal – Terminal (3) 2) Confirm that fuel feed hose joint cannot
NOTE disconnected by hand.

The battery must be in fully charged

Fuel Feed Hose Inspection
condition. BENM23K11706004
Refer to “Fuel Tank Cover Removal and Installation” in
FP discharge amount per 10 seconds Section 9D (Page 9D-27).
56 ml (1.89 US oz, 1.97 Imp oz) or more Inspect the fuel feed hose (1) for damage and fuel
leakage. If any defects are found, the fuel feed hose
3 2 must be replaced.

IG34J1172007-01 1
6) After finishing the fuel discharge inspection, reinstall
the removed parts.

IH23K4170004-02

Fuel Feed Hose Removal and Installation

BENM23K11706005
Removal
1) Remove fuel tank covers. (Page 9D-27).
 Fuel System: 1G-6

2) Disconnect the fuel feed hose (1) from the fuel hose 4) Disconnect the fuel feed hose (1) from the fuel pump
joint. (Page 1G-5) assembly.

1
1

IH23K4170006-02 IH23K4170007-02
3) Lift and support the fuel tank with a wooden block or
the like. Installation
Install the fuel feed hose in the reverse order of removal.

Fuel Tank Construction

BENM23K11706006
GSX R 125 Model

4
3 (c)

6 (a)

8 9 (b)

1
10
(b) (b)

IM23K1170001-02

1. Fuel tank 6. Fuel tank cover screw : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
2. Fuel filler cap 7. Cushion : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
3. Fuel filler cap bolt 8. Clip : 3.0 Nm (0.3 kgf-m, 2.2 lbf-ft)
4. Fuel tank center cover 9. Bolt
5. Fuel tank cover 9. Washer
1G-7 Fuel System:

GSX S 125 Model

4
3 (c)

6 (a)

8 9 (b)

1
10
(b)
(b)

5
7

IM23K1170002-02

1. Fuel tank 6. Fuel tank cover screw : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
2. Fuel filler cap 7. Cushion : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
3. Fuel filler cap bolt 8. Clip : 3.0 Nm (0.3 kgf-m, 2.2 lbf-ft)
4. Fuel tank center cover 9. Bolt
5. Fuel tank cover 10. Frame front inner cover bracket

Fuel Tank Cap Removal and Installation Installation

BENM23K11706007 Install the fuel tank cap in the reverse order of removal.
Removal
Pay attention to the following point:
1) Open the fuel tank cap with the ignition key.
• Tighten the fuel tank cap bolts (1) to the specified
2) Remove the fuel tank cap (1) by loosen fuel filler cap torque.
bolt.
Tightening torque
Fuel filler cap bolt (a): 3.0 N·m (0.30 kgf-m, 2.21
lbf-ft)

IH23K4170008-02

1, (a)
IH23K4170009-02
 Fuel System: 1G-8

Fuel Tank Removal and Installation 6) Disconnect the fuel pump coupler (1).
BENM23K11706008
Removal
1) Remove frame cover. (Page 9D-31)
2) Remove fuel tank bolt.

IH23K4170012-02

7) If necessary, remove fuel tank cover. (Page 9D-27)

8) Remove fuel tank (1).
IH23K1170009-01

3) Disconnect the fuel feed hose (1) from the fuel hose
joint. (Page 1G-5)
1

IH23K1170008-02

9) Disconnect the fuel feed hose (1).

IH23K4170010-02

4) Lift and support the fuel tank with a wooden block or

the like.
5) Disconnect the fuel tank drain hose (1) and fuel tank
breather hose (2) (if equipped).

1 1

IH23K4170013-02

IH23K4170011-02
1G-9 Fuel System:

Installation
Install the fuel tank in the reverse order of removal. Pay
attention to the following point: (a) (a)
• Tighten the fuel tank brace mounting bolts and fuel
tank mounting bolts to the specified torque.
Tightening torque
Fuel tank mounting bolt (a): 10 N·m (1.0 kgf-m,
7.3 lbf-ft)

IH23K1170010-01

Fuel Pump Components

BENM23K11706009

2
4

3
2
5

(a)

IG34J1172014-01

1. Fuel pump assembly 4. Fuel level gauge : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
2. O-ring 5. Fuel feed hose : Apply engine oil.

3. Fuel mesh filter 6. Flange : Do not reuse.

 Fuel System: 1G-10

Fuel Pump On-Vehicle Inspection Installation

BENM23K11706010
1) Install the new O-ring (1) to the fuel pump assembly.
Turn the ignition switch ON and check that the fuel pump
operates for a few seconds.
If the fuel pump motor does not make operating sound,
inspect the fuel pump circuit connection. (Page 1A-43)
If the fuel pump circuit connection is OK, the fuel pump
may be faulty, replace the fuel pump with a new one.
(Page 1G-10)

Fuel Pump Assembly Removal and Installation

BENM23K11706011 1

Removal
1) Remove the fuel tank. (Page 1G-8)
2) Remove the fuel pump mounting bolts (1) diagonally, IH23K1170012-02

and remove the plate (2) and fuel pump assembly 2) Set the fuel pump assembly (1) so that the arrow
(3). mark (2) on the plate forward.

1
IH23K1170013-01

3) When tightening the fuel pump mounting bolts (1),

first tighten all bolts lightly in the ascending order and
then tighten them to the specified torque in the
figure.
IH23K1170011-02
Tightening torque
3) Remove the O-ring (1). Fuel pump mounting nut (a): 10 N·m (1.0 kgf-m,
7.3 lbf-ft)

“2”

“5” “4”

“3” 1, (a)
“1”, “6”
IH23K1170012-02

IH23K1170014-01
1G-11 Fuel System:

Fuel Pump Disassembly and Reassembly 3) Unhook the hooks (1) and remove the fuel level
BENM23K11706012 gauge (2).
Refer to “Fuel Pump Assembly Removal and
Installation” (Page 1G-10).

Disassembly
1) Remove fuel pump plate (1).
2

IH23K1170017-01

4) Disconnect the fuel pump lead wires (1).

IH23K1170015-01

2) Disconnect the fuel level gauge lead wires (1).

1

IH23K1170018-01

5) Remove the fuel pump assembly (1) from the flange

(2).
1

IH23K1170016-01

IK23K4170001-01
 Fuel System: 1G-12

6) Remove the O-ring (1). Reassembly

Reassemble the fuel pump in the reverse order of the
disassembly. Pay attention to the following points:
• Apply engine oil lightly to the new O-rings (1) and
install them.
1

1
1

IH23K1170020-01

7) Remove the fuel mesh filter (1).

IK23K4170002-01

• Lock the fuel level gauge hooks in order of “1” → “2”.

“2”
1
“1”

IK23K4170003-01

8) Remove the O-ring (1). IH23K1170024-01

• Connect all lead wires securely so as not to cause

contact failure.
• Route all lead wires securely.

3 4

IK23K4170004-01

1 2

IK23K4170005-01

1. Fuel level gauge (+) lead wire (R)

2. Fuel level gauge (–) lead wire (B)
3. Fuel pump (+) lead wire (R)
4. Fuel pump (–) lead wire (B)
1G-13 Fuel System:

Fuel Mesh Filter Inspection Fuel Injector On-Vehicle Inspection

BENM23K11706013 BENM23K11706015
Refer to “Fuel Pump Disassembly and Reassembly” 1) Remove fuel tank. “Fuel Tank Removal and
(Page 1G-11). Installation” (Page 1G-8)
Inspect the fuel mesh filter for dirt. If the fuel mesh filter
2) Remove EVAP control system. (Page 1B-13)
is dirtied excessively, replace the fuel mesh filter with a
new one. 3) Turn the ignition switch OFF.
4) Remove fuel injector cover (1).

IG34J1172029-01

Fuel Level Gauge Inspection

BENM23K11706014
Refer to “Fuel Pump Assembly Removal and
Installation” (Page 1G-10).
IK23K4170006-01
Measure the resistance at each float position of the fuel
level gauge. If the resistance is incorrect, replace the 5) Disconnect the fuel injector coupler (1).
fuel level gauge with a new one.
Float position Resistance
120 mm
“a” 4 – 10 Ω
(4.72 in)
5 mm 1
“b” 213 – 219 Ω
(0.19 in)

IK23K4170007-01

“a”

“b”

IM23K1170004-01
 Fuel System: 1G-14

6) Measure the fuel injector resistance between 4) Disconnect the fuel feed hose (1) from the fuel hose
terminals using the multi circuit tester. If resistance is joint. (Page 1G-5)
out of specification, replace the fuel injector with a
new one. (Page 1G-14)
Fuel injector resistance
11.5 – 12.5 Ω at 20 °C (68 °F)

IK23K4170010-01

5) Remove the fuel hose joint (1) and fuel injector (2)
pulling them straight from the intake pipe.

IK23K4170008-01

7) After finishing the fuel injector inspection, install the 2

removed parts.

Fuel Injector Removal and Installation

BENM23K11706016
Removal
1
1) Remove fuel tank. “Fuel Tank Removal and
Installation” (Page 1G-8)
2) Remove EVAP control system. (Page 1B-13)
IG34J1172034-01
3) Disconnect the fuel injector coupler (1).
6) Remove the fuel injector (1) pulling it straight from
the fuel hose joint (2).

IK23K4170009-01

IH23K1170030-01
1G-15 Fuel System:

7) Remove the seal ring (1) and O-ring (2). • Install the fuel hose joint (1) and fuel injector (2)
pushing them straight to the intake pipe, and tighten
the fuel hose joint mounting bolt to the specified
torque.

NOTICE
Never turn the fuel hose joint and fuel
injector while installing them.
1
Tightening torque
Fuel hose joint mounting bolt (a): 10 N·m (1.0 kgf-
2 m, 7.3 lbf-ft)

IK23K4170011-02 2
(a)
Installation
Install the fuel injector in the reverse order of removal.
Pay attention to the following points:
• Install the new seal ring (1) and new O-ring (2) to the 1
fuel injector and apply thin coat of the engine oil to the
seal ring and O-ring.

IG34J1172038-01

Fuel Injector Inspection and Cleaning

BENM23K11706017
Refer to “Fuel Injector Removal and Installation” (Page
1G-14).
Check the fuel injector filter for evidence of dirt and
1 contamination. If present, clean and check for presence
of dirt in the fuel line and fuel tank.

IK23K4170011-02

• Connect the fuel injector (1) pushing it straight to the

fuel hose joint (2).

NOTICE
Never turn the fuel injector while pushing it.

IG34J1172039-01

IK23K4170012-01
 Fuel System: 1G-16

Specifications
Tightening Torque Specifications
BENM23K11707001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Fuel filler cap bolt 3.0 0.30 2.21 (Page 1G-7)
Fuel tank mounting bolt 10 1.0 7.3 (Page 1G-9)
Fuel pump mounting nut 10 1.0 7.3 (Page 1G-10)
Fuel hose joint mounting bolt 10 1.0 7.3 (Page 1G-15)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fuel Tank Construction” (Page 1G-6)
“Fuel Pump Components” (Page 1G-9)
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Recommended Service Material
BENM23K11708001
NOTE
Required service material(s) is also described in:
“Fuel Pump Components” (Page 1G-9)

Special Tool
BENM23K11708002
09915–74511 09940–40211
Oil pressure gauge set (600 Fuel pressure gauge
kPa) adapter
1. Gauge 2. Hose Discontinued
(Page 1G-4) (Page 1G-4)

09940–40220
Fuel pressure gauge
attachment
(Page 1G-4)
1H-1 Ignition System:

Ignition System
Engine

Schematic and Routing Diagram

Ignition System Diagram
BENM23K11802001

R
2 6

B/W 3 Y/B O/B

O/B
W/R
1
7 8
LG Dg B/Y

Y B B/Br 9
4
5

B/W

IG12K1180001-02

1. Battery 4. Generator 7. ECM

2. Main fuse (20 A) 5. CKP sensor 8. Ignition coil
3. Regulator/rectifier 6. Ignition switch 9. Spark plug

Ignition System Components Location

BENM23K11802002
Refer to “Electrical Components Location” in Section 0A (Page 0A-6).
 Ignition System: 1H-2

Diagnostic Information and Procedures

Ignition System Symptom Diagnosis
BENM23K11804001

Condition Possible cause Correction / Reference Item

Spark plug not sparking Damaged spark plug. Replace. (Page 1H-5)
Fouled spark plug. Replace. (Page 1H-5)
Wet spark plug. Dry or replace. (Page 1H-6)
Defective ignition coil or spark plug cap. Replace. (Page 1H-6)
Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Defective ECM. Replace. (Page 1C-2)
Open-circuited wiring connections. Repair or replace. (Page 9A-3)
Open or short in high-tension cord. Replace. (Page 1H-6)
Engine stalls easily (No Fouled spark plug. Replace. (Page 1H-5)
spark) Defective CKP sensor. Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Defective ECM. Replace. (Page 1C-2)
Spark plug is wet or Excessively rich air/fuel mixture. Inspect FI system.
quickly becomes fouled Excessively idling speed. Inspect FI system.
with carbon Incorrect gasoline. Change.
Dirty air cleaner element. Replace. (Page 1D-9)
Incorrect spark plug (Cold type). Change to standard spark plug. (Page 1H-5)
Spark plug quickly Worn piston rings. Replace. (Page 1D-39)
becomes fouled with oil Worn piston. Replace. (Page 1D-39)
or carbon Worn cylinder. Replace. (Page 1D-29)
Excessive valve-stem to valve-guide Replace. (Page 1D-34)
clearance.
Worn valve stem oil seals. Replace. (Page 1D-34)
Spark plug electrodes Incorrect spark plug (Hot type). Change to standard spark plug. (Page 1H-5)
overheat or burn Overheated engine. Tune-up.
Loose spark plug. Tighten. (Page 1H-5)
Excessively lean air/fuel mixture. Inspect FI system.

No Spark or Poor Spark

BENM23K11804002
Troubleshooting

NOTE
Check for the following points before diagnosing.
• The transmission is in neutral.
• The fuse is not blown.
• The battery is fully-charged.

Step 1
1) Check the ignition system couplers for poor connections.
Is there connection in the ignition system couplers?

Yes Go to Step 2.

No Repair or replace defective part.

1H-3 Ignition System:

Step 2
1) Turn the ignition switch ON.
2) Measure the battery voltage between O/B wire (+) and B/W wire (–) of ECM. (Page 1H-1)
Is the voltage OK?

Yes Go to Step 3.

No • Faulty ignition switch.

• Broken wire harness or poor connection of related circuit couplers.

Step 3
Measure the ignition coil primary peak voltage. (Page 1H-7)
Is the peak voltage OK?

Yes Go to Step 4.

No Go to Step 5.

Step 4
Inspect the spark plug. (Page 1H-6)
Is the spark plug OK?

Yes Go to Step 5.

No Faulty spark plug.

Step 5
Inspect the ignition coil. (Page 1H-7)
Is the ignition coil OK?

Yes Go to Step 6.

No Faulty ignition coil.

Step 6
Measure the CKP sensor peak voltage and its resistance. (Page 1C-10)
Are the peak voltage and resistance OK?

Yes • Faulty ECM.

• Open or short circuit in wire harness.
• Poor connection of ignition couplers.

No • Faulty CKP sensor.

• Metal particles or foreign material being stuck on the CKP sensor and rotor tip.
 Ignition System: 1H-4

Repair Instructions
Ignition Coil Construction
BENM23K11806001

2 [B]

[A]
(a)

IM23K1180001-01

[A]: Insert the clamp to the bottom of bracket. 1. Ignition coil : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
[B]: Cover the plug hole with high tension code seal. 2. High tension code seal

Keyless Control Unit Construction

BENM23K11806002

IH23K1180012-03
1H-5 Ignition System:

[A]: Narrow side [D]: Match the upper side of keyless controller holder and 3. Label
upper side of keyless control unit.
[B]: Wide side 1. Keyless control unit
: The label side is upper side.
[C]: Match the groove of keyless controller holder 2. Keyless controller holder
and groove of keyless control unit.

Spark Plug Removal and Installation Installation

BENM23K11806003 Install the spark plug in the reverse order of removal.
Removal
Pay attention to the following point:
! WARNING • Screw the spark plug into the cylinder head with
fingers, and then tighten it to the specified torque.
The hot engine can burn you.
Wait until the engine is cool enough to touch. NOTICE
Do not cross thread or over tighten the spark
1) Remove the front fairing. (Page 9D-22) plug, or such an operation will damage the
2) Disconnect the spark plug cap (1). aluminum threads of the cylinder head.
3) Remove the spark plug using the special tool.
Special tool
Special tool (A): 09930–10121
(A): 09930–10121
Tightening torque
Spark plug (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

(A)
(A), (a)

IH23K4180001-01

IH23K4180004-01
 Ignition System: 1H-6

Spark Plug Inspection and Cleaning Ignition Coil Removal and Installation
BENM23K11806004 BENM23K11806005
Refer to “Ignition Coil Construction” (Page 1H-4).
Carbon Deposits
Check carbon deposits on the spark plug. Removal
If carbon is deposited, remove it using a spark plug 1) Remove the following parts.
cleaner machine or carefully use a tool with a pointed
a) GSX R150
end.
Front fairing. (Page 9D-22)
b) GSX S150
Fuel tank side cover assembly (Page 9D-25)
and Under cowling assembly. (Page 9D-26)
2) Disconnect the spark plug cap. (Page 1H-5)
3) Disconnect the ignition coil primary lead wire
couplers (1).
4) Remove the ignition coil (2).

I649G1020010-02

1
Spark Plug Gap
Measure the spark plug gap “a” using a thickness gauge.
Adjust the spark plug gap if necessary.
Spark plug
Type [Standard]: NGK MR8E-9 or DENSO U24EPR-
N9
Gap [Standard]: 0.8 – 0.9 mm (0.031 – 0.035 in) 2

IK23K4180002-01

Installation
Install the ignition coil in the reverse order of removal.
“a” Pay attention to the following point:
• Tighten the ignition coil mounting bolts to the specified
ID26J1180010-03 torque.
Tightening torque
Electrodes Condition
Ignition coil mounting bolt (a): 10 N·m (1.0 kgf-m,
Check the worn or burnt condition of the electrodes.
7.3 lbf-ft)
If it is extremely worn or burnt, replace the spark plug.
Also replace the spark plug if it has a broken insulator, or
damaged thread.

NOTICE (a)
Confirm the thread size and reach when
replacing the spark plug. If the reach is too
short, carbon will be deposited on the screw
portion of the spark plug hole and engine
damage may result.

IK23K4180001-01
1H-7 Ignition System:

Ignition Coil Inspection
BENM23K11806006
Ignition Coil Primary Peak Voltage
1) Disconnect the spark plug cap. (Page 1H-5)
2) Connect a new spark plug to the spark plug cap and
ground it to the cylinder head.
NOTE
Be sure that the spark plug is connected
properly and the battery used is in fully-
charged condition.
4) Measure the ignition coil primary peak voltage in the
following procedures:
! WARNING
Do not touch the tester probes and spark
plug to prevent an electric shock while
testing.
a) Shift the transmission to the neutral and turn the
ignition switch ON.
b) Grasp the clutch lever.
c) Press the starter switch and allow the engine to
crank for a few seconds, and then measure the
ignition coil primary peak voltage.
5) Repeat the c) procedure several times and measure
the highest peak voltage.
If the voltage is lower than standard range, replace
the ignition coil. (Page 1H-6)
Ignition coil primary peak voltage
[Standard]: 150 V
6) After measuring the ignition coil primary peak
voltage, install the removed parts.

Ignition Coil Resistance

IH23K1180003-02 1) Disconnect the spark plug cap. (Page 1H-5)
3) Connect the multi circuit tester with the peak voltage 2) Disconnect the ignition coil lead wire couplers (1).
adapter (1) as follows:

NOTE
Do not disconnect the ignition coil primary 1
lead wire.

Ignition coil – circuit tester connection

(+) Probe (–) Probe
Ignition coil (2) B/Y wire terminal O/B wire terminal

V
1
IK23K4180003-01

4 2 3

IF34J1180008-02

3. New spark plug 4. ECM

 Ignition System: 1H-8

3) Measure the ignition coil for resistance in both

primary and secondary coils. If the resistance is not
within the standard range, replace the ignition coil
with a new one.
Ignition coil resistance at 25 °C (77 °F)
Primary [Standard]: 1.84 – 2.76 Ω ((+) terminal – 1
(–) terminal)
Secondary [Standard]: 10.01 – 18.59 kΩ ((+)
terminal – Plug cap)
2
4
3
( ) IE31J1160038-01

4) Install the removed parts.

Ignition Switch Inspection

BENM23K11806008
( )
Ignition Switch Model
1) Disconnect the battery (–) lead wire. Refer to
“Battery Removal and Installation” in Section 1J
(Page 1J-13).
IG12K1180009-01 2) Remove fuel tank. (Page 1G-8)
3) Disconnect the ignition switch coupler (1).

( )

Ω
1
( ) kΩ

IG12K1180010-01

4) After measuring the ignition coil resistance, install

the removed parts.

Ignition Relay Inspection (Keyless Start Model) IK23K4180004-01

BENM23K11806007
4) Inspect the ignition switch for continuity with a circuit
1) Remove the fuel tank covers. (Page 9D-27) tester. If any defect is found, replace the ignition
2) Disconnect the coupler (1) and remove the ignition switch with a new one.
relay (2).
Color
R O
Position
ON
OFF
LOCK
IF34J1180015-01

IH23K1180013-01

3) First check the insulation between (3) and (4)

terminals with a circuit tester. Then apply 12 V to (1)
and (2) terminals, (+) to (1) and (–) to (2), and check
the continuity between (3) and (4). If there is no
continuity, replace it with a new one.
1H-9 Ignition System:

Keyless Start Model Ignition Switch Removal and Installation

BENM23K11806009
1) Remove the fuel tank. (Page 1G-8) Ignition Switch Model
2) Disconnect the ignition switch coupler (1). Removal
1) Disconnect the battery (–) lead wire. Refer to
“Battery Removal and Installation” in Section 1J
(Page 1J-13).
1
2) Remove fuel tank. (Page 1G-8)
3) GSX R 125 Model
Disconnect the right handle switch coupler (1), left
handle switch coupler (2), ignition switch coupler (3),
clutch lever switch coupler (4), and harness clamp
(5).
GSX S 125 Model
Disconnect the ignition switch coupler (3) and
IH23K1180014-01
harness clamp (5).
3) Inspect the ignition switch for continuity with a circuit
tester. If any abnormality is found, replace the
ignition switch with a new one.

Color
R B/W 1
Position
ON
“ • ” (ACC)
OFF
LOCK
IH23K1180015-02 2

4) Inspect the ignition switch for operation. If any

abnormality is found, replace the ignition switch with
a new one.
IK23K4180005-01

Color Ignition Key Steering Request

remove and Fit Solenoid
Lock Switch
Position install
ON 5
“ • ” (ACC)
OFF
3
LOCK
IH23K1180016-02

5) After finishing the ignition switch inspection, reinstall 4

the removed parts.

IH23K1180006-01
 Ignition System: 1H-10

4) Remove ignition switch (1). Keyless Start Model

Removal
1) Remove the fuel tank. (Page 1G-8)
2) Remove the clamp (1) and the ignition relay (2), and
then disconnect the ignition switch couplers (3).

1
2

IH23K2180001-01
3

Installation IH23K1180017-01
Install the ignition switch in the reverse order of removal. 3) Remove the ignition switch mounting bolts (1) with a
Pay attention to the following point: chisel.
• Tighten new ignition switch mounting bolt (1) with the 4) Remove the ignition switch (2).
special tool until head (2) of each bolt (1) is broken off.
Special tool
: 09930–11940 1
: 09940–63110

2
1
1
IH23K1180018-01

IF04K1180022-02
1H-11 Ignition System:

Installation 4) Disconnect the PCV hose (1), disconnect the PAIR

Install the ignition switch in the reverse order of removal. air hose (2) and remove the bolt (3).
Pay attention to the following point:
• Tighten new ignition switch mounting bolts (1) with the
special tool until head of each bolt is broken off.
Special tool
: 09930–11940
: 09940–63110
3
2

IH23K4180002-02

5) Move the air cleaner box backward.

IH23K1180019-02

Keyless Control Unit Removal and Installation

BENM23K11806010
Removal IH23K1180022-01
1) Remove the fuel tank. (Page 1G-8) 6) Disconnect the coupler (1) and remove the keyless
2) Remove the rear fender front. (Page 9D-32) control unit (2).
3) Loosen the air cleaner outlet tube clamp screw (1)
and remove the bolts (2).

2 2

1 IH23K1180023-01

IH23K1180020-01
 Ignition System: 1H-12

Installation • Tighten the air cleaner bolts (1) to the specified

Install the keyless control unit in the reverse order of torque.
removal. Pay attention to the following points:
Tightening torque
• Match the upper surfaces of the keyless control unit Air cleaner bolt (a): 10 N·m (1.0 kgf-m, 7.3 lbf-ft)
and the keyless controller holder, and assemble.
(Page 1H-4)
• Tighten the outlet tube clamp (1) to the specified
torque.
1, (a) 1, (a)
Tightening torque
Outlet tube (a): 1.5 N·m (0.15 kgf-m, 1.10 lbf-ft)

1, (a)
IH23K1180025-02

IH23K1180024-01
1, (a)

IH23K4180003-02

Specifications
Tightening Torque Specifications
BENM23K11807001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Spark plug 11 1.1 8.5 (Page 1H-5)
Ignition coil mounting bolt 10 1.0 7.3 (Page 1H-6)
Outlet tube 1.5 0.15 1.10 (Page 1H-12)
Air cleaner bolt 10 1.0 7.3 (Page 1H-12)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Ignition Coil Construction” (Page 1H-4)
“Fasteners Information” in Section 0C (Page 0C-10)
1H-13 Ignition System:

Special Tools and Equipment

Special Tool
BENM23K11808001
09930–10121 09930–11940
Spark plug socket set Torx® bit holder (3/8 sq.)
(Page 1H-5) / Torx® is the registered
(Page 1H-5) trademark of Camcar
Division of Textron inc.
U.S.A.
(Page 1H-10) /
(Page 1H-11)
09940–63110
Torx® bit (E8)
Torx® is the registered
trademark of Camcar
Division of Textron inc.
U.S.A.
(Page 1H-10) /
(Page 1H-11)
 Starting System: 1I-1

Starting System
Engine

Schematic and Routing Diagram

Starting System Diagram
BENM23K11902001

1 4
9

13
6 [A]
2
11

10
7
14
5 8

3
12

15

16

IH23K1190009-02

[A]: To each lights 6. Keyless control unit 12. Regulator/rectifier

1. ECM 7. Ignition switch 13. Sub fuse
2. Starter relay 8. Ignition solenoid 14. Fan fuse
3. Starter motor 9. Main relay 15. Main fuse
4. Starter switch 10. Ignition relay 16. Battery
5. Engine stop switch 11. Keyless indicator light

Component Location
Starting System Components Location
BENM23K11903001
Refer to “Electrical Components Location” in Section 0A (Page 0A-6).
1I-2 Starting System:

Diagnostic Information and Procedures

Starting System Symptom Diagnosis
BENM23K11904001
Possible symptoms of starting system trouble are as follows:
• Starter motor does not run.
• Engine does not turn though the starter motor runs.
Proper diagnosis must be made to determine in which of the battery, wiring harness, starting motor and engine the
cause of each trouble lies.
Before removing the starting motor, check the following items to identify most possible cause of trouble.
• Condition of trouble
• Tightness of battery terminals (including ground cable connection on engine) and starting motor terminals
• Discharge of battery
• Mounting of starting motor

Condition Possible cause Correction / Reference Item

Stater motor does not run Battery voltage is too low. Check battery. (Page 1J-12)
Poor battery terminal connection. Check terminal connection or replace battery.
(Page 1J-13)
Poor ground cable connection. Tighten ground cable.
Blown fuse. Replace fuse and check its circuit.
Brushes not seating properly on starter Repair or replace. (Page 1I-7)
motor. commutator.
Defective relays. Replace. (Page 1I-8)
(Page 1H-8)
Defective switches. Replace. (Page 1H-9)
Defective ECM. Replace. (Page 1C-2)
Open circuit in wire harness. Repair wiring. (Page 9A-3)
Remote controller battery voltage is too Replace. (Page 1C-16)
low.
The remote controller will not Registration. (Page 1C-13)
authenticated.
Engine does not turn Faulty starter clutch. Replace. (Page 1I-10)
though the starter motor Faulty starter idle gear. Replace.
runs Faulty starter pinion gear. Replace. (Page 1I-6)

Starter Motor Will Not Run

BENM23K11904002
Troubleshooting Step 2
Starter switch input circuit check
Step 1
Sub relay operating sound check 1) Turn the ignition switch off and disconnect the
starter switch coupler.
1) Turn the ignition switch on and check for a click
from the sub relay. 2) Check for proper terminal connection to the starter
switch coupler.
Does the sub relay click?
3) If connection is OK, turn the ignition switch on.
Yes Go to Step 2. 4) Check that voltage between O wire terminal and
ground is battery voltage.
No • Faulty sub relay.
• Faulty ignition switch. Is check result OK?

• Faulty regulator/rectifier. Yes Go to Step 3.

• Open circuit in wire harness. No • Faulty “A1” circuit.
• Open circuit in wire harness.
 Starting System: 1I-3

2) Check for starter relay. (Page 1I-9)

Step 3
Starter switch check Is check result OK?
1) Turn the ignition switch off.
Yes Go to Step 8.
2) Check for starter switch. (Page 1I-12)
No Faulty starter relay.
Is check result OK?

Yes Go to Step 4. Step 8

Starter relay drive circuit check
No Faulty starter switch. 1) Disconnect the ECM coupler.
2) Check for proper terminal connection to the ECM
Step 4
coupler.
Starter switch signal circuit check
3) If connections are OK, check the following points.
1) Disconnect the ECM coupler.
• Resistance of B/Y circuit: less than 1 Ω
2) Check for proper terminal connection to the ECM
coupler. • Resistance between B/Y wire terminal and
ground: infinity
3) If connection is OK, check the following points.
• Resistance between B/Y wire terminal and
• Resistance of Y/G circuit: less than 1 Ω
other terminal at starter relay coupler: infinity
• Resistance between Y/G wire terminal and
ground: infinity Is check result OK?
• Resistance between Y/G wire terminal and Yes Go to Step 9.
other terminal at starter switch coupler: infinity
No Faulty “B3” circuit.
Is check result OK?

Yes Go to Step 5. Step 9

ECM ground circuit check
No Faulty “A2” circuit. 1) Check that resistance between B/W (C1) wire
terminal and ground is less than 1 Ω.
Step 5
Starter relay operating sound check Is check result OK?
1) Connect the starter switch and ECM coupler. Yes Faulty ECM.
2) Turn the ignition switch on.
No Faulty “C1” circuit.
3) Push the starter switch and check for a click from
the starter relay. Step 10
Does the starter relay click? Starter relay power supply circuit (switch side)
check
Yes Go to Step 10. 1) Check that voltage between “B2” circuit and
No Go to Step 6. ground is battery voltage.
Is check result OK?
Step 6
Starter relay power supply circuit (coil side) check Yes Go to Step 11.
1) Turn the ignition switch off and disconnect the
No Faulty “B2” circuit.
starter relay coupler.
2) Check for proper terminal connection to the starter Step 11
relay terminal. Starter motor power supply circuit check
3) If connection is OK, turn the ignition switch on. 1) Connect the ECM and starter relay couplers.
4) Check that voltage between O/B wire terminal and 2) Turn the ignition switch on.
ground is battery voltage. 3) Push the starter switch and check that voltage
Is check result OK? between “B4” circuit and ground is battery voltage.

Yes Go to Step 7. Is check result OK?

No Faulty “B1” circuit. Yes Faulty starter motor.

No • Faulty “B4” circuit.

Step 7
Starter relay check • Faulty “B5” circuit.
1) Turn the ignition switch off.
1I-4 Starting System:

Starter Motor Runs But Does Not Crank the Engine

BENM23K11904003

Step 1
Check the starter clutch. (Page 1I-12)
Is the starter clutch OK?

Yes Faulty starter motor.

No Faulty starter clutch.

Repair Instructions
Starter Motor Components
BENM23K11906001

2 (a)
3 (b)

9 7

10

4
4

11 4

12 (c)

IG12K1190003-02

1. Rear bracket 8. Armature : 2.7 Nm (0.28 kgf-m, 2.0 lbf-ft)

2. Starter motor mounting bolt 9. Starter motor case : Apply grease.
: For installation, refer to “Starter Motor Assembly Removal and
Installation” (Page 1I-5).
3. Starter motor lead wire mounting nut 10. Oil seal : Apply moly past.
4. O-ring 11. Front bracket : Apply engine oil.

5. Brush sub assembly 12. Housing bolt : Do not reuse.

6. Brush holder : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
7. Brush : 4.9 Nm (0.50 kgf-m, 3.65 lbf-ft)
 Starting System: 1I-5

Keyless Start System Inspection Starter Motor Assembly Removal and

BENM23K11906002
Riding Mode Inspection
Installation
BENM23K11906003
1) Check that the remote controller is in the
communication mode. Removal
2) Place the remote controller within the engine 1) Turn the ignition switch OFF and disconnect the
operation range (1). battery (–) lead wire. Refer to “Battery Removal and
Installation” in Section 1J (Page 1J-13).
2) Remove the right under cowling. (Page 9D-26)
3) Disconnect the ECT sensor coupler (1).

1
IH23K1190010-01

3) Check that the ignition switch has been set to the

OFF or LOCK position, and then, push the request IH23K1190001-01
switch. 4) Disconnect the starter motor read wire (1) and
4) Check that the keyless indicator light is turned on. remove the starter motor mounting bolts (2).
5) While the keyless indicator light is on, set the ignition
switch to ON position.
6) Inspect the combination meter operation.
7) Check that the engine is started when the starter
1
switch is pushed with the engine stop switch set to
the RUN position. (all interlocks for engine start are
released)

Alighting Mode Inspection 2

1) Check the hazard light blinks once when the ignition
key is turned to OFF.
IG12K1190005-01
2) Check that the ignition key can be removed at the 5) Remove the starter motor (1).
ignition switch “ • ” (ACC) position when the keyless
indicator light is on.
3) Check that the operation switch mode is changed to
the alighting mode when no operation is made for 4
seconds after the request switch is pushed and the
keyless indicator light is turned on.

IG12K1190006-01
1I-6 Starting System:

Installation Starter Motor Disassembly and Reassembly

Install the starter motor in the reverse order of removal. BENM23K11906004

Pay attention to the following points:

• Apply grease to a new O-ring (1).
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)
• Apply engine oil to the armature shaft (2).
1, “A”
Disassembly
Disassemble the starter motor. (Page 1I-4)
Reassembly
Reassemble the starter motor in the reverse order of
disassembly. Pay attention to the following points:
• Replace the O-rings with new ones.
• Apply grease to the lip of the oil seal and bushings.
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

“A” “A”

IG12K1190007-02

• Tighten the starter motor mounting bolts (1) to the

specified torque in order of “1” → “2”.
“A”
• Set the starter motor read wire in the specified
position and tighten the nut (2) to the specified torque.
(Page 9A-11) IG12K1190009-01

Tightening torque
Starter motor mounting bolt (a): 10 N·m (1.0 kgf-
m, 7.3 lbf-ft) “A”
Starter motor lead wire mounting nut (b): 4.9 N·m
(0.50 kgf-m, 3.65 lbf-ft)

2, (b)

IG12K1190010-01

• Apply a small quantity of moly paste to the armature

shaft.
1, “1”, (a) 1, “2”, (a)
“A”: Assembly lubrication 99000–25140 (SUZUKI
MOLY PASTE)
IG12K1190008-02

“A”
IG12K1190011-01
 Starting System: 1I-7

• Align the terminal (1) on the rear bracket with the Starter Motor Inspection
punch mark (2) on the starter motor case. BENM23K11906005
Refer to “Starter Motor Disassembly and Reassembly”
(Page 1I-6).

Carbon Brush
1 Inspect the carbon brushes for abnormal wear, cracks or
smoothness in the brush holder.
If any damages are found, replace the brush holder or
brush terminal set with a new one.
Make sure that the length “a” is not less than the service
2 limit. If this length becomes less than the service limit,
replace the brush with a new one.

IG12K1190012-01
Special tool
09900–20102
• Align the dent (1) near the projection on the front
bracket with the line mark (2) on the starter motor Starter motor brush length “a”
case. [Limit]: 3.5 mm (0.14 in)

“a”
1

IF34J1190054-01

2 Commutator
Inspect the commutator for discoloration, abnormal wear
or undercut “a”.
IG12K1190013-01
If the commutator is abnormally worn, replace the
armature.
• Apply grease to a new O-ring (1) and then tighten the
If the commutator surface is discolored, polish it with
housing bolts (2) to the specified torque.
#400 sandpaper and wipe it using a clean, dry cloth.
“A”: Grease 99000–25011 (SUZUKI SUPER If there is no undercut, scrape out the insulator (1) with a
GREASE A) saw blade.
Tightening torque
Housing bolt (a): 4.9 N·m (0.49 kgf-m, 3.61 lbf-ft)

1, “A”

2, (a) IE31J1190009-01

2. Segment

2, (a)
IG12K1190014-01
1I-8 Starting System:

Armature Coil Starter Relay Removal and Installation

Measure for continuity between each segment. Measure BENM23K11906006

for continuity between each segment and the armature Removal

shaft.
If there is no continuity between the segments or there is
continuity between the segments and shaft, replace the
starter motor assembly with a new one.
1) Disconnect the battery (–) lead wire. Refer to
“Battery Removal and Installation” in Section 1J
(Page 1J-13).
2) Disconnect the starter relay coupler (1) and remove
the starter relay cover (2).

IG12K1190015-01

Oil Seal
Check the seal lip (1) for damage.
If any damage is found, replace the starter motor IK23K4190001-01
assembly with a new one. 3) Disconnect the starter motor lead wire (1) and
battery (+) lead wire (2).

NOTE
1
Be sure to disconnect the starter motor lead
wire first, then disconnect the battery (+) lead
wire.

4) Remove the starter relay (3).

IG12K1190016-01
2

Bushing 1
Inspect the bushing (1) for wear and damage. If any
defects are found, replace the starter motor assembly
with a new one.

3
1

IH23K1190004-02

Installation
Install the starter relay in the reverse order of removal.
Pay attention to the following point:
• Tighten the starter relay terminal nuts (1) to the
specified torque.
IG12K1190017-01

Tightening torque
Starter relay terminal nut (a): 4.4 N·m (0.45 kgf-
m, 3.25 lbf-ft)
 Starting System: 1I-9

2) Measure the relay coil resistance between the

terminals using the circuit tester. If the resistance is
not within the specified value, replace the starter
relay with a new one.
1, (a)
Starter relay resistance
[Standard]: 3 – 6 Ω

IH23K1190008-02

Starter Relay Inspection

BENM23K11906007
Refer to “Starter Relay Removal and Installation” (Page
1I-8).
1) Apply 12 V to (1) and (2) terminals and check for
continuity between the positive and negative
terminals using the multi circuit tester. If the starter
relay clicks and continuity is found, the relay is OK.
NOTICE
Do not apply battery voltage to the starter
relay for five seconds or more, otherwise the
relay coil may overheat and get damaged.
IG12K1190023-01
Starter Interlock System Parts Inspection
BENM23K11906008
Check the interlock system for proper operation. If the
interlock system does not operate properly, check each
component for damage or abnormalities. If any
abnormality is found, replace the component with a new
one.
Side-stand Switch
1) Turn the ignition switch OFF.
2) disconnect the sidestand switch coupler (1).

1 2 3

IG12K1190021-01

IH23K5190001-02
1 2 3) Set the “Diode test” of the multi circuit tester. Refer to
“Precautions for Circuit Tester” in Section 00 (Page
To battery 00-7)
4) Check that the tester reads 1.4 V or more.

NOTE
If the tester reads less than 1.4 V when the
tester probes are not connected, replace its
To starter battery.
motor

IG12K1190058-01
1I-10 Starting System:

5) Measure the voltage between O ((+) probe) and B/W 4) Remove the key (1) and starter clutch gear (2).
((–) probe) lead wires of the side-stand switch.
Side-stand switch voltage
ON (Side-stand retracted) [Standard]: 0.4 – 0.6 V
1 2
OFF (Side-stand on the ground) [Standard]: 1.4 V
or more

IG12K1190026-01

5) Remove the starter clutch gear bearing (1).

IH23K5190002-02

Starter Clutch Removal and Installation

BENM23K11906009 1
Removal
1) Remove the generator cover, gasket and duel pins.
Refer to “Generator Removal” in Section 1J (Page IG12K1190027-01
1J-5). 6) Hold the generator rotor with the special tool and
2) Remove the shaft (1), spacer (2) and starter idle remove the starter clutch (1).
gear (3).
Special tool
(A): 09930–44521

3
1 (A)

1
IG12K1190024-01

3) Remove the generator rotor (1). (Page 1J-5)

IG12K1190028-01

IG12K1190025-01
 Starting System: 1I-11

Installation • Fit the key (1) in the key slot on the crankshaft.
Install the starter clutch in the reverse order of removal.
Pay attention to the following points:
• Apply engine oil to the one way clutch (1).
1
• Install the one way clutch pointing the plate side (2)
toward the generator rotor.

IG12K1190031-01

• Install the generator rotor onto crankshaft. Refer to

1
“Generator Installation” in Section 1J (Page 1J-7).
• Apply engine oil to the starter idle gear shaft holes (1),
starter idle gear (2) and shaft (3).
IG12K1190029-01

• Apply thread lock to the starter clutch bolts (1), and

then tighten them to the specified torque with the 1
special tool. 1
Special tool
(A): 09930–44521
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
Tightening torque
Starter clutch bolt (a): 10 N·m (1.0 kgf-m, 7.3 lbf-
IG12K1190032-01
ft)

1, “A”, (a)

(A) 3

IG12K1190030-01 IG12K1190033-01

• Apply engine oil to the starter clutch gear bearing (1)

and install it to the crankshaft.

IG12K1190027-01
1I-12 Starting System:

Starter Clutch Inspection Starter Switch Inspection

BENM23K11906010 BENM23K11906011
GSX R 125 Model
Starter Clutch 1) Remove fuel tank. (Page 1G-8)
1) Install the starter clutch gear onto the starter clutch. 2) Disconnect the right handle switch lead wire coupler
2) Turn the starter clutch gear by hand to inspect the (1).
starter clutch for a smooth movement. The gear
turns in one direction only. If a large resistance is felt
for rotation, inspect the starter clutch or the starter
clutch contacting surface on the starter clutch gear
for wear or damage.
If they are found to be damaged, replace them with 1
new ones.

IH23K1190003-02

3) Inspect the starter switch for continuity with a tester.

If any defect is found, replace the right handle switch
with a new one. Refer to “Handlebar Removal and
Installation” in Section 6B (Page 6B-4).
IG12K1190034-01

Starter Idle Gear Color

Y/G O/W
Inspect the starter idle gear for wear or damage. If any Position
defects are found, replace it with a new one.
PUSH
IH23K1190005-01

4) After finishing the starter switch inspection, install the

removed parts.

GSX S 125 Model

1) Remove front headlight assembly. (Page 9B-2)
2) Disconnect the right handle switch lead wire coupler
(1).

IG12K1190035-01

Starter Clutch Gear Bearing

Inspect the starter clutch gear bearing for any
abnormality, especially cracks. If any defects are found,
replace the starter clutch gear bearing with a new one.
1

IH23K2190001-01

IG12K1190036-01
 Starting System: 1I-13

3) Inspect the starter switch for continuity with a tester.

If any defect is found, replace the right handle switch Color
with a new one. Refer to “Handlebar Removal and Y/G O/W
Position
Installation” in Section 6B (Page 6B-4).
PUSH
IH23K1190005-01

4) After finishing the starter switch inspection, install the

removed parts.

Kick Starter Components (If Equipped)

BENM23K11906012

3
4
5

(b)
6
(a)

10

9 8

IG12K1190039-02

1. Kick starter lever 6. Kick starter spring : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
For installation, refer to “Kick Starter Lever
Removal and Installation” (Page 1I-14).
2. Kick starter shaft oil seal 7. Return spring : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
3. Kick starter drive gear 8. Kick starter return spring guide : Apply grease oil.
4. Kick starter shaft 9. Kick starter guide : Apply thread lock to the thread part.
5. Kick starter 10. Kick starter stopper : Do not reuse.
For installation, refer to “Kick Starter Shaft
Removal and Installation” (Page 1I-14).
1I-14 Starting System:

Kick Starter Lever Removal and Installation Kick Starter Shaft Removal and Installation
BENM23K11906013 BENM23K11906014
Removal
1) Remove the kick starter lever (1). Removal
1) Remove the engine assembly. (Page 1D-46)
2) Remove the right crankcase. (Page 1D-50)
3) Remove the kick starter guide (1).
1

IH23K1190006-02

IG12K1190042-01
Installation 4) Turn the kick starter shaft (1) until the kick starter (2)
1) Install the kick starter lever (1) as shown in the is free of the kick starter stopper (3), and then
illustration. remove the kick starter stopper.
2) Tighten the kick starter lever bolt (2) to the specified
torque.
Tightening torque 1
Kick starter lever bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)

3
3 2
IG12K1190043-01
1
5) Remove the kick starter drive gear (1), kick starter
(2) and kick starter spring (3).

2,(a) 2

IH23K1190007-01

3. Frame IG12K1190044-01
 Starting System: 1I-15

6) Remove the kick starter shaft (1). • Install the kick starter shaft as follows.
a. Set the kick shaft return spring (1) as shown.

1
IG12K1190045-02

7) Remove the following parts from the kick starter IG12K1190048-01

shaft. b. Install the kick starter spring (1) and kick starter
• Kick shaft return spring guide (1) (2).
• Kick shaft return spring (2)
• Kick starter spring plate (3)
2

3
2 IG12K1190049-01

c. Install the kick starter lever (1) and turn the starter
IG12K1190046-01
shaft counter-clockwise approx. 135° and hold it in
place.
Installation
Install the kick starter shaft in the reverse order of
removal. Pay attention to the following points:
• Install the return spring guide (1) to the kick starter
shaft as shown. 1

IG12K1190050-01

d. Install the kick starter spring (1) and kick starter

(2).
1

IG12K1190047-01

IG12K1190051-01
1I-16 Starting System:

• Install the kick starter stopper (1) and kick starter Installation
guide (2). 1) Install the kick starter oil seal (1) using the special
• Apply thread lock to the kick starter guide bolts (3) and tool.
tighten them to the specified torque.
Special tool
“A”: Thread lock cement 99000–32150 (THREAD (A): 09913–70210
LOCK CEMENT 1322D)
“a”
Tightening torque
Kick starter guide bolt (a): 10 N·m (1.0 kgf-m, 7.3
lbf-ft)
(A)

3, (a) 2
IG12K1190054-01

2. Right crankcase “a”: 1.0 – 2.0 mm (0.040 – 0.078 in)

1 2 2) Install the removed parts.

“A”
IG12K1190052-01
Kick Starter Parts Inspection
BENM23K11906016
Kick Starter Shaft Oil Seal Removal and Refer to “Kick Starter Shaft Removal and Installation”
Installation (Page 1I-14).
BENM23K11906015
Removal
Kick Starter Shaft
1) Remove the right crankcase. (Page 1D-50)
Inspect the kick starter shaft for wear or bend. If any
2) Remove the kick starter oil seal (1). defects are found, replace the kick starter shaft with a
new one.

IG12K1190053-01

IG12K1190055-02
 Starting System: 1I-17

Return Spring
Inspect the return spring for damage or fatigue. If any
defects are found, replace the return spring with a new
one.
Kick Starter / Kick Starter Drive Gear / Kick Starter
Idle Gear
Inspect the kick starter (1) and kick starter drive gear (2)
for wear and damage. If any defects are found, replace
the defective part with a new one.

1
2
IG12K1190056-01
IG12K1190057-01

Specifications
Tightening Torque Specifications
BENM23K11907001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Starter motor mounting bolt 10 1.0 7.3 (Page 1I-6)
Starter motor lead wire mounting nut 4.9 0.50 3.65 (Page 1I-6)
Housing bolt 4.9 0.49 3.61 (Page 1I-7)
Starter relay terminal nut 4.4 0.45 3.25 (Page 1I-8)
Starter clutch bolt 10 1.0 7.3 (Page 1I-11)
Kick starter lever bolt 23 2.3 17.0 (Page 1I-14)
Kick starter guide bolt 10 1.0 7.3 (Page 1I-16)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Starter Motor Components” (Page 1I-4)
“Kick Starter Components (If Equipped)” (Page 1I-13)
“Fasteners Information” in Section 0C (Page 0C-10)
1I-18 Starting System:

Special Tools and Equipment

Recommended Service Material
BENM23K11908001
Material SUZUKI recommended product or Specification Note
Assembly lubrication SUZUKI MOLY PASTE P/No.: 99000–25140 (Page 1I-6)
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 1I-6) / (Page 1I-6)
/ (Page 1I-7)
Thread lock cement THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 1I-11) / (Page 1I-
16)

NOTE
Required service material(s) is also described in:
“Starter Motor Components” (Page 1I-4)
“Kick Starter Components (If Equipped)” (Page 1I-13)

Special Tool
BENM23K11908002
09900–20102 09913–70210
Vernier calipers (200 mm) Bearing installer set
(Page 1I-7) (Page 1I-16)

09930–44521
Rotor holder
(Page 1I-10) /
(Page 1I-11)
 Charging System: 1J-1

Charging System
Engine

Schematic and Routing Diagram

Charging System Diagram
BENM23K11A02001

3
6

7
1
5 4
8

9
IK23K41A0001-01

1. Generator 3. Ignition switch 5. Load 7. IC 9. Resistor (if equipped)

2. Regulator/rectifier 4. Battery 6. Main fuse 8. LED headlight

Component Location
Charging System Components Location
BENM23K11A03001
Refer to “Electrical Components Location” in Section 0A (Page 0A-6).
1J-2 Charging System:
Diagnostic Information and Procedures
Charging System Symptom Diagnosis
Condition Possible cause
Generator does not Open- or short-circuited lead wires, or
charge loose lead connections.
Short-circuited, grounded or open
generator coil.
Short-circuited or punctured regulator/
rectifier.
Generator does charge, Lead wires tend to get short- or open-
but charging rate is below circuited or loosely connected at
the specification terminals.
Grounded or open-circuited generator
coil.
Defective regulator/rectifier.
Defective cell plates in the battery.
Generator overcharges Internal short-circuit in the battery.
Damaged or defective regulator/rectifier. Replace. (Page 1J-10)
Poorly grounded regulator/rectifier.
Unstable charging Lead wire insulation frayed due to
vibration, resulting in intermittent short-
circuiting.
Internally short-circuited generator.
Defective regulator/rectifier.
Battery overcharges Faulty regulator/rectifier.
Faulty battery.
Poor contact of generator lead wire
coupler.
Battery runs down quickly Trouble in charging system.
Cell plates have lost much of their active Replace the battery and correct the charging
materials a result of overcharging.
Internal short-circuit in the battery.
Too low battery voltage.
Too old battery.
Battery “sulfation” Incorrect charging rate. (When not in
use battery should be checked at least
once a month to avoid sulfation.)
The battery was left unused in a cold
climate for too long.
“Sulfation”, acidic white Cracked battery case.
powdery substance or Battery has been left in a run-down
spots on surface of cell condition for a long time.
plates
BENM23K11A04001
Correction / Reference Item
Repair, replace or connect properly.
Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Replace. (Page 1J-10)
Repair or retighten.
Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Replace. (Page 1J-10)
Replace the battery. (Page 1J-13)
Replace the battery. (Page 1J-13)
Clean and tighten ground connection.
Repair or replace.
Replace.
• Removal: (Page 1J-5)
• Installation: (Page 1J-7)
Replace. (Page 1J-10)
Replace. (Page 1J-10)
Replace. (Page 1J-13)
Repair.
Check the generator, regulator/rectifier and
circuit connections and make necessary
adjustments to obtain specified charging
operation. (Page 1J-4)
system. (Page 1J-13)
Replace the battery. (Page 1J-13)
Recharge the battery fully. (Page 1J-12)
Replace the battery. (Page 1J-13)
Replace the battery. (Page 1J-13)
Replace the battery if badly sulfated. (Page
1J-13)
Replace the battery. (Page 1J-13)
Replace the battery. (Page 1J-13)
 Charging System: 1J-3

Battery Runs Down Quickly

BENM23K11A04002
Troubleshooting

Step 1
Check accessories which use excessive amounts of electricity.
Are accessories installed?

Yes Remove accessories.

No Go to Step 2.

Step 2
Check the battery for current leakage. (Page 1J-4)
Is the battery for current leakage OK?

Yes Go to Step 3.

No • Short circuit of wire harness.

• Faulty electrical equipment.

Step 3
Measure the regulated voltage between the battery terminals. (Page 1J-4)
Is the regulated voltage OK?

Yes • Faulty battery.

• Abnormal driving condition.

No Go to Step 4.

Step 4
Measure the resistance of the generator coil. (Page 1J-4)
Is the resistance of generator coil OK?

Yes Go to Step 5.

No • Faulty generator coil.

• Poor contact of couplers.

Step 5
Measure the generator no-load performance. (Page 1J-4)
Is the generator no-load performance OK?

Yes Go to Step 6.

No Faulty generator.

Step 6
Inspect wirings.
Is the wirings OK?

Yes • Faulty battery.

• Faulty regulator/rectifier.

No • Short circuit of wire harness.

• Poor contact of couplers.
1J-4 Charging System:

Repair Instructions
Battery Current Leakage Inspection
BENM23K11A06001
1) Disconnect the battery (–) lead wire. Refer to
“Battery Removal and Installation” (Page 1J-13).
2) Measure the current between battery (–) terminal
and the battery (–) lead wire using the multi circuit
tester. If the reading exceeds the specified value,
leakage is evident.
V
NOTICE
• In case of a large current leak, turn the
tester to high range first to avoid tester
damage.
• Do not turn the ignition switch to ON
IH23K11A0004-01
position when measuring current.

Battery leakage current Generator Inspection

BENM23K11A06003
[Standard]: 10 mA Generator Coil Resistance
1) Remove the frame cover assembly. (Page 9D-31)
mA
2) Disconnect the generator lead wire coupler (1).

I649G11A0002-03

3) Connect the battery (–) terminal and close the seat.

(Page 1J-13) 1

Regulated Voltage Inspection

BENM23K11A06002
1) Open the seat.
IK23K41A0003-02
2) Start the engine and keep it running at 5000 r/min
with the dimmer switch turned HI position. 3) Measure the resistance of generator coil.
If the resistance is out of specified value, replace
3) Measure the DC voltage between the battery (+) and
generator stator with a new one. Also, check that the
(–) terminals using the multi circuit tester. If the
generator core is insulated properly.
voltage is not within the specified value, inspect the
generator. (Page 1J-4) Generator coil resistance
If the generator is in good condition, replace the [Standard]: Approx. 0.3 Ω - 2.0 Ω
regulator and recheck the regulated voltage.

NOTE
Y
When making this test, be sure that the
battery is in fully charged condition.

Regulated voltage
Charging output
At 5000 r/min [Standard]: 14 – 15 V
IG12K11A0004-01
 Charging System: 1J-5

No-load Performance Generator Removal

BENM23K11A06004
1) Remove the frame cover assembly. (Page 9D-31)
1) Disconnect the battery (–) lead wire. Refer to
2) Disconnect the generator lead wire coupler (1). “Battery Removal and Installation” (Page 1J-13).
2) Drain engine oil. (Page 1E-5)
3) Remove the frame cover assembly. (Page 9D-31)
4) Remove the gearshift lever (1) and left footrest (2).

IK23K41A0003-02

3) Start the engine and keep it running at 5000 r/min.

1
4) Using multi circuit tester, measure the voltage of the
generator coil.
IH23K11A0006-01
If tester reads under the specified value, replace
generator stator with a new one. 5) Remove speed sensor (1) from engine sprocket
cover.
Generator no-load voltage
6) Remove engine sprocket cover (2) and dowel pins
When engine cold
(3).
At 5000 r/min [Standard]: 60 V (AC) or more

1
3
IG12K11A0005-01

2
IK23K41A0004-01
1J-6 Charging System:

7) Disconnect CKP sensor lead wire coupler (1) and 10) Hold the generator rotor (1) with the special tool and
generator lead wire coupler (2). remove the generator rotor nut (2).
Special tool
(A): 09930–44521

1
1

2
2

(A)
IG12K11A0011-02
IK23K41A0005-01
11) Remove the generator rotor (1) with the special tool.
8) Remove the generator cover (1).
Special tool
(A): 09930–34932

(A)
1 IG12K11A0012-02
IK23K41A0006-01 12) Remove the generator stator (1), CKP sensor (2),
9) Remove the gasket (1) and dowel pins (2). lead wire clamp (3) and grommet (4).

4
2

2 1
1
IG12K11A0010-01 IG12K11A0013-01
 Charging System: 1J-7

Generator Installation 2) Apply sealant to the grommet (1) as shown and

BENM23K11A06005 install it to the generator cover.
1) Install the generator stator (1), lead wire clamp (2)
and CKP sensor (3), and tighten the bolts to the “A”: Sealant 99000–31140 (SUZUKI BOND
specified torque. 1207B)

NOTE
Pass the generator lead wire (4) between the
generator cover ribs (5) and lead wire clamp.
1
Be careful not to pinch the wire.

Tightening torque
Generator stator bolt (a): 5.0 N·m (0.51 kgf-m,
3.70 lbf-ft)
CKP sensor bolt (b): 5.0 N·m (0.51 kgf-m, 3.70 “A”
lbf-ft)
Lead wire clamp bolt (c): 5.0 N·m (0.51 kgf-m, IG12K11A0016-01
3.70 lbf-ft) 3) Degrease the tapered portion (1) of crankshaft and
also the generator rotor (2). Use nonflammable
2 cleaning solvent to wipe off oily or greasy matter and
make these surfaces completely dry.
1
4) Align the key (3) and key slot on the generator rotor.
(c)

3
(a)
3
2
(b)

IG12K11A0014-01
1

2
4 IG12K11A0017-01

5) Install the generator rotor (1) on the crankshaft.

5 6) Hold the generator rotor with the special tool and
5 tighten its nut to the specified torque.
Special tool
(A): 09930–44521
Tightening torque
IG12K11A0015-01
Generator rotor nut (a): 140 N·m (14.3 kgf-m,
103.5 lbf-ft)

(a)

1 (A)
IG12K11A0018-01
1J-8 Charging System:

7) Install the dowel pins (1) and new gasket (2). 10) Install the dowel pins and engine sprocket cover (1),
and then tighten its bolts to the specified torque.
Refer to “Engine Sprocket Removal and Installation”
in Section 3A (Page 3A-4).

1
1

1
2
IG12K11A0019-01

8) Install the generator cover (1) and tighten the bolts to

the specified torque.

! CAUTION
Be careful not to pinch the finger between the
IH23K11A0011-01
generator cover and the crankcase.
11) Install the speed sensor. (Page 1C-12)
Tightening torque 12) Connect the generator lead wire coupler (1) and
Generator cover bolt (a): 10 N·m (1.0 kgf-m, 7.3 CKP sensor lead wire coupler (2).
lbf-ft)

1
1

(a)
IK23K41A0008-01

IK23K41A0007-01 13) Clamp the generator lead wire and CKP sensor lead
9) Route the GP switch lead wire. (Page 9A-11) wire. (Page 9A-11)
14) Connect the battery (–) lead wire. (Page 1J-13)
15) Pour engine oil. (Page 1E-5)
16) Install the removed parts.
 Charging System: 1J-9

Regulator / Rectifier Construction

BENM23K11A06006

3
[B] 1
(a)

[A] (a)

IH23K11A0017-01

[A]: Pass harness through plate rectifier 2. Rectifier bracket

[B]: Pass harness through between air cleaner wall and frame. 3. Air cleaner assembly
1. Regulator/rectifier : 10 Nm (1.0 kgf-m, 7.5 lbf-ft)
1J-10 Charging System:

Regulator / Rectifier Removal and Installation 5) Disconnect the regulator/rectifier coupler (1), loosen
BENM23K11A06007 the bolt (3), and remove the regulator/rectifier (2).
Removal
1) Disconnect battery (–) lead wire. Refer to “Battery
Removal and Installation” (Page 1J-13).
2) Remove frame cover. (Page 9D-31)
3) Remove the regulator/rectifier plate (1).

1 3

1
IK23K41A0010-01

Installation
1) Connect the regulator/rectifier coupler (1), and then
install the regulator/rectifier (2) using the bolt and
nut.
IK23K41A0009-01
2) Tighten the regulator/rectifier bolt (3) to the specified
4) Remove the regulator/rectifier bolt (1). Refer to
torque.
“Regulator / Rectifier Construction” (Page 1J-9).
Tightening torque
Regulator/rectifier bolt (a): 10 N·m (1.0 kgf-m,
7.3 lbf-ft)
1

3, (a)
1

IH23K11A0016-01 2

NOTE
Do not depress the rear fender front too far. IK23K41A0011-01
Otherwise, the installation position of the TO
sensor may change, preventing the engine
from starting.
 Charging System: 1J-11

3) Install the regulator/rectifier plate (1). Tightening torque

Regulator/rectifier plate bolt (a): 10 N·m (1.0 kgf-
m, 7.3 lbf-ft)
(a)
4) Install the removed parts.

IK23K41A0012-01

Battery Construction
BENM23K11A06008

[A]
1
2

5
IK23K41A0002-01

[A]: Do not clip lead wire with a rubber bracket of the ECM 3. Motor starter relay assembly
1. ECM 4. Frame
2. Battery 5. Battery protector
• Remove stains including oil, dust, and powder of painting from
surface before attaching label.
• Label should be pressed after attaching of cushion.
1J-12 Charging System:

Battery Charging 3) After recharging, wait at least 30 minutes and then

BENM23K11A06009 measure the battery voltage using the multi circuit
Initial Charging
tester.
For initial charging, use the charger specially designed
If the battery voltage is less than 12.5 V, recharge
for MF battery.
the battery again.
NOTICE If the battery voltage is still less than 12.5 V after
recharging, replace the battery with a new one.
• For charging the battery, make sure to use
the charger specially designed for MF 1
battery. Otherwise, the battery may be 2
overcharged resulting in shortened service
life.
• Do not remove the cap during charging.
• Position the battery with the cap facing
upward during charging.

Battery Recharging

NOTICE ID26J11A0039-02

Do not remove the caps on the battery top 1. Charging period 2. Stop charging
while recharging.
4) Install the battery to the motorcycle. (Page 1J-13)
NOTE
When the motorcycle is not used for a long
period, check the battery every 1 month to
prevent the battery discharge.

1) Remove the battery from the motorcycle. (Page

1J-13)
2) Measure the battery voltage using the multi circuit
tester.
If the voltage reading is less than the 12 V (DC),
recharge the battery with a battery charger.
IF34J11A0032-01
NOTICE
[A]: Battery charged condition
Be careful not to permit the charging current
to exceed 5 A at any time.

Reaching time
Standard charging [Standard]: 0.5 A for 5 to 10
hours
Fast charging [Standard]: 5 A for 0.5 hours
 Charging System: 1J-13

Battery Removal and Installation Battery Visual Inspection

BENM23K11A06010
Removal
1) Open the seat. (Page 9D-20)
2) Disconnect the battery (–) lead wire (1).
3) Disconnect the battery (+) lead wire (2).
NOTE
Disconnect the battery (–) lead wire (1) first,
then disconnect the battery (+) lead wire (2).
4) Remove the battery band (3) and battery (4) from the
motorcycle.
BENM23K11A06011
1) Open front seat.
2) Visually inspect the surface of the battery container.
If any signs of cracking or electrolyte leakage from
the sides of the battery have occurred, replace the
battery with a new one. (Page 1J-13)
If the battery terminals are found to be coated with
rust or an acidic white powdery substance, clean the
battery terminals with sandpaper.
3) Close the seat.

IH23K11A0015-02

Installation
Install the battery in the reverse order of removal. Pay
attention to the following points:

NOTICE
Never use anything except the specified
battery.

• Connect the battery (+) lead wire (1) first, then

connect battery (–) lead wire (2).
• Tighten the battery lead wire mounting bolts securely.

IH23K11A0015-02
1J-14 Charging System:

Specifications
Tightening Torque Specifications
BENM23K11A07001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Generator stator bolt 5.0 0.51 3.70 (Page 1J-7)
CKP sensor bolt 5.0 0.51 3.70 (Page 1J-7)
Lead wire clamp bolt 5.0 0.51 3.70 (Page 1J-7)
Generator rotor nut 140 14.3 103.5 (Page 1J-7)
Generator cover bolt 10 1.0 7.3 (Page 1J-8)
Regulator/rectifier bolt 10 1.0 7.3 (Page 1J-10)
Regulator/rectifier plate bolt 10 1.0 7.3 (Page 1J-11)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Regulator / Rectifier Construction” (Page 1J-9)
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Recommended Service Material
BENM23K11A08001
Material SUZUKI recommended product or Specification Note
Sealant SUZUKI BOND 1207B P/No.: 99000–31140 (Page 1J-7)

Special Tool
BENM23K11A08002
09930–34932 09930–44521
Rotor remover Rotor holder
(Page 1J-6) (Page 1J-6) /
(Page 1J-7)
 Exhaust System: 1K-1

Exhaust System
Engine

Precautions
Precautions for Exhaust System
BENM23K11B00001
! WARNING
To avoid the risk of being burned, do not touch the exhaust system when the system is hot.

NOTICE
After installation of the muffler, make sure that there is no leakage of exhaust gas.

Repair Instructions
Exhaust System Components
BENM23K11B06001

(a)
4 (c)

(b)

5
6

10

9 (a)

11 (b)

1
7

(b)
IH23K51B0001-01

1. Body muffler 6. Muffler rear cover stay 11. Screw

2. Gasket 7. Protector : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
3. Muffler cover 8. Cushion : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
O2 sensor
4. 9. Bolt : 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
: Apply nickel based anti seize to the thread part of O2 sensor.
5. Muffler rear cover 10. Nut : Do not reuse.
1K-2 Exhaust System:

Muffler Removal and Installation 4) Remove the muffler (1) by removing muffler
BENM23K11B06002 mounting bolt (2) and nut (3).
Removal
1) GSX R 125 Model
Remove right front fairing. (Page 9D-22) 3
GSX S 125 Model
a) Remove under cowling assembly. Refer to
“Under Cowling Removal and Installation” in 2
Section 9D (Page 9D-26).
b) Remove fuel tank side cover. Refer to “Fuel Tank
Side Cover Assembly Removal and Installation” 1
in Section 9D (Page 9D-25).
2) Disconnect the O2 sensor lead wire coupler (1) and
remove the O2 sensor lead wire clamp (2).

IH23K51B0002-01

5) Remove the exhaust pipe gasket (1).

IH23K41B0002-01

3) Remove the exhaust pipe bolts (1).

IK23K41B0001-01

6) If necessary, remove the muffler cover (1).

IK23K41B0002-01

1
IH23K51B0003-01
 Exhaust System: 1K-3

7) Remove the O2 sensor (1), if necessary. 3) Install the muffler.

4) Tighten the exhaust pipe bolts (1) first, and then
tighten the muffler mounting bolt (2) to the specified
torque.
Tightening torque
1 Exhaust pipe bolt (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)
Muffler mounting bolt (b): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)

1, (a)

IK23K41B0003-01

Installation
1) Install the muffler cover (1) and tighten the bolt to the
specified torque.
Tightening torque
Muffler cover bolt (a): 10 N·m (1.0 kgf-m, 7.3 lbf-
ft)
IK23K41B0005-02

(a)

2, (b)

1 IH23K51B0005-02
IH23K51B0004-01

2) Install a new exhaust pipe gasket (1).

IK23K41B0004-01
1K-4 Exhaust System:

5) Install the O2 sensor, if necessary. (Page 1C-8) Tightening torque

6) Connect the O2 sensor lead wire coupler (1) and Exhaust pipe bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
clamp the O2 sensor lead wire. (Page 9A-11) Muffler mounting bolt (b): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)

1, (a)

IK23K41B0005-02
IH23K41B0003-02

7) GSX R 125 Model

Install the right front fairing. (Page 9D-26)

GSX S 125 Model

Install the under cowling assembly. (Page 9D-26)

Exhaust System Inspection 2, (b)

BENM23K11B06003
Inspect the muffler connection for exhaust gas leakage
and mounting condition. If any defect is found, replace
the muffler with a new one.
Check the exhaust pipe bolts (1) and muffler mounting
bolt (2) are tightened to their specified torque.

IH23K51B0005-02

Specifications
Tightening Torque Specifications
BENM23K11B07001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Muffler cover bolt 10 1.0 7.3 (Page 1K-3)
Exhaust pipe bolt (Page 1K-3) /
23 2.3 17.0
(Page 1K-4)
Muffler mounting bolt (Page 1K-3) /
23 2.3 17.0
(Page 1K-4)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Exhaust System Components” (Page 1K-1)
“Fasteners Information” in Section 0C (Page 0C-10)

Section 2
Suspension
CONTENTS
Precautions .................................................2-1
Precautions............................................................. 2-1
Precautions for Suspension .................................. 2-1
Wheels and Tires ..................................... 2D-1
Suspension General Diagnosis.............. 2A-1
Diagnostic Information and Procedures............2A-1
Suspension and Wheel Symptom Diagnosis ...... 2A-1
Front Suspension .................................... 2B-1
Repair Instructions ..............................................2B-1
Front Fork Components ...................................... 2B-1
Front Fork On-Vehicle Inspection ....................... 2B-2
Front Fork Assembly Removal and
Installation ......................................................... 2B-2
Front Fork Disassembly and Reassembly .......... 2B-4
Front Fork Inspection .......................................... 2B-9
Specifications.....................................................2B-10
Tightening Torque Specifications...................... 2B-10
Special Tools and Equipment ...........................2B-10
Recommended Service Material ....................... 2B-10
Special Tool ...................................................... 2B-10
Rear Suspension ..................................... 2C-1
Repair Instructions ..............................................2C-1
Rear Suspension Components ...........................2C-1
Rear Suspension On-vehicle Inspection .............2C-2
Rear Shock Absorber Removal and
Installation .........................................................2C-2
Rear Shock Absorber Inspection ........................2C-3
Swingarm Removal and Installation....................2C-3
Swingarm Inspection...........................................2C-5
Specifications.......................................................2C-6
Tightening Torque Specifications........................2C-6
Table of Contents 2- i
Special Tools and Equipment .............................2C-6
2
Special Tool ........................................................2C-6
Precautions...........................................................2D-1
Precautions for Wheel and Tire...........................2D-1
Repair Instructions ..............................................2D-1
Front Wheel Components ...................................2D-1
Front Wheel Assembly Construction...................2D-2
Front Wheel Assembly Removal and
Installation .........................................................2D-3
Front Wheel Dust Seal / Front Wheel Bearing
Removal and Installation...................................2D-4
Rear Wheel Components....................................2D-6
Rear Wheel Assembly Construction ...................2D-7
Rear Wheel Assembly Removal and
Installation .........................................................2D-7
Rear Wheel Dust Seal / Rear Wheel Bearing
Removal and Installation...................................2D-8
Wheel / Wheel Axle Inspection .........................2D-10
Rear Wheel Damper Removal and Installation ..2D-12
Rear Wheel Damper Inspection ........................2D-12
Tire Inspection and Cleaning ............................2D-12
Tire Removal and Installation............................2D-13
Wheel Rim / Air Valve Inspection and
Cleaning ..........................................................2D-14
Air Valve Removal and Installation ...................2D-15
Specifications .....................................................2D-15
Tightening Torque Specifications......................2D-15
Special Tools and Equipment ...........................2D-16
Recommended Service Material .......................2D-16
Special Tool ......................................................2D-16
2-1 Precautions:

Precautions
Suspension

Precautions
Precautions for Suspension
BENM23K12000001
Refer to “General Precautions” in Section 00 (Page 00-1).

! WARNING

• Never attempt to heat, quench or straighten any suspension part. If any damage or deformation is
found, replace the part with a new one without correct it.
• When removing or installing the suspension or wheel, place the motorcycle on a level surface and
support it securely with a hoist or jack etc.
• Do not support the motorcycle with the muffler.

Suspension General Diagnosis
Suspension
Diagnostic Information and Procedures
Suspension and Wheel Symptom Diagnosis
Condition Possible cause
Wobbly front wheel Distorted wheel rim.
Worn front wheel bearings.
Defective or incorrect tire.
Loose front axle nut.
Incorrect fork oil level.
Front suspension too soft Insufficiently viscous fork oil.
Insufficient fork oil.
Weak spring.
Front suspension too stiff Excessively viscous fork oil.
Excessive fork oil.
Front suspension too Insufficient fork oil.
noisy Loose front suspension fastener.
Wobbly rear wheel Distorted wheel rim.
Worn rear wheel bearings.
Defective or incorrect tire.
Worn swingarm bushings.
Loose rear suspension fastener.
Loose rear axle nut.
Rear suspension too soft Weak rear shock absorber spring.
Rear shock absorber leaks oil.
Rear suspension too stiff Bent rear shock absorber shaft.
Worn swingarm bushings.
Bent swingarm pivot shaft.
Rear suspension too Loose rear suspension fastener.
noisy Worn swingarm bushings.
Suspension General Diagnosis: 2A-1
BENM23K12104001
Correction / Reference Item
Replace. (Page 2D-13)
Replace. (Page 2D-4)
Replace. (Page 2D-13)
Tighten. (Page 2D-3)
Adjust. (Page 2B-4)
Replace. (Page 2B-4)
Check level and add. (Page 2B-4)
Replace. (Page 2B-4)
Replace. (Page 2B-4)
Check level and drain. (Page 2B-4)
Check level and add. (Page 2B-4)
Tighten. (Page 2B-2)
Replace. (Page 2D-13)
Replace. (Page 2D-8)
Replace. (Page 2D-13)
Replace. (Page 2C-3)
Tighten. (Page 2C-2)
Tighten. (Page 2D-7)
Replace. (Page 2C-2)
Replace. (Page 2C-2)
Replace. (Page 2C-2)
Replace. (Page 2C-3)
Replace. (Page 2C-3)
Tighten. (Page 2C-2)
Replace. (Page 2C-3)
2B-1 Front Suspension:

Front Suspension
Suspension

Repair Instructions
Front Fork Components
BENM23K12206001

8
1

9
3

4
5
12

10
6
13

14
7 15
16

11

17

18

19 (a)
IH23K1220001-03

1. Front fork cap 7. Front spring 13. Snap ring 19. Bolt
2. Stopper ring 8. Ring 14. Oil seal : 20 Nm (2.0 kgf-m, 15.0 lbf-ft)
3. Spring seat 9. Cylinder 15. Seal spacer : Apply fork oil.
4. O-ring 10. Rebound spring 16. Oil lock piece : Apply thread lock to the thread part.
5. Spring spacer 11. Inner tube 17. Outer tube : Do not reuse.
Apply fork oil to the inside of
the outer tube.
6. Spring joint 12. Dust seal 18. Gasket
 Front Suspension: 2B-2

Front Fork On-Vehicle Inspection
BENM23K12206002
Inspect front forks for oil leakage, scoring or scratches
on outer surface of inner tubes (1).
Replace any defective parts, if necessary. (Page 2B-4)
Front Fork Assembly Removal and Installation
BENM23K12206003
GSX R 125 Model
Refer to “Front Wheel Assembly Removal and
Installation” in Section 2D (Page 2D-3).

GSX R 125 Model NOTE

The right and left front forks are installed
symmetrically (except front brake caliper)
and therefore the removal procedure for one
side is the same as that for the other side.

Removal
1 1) Remove front side reflector (1), brake hose clamp (2)
and front brake caliper (3).
2) Remove front fender assembly (4). (Page 9D-31)

IK23K4220002-01

GSX S 125 Model 1

1
IM23K1220001-02

3) Loosen front fork upper clamp bolt (1) and handlebar

bolt (2).
GSX R 125

IH23K2220001-01

IH23K1220003-01
2B-3 Front Suspension:

GSX S 125

(a)

IH23K1220006-01

4) Tighten front fork upper clamp bolt and handlebar

bolt.
IH23K2220002-01
Tightening torque
4) Loosen front fork lower clamp bolts (1), and then Front fork upper clamp bolt (a): 23 N·m (2.3 kgf-
remove front fork (2) by supporting it. m, 17.0 lbf-ft)
Handlebar bolt (b): 28 N·m (2.8 kgf-m, 20.6 lbf-ft)

GSX R 125

(a)
1

IH23K1220004-02
(b)
Installation
1) Set front fork (2) to steering stem lower bracket IH23K1220007-01
temporarily by tightening lower clamp bolts (1).
GSX S 125

(a)

IH23K1220004-02

2) Loosen the lower clamp bolts.

3) Tighten the front fork lower clamp bolts to specified
torque. IH23K2220003-01

Tightening torque 5) Install front side reflector (1), brake hose clamp (2),
Front fork lower clamp bolts (a): 23 N·m (2.3 kgf- and front brake caliper (3).
m, 17.0 lbf-ft) 6) Install front fender assembly (4). (Page 9D-31)
 Front Suspension: 2B-4

2
1
2
3

3
IG12K1220011-01

3) Invert the fork and stroke it several times to drain out

fork oil.
4) Hold the fork inverted for a few minutes to drain oil.
IM23K1220001-02

Front Fork Disassembly and Reassembly

BENM23K12206004
Refer to “Front Fork Assembly Removal and Installation”
(Page 2B-2).

NOTE
The right and left front forks are installed
symmetrically and therefore the disassembly
procedure for one side is the same as that for
the other side.
I649G1220012-02

Disassembly 5) Remove cylinder bolt using special tools.

1) Remove front fork cap bolt (1). Special tool
NOTICE (A): 09940–34520
(B): 09940–34561
Hold front fork cap bolt by hand when
removing the bolt. The cap bolt may pop up
pushed by the spring.

(A)

(B)

IH23K1220011-02

6) Remove cylinder (1) and rebound spring (2), and

then remove piston ring (3).
IH23K1220009-01

2) Remove spacer (1), washer (2) and spring (3).

1
2

IG12K1220013-01
2B-5 Front Suspension:

7) Remove inner tube (1). 11) Remove all oil seal component.

IH23K1220010-01 IH23K1220014-02

8) Remove dust seal (1).

Reassembly
9) Remove oil seal stopper ring (2).
NOTICE
• Thoroughly wash all component parts
being assembled.
Insufficient washing can result in oil
leakage or premature wear of parts.
• When reassembling front fork, use new
fork oil.
1
• Use specified fork oil for front fork.

1) Apply fork oil to the inside of outer tube (1).

2
IH23K1220012-01 “A”: Fork oil 99000–99001–SS8 (SUZUKI FORK
10) Remove oil seal (1) using special tool. OIL SS-8)
Special tool
(A): 09913–50121
1

(A)

“A”
IH23K1220015-01
1

IH23K1220013-01
 Front Suspension: 2B-6

2) Install inner tube (1) into the outer tube. 7) Install piston ring (1) to the cylinder.

1 1

IH23K1220016-01 IG12K1220021-01

3) Apply fork oil to oil seal lip. 8) Install rebound spring (1) to the cylinder (2).
“A”: Fork oil 99000–99001–SS8 (SUZUKI FORK 9) Apply fork oil to piston ring (3) and insert cylinder into
OIL SS-8) the inner tube.

4) Install a new oil seal (1) into the outer tube using “A”: Fork oil 99000–99001–SS8 (SUZUKI FORK
special tool. OIL SS-8)

Special tool
(A): 09940–52861

3, “A”

2
1
(A)

1, “A”
IG12K1220022-02

IG12K1220031-01

5) When installing the oil seal stopper ring (1), make

sure that the oil seal stopper ring is fitted securely
into the groove.
6) Install a new dust seal (2).

IF34J1220020-01
2B-7 Front Suspension:

10) Install a new cylinder bolt gasket (1). 12) Place front fork vertically without spring.
11) Apply thread lock to cylinder bolt (2), and tighten it to 13) Compress it fully.
specified torque using hexagon wrench and special 14) Pour specified front fork oil to inner tube.
tools.
“A”: Fork oil 99000–99001–SS8 (SUZUKI FORK
NOTE OIL SS-8)
Check the front fork for smoothness by Front fork oil capacity
stroking it after installing the cylinder. Each leg [Standard]: 196 ml (6.6 US oz, 6.9 Imp
oz)
Special tool
(A): 09940–34520
(B): 09940–34561
“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
Tightening torque
“A”
Front fork cylinder bolt (a): 20 N·m (2.0 kgf-m,
15.0 lbf-ft)

ID26J1220030-01

15) Move the inner tube up and down several strokes

until bubbles do not come out from the oil.
16) Keep front fork vertically and wait 5 – 6 minutes.
2, (a)

“A”
1
IH23K1220017-01

(A) I717H1220029-01

(B)

IH23K1220011-02
 Front Suspension: 2B-8

17) Hold front fork vertically and adjust fork oil level “a” 20) Apply fork oil lightly to a new front fork cap bolt O-
with special tool. ring (1).

NOTE “A”: Fork oil 99000–99001–SS8 (SUZUKI FORK

OIL SS-8)
When adjusting fork oil level, remove fork
spring and compress inner tube fully.

Special tool
(A): 09943–74111
Fork oil level
Without spring, inner tube fully compressed
[Standard]: 122 mm (4.80 in)

1, “A”
(A)

IH23K1220018-01

21) Temporarily tighten front fork cap bolt (1) pushing it

down.
“a”
1

IF34J1220030-01

18) Install fork spring (1) into the inner tube with its
smaller pitch “a” facing the bottom side.
19) Install washer (2) and spacer (3).

IH23K1220019-01

“a”

IG12K1220024-01

IG12K1220025-01
2B-9 Front Suspension:

Front Fork Inspection

BENM23K12206005
Refer to “Front Fork Disassembly and Reassembly”
(Page 2B-4).

Inner Tube / Outer Tube

Inspect inner tube sliding surface and outer tube sliding
surface for scuffing. If any defect is found, replace the
part with a new one.

IH23K1220020-01

Fork Spring
Measure the fork spring free length “a”. If it is shorter
than the service limit, replace it with a new one.
Front fork spring free length
[Limit]: 378 mm (14.9 in)

“a”

IG12K1220028-01

Cylinder / Piston Ring

Inspect the cylinder (1) and piston ring (2) for wear or
damage. If any defects are found, replace the cylinder or
piston ring with a new one.

IH23K1220021-01
 Front Suspension: 2B-10

Specifications
Tightening Torque Specifications
BENM23K12207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Front fork lower clamp bolts 23 2.3 17.0 (Page 2B-3)
Front fork upper clamp bolt 23 2.3 17.0 (Page 2B-3)
Handlebar bolt 28 2.8 20.6 (Page 2B-3)
Front fork cylinder bolt 20 2.0 15.0 (Page 2B-7)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Fork Components” (Page 2B-1)
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Recommended Service Material
BENM23K12208001
Material SUZUKI recommended product or Specification Note
Fork oil SUZUKI FORK OIL SS-8 P/No.: 99000–99001– (Page 2B-5) / (Page 2B-
SS8 6) / (Page 2B-6) / (Page
2B-7) / (Page 2B-8)
Thread lock cement THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 2B-7)

NOTE
Required service material(s) is also described in:
“Front Fork Components” (Page 2B-1)

Special Tool
BENM23K12208002
09913–50121 09940–34520
Oil seal remover T-handle (Long shank: 3/8
sq.)
(Page 2B-5) This tool is included in Front
fork assembling tool set
(09940-34517).
(Page 2B-4) /
(Page 2B-7)
09940–34561 09940–52861
Front fork assembling Front fork oil seal installer
attachment (D) set
This tool is included in Front 1. Hammer (09941-53610)
fork assembling tool set 2. Attachment (09940-
(09940-34517). 52870) 3. Attachment
(Page 2B-4) / (09940-52880)
(Page 2B-7) (Page 2B-6)
09943–74111
Front fork oil level gauge
(Page 2B-8)
2C-1 Rear Suspension:

Rear Suspension
Suspension

Repair Instructions
Rear Suspension Components
BENM23K12306001

25
24 12
10
25
22 (c)

27
11 (b)
(c) 26
12

28 21 8 (a)
5
6
30 (d) 3
29 (d) 4

19 (c)
23 13
16 31
15

2 9
1
15
17
14

20 4
18 3
6
5

7
IH23K1230001-03

1. Swingarm 13. Rear cushion lever 25. Rear cushion lever rod bearing
2. Swingarm pivot spacer 14. Rear cushion lever front bearing 26. Rear cushion lever rod spacer
3. Swingarm bearing 15. Rear cushion lever center bearing 27. Rear cushion lever rod upper bolt
4. Swingarm spacer 16. Rear cushion lever rear bearing 28. Rear shock absorber
5. Swingarm pivot dust cover 17. Rear cushion lever front spacer 29. Rear shock absorber upper bolt
6. Swingarm washer 18. Rear cushion lever bolt 30. Rear shock absorber lower nut
7. Swingarm pivot shaft 19. Rear cushion lever nut 31. Rear shock absorber lower bolt
8. Swingarm pivot nut 20. Rear cushion lever center spacer : 57.5 Nm (5.9 kgf-m, 42.7 lbf-ft)
9. Chain buffer 21. Rear cushion lever rod lower bolt : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
10. Chain case 22. Rear cushion lever rod nut : 85 Nm (8.7 kgf-m, 63.0 lbf-ft)
11. Chain case bolt 23. Rear cushion lever rear spacer : 50 Nm (5.1 kgf-m, 37.0 lbf-ft)
12. Chain case clip 24. Rear cushion lever rod : Do not reuse.
 Rear Suspension: 2C-2

Rear Suspension On-vehicle Inspection Rear Shock Absorber Removal and Installation
BENM23K12306002 BENM23K12306003
Inspect the rear shock absorber (1) for oil leakage and
check that there is no play in the swingarm (2). Removal
Replace any defective parts, if necessary. 1) Support the motorcycle with center stand to relieve
• Rear shock absorber replacement: (Page 2C-2) load on the rear shock absorber.
• Swingarm inspection: (Page 2C-5) 2) Remove the following parts.
a) Under cowling: (Page 9D-26)
1 b) Left frame cover: (Page 9D-31)
3) Remove rear shock absorber lower mounting nut (1)
and bolt.

IH23K1230002-01

IH23K1230004-01

4) Remove rear shock absorber upper mounting bolt

(1).

1
IH23K1230003-01

IH23K1230005-01

5) Remove the rear shock absorber (1).

IH23K1230006-01
2C-3 Rear Suspension:

Installation Rear Shock Absorber Inspection

1) Install rear shock absorber.
2) Insert rear shock absorber upper mounting bolt (1)
and lower mounting bolt (2) from left side.
3) Tighten upper mounting bolt and new lower
mounting nut (3) to specified torque.
Tightening torque
Rear shock absorber upper mounting bolt (a):
50 N·m (5.1 kgf-m, 37.0 lbf-ft)
Rear shock absorber lower mounting nut (b): 50
N·m (5.1 kgf-m, 37.0 lbf-ft)
BENM23K12306004
Refer to “Rear Shock Absorber Removal and
Installation” (Page 2C-2).
Inspect the rear shock absorber for damage and oil
leakage, and absorber bushing (1) for wear and
damage. If any defect is found, replace the rear shock
absorber with a new one.
NOTICE
Do not attempt to disassemble the rear shock
absorber. It is unserviceable.

Upper side
1

1, (a)

IH23K1230009-01

IH23K1230007-01
Swingarm Removal and Installation
BENM23K12306005
Lower side
Removal
1) Remove rear wheel assembly. (Page 2D-7)
2) Remove rear shock absorber. (Page 2C-2)
3) Remove chain case (1).

3, (b)
1
2

IH23K1230008-01

IH23K1230010-01

4) Remove rear brake caliper (1) and brake hose (2)

from swingarm.

2
1

IH23K1230011-02
 Rear Suspension: 2C-4

5) Remove swingarm pivot nut (1) and draw out the Installation
pivot shaft (2). 1) Install chain buffer (1).
6) Remove swingarm assembly.

1
2

IH23K1230014-02
IH23K1230012-01 2) Pass drive chain (1) to swingarm and then install
7) Remove chain adjusters (1). swingarm assembly (2).

1
1 2

IH23K1230013-02 IH23K1230015-01

8) Remove chain buffer (1). 3) Insert swingarm pivot shaft (1) from left side and
tighten a new swingarm pivot nut (2) temporarily.

2
1

IH23K1230014-02

IH23K1230016-01
2C-5 Rear Suspension:

4) Install rear shock absorber. (Page 2C-2) 8) Install chain case (1) and tighten its bolts to specified
5) Tighten swingarm pivot nut to specified torque. torque.

Tightening torque Tightening torque

Swingarm pivot nut (a): 57.5 N·m (5.9 kgf-m, Chain case bolt (a): 5.5 N·m (0.56 kgf-m, 4.05
42.7 lbf-ft) lbf-ft)

1
(a)

(a)

IH23K1230017-01 IH23K1230018-01

6) Install the chain adjusters (1). 9) Install rear wheel assembly. (Page 2D-7)

Swingarm Inspection
BENM23K12306006
Refer to “Swingarm Removal and Installation” (Page 2C-
3).

Bushing
Inspect bushings (1) for wear and damage. If any defect
is found, replace swingarm assembly with a new one.
1

IH23K1230013-02

7) Install rear brake caliper (1) and brake hose (2).

2
1
1

IH23K1230019-01

Chain Buffer
Inspect chain buffer for wear and damage. If any defect
is found, replace chain buffer with a new one.
IH23K1230011-02

IH23K1230020-01
 Rear Suspension: 2C-6

Swingarm Special tool

Inspect swingarm for damage. If any defect is found, (A): 09900–20607
replace swingarm with a new one. (B): 09900–20701
(C): 09900–21304
Swingarm pivot shaft runout
[Limit]: 0.3 mm (0.01 in)

(A )
(B)

IH23K1230021-01

Swingarm Pivot Shaft (C)

Using a dial gauge, check swingarm pivot shaft for IF34J1230026-01
runout. If the runout exceeds the service limit, replace
pivot shaft.

Specifications
Tightening Torque Specifications
BENM23K12307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear shock absorber upper mounting bolt 50 5.1 37.0 (Page 2C-3)
Rear shock absorber lower mounting nut 50 5.1 37.0 (Page 2C-3)
Swingarm pivot nut 57.5 5.9 42.7 (Page 2C-5)
Chain case bolt 5.5 0.56 4.05 (Page 2C-5)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Rear Suspension Components” (Page 2C-1)
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Special Tool
BENM23K12308001
09900–20607 09900–20701
Dial gauge (10 x 0.01 mm) Dial gauge chuck
(Page 2C-6) (Page 2C-6)

09900–21304
V blocks
(Page 2C-6)
2D-1 Wheels and Tires:

Wheels and Tires

Suspension

Precautions
Precautions for Wheel and Tire
BENM23K12400001
Refer to “General Precautions” in Section 00 (Page 00-1).

! WARNING

• Replace the wheel when wheel runout exceed the service limit or if find damage such as distortion,
crack, nick or scratch.
• When tire replacement is necessary, the original equipment type tire should be used.
• Replacement wheel must be equivalent to the original equivalent wheel.

Repair Instructions
Front Wheel Components
BENM23K12406001

2 (b)
11

12
3 7

6
4
8

5
5
4

4 9
6 (a)

10
IH23K4240001-01

1. Front axle 6. Bearing 11. Front wheel speed sensor rotor (if equipped) : Apply thread lock to the thread part.
2. Brake disc bolt 7. Front tire 12. Front wheel speed sensor rotor bolt (if : Do not reuse.
equipped)
3. Brake disc 8. Front wheel : 44 Nm (4.4 kgf-m, 31.8 lbf-ft)
4. Spacer 9. Front axle nut : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
5. Dust seal 10. Air valve : Apply grease.
 Wheels and Tires: 2D-2

Front Wheel Assembly Construction

BENM23K12406002

LH RH

2 (b)

1 (a)

8
2 (b)

4
3 (c)
7

“a” 5
6
IH23K4240003-01

1. Brake disc bolt 6. Front wheel speed sensor rotor (if equipped) : 30 Nm (3.0 kgf-m, 22.1 lbf-ft)
2. Brake caliper mounting bolt 7. Front wheel speed sensor comp (if equipped) : 44 Nm (4.4 kgf-m, 31.8 lbf-ft)
3. Front axle nut 8. Front fork assembly : Apply grease.
4. Front axle bolt “a”: Clearance : Apply thread lock to the thread part.
5. Front wheel speed sensor bolt (if equipped) : 23 Nm (2.3 kgf-m, 17.0 lbf-ft) : Do not reuse.
2D-3 Wheels and Tires:

Front Wheel Assembly Removal and Installation Installation

BENM23K12406003
1) Install spacers (1) into both sides of the wheel.
Removal
1) Remove the front wheel speed sensor (1) (if
equipped).
2) Disconnect the front wheel speed sensor lead wire 1
from the clamp (2) (if equipped).
1
3) Remove front axle nut (1).

IH23K4240007-01

2 2) Install front wheel with front axle and tighten a new

1 front axle nut temporarily.
3) Remove the jack or wooden block.
4) Install the front wheel speed sensor (if equipped).
IH23K4240004-01 5) Tighten front axle nut to specified torque.
4) Raise front wheel off the ground and support the
Tightening torque
motorcycle with a jack or a wooden block.
Front axle nut (a): 44 N·m (4.4 kgf-m, 31.8 lbf-ft)
5) Draw out front axle (1) and remove front wheel.

(a)
1

IK23K4240001-02
IH23K4240005-01

6) Remove spacers (1).

IH23K4240006-01
 Wheels and Tires: 2D-4

Front Wheel Dust Seal / Front Wheel Bearing 4) Remove bearings (1) on both sides using special
Removal and Installation tool.
BENM23K12406004
Special tool
Removal (A): 09921–20240
1) Remove front wheel. (Page 2D-3)
2) Remove the front wheel speed sensor rotor (1) (if
equipped).

(A)

1 IH23K1240030-01

5) Remove spacer (1).

IH23K4240008-01

3) Remove dust seals (1) on both sides using special

tool. IH23K1240031-01

Special tool
(A): 09913–50121

(A)

IH23K1240028-01
2D-5 Wheels and Tires:

Installation 3) Install new dust seals on both sides using special

1) Apply grease to new wheel bearings. tool.

Grease 99000–25011 (SUZUKI SUPER GREASE Special tool

A) (A): 09913–70210

(A)

I649G1240019-02

2) First install right wheel bearing (1), then install IH23K1240033-01

spacer (2) and left wheel bearing (3) using special 4) Apply grease to the lip of dust seals.
tool. “A”: Grease 99000–25011 (SUZUKI SUPER
Special tool GREASE A)
(A): 09924–84510
(B): 09924–84521

“A”
“A”

(B)

1
IH23K1240034-01

5) Install the front wheel speed sensor rotor (1) (if

IH23K1240032-01 equipped).

LH RH
(A)
(B)
(B)
1

1
LH RH

2 (B)
(B)

IH23K4240009-01

3
“a”
IF34J1240009-01

“a”: Clearance
 Wheels and Tires: 2D-6

Rear Wheel Components

BENM23K12406005

4
17
15
12
16
7 6
10 8
9
18 5
14 (b)
6

19
13

1
6
2
3 (c)

22 (c)
7
5
17

11 (a)
20 5

21 15
18
16
IH23K4240010-01

1. Rear wheel 11. Rear axle nut 21. Rear wheel speed sensor rotor (if equipped)
2. Brake disc 12. Rear sprocket 22. Rear wheel speed sensor rotor bolt (if equipped)
3. Brake disc bolt 13. Rear sprocket bolt : 65 Nm (6.5 kgf-m, 47.0 lbf-ft)
4. Rear axle 14. Rear sprocket nut : 28 Nm (2.9 kgf-m, 21.0 lbf-ft)
5. Spacer 15. Chain adjuster : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
6. Bearing 16. Chain adjuster guide plate : Apply grease.
7. Dust seal 17. Washer : Apply thread lock to the thread part.
8. Rear wheel damper 18. Chain adjuster nut : Do not reuse.
9. Retainer 19. Rear tire
10. Rear sprocket mounting drum 20. Air valve
2D-7 Wheels and Tires:

Rear Wheel Assembly Construction

BENM23K12406006

LH RH

2 (b)

4 (c)

7
1 (a) 6
3 3
“a” 8
IH23K4240011-01

1. Rear sprocket nut
2. Brake disc bolt
3. Chain adjuster nut
4. Rear axle nut
5. Rear axle
6. Rear wheel speed sensor rotor (if equipped)
7. Rear wheel speed sensor comp (if equipped)
8. Rear wheel speed sensor bolt (if equipped)
“a”: Clearance
: 28 Nm (2.9 kgf-m, 21.0 lbf-ft)
: 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: 65 Nm (6.5 kgf-m, 47.0 lbf-ft)
: Apply grease.
: Apply thread lock to the thread part.
: Do not reuse.

Rear Wheel Assembly Removal and Installation

BENM23K12406007
7
Removal 8
5
1) Support motorcycle with stand or center stand. 6
2) Remove rear brake pads. (Page 4C-2)
3) Remove rear axle nut (1) and washer (2).
4) Remove the rear wheel speed sensor bolt (7).
5) Remove the front wheel speed sensor lead wire from
the clamp (8). 3
6) Loosen drive chain adjuster nuts (3). 2 1
4 3
7) Disengage drive chain (4) from rear sprocket.
IH23K4240012-02
8) Draw out rear axle (5) and washer (6).
9) Remove rear wheel assembly.
 Wheels and Tires: 2D-8

10) Remove right and left spacers (1). 6) Adjust drive chain slack. (Page 3A-2)
7) Tighten rear axle nut (5) to specified torque.
Tightening torque
Rear axle nut (a): 65 N·m (6.5 kgf-m, 47.0 lbf-ft)
8) Install rear brake pads. (Page 4C-2)
1 1 9) Install the rear wheel speed sensor (6) (if equipped).
10) Install the rear wheel speed sensor lead wire to the
clamp (7) (if equipped).

Rear Wheel Dust Seal / Rear Wheel Bearing

Removal and Installation
BENM23K12406008

Removal
IH23K4240013-04
1) Remove rear sprocket mounting drum assembly.
(Page 3A-6)
Installation
2) Remove rear wheel speed sensor rotor (1) (if
1) Install right and left spacers (1).
equipped).

1 1
1

IH23K4240014-02

2) Install rear wheel assembly.

3) Install rear axle (1) and washer (2). IH23K4240016-01
4) Engage drive chain (3) to rear sprocket. 3) Remove dust seal (1) using special tool.
5) Install washer (4) and tighten a new rear axle nut (5)
Special tool
temporarily.
(A): 09913–50121

6
7 1
2 (A)
1

4 5, (a)
3 IH23K1240039-01
IH23K4240015-01
2D-9 Wheels and Tires:

4) Remove bearings (1) on both sides using special Special tool

tool. (A): 09924–84521
(B): 09924–84510
Special tool
(C): 09913–70210
(A): 09921–20240

(A)
(A)

IH23K1240042-01
IH23K1240040-01

5) Remove spacer (1).

(C)

(A)
3

IH23K1240043-01

IH23K1240041-01
LH RH
Installation
(A)
1) Apply grease to new wheel bearings. (A)

Grease 99000–25011 (SUZUKI SUPER GREASE

A)

(B) 1

LH RH

(A) (A)

I649G1240019-02

2) First install the right wheel bearing (1), then install

spacer (2) and left wheel bearing (3) using special
2
tools. (C) 1

NOTICE 3 “a”
IG12K1240021-03
The sealed cover of the bearing must face “a”: Clearance
outside.
 Wheels and Tires: 2D-10

3) Install a new dust seal (1) using the special tool. Wheel / Wheel Axle Inspection
BENM23K12406009
Special tool Refer to “Front Wheel Assembly Removal and
(A): 09913–70210 Installation” (Page 2D-3).
Refer to “Rear Wheel Assembly Removal and
Installation” (Page 2D-7).
(A)
Wheel
1) Remove brake pads.
• Front: (Page 4B-2)
• Rear: (Page 4C-2)
2) Make sure that the wheel runout checked as shown
1
does not exceed the service limit. An excessive
runout is usually due to worn or loosened wheel
IH23K1240044-01
bearings and can be reduced by replacing the
bearings.
4) Apply grease to the lip of the dust seal.
• Front: (Page 2D-4)
“A”: Grease 99000–25011 (SUZUKI SUPER
• Rear: (Page 2D-8)
GREASE A)
If bearing replacement fails to reduce the runout,
replace the wheel.
Special tool
“A” (A): 09900–20607
Wheel rim runout
Front
Axial & Radial [Limit]: 2.0 mm (0.08 in)
Rear
Axial & Radial [Limit]: 2.0 mm (0.08 in)

IH23K1240045-01
(A)
5) Install the removed parts.

ID26J1240033-01

3) Install brake pads.

• Front: (Page 4B-2)
• Rear: (Page 4C-2)
2D-11 Wheels and Tires:

Wheel Axle Rear

Using a dial gauge, check the wheel axle for runout. If
the runout exceeds the limit, replace the wheel axle.
Special tool
(A): 09900–20607
(B): 09900–20701
(C): 09900–21304 1
Wheel axle runout
Front & Rear [Limit]: 0.25 mm (0.010 in)

(A)
(B)

IH23K4240018-01

Wheel Bearing
(C) 1) Remove rear sprocket mounting drum assembly.
IF34J1240025-01
(Page 3A-6)
Dust Seal 2) Inspect the play of the wheel bearings by hand while
Inspect dust seals lips (1) for wear or damage. If any they are in the wheel. Rotate the inner race by hand
defect is found, replace dust seals with new ones. to inspect for abnormal noise and smooth rotation.
• Front: (Page 2D-4) Replace the bearing if there is anything unusual.
• Rear: (Page 2D-8) • Front: (Page 2D-4)
• Rear: (Page 2D-8)
Front

1 I649G1240015-02

3) Install rear sprocket mounting drum assembly.

(Page 3A-6)

Brake Disc
• Front: (Page 4B-8)
• Rear: (Page 4C-7)
IH23K4240017-01
Rear Sprocket
Refer to “Rear Sprocket Mounting Drum / Sprocket
Inspection” in Section 3A (Page 3A-7).

Tire
Refer to “Tire Inspection and Cleaning” (Page 2D-12).
 Wheels and Tires: 2D-12

Rear Wheel Damper Removal and Installation Tire Inspection and Cleaning
BENM23K12406010 BENM23K12406012
Tire
Wipe the tire clean and check for the following points:
Removal • Nick and rupture on side wall
1) Remove rear sprocket mounting drum assembly. • Tread separation
(Page 3A-6)
• Abnormal, uneven wear on tread
2) Remove rear wheel damper (1).
• Surface damage on bead
• Localized tread wear due to skidding (Flat spot)
• Abnormal condition of inner liner
1 Tire size
Front [Standard]: 90/80-17 M/C 46S, tubeless
Rear [Standard]: 130/70-17 M/C 62S, tubeless
Tire type
Front [Standard]: DUNLOP/D102FAJ
Rear [Standard]: DUNLOP/D102AJ

IH23K1240048-01

Installation
Install rear wheel damper in reverse order of removal.
Pay attention to the following point:
• Install the rear wheel damper aligning its groove (1)
with the rib (2) of the rear wheel.
I649G1240042-02

Tire tread condition

Operating the motorcycle with excessively worn tires will
decrease riding stability and consequently invite a
1 dangerous situation. It is highly recommended to replace
a tire when the remaining depth of tire tread reaches the
following specification.
2 Special tool
09900–20805
Tire tread depth
IH23K1240049-01
Recommend depth
Front [Standard]: 1.6 mm (0.062 in)
Rear Wheel Damper Inspection Rear [Standard]: 1.6 mm (0.062 in)
BENM23K12406011
Inspect rear wheel damper for wear and damage.
Replace the damper if there is anything unusual.

I310G1020068-02

IH23K1240050-01
2D-13 Wheels and Tires:

Tire pressure Installation

If the tire pressure is too high or too low, steering will be 1) Apply tire lubricant to the tire bead.
adversely affected and tire wear increased. Therefore,
maintain the correct tire pressure for good roadability or NOTICE
shorter tire life will result. Cold inflation tire pressure is as
• Do not use oil, grease or gasoline in place
follows.
of tire bead lubricant.
Cold inflation tire pressure • Do not reuse the air valve which has been
Solo riding once removed.
Front [Standard]: 175 kPa (1.75 kgf/cm2, 25 psi)
Rear [Standard]: 200 kPa (2.00 kgf/cm2, 29 psi)
Dual riding
Front [Standard]: 200 kPa (2.00 kgf/cm2, 29 psi)
Rear [Standard]: 225 kPa (2.30 kgf/cm2, 32 psi)

I649G1240038-02

2) Install the tire aligning the arrow (1) on the side wall
with the direction of wheel rotation.

I310G1020069-02 NOTICE
• When installing a repaired tire, align the
Tire Removal and Installation
BENM23K12406013 chalk mark put on the tire at the time of
Refer to “Front Wheel Assembly Removal and removal with the valve position.
Installation” (Page 2D-3). • When installing a new tire, align the light
Refer to “Rear Sprocket Mounting Drum Assembly point mark (2) on the tire side wall with the
Removal and Installation” in Section 3A (Page 3A-6). valve position.

Removal

! CAUTION
For removal and installation procedure of
tire, follow the instructions given by the tire
changer manufacturer.

NOTE
1
2
When removing the tire in case of repair or IF04K1240038-01
inspection, mark the tire with a chalk to
3) Bounce the tire several times while rotating. This
indicate the tire position relative to the valve
makes the tire bead expand outward to contact the
position.
wheel, thereby facilitating air inflation.
4) Inflate the tire.

! WARNING

• Do not stand over a tire being inflated. Tire

bead may break when the bead snaps over
rim’s safety hump and cause serious
personal injury.
• Do not inflate tires exceeding 400 kPa (4.0
kgf/cm2, 57 psi). Over-inflation may cause
IE31J1240036-01 the bead to break, which may cause
1. Chalk mark
serious personal injury.
 Wheels and Tires: 2D-14

5) Check “rim line” (1) cast on the tire side walls. The Air Valve
line must be equidistant from wheel rim all around. If • Inspect the air valve (1) for peeling and damage. If
the distance between rim line and wheel rim varies, any defect is found, replace air valve with a new one.
this indicates that the bead is not properly seated. If
this is the case, deflate the tire completely and
unseat the bead for both sides. Coat the bead with
lubricant and fit the tire again.

IE31J1240038-01

• Inspect valve core seal (1) for wear and damage. If

IE31J1240037-01 any defect is found, replace valve core with a new
6) When the bead has been fitted properly, install the one.
valve core and adjust the pressure to specification.
(Page 2D-12)

Wheel Rim / Air Valve Inspection and Cleaning

BENM23K12406014
Refer to “Tire Removal and Installation” (Page 2D-13).
Refer to “Air Valve Removal and Installation” (Page 2D- IE31J1240039-01
15).

Wheel Rim
Wipe the wheel clean and check for the following points:
• Distortion and crack.
• Any flaws and scratches at the bead seating area.
• Wheel rim runout. (Page 2D-10)
Wheel rim size
Front [Standard]: 17 M/C x MT 2.15
Rear [Standard]: 17 M/C x MT 3.50

I649G1240041-02
2D-15 Wheels and Tires:

Air Valve Removal and Installation 2) Install a new air valve (1) into the air valve hole with
BENM23K12406015 a special tire lubricant or neutral soapy liquid applied
Refer to “Tire Removal and Installation” (Page 2D-13).
at valve lip (2).
Removal NOTICE
1) Remove air valve (1) from the wheel. Be careful not to damage the valve lip of the
air valve.

2 1

IE31J1240040-01

Installation IF34J1240030-01

1) Clean off the dirt around the valve hole (1). 3. Wheel

IE31J1240041-01

Specifications
Tightening Torque Specifications
BENM23K12407001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Front axle nut 44 4.4 31.8 (Page 2D-3)
Rear axle nut 65 6.5 47.0 (Page 2D-8)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Wheel Components” (Page 2D-1)
“Front Wheel Assembly Construction” (Page 2D-2)
“Rear Wheel Components” (Page 2D-6)
“Rear Wheel Assembly Construction” (Page 2D-7)
“Fasteners Information” in Section 0C (Page 0C-10)
 Wheels and Tires: 2D-16

Special Tools and Equipment

Recommended Service Material
BENM23K12408001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 2D-5) / (Page 2D-
5) / (Page 2D-9) / (Page
2D-10)

NOTE
Required service material(s) is also described in:
“Front Wheel Components” (Page 2D-1)
“Front Wheel Assembly Construction” (Page 2D-2)
“Rear Wheel Components” (Page 2D-6)
“Rear Wheel Assembly Construction” (Page 2D-7)

Special Tool
BENM23K12408002
09900–20607 09900–20701
Dial gauge (10 x 0.01 mm) Dial gauge chuck
(Page 2D-10) / (Page 2D-11)
(Page 2D-11)

09900–20805 09900–21304
Tire depth gauge V blocks
(Page 2D-12) (Page 2D-11)

09913–50121 09913–70210
Oil seal remover Bearing installer set
(Page 2D-4) / (Page 2D-5) /
(Page 2D-8) (Page 2D-9) /
(Page 2D-10)

09921–20240 09924–84510
Bearing remover set Bearing installer set
(Page 2D-4) / (Page 2D-5) /
(Page 2D-9) (Page 2D-9)

09924–84521
Bearing installer set
(Page 2D-5) /
(Page 2D-9)
2D-17 Wheels and Tires:

Section 3
Driveline / Axle
CONTENTS
Precautions .................................................3-1
Precautions............................................................. 3-1
Precautions for Driveline / Axle ............................. 3-1
Drive Chain / Drive Train / Drive Shaft... 3A-1
Diagnostic Information and Procedures............3A-1
Drive Chain and Sprocket Symptom
Diagnosis .......................................................... 3A-1
Repair Instructions ..............................................3A-1
Drive Chain Related Components....................... 3A-1
Drive Chain Inspection and Adjustment .............. 3A-2
Drive Chain Cleaning and Lubricating................. 3A-4
Engine Sprocket Removal and Installation ......... 3A-4
Table of Contents 3- i
Rear Sprocket Removal and Installation.............3A-6
Rear Sprocket Mounting Drum Assembly
Removal and Installation...................................3A-6
Rear Sprocket Mounting Drum / Sprocket
Inspection..........................................................3A-7
Rear Sprocket Mounting Drum Dust Seal / 3
Bearing Removal and Installation .....................3A-8
Drive Chain Replacement Change......................3A-9
Specifications .....................................................3A-12
Tightening Torque Specifications......................3A-12
Special Tools and Equipment ...........................3A-12
Recommended Service Material .......................3A-12
Special Tool ......................................................3A-12
3-1 Precautions:

Precautions
Driveline / Axle

Precautions
Precautions for Driveline / Axle
BENM23K13000001
Refer to “General Precautions” in Section 00 (Page 00-1).

! WARNING
Never inspect or adjust the drive chain while the engine is running.

NOTICE
• Do not use trichloroethylene, gasoline or any similar solvent. These fluids will damage the O-rings
of the drive chain.
• Clean the drive chain with a spray-type chain cleaner and blow dry with compressed air. If the drive
chain cannot be cleaned with a spray cleaner, it may be necessary to use a kerosine. Always follow
the chemical manufacturer’s instructions on proper use, handling and storage.
• Lubricate the drive chain with a heavy weight motor oil. Wipe off any excess oil or chain lubricant.
Do not use any oil sold commercially as “drive chain oil”. Such oil can damage the O-rings.
 Drive Chain / Drive Train / Drive Shaft: 3A-1

Drive Chain / Drive Train / Drive Shaft

Driveline / Axle

Diagnostic Information and Procedures

Drive Chain and Sprocket Symptom Diagnosis
BENM23K13104001

Condition Possible cause Correction / Reference Item

Noisy Drive Chain Worn sprocket. Replace. (Page 3A-4)
(Page 3A-6)
Worn drive chain. Replace. (Page 3A-9)
Stretched drive chain. Replace. (Page 3A-9)
Too large drive chain slack. Adjust. (Page 3A-2)
Drive chain out of adjustment. Adjust. (Page 3A-2)

Repair Instructions
Drive Chain Related Components
BENM23K13106001

3 (a)
2

6 4
5
1
7
10
11 12 16

14 15
9
8 (b)
11

13

IH23K5310002-01

1. Drive chain 8. Nut 15. Rear sprocket drum retainer

2. Engine sprocket 9. Rear sprocket nut 16. Rear hub shock absorber
3. Engine sprocket bolt 10. Rear sprocket drum spacer 17. Rear tire
4. Rear sprocket 11. Rear sprocket mounting drum seal : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
5. Chain adjuster 12. Bearing : 28 Nm (2.9 kgf-m, 21.0 lbf-ft)
6. Rear axle washer 13. Rear sprocket drum : Apply grease.
7. Chain adjuster guide plate 14. Bolt : Do not reuse.
3A-2 Drive Chain / Drive Train / Drive Shaft:

Drive Chain Inspection and Adjustment Drive Chain Length Inspection

BENM23K13106002
Drive Chain Visual Check 1) Support the motorcycle with the center stand.
1) With the transmission in neutral, support the 2) Loosen the rear axle nut (1).
motorcycle with the center stand and turn the rear 3) Give tension to the drive chain fully by turning both
wheel slowly by hand. chain adjuster nuts (2).
2) Visually check the drive chain for the possible
defects listed as follows. If any defects are found, the
drive chain must be replaced. (Page 3A-9)
• Loose pins
• Damaged rollers
• Dry or rusted links 2
• Kinked or binding links
• Excessive wear
• Improper chain adjustment
2
• Missing O-rings (1)

NOTE 1
When replacing the drive chain, replace the IH23K4310002-01
drive chain and sprockets as a set.
4) Count out 21 pins (20 pitches) on the chain and
measure the distance between the two points. If the
2 distance exceeds the service limit, the chain must be
replaced. (Page 3A-9)
1 Drive chain 20-pitch length
[Limit]: 255.5 mm (10.06 in)

1 2 3 20 21 22

IF34J1310002-01
0 1 2 3 4 5 6

2. Grease

IG12K1310002-02

5) After finishing the drive chain length inspection,

adjust the drive chain slack. (Page 3A-3)
 Drive Chain / Drive Train / Drive Shaft: 3A-3

Drive Chain Slack Adjustment

1) Support the motorcycle with the center stand.
2) Loosen the rear axle nut (1). 2

IM23K1310001-01

“a”
IF34J1310031-02
IH23K4310003-01

3) Loosen or tighten both chain adjuster nuts (1) until 4) After adjusting the drive chain, tighten the rear axle
the slack “a” at the middle of the chain between the nut (1) to the specified torque.
engine and rear sprockets becomes within the Tightening torque
standard range. Rear axle nut (a): 65 N·m (6.5 kgf-m, 47.0 lbf-ft)
NOTICE
The reference marks (2) on both sides of the
chain adjuster and the edge of each
swingarm hole (rear side or front side) must
be aligned and same number to ensure that
the front and rear wheels are correctly
aligned.

Drive chain slack

On Side-stand position [Standard]: 20 – 30 mm
(0.8 – 1.1 in)
1, (a)

2
IH23K5310001-01

2 5) Recheck the drive chain slack after tightening the

axle nut.
6) Tighten both chain adjuster nuts securely.

1
1

IH23K4310004-01
3A-4 Drive Chain / Drive Train / Drive Shaft:

Drive Chain Cleaning and Lubricating Engine Sprocket Removal and Installation
BENM23K13106003 BENM23K13106004
1) Remove dirt and dust from the drive chain (1). Be
careful not to damage the O-rings. Removal
2) Clean the drive chain with a sealed drive chain 1) Remove the gearshift link arm (1).
cleaner, or water and neutral detergent.

NOTICE
Cleaning the drive chain improperly can
damage O-rings and ruin the drive chain.
1
• Do not use a volatile solvent such as paint
thinner, kerosene and gasoline.
• Do not use high pressure cleaners to clean
the drive chain.
• Do not use a wire brush to clean the drive
chain.

3) Use a soft brush to clean the drive chain. Be careful

not to damage the O-rings even when using a soft
brush. IK23K4310002-01

4) Wipe off water and neutral detergent. 2) Remove the speed sensor (1) from the engine
sprocket cover.
5) Lubricate with a motorcycle sealed drive chain
lubricant or high viscosity oil. 3) Remove the engine sprocket cover (2) and dowel
pins (3).
NOTICE
Some drive chain lubricants contain solvents
and additives which could damage the O-
rings in the drive chain.
Use sealed drive chain lubricant which is
specifically intended for use with sealed
drive chains.

6) Lubricate both front and back plates of the drive 1

chain. 3
7) Wipe off excess lubricant after lubricating all around
of the drive chain.

NOTE 2
The standard drive chain is a RK 428KLO, 116 IK23K4310003-01
Links. SUZUKI recommends to use this 4) Remove the engine sprocket bolts (1) while
standard drive chain as a replacement. depressing the rear brake pedal.
5) Remove the lock washer (2).

IH23K1310005-01
IK23K4310004-01
 Drive Chain / Drive Train / Drive Shaft: 3A-5

6) Support the motorcycle with the center stand. Installation

7) Loosen the rear axle nut (1). 1) Install the engine sprocket (1) and lock washer (2).
8) Loosen the adjuster nuts (2) to provide additional 2) Tighten the engine sprocket bolts to the specified
chain slack. torque.

NOTE
The stamped mark (3) on the engine sprocket
should face outside.

Tightening torque
2 Engine sprocket bolt (a): 10 N·m (1.0 kgf-m, 7.5
lbf-ft)

1 3
IH23K4310002-01
1 2
9) Remove the engine sprocket (1).

1 (a)
IH23K1310011-01

3) Install the dowel pins (1) and engine sprocket cover

(2) and tighten its bolts to the specified torque.
Tightening torque
Engine sprocket cover bolt (a): 4.0 N·m (0.41
kgf-m, 2.95 lbf-ft)

IK23K4310005-02

2, (a)

IK23K4310006-01

4) Install the speed sensor. (Page 1C-12)

5) Install the left front footrest. (Page 9E-4)
6) Install the gearshift lever. (Page 5B-12)
7) Adjust the drive chain slack. (Page 3A-2)
3A-6 Drive Chain / Drive Train / Drive Shaft:

Rear Sprocket Removal and Installation Rear Sprocket Mounting Drum Assembly
BENM23K13106005
Removal
Removal and Installation
BENM23K13106006
8) Remove the rear wheel. (Page 2D-7) Removal
9) Remove the rear sprocket (1). 1) Remove the rear wheel. (Page 2D-7)
2) Remove the rear sprocket mounting drum assembly
(1).

IH23K1310013-01 1
Installation IH23K1310015-01
Install the rear sprocket in the reverse order of removal. 3) Remove the retainer (1).
Pay attention to the following point:
• Tighten the rear sprocket nuts to the specified torque.

NOTE
1
The stamped mark (1) on the sprocket should
face outside.

Tightening torque
Rear sprocket nut (a): 28 N·m (2.85 kgf-m, 20.6
lbf-ft)

(a)

IH23K1310016-01

(a)
1
IH23K1310014-01
 Drive Chain / Drive Train / Drive Shaft: 3A-7

Installation Dust Seal

1) Install the retainer (1). Inspect the sprocket mounting drum dust seal (1) for
wear or damage. If any defect is found, replace the dust
seal with a new one. (Page 3A-8)

IH23K1310017-01

2) Apply grease to the contacting surface between the

IH23K1310019-01
rear wheel hub and the rear sprocket mounting
drum.
Bearing
“A”: Grease 99000–25011 (SUZUKI SUPER Inspect the play of the rear sprocket mounting drum
GREASE A) bearing by hand while they are in the wheel and drum.
Rotate the inner race by hand to inspect for abnormal
noise and smooth rotation. Replace the bearing if there
is anything unusual. (Page 3A-8)
“A”

I649G1310015-03

Sprocket
1) Remove the engine sprocket cover. (Engine
sprocket only) (Page 3A-4)
IH23K1310018-01
2) Inspect the sprocket teeth for wear. If they are worn
3) Install the rear sprocket mounting drum assembly to
as shown, replace the engine sprocket, rear
the rear wheel assembly.
sprocket and drive chain as a set.
• Engine sprocket: (Page 3A-4)
Rear Sprocket Mounting Drum / Sprocket
Inspection • Rear sprocket: (Page 3A-6)
BENM23K13106007
Refer to “Rear Wheel Assembly Removal and
Installation” in Section 2D (Page 2D-7).

1 2
IE31J1310022-02

1. Normal wear 2. Excessive wear

3) Install the engine sprocket cover. (Engine sprocket

only) (Page 3A-4)
3A-8 Drive Chain / Drive Train / Drive Shaft:

Wheel Damper Installation

Refer to “Rear Wheel Damper Inspection” in Section 2D 1) Apply grease to a new bearing.
(Page 2D-12).
Grease 99000–25011 (SUZUKI SUPER GREASE
Drive Chain A)
Refer to “Drive Chain Inspection and Adjustment” (Page
3A-2).

Rear Sprocket Mounting Drum Dust Seal /

Bearing Removal and Installation
BENM23K13106008

Removal
1) Remove the rear sprocket mounting drum assembly.
(Page 3A-6)
2) Remove the dust seal (1) using the special tool. I649G1310020-02

Special tool 2) Install the bearing (1) using the special tool.
(A): 09913–50121 Special tool
(A): 09913–70210
(A) (B): 09924–84510

(B)

1
1 (A)

IH23K1310020-01

3) Remove the bearing (1) using the special tool.

Special tool IH23K1310022-01

(A): 09921–20240 3) Install a new dust seal (1) using the special tool.
Special tool
(A): 09913–70210

(A)
(A)

IH23K1310021-01 1

IH23K1310023-01
 Drive Chain / Drive Train / Drive Shaft: 3A-9

4) Apply grease to the dust seal lip. Drive Chain Cutting

“A”: Grease 99000–25011 (SUZUKI SUPER 1) Set up special tool
GREASE A)
1
5
“A” 6
4
3

IF04K1310025-03

1. Tool body 4. Pressure bolt B

2. Grip handle 5. Adjuster bolt
3. Pressure bolt A 6. Cutting pin

IH23K1310024-01
2) The tip of cutting pin (1) should be positioned inside
“a” approximately 5 mm (0.2 in) from the end face of
pressure bolt A (2).
Drive Chain Replacement Change
BENM23K13106009
Use the special tool in the following procedure, to cut “a”
and rejoin the drive chain.

NOTE
When using the special tool, apply a small
quantity of grease to the threaded parts of
the special tool.
2
Special tool
: 09922–22712 1
IE31J1310029-02
: 09900–14803
3) Turn in both the adjuster bolt (2) and pressure bolt A
(3) so that each of their end hole fits over the joint pin
properly.
4) Place the drive chain link being disjointed on the
guide plate (1) of the tool.
5) Tighten the pressure bolt A (3).

1 3

IF04K1310024-02

IF04K1310026-04
3A-10 Drive Chain / Drive Train / Drive Shaft:

6) Turn in the pressure bolt B (1) with the wrench (2) Drive Chain Connecting
and force out the joint pin (3).
! WARNING
NOTE
Do not use joint clip type of drive chain. The
Continue turning in the pressure bolt B (1) joint clip may have a chance to drop which
until the joint pin should been completely may cause severe damage to motorcycle and
pushed out of the drive chain. severe injury.
7) After the joint pin (3) is removed, loosen the pressure
bolt B (1) and then pressure bolt A (4). Joint Plate Installation
1) Set up the special tool.
1
4
1
3
2
4 5

IF04K1310027-06
IF04K1310028-05

3 4 1. Tool body 4. Adjuster bolt

2. Grip handle 5. Pressure bolt A
3. Wedge holder

2) Connect both ends of the drive chain with the joint

pins (1) inserted from the wheel side [a] as installed
on the motorcycle.
1 Joint set part number
IE31J1310032-02 27620-12K00

IF04K1310035-01

2. Seal ring 3. Joint plate

 Drive Chain / Drive Train / Drive Shaft: 3A-11

3) Apply grease on the recessed portion of the Joint pin staking

pressure holder (1). Then install the joint plate (2) on 1) Set up the special tool
the tool, its stamp mark must face the pressure
holder (1) side. 1
: Grease 99000–25011 (SUZUKI SUPER GREASE 5
A) 6
4
4) Set the drive chain on the tool as illustrated and turn
in the adjuster bolt (3) to secure the wedge holder (4) 3
with joint pin.
2
1, “A”
2

IF04K1310031-03

1. Tool body 4. Adjuster bolt

4
2. Grip handle 5. Flare pin
3 3. Pressure bolt A 6. Back-up pin

2) Apply grease to the flare pin (1).

IF04K1310029-04
: Grease 99000–25011 (SUZUKI SUPER GREASE
A)
5) Turn in the pressure bolt A (1) and align two joint
pins (2) properly with the respective holes of the joint 3) Stake the joint pin by turning (approximately 7/8 turn)
plate (3). the pressure bolt A (2) until the pin end diameter “a”
6) Turn in the pressure bolt A (1) further using the becomes the specified dimension.
wrench (4) to press the joint plate over the joint pins. 4) After joining of the drive chain has been completed,
check to make sure that the link is smooth and no
2 abnormal condition (no cracked joint pin, etc) is
1
found.
Pin end diameter specification
3 [Standard]:4.65 - 4.66 mm
4

2
1, “A”

IF04K1310030-04

7) Continue pressing the joint plate until the distance

“a” between the two joint plates come to the
specification.
Joint plate distance specification
IF04K1310032-03
[Standard]:16.45 - 16.75 mm

NOTICE
If pressing of the joint plate makes the
dimension out of specification excessively,
the work must be carried out again by using “a”
new joint parts.

I649G1310036-03
“a”
5) Adjust the drive chain slack, after connecting it.
Refer to “Drive Chain Inspection and Adjustment”
I649G1310033-03 (Page 3A-2).
3A-12 Drive Chain / Drive Train / Drive Shaft:

Specifications
Tightening Torque Specifications
BENM23K13107001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear axle nut 65 6.5 47.0 (Page 3A-3)
Engine sprocket bolt 10 1.0 7.5 (Page 3A-5)
Engine sprocket cover bolt 4.0 0.41 2.95 (Page 3A-5)
Rear sprocket nut 28 2.85 20.6 (Page 3A-6)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Drive Chain Related Components” (Page 3A-1)
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Recommended Service Material
BENM23K13108001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 3A-7) / (Page 3A-
8) / (Page 3A-9) / (Page
3A-11) / (Page 3A-11)

NOTE
Required service material(s) is also described in:
“Drive Chain Related Components” (Page 3A-1)

Special Tool
BENM23K13108002
09900–14803 09913–50121
Chain cutting and joint tool Oil seal remover
set (428)
1. Cutting pin (428) (09900- (Page 3A-8)
14804) 2. Guide plate (428)
(09900-14805) 3. Pressure
holder (428) (09900-14806)
4. Flare pin (428) (09900-
14807)
(Page 3A-9)
09913–70210 09921–20240
Bearing installer set Bearing remover set
(Page 3A-8) / (Page 3A-8)
(Page 3A-8)

09922–22712 09924–84510
Drive chain cut / rivet tool set Bearing installer set
(Page 3A-9) (Page 3A-8)

Section 4
Brakes
CONTENTS
Precautions .................................................4-1
Precautions............................................................. 4-1
Precautions for Brake System .............................. 4-1
Brake Fluid Information ......................................... 4-1
Brake Control System and Diagnosis ... 4A-1
Schematic and Routing Diagram........................4A-1
Front Brake Hose Routing Diagram (without
ABS).................................................................. 4A-1
Front Brake Hose Routing Diagram (with
ABS).................................................................. 4A-3
Rear Brake Hose Routing Diagram (without
ABS).................................................................. 4A-5
Rear Brake Hose Routing Diagram (with
ABS).................................................................. 4A-6
Diagnostic Information and Procedures............4A-8
Brake Symptom Diagnosis.................................. 4A-8
Repair Instructions ..............................................4A-9
Front Brake Light Switch Inspection ................... 4A-9
Rear Brake Light Switch Inspection .................... 4A-9
Rear Brake Light Switch Inspection and
Adjustment ........................................................ 4A-9
Brake Fluid Level Check ................................... 4A-10
Brake Hose Inspection ...................................... 4A-10
Brake Pedal Height Inspection and
Adjustment ...................................................... 4A-12
Air Bleeding from Brake Line ............................ 4A-13
Brake Fluid Replacement.................................. 4A-15
Front Brake Hose Removal and Installation...... 4A-17
Rear Brake Hose Removal and Installation ...... 4A-18
Front Brake Master Cylinder Assembly /
Brake Lever Components ............................... 4A-21
Front Brake Master Cylinder Assembly
Removal and Installation................................. 4A-22
Front Brake Master Cylinder Assembly /
Brake Lever Disassembly and Reassembly ... 4A-23
Front Brake Master Cylinder Parts Inspection .. 4A-25
Rear Brake Master Cylinder Assembly
Components.................................................... 4A-26
Rear Brake Master Cylinder Assembly
Removal and Installation................................. 4A-27
Rear Brake Master Cylinder Disassembly and
Reassembly .................................................... 4A-28
Rear Brake Master Cylinder Parts Inspection ... 4A-30
Rear Brake Pedal Components ........................ 4A-30
Table of Contents 4- i
Rear Brake Pedal Removal and Installation .....4A-31
Rear Brake Pedal Inspection ............................4A-32
Specifications .....................................................4A-32
Tightening Torque Specifications......................4A-32
Special Tools and Equipment ...........................4A-33
Recommended Service Material .......................4A-33
Special Tool ......................................................4A-33
Front Brakes ............................................ 4B-1
Repair Instructions ..............................................4B-1 4
Front Brake Components ....................................4B-1
Front Brake Pad Inspection.................................4B-2
Front Brake Pad Replacement............................4B-2
Front Brake Caliper Removal and Installation.....4B-3
Front Brake Caliper Disassembly and
Reassembly ......................................................4B-4
Front Brake Caliper Parts Inspection ..................4B-7
Front Brake Disc Removal and Installation .........4B-8
Front Brake Disc Inspection ................................4B-8
Specifications .......................................................4B-9
Tightening Torque Specifications........................4B-9
Special Tools and Equipment .............................4B-9
Recommended Service Material .........................4B-9
Special Tool ........................................................4B-9
Rear Brakes.............................................. 4C-1
Repair Instructions ..............................................4C-1
Rear Brake Components.....................................4C-1
Rear Brake Pad Inspection .................................4C-1
Rear Brake Pad Replacement ............................4C-2
Rear Brake Caliper Removal and Installation .....4C-3
Rear Brake Caliper Disassembly and
Reassembly ......................................................4C-3
Rear Brake Caliper Parts Inspection...................4C-5
Rear Brake Disc Removal and Installation..........4C-6
Rear Brake Disc Inspection.................................4C-7
Specifications .......................................................4C-8
Tightening Torque Specifications........................4C-8
Special Tools and Equipment .............................4C-8
Recommended Service Material .........................4C-8
Special Tool ........................................................4C-8
ABS ........................................................... 4E-1
Precautions...........................................................4E-1
4-ii Table of Contents
Precautions for ABS Service............................... 4E-1
Precautions for Diagnosing Troubles .................. 4E-1
Precautions for ABS............................................ 4E-1
General Description ............................................. 4E-2
ABS Description .................................................. 4E-2
Wheel Speed Sensor Description ....................... 4E-3
Self-diagnosis Function and ABS Indicator
Light Description ............................................... 4E-4
Fail-safe Function Description............................. 4E-5
Schematic and Routing Diagram........................ 4E-6
ABS Circuit Diagram ........................................... 4E-6
Front Wheel Speed Sensor Routing Diagram..... 4E-8
Rear Wheel Speed Sensor Routing Diagram ..... 4E-9
Component Location .........................................4E-10
ABS Components Location ...............................4E-10
Diagnostic Information and Procedures.......... 4E-11
ABS Check........................................................ 4E-11
Visual Inspection ...............................................4E-13
ABS Symptom Diagnosis ..................................4E-14
ABS Indicator Light Inspection .......................... 4E-14
DTC (Diagnostic Trouble Code) Output ............4E-17
DTC (Diagnostic Trouble Code) Deleting.......... 4E-18
ABS Hydraulic Unit Operation Check................ 4E-20
DTC Table.........................................................4E-21
Scan Tool Data ................................................. 4E-22
DTC C1625 (25)................................................4E-23
DTC C1635 (35)................................................4E-24
DTC C1641 (41)................................................4E-25
DTC C1642 (42)................................................4E-26
DTC C1644 (44)................................................4E-28
DTC C1645 (45)................................................4E-29
DTC C1647 (47) / C1648 (48) ...........................4E-31
DTC C1655 (55)................................................4E-32
DTC C1661 (61)................................................4E-33
Repair Instructions ............................................4E-34
Front Wheel Speed Sensor Removal and
Installation .......................................................4E-34
Rear Wheel Speed Sensor Removal and
Installation .......................................................4E-34
Front Wheel Speed Sensor Rotor Removal
and Installation ................................................4E-35
Rear Wheel Speed Sensor Rotor Removal
and Installation ................................................4E-35
Wheel Speed Sensor and Sensor Rotor
Inspection........................................................4E-36
ABS Control Unit / HU Removal and
Installation .......................................................4E-37
Specifications .....................................................4E-39
Tightening Torque Specifications......................4E-39
Special Tools and Equipment ...........................4E-39
Special Tool ......................................................4E-39
 Precautions: 4-1

Precautions
Brakes

Precautions
Precautions for Brake System
BENM23K14000001
Refer to “General Precautions” in Section 00 (Page 00-1), “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2) and “Precautions for Circuit Tester” in Section 00 (Page 00-7).

Brake Fluid Information

BENM23K14000002
! WARNING

• This brake system is filled with an ethylene glycol-based DOT 3 or DOT 4 brake fluid. Do not use or
mix different types of fluid, such as silicone-based or petroleum-based.
• Do not use any brake fluid taken from old, used or unsealed containers. Never reuse brake fluid left
over from the last servicing or which has been stored for a long period of time.
• When storing brake fluid, seal the container completely and keep it away from children.
• When replenishing brake fluid, take care not to get dust into the fluid.
• When washing brake components, use new brake fluid. Never use cleaning solvent.
• A contaminated brake disc or brake pad reduces braking performance. Discard contaminated pads
and clean the disc with high quality brake cleaner or neutral detergent.
• After removal and installation of the brake caliper, master cylinder, brake hose and ABS control unit/
HU (if equipped), be sure to carry out the air bleeding operation.
• Brake hose seal washers should be replaced with the new ones to prevent fluid leakage.

NOTICE
The brake fluid is damaging to painted surfaces, plastics and rubber materials, and do not allow the
fluid to spill on the surrounding parts.
If the fluid is spilled, flush it with water immediately.
4A-1 Brake Control System and Diagnosis:

Brake Control System and Diagnosis

Brakes

Schematic and Routing Diagram

Front Brake Hose Routing Diagram (without ABS)
BENM23K14102001
GSX R 125 Model

5
(a)

[B]

“a”

[D] [A]

[C]

[C]

“b”
3
[B]

(a)
5

IH23K1410040-02

[A]: Pass the brake hose in rear of the throttle cable. 4. Front master cylinder
[B]: After the brake hose union has contacted the stopper, tighten the union bolt to the specified torque. 5. Seal washer
[C]: Fix the hose sleeve to the clamp firmly. “a”: 14°
[D]: Assemble the brake hose firmly. “b”: 28°
1. Front brake hose : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
2. Front brake hose lower clamp : Do not reuse.
3. Front caliper
 Brake Control System and Diagnosis: 4A-2

GSX S 125 Model

5
(a)

“a”

[D]

A
[E]
1 [C]

[C]

“b” [E]
[B]
3

(a)
View A
5
IM23K1410001-01

[A]: Pass the brake hose in rear of the throttle cable. 3. Front caliper
[B]: After the brake hose union has contacted the stopper, tighten the union bolt to the specified torque. 4. Front master cylinder
[C]: Fix the hose sleeve to the clamp firmly. 5. Seal washer
[D]: Assemble the brake hose front of throttle cable. “a”: 14°
[E]: After the clamp has contacted the stopper, tighten the bolt to the specified torque. “b”: 28°
1. Front brake hose : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
2. Front brake hose lower clamp : Do not reuse.
4A-3 Brake Control System and Diagnosis:

Front Brake Hose Routing Diagram (with ABS)

BENM23K14102002

22

[B]
[A]

1
[F]

5
9
[E]
4
2 3 7
“a” “b”
“c” [C] 8
“d” 6
1

[D]

11

10

[H]
12

[E] [G]

[J]
13
14
15 18
“b”
17 19

[I]
20

16 21

17 (a)

IK23K4410001-01

[A]: Pass the brake pipe front side of harness. 10. Front brake master hose bolt.
 Brake Control System and Diagnosis: 4A-4

[B]: Pass the brake pipe upside of reservoir tank inlet hose. 11. Front brake hose (Front brake master to ABS
/ Hydraulic control unit).
[C]: Clamp marking part of the sensor lead wire front side of brake hose. 12. Front brake hose (ABS / Hydraulic control
unit to front brake caliper).
[D]: Clamp marking part of the sensor lead wire outside of end fitting of brake hose. 13. Front brake hose lower clamp.
[E]: Tightening bolt with clamp contacted with stopper. 14. Front brake hose lower clamp bolt.
[F]: Clamp the sensor lead wire on upper side of brake pipe protector. 15. Front brake caliper
[G]: Clamp sleeve of the brake hose firmly. 16. Brake fluid washer.
[H]: Clamp sleeve firmly. 17. Brake hose union bolt.
[I]: Tightening bolt with end-fitting contacted with stopper. 18. Front wheel speed sensor lead wire clamp.
[J]: Tightening bolt with clamp contacted with stopper. 19. Front wheel speed sensor lead wire clamp
bolt.
1. ABS / Hydraulic control unit. 20. Front wheel speed sensor.
2. ABS / Hydraulic control unit bolt. 21. Front wheel speed sensor bolt.
3. ABS / Hydraulic control unit holder. 22. Brake pipe.
4. Hose clamp (Front brake pipe) : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: Clamp brake pipe on marking point.
5. Reservoir tank inlet hose. : Do not reuse.
6. Front brake hose bolt. “a”: Blue paint
7. Front brake hose clamp upper. “b”: Yellow paint
8. Front brake hose clamp upper bolt. “c”: Orange paint
9. Stopper “d”: No paint
4A-5 Brake Control System and Diagnosis:

Rear Brake Hose Routing Diagram (without ABS)

BENM23K14102003

[D]

[A]

“c” 6

[A]
View A 6 View B View C

5 B

(a)
4
C
7 2
(a) 7 [B]

A 1 3 “a”

“b”

(b)
[C] D
[A]

8
10

9 [E]
View D
IH23K1410041-02

[A]: After the brake hose union has contacted the stopper, tighten the union bolt to the specified torque. 7. Seal washer
[B]: Insert reservoir hose with white paint to outside. 8. Rear master pin
[C]: Pass the brake hose into the guide. 9. Rear master washer
[D]: Assemble clip as shown 10. Rear master cylinder cotter pin
[E]: Outside “a”: 42°
1. Rear brake hose “b”: 56°
2. Reservoir tank hose “c”: 35°
3. Hose clamp (Master cylinder side) : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: Hose clamp ends should face front side.
4. Hose clamp (Reservoir tank side) : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
: Hose clamp ends should face as shown in the figure.
5. Reservoir tank cap guard : Do not reuse.
6. Reservoir tank
 Brake Control System and Diagnosis: 4A-6

Rear Brake Hose Routing Diagram (with ABS)

BENM23K14102004

[E] 12

[D] [G] [F]

[D] “A”
12

18

12
18 23

View “A”

1
20

19
[E]
3

15
[A]
16
12 11 (a)
11 (a) 7
4 9
14
[B] 14
10
8
6
“a”

13 (b)

2
[C]
5 17

20
21

22

IK23K4410002-01
4A-7 Brake Control System and Diagnosis:

[A]: Insert reservoir hose with white paint to outside. 11. Brake hose union bolt.
[B]: Clamp marking part of the rear wheel speed sensor lead wire outside of end fitting brake 12. Rear wheel speed sensor lead wire clamp.
hose. :Clamp marking part of the rear wheel speed
sensor lead wire underside of brake hose.
[C]: Pass the brake hose and rear wheel speed sensor lead wire into the guide. 13. Rear brake master cylinder bolt.
[D]: Assemble clip as shown 14. Brake fluid washer.
[E]: Clamp marking part of the rear wheel speed sensor lead wire outside of brake hose. 15. Brake pipe (Rear brake master cylinder to ABS /
Hydraulic control unit).
[F]: Pass the brake pipe underside of harness. 16. Brake pipe (ABS / Hydraulic control unit to rear
brake caliper).
[G]: Pass the brake pipe inside of harness. 17. Swingarm.
1. ABS / Hydraulic control unit. 18. Harness.
2. Rear brake master cylinder. 19. Rear brake hose.
3. Reservoir tank hose 20. Stopper.
4. Rear brake caliper 21. Wheel speed sensor bolt.
5. Rear wheel speed sensor. 22. Rear wheel speed sensor lead wire clamp.
6. Rear brake hose assembly (Rear brake master cylinder to ABS / Hydraulic control unit). 22. Rear wheel speed sensor coupler.
7. Rear brake hose assembly (ABS / Hydraulic control unit to rear brake caliper). “a”: 55°
8. Rear wheel speed sensor lead wire. : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
9. Fuel tank water drain hose. : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
10. Reservoir tank hose. : Do not reuse.
 Brake Control System and Diagnosis: 4A-8

Diagnostic Information and Procedures

Brake Symptom Diagnosis
BENM23K14104001

Condition Possible cause Correction / Reference Item

Insufficient brake power Leakage of brake fluid from hydraulic Repair or replace.
system.
Worn pads and/or disc. Replace.
• Pad
– Front: (Page 4B-2)
– Rear: (Page 4C-2)
• Disc
– Front: (Page 4B-8)
– Rear: (Page 4C-6)
Oil adhesion on friction surface of pads. Clean disc and pads.
Air in hydraulic system. Bleed air. (Page 4A-13)
Not enough brake fluid in the reservoir. Replenish. (Page 4A-10)
Brake squeaking Carbon adhesion on pad surface. Repair surface with sandpaper.
Tilted pad. Correct pad fitting or replace.
• Front: (Page 4B-2)
• Rear: (Page 4C-2)
Damaged wheel bearing. Replace.
• Front: (Page 2D-4)
• Rear: (Page 2D-8)
Loose front wheel axle or rear wheel Tighten to specified torque. (Page 0B-3)
axle.
Worn pads and/or disc. Replace.
• Pad
– Front: (Page 4B-2)
– Rear: (Page 4C-2)
• Disc
– Front: (Page 4B-8)
– Rear: (Page 4C-6)
Foreign material in brake fluid. Replace brake fluid. (Page 4A-15)
Clogged return port of master cylinder. Disassemble and clean master cylinder.
Excessive brake lever Air in hydraulic system. Bleed air. (Page 4A-13)
stroke Insufficient brake fluid. Replenish fluid to specified level. (Page 4A-
10)
Improper quality of brake fluid. Replace with correct fluid. (Page 4A-15)
Leakage of brake fluid Insufficient tightening of connection Tighten to specified torque. (Page 0B-3)
joints.
Cracked hose. Replace.
• Front: (Page 4A-17)
• Rear: (Page 4A-18)
Worn master cylinder piston and/or cup. Replace master cylinder piston and/or cup.
• Front: (Page 4A-23)
• Rear: (Page 4A-28)
Worn brake caliper piston seal and dust Replace brake caliper piston seal and dust
seal. seal.
• Front: (Page 4B-4)
• Rear: (Page 4C-3)
Brake drags Rusty part. Clean and lubricate. (Page 0B-6)
Insufficient front brake lever or rear Lubricate. (Page 0B-6)
brake pedal pivot lubrication.
4A-9 Brake Control System and Diagnosis:

Repair Instructions
Front Brake Light Switch Inspection Rear Brake Light Switch Inspection
BENM23K14106001 BENM23K14106002
1) Grasp the front brake lever, and then remove the 1) Right frame cover and right frame front cover:
front brake light switch (1). (Page 9D-31)
2) Disconnect the front brake light switch lead wire 2) Disconnect the rear brake light switch lead wire
coupler (2). coupler (1).

2 1

IH23K1410001-02
3) Inspect the switch for continuity with a circuit tester.
If any abnormality is found, replace the front brake
light switch with a new one.
IK23K4410003-01
3) Inspect the switch for continuity with a tester.
If any abnormality is found, replace the rear brake
light switch with a new one.

Color Color
Terminal (O) Terminal (W/B) Terminal (O) Terminal (W/B)
Position Position
OFF OFF
ON ON
IF04K1410008-01
IF04K1410008-01
4) Connect the front brake light switch lead wire coupler 4) Connect the rear brake light switch lead wire coupler.
(1).
5) Install the removed parts.
5) When installing the brake light switch, align the
projection (2) on the switch with the hole (3) in the
Rear Brake Light Switch Inspection and
master cylinder.
Adjustment
6) Tighten the brake light switch screw to the specified BENM23K14106003
torque. Check the rear brake light switch so that the brake light
will come on just before pressure is felt when the brake
Tightening torque pedal is depressed. If the brake light switch adjustment
Brake light switch screw: 1.2 N·m (0.12 kgf-m, is necessary, turn the adjuster nut (1) in or out while
0.90 lbf-ft) holding the brake pedal.

2
IG12K1410005-01

IH23K1410042-01
 Brake Control System and Diagnosis: 4A-10

Brake Fluid Level Check Brake Hose Inspection

BENM23K14106004 BENM23K14106005
1) Keep the motorcycle upright and place the GSX R 125 Model
handlebars straight. 1) Inspect the brake hoses and hose joints for crack,
2) Check the brake fluid level by observing the lower damage or brake fluid leakage. If any defects are
limit lines (1) on the front and rear brake fluid found, replace the brake hose with a new one.
reservoirs. When the brake fluid level is below the • Front: (Page 4A-17)
lower limit line, inspect for brake pad wear and leaks • Rear: (Page 4A-18)
and replenish with brake fluid that meets the
following specification.
Brake fluid (DOT 3)
Brake fluid (DOT 4)

IH23K1410004-01

IG12K1410008-01 Without ABS

IH23K1410006-02
IK23K4410004-01

With ABS

IH23K4410004-01
4A-11 Brake Control System and Diagnosis:

Without ABS GSX S 125 Model

1) Inspect the brake hoses and hose joints for crack,
damage or brake fluid leakage. If any defects are
found, replace the brake hose with a new one.
• Front: (Page 4A-17)
• Rear: (Page 4A-18)

IH23K1410005-03

With ABS

IH23K2410002-01

Without ABS

IH23K4410005-01

IH23K2410003-01

With ABS

IH23K1410007-01

IH23K4410006-01
 Brake Control System and Diagnosis: 4A-12

Without ABS Brake Pedal Height Inspection and Adjustment

BENM23K14106006
1) Inspect the brake pedal height “a” between the pedal
top face and footrest.
Adjust the brake pedal height if necessary.
Brake pedal height
[Standard]: 48.7 – 58.7 mm (1.92 – 2.31 in)

“a”

IH23K2410004-01

With ABS

IH23K2410005-01

2) Loosen the lock-nut (1).

3) Turn the push rod (2) in or out until the brake pedal
height is within the specification.
4) Tighten the lock-nut to the specified torque.
Tightening torque
Rear brake master cylinder rod lock-nut (a): 18
N·m (1.8 kgf-m, 13.5 lbf-ft)

2
IH23K4410007-01

1, (a)

IK23K4410005-01

5) After finishing the brake pedal height inspection and

adjustment, check the rear brake light switch.
(Page 4A-9)
IH23K1410007-01

2) Install the removed parts.

4A-13 Brake Control System and Diagnosis:

Air Bleeding from Brake Line

BENM23K14106007
Trapped air in the brake lines acts like a cushion to
absorb a large proportion of the pressure developed by
the master cylinder and thus greatly reduces the braking
force. The presence of air bubbles is indicated by a
“spongy” feel in the brake lever and low braking force.
This condition is extremely dangerous, and therefore the
air must be bled every time after replacing any parts in
the brake lines in the following manner.

Front Brake
1) Place the motorcycle on a level surface and keep the
handlebars straight.
2) Remove the reservoir cap (1), plate and diaphragm.
IH23K1410012-01
3) Fill the master cylinder reservoir with new brake fluid
6) Tighten the air bleeder valve and release the brake
to the top of the inspection window (2). Place the
lever slowly.
reservoir cap to prevent dirt from entering.
7) Repeat the steps 5) and 6) until the fluid is flowing
Brake fluid (DOT 3) out without bubbles.
Brake fluid (DOT 4)
NOTE
While bleeding the brake system, replenish
1 the reservoir with the brake fluid as
necessary to keep the fluid above the lower
level.

8) Tighten the air bleeder valve to the specified torque.

Tightening torque
2
Front brake air bleeder valve: 8.5 N·m (0.86 kgf-
m, 6.26 lbf-ft)
9) Fill the reservoir with brake fluid to the line “a”.

IH23K1410010-01

4) Remove the bleeder valve cap and attach a clear

hose to the air bleeder valve, and insert the free end
of the hose into a receptacle.
5) Operate the brake lever several times and, while
holding the lever gripped, loosen the air bleeder “a”
valve (1) and drain the brake fluid into a receptacle.

IH23K1410013-01

IH23K4410008-01
 Brake Control System and Diagnosis: 4A-14

10) Install the diaphragm, plate and reservoir cap (1). 3) Remove the reservoir cap (1), ring and diaphragm.
11) Tighten the reservoir cap screws (2) to the specified 4) Fill the reservoir with brake fluid up to the upper level
torque. (2) of the reservoir. Place the reservoir cap to
prevent dirt from entering.
Tightening torque
Front reservoir cap screw (a): 1.15 N·m (0.11
kgf-m, 0.84 lbf-ft)
1
2, (a)

2
1

IH23K1410016-01

5) Remove the bleeder valve cap and attach a clear

IH23K1410014-01
Rear Brake
1) Place the motorcycle on a level surface.
2) Remove the reservoir tank bracket bolt (1) and move
the reservoir tank outside of the frame.
hose to the air bleeder valve, and insert the free end
of the hose into a receptacle.
6) Operate the brake pedal several times and, while
pushing the pedal, loosen the air bleeder valve (1)
and drain the brake fluid into a receptacle.

IH23K4410009-01

IK23K4410006-03

IH23K1410018-02
4A-15 Brake Control System and Diagnosis:

7) Tighten the air bleeder valve and release the brake Brake Fluid Replacement
pedal slowly. BENM23K14106008
Front Brake
8) Repeat the steps 6) and 7) until the fluid is flowing
out without bubbles. 1) Place the motorcycle on a level surface and keep the
handlebars straight.
NOTE 2) Remove the brake fluid reservoir cap, plate and
While bleeding the brake system, replenish diaphragm.
the reservoir with the brake fluid as 3) Suck up the old brake fluid as much as possible.
necessary to keep the fluid above the lower
level.

9) Tighten the air bleeder valve to the specified torque.

Tightening torque
Rear brake air bleeder valve: 5.5 N·m (0.56 kgf-
m, 4.05 lbf-ft)
10) Fill the reservoir with brake fluid to the upper level (1)
of the reservoir.

IH23K1410021-01

4) Fill the reservoir with new brake fluid.

Brake fluid (DOT 3)
Brake fluid (DOT 4)
1 5) Remove the bleeder valve cap and attach a clear
hose to the air bleeder valve (1), and insert the free
end of the hose into a receptacle.
6) Loosen the air bleeder valve, squeeze and release
the brake lever and drain the old brake fluid out of
IH23K1410019-01
the brake system.
11) Install the diaphragm, ring and reservoir cap (1).
NOTE
When replacing the brake system, replenish
1 the reservoir with the brake fluid as
necessary to keep the fluid above the lower
level.

IH23K1410020-01

12) Install the reservoir tank. Refer to “Rear Brake Hose 1

Routing Diagram (without ABS)” (Page 4A-5).
13) Install the removed parts.

IH23K4410010-01
 Brake Control System and Diagnosis: 4A-16

5) Fill the reservoir with new brake fluid.

Brake fluid (DOT 3)
Brake fluid (DOT 4)
6) Remove the bleeder valve cap and attach a clear
hose to the air bleeder valve (1) and insert the free
end of the hose into a receptacle.
7) Loosen the air bleeder valve and pump the brake
pedal until the old brake fluid flows out of the brake
system.

NOTE
When replacing the brake system, replenish
the reservoir with the brake fluid as
IH23K1410023-01
necessary to keep the fluid above the lower
level.
7) Bleed the air from the front brake system. (Page
4A-13)

Rear Brake
1) Place the motorcycle on a level surface.
1
2) Remove the reservoir tank bracket bolt (1) and move
the reservoir tank outside of the frame.

IH23K4410011-01

IK23K4410006-03

3) Remove the brake fluid reservoir cap, ring and

diaphragm.
4) Suck up the old brake fluid as much as possible.

IH23K1410018-02

8) Bleed the air from the rear brake system. (Page

4A-13)

IH23K1410024-01
4A-17 Brake Control System and Diagnosis:

Front Brake Hose Removal and Installation
BENM23K14106009
Refer to “Front Brake Hose Routing Diagram (without
ABS)” (Page 4A-1)and “Front Brake Hose Routing
Diagram (with ABS)” (Page 4A-3).
Removal (without ABS)
1) Drain brake fluid. (Page 4A-15)
2) Remove the front brake hose (1).
3) Remove the following part.
• GSX R125 ModelRemove front fairing. Refer to
“Front Fairing Assembly Removal and Installation”
in Section 9D (Page 9D-22).
• GSX S125 ModelRemove fuel tank side cover.
Refer to “Fuel Tank Side Cover Assembly
Removal and Installation” in Section 9D (Page
9D-25).
4) Remove the front brake hose (1).
• Front brake master cylinder to ABS / Hydraulic
control unit.

1 1
1

IH23K1410026-01

IH23K4410022-01

1 • ABS / Hydraulic control unit to front brake caliper.

IH23K2410006-01

Removal (with ABS) 1

1) Drain brake fluid. (Page 4A-15)
2) Disconnect the speed sensor lead wire from the
IH23K4410013-01
clamp.

IH23K4410017-01
 Brake Control System and Diagnosis: 4A-18

Installation Rear Brake Hose Removal and Installation

BENM23K14106010
1) Install the brake hose union bolt (1) and seal Refer to “Rear Brake Hose Routing Diagram (without
washers (2). ABS)” (Page 4A-5)and “Rear Brake Hose Routing
NOTE Diagram (with ABS)” (Page 4A-6).

Do not reuse seal washers (2). Removal (without ABS)

Replace with the new one.
1) Drain brake fluid. (Page 4A-15)
2) Remove rear brake master cylinder (1), chain case
(2), loosen brake hose union bolt and then remove
2 the rear brake hose (3).

1
2
1
3

IG12K1410070-01

2) Install the front brake hose. Refer to “Front Brake

Hose Routing Diagram (without ABS)” (Page 4A-
1)and “Front Brake Hose Routing Diagram (with
ABS)” (Page 4A-3)
3) Tighten the union bolt (1) to the specified torque. IH23K4410028-01

Tightening torque
Brake hose union bolt (a): 23 N·m (2.3 kgf-m, Removal (with ABS)
17.0 lbf-ft) 1) Drain brake fluid. (Page 4A-15)
2) Disconnect the speed sensor lead wire (if equipped)
from the clamp.
1, (a)

1, (a)

IH23K4410018-01 IH23K4410020-01

4) Bleed air from the front brake system. (Page 4A-

13)
4A-19 Brake Control System and Diagnosis:

3) Remove rear brake master cylinder bolt (1), chain • ABS / Hydraulic control unit to rear brake caliper.
case (2), rear brake reservoir tank (3).

2
3

1 1
1

IH23K4410025-01
IH23K4410019-01

4) Remove rear brake hose bolt (1). Installation

1) Install the brake hose union bolt (1) and seal
washers (2).

NOTE
3
Do not reuse seal washers (2).
Replace with the new one.

IH23K4410024-01

5) Remove rear brake hose (1).

• Rear brake master cylinder to ABS / Hydraulic
control unit.

IG12K1410070-01

2) Install the rear brake hose. Refer to “Rear Brake

Hose Routing Diagram (without ABS)” (Page 4A-
5).and “Rear Brake Hose Routing Diagram (with
ABS)” (Page 4A-6)
1 3) Tighten the union bolt (1) to the specified torque.
Tightening torque
Brake hose union bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)

IH23K4410023-01
 Brake Control System and Diagnosis: 4A-20

1, (a)

1, (a)

1, (a)

IH23K1410030-02 IH23K4410026-01

4) Bleed air from the rear brake system. (Page 4A-

13)
5) Tighten rear brake master cylinder bolt.
Tightening torque
Rear brake master cylinder bolt (a): 10 N·m (1.0
kgf-m, 7.3 lbf-ft)
4A-21 Brake Control System and Diagnosis:

Front Brake Master Cylinder Assembly / Brake Lever Components

BENM23K14106011

(a)

(b)

8
7

5
6

(f)

4
11
9 (c)

10

(e) (d)
IG12K1410029-06

1. Reservoir cap 8. Dust boot : 1.2 Nm (0.12 kgf-m, 0.90 lbf-ft)
2. Plate 9. Brake hose union bolt : 6.0 Nm (0.61 kgf-m, 4.45 lbf-ft)
3. Diaphragm 10. Brake light switch : 1.0 Nm (0.10 kgf-m, 0.75 lbf-ft)
4. Master cylinder 11. Brake lever : Apply silicone grease.
5. Piston/Cup set : 1.5 Nm (0.15 kgf-m, 1.10 lbf-ft) : Apply brake fluid.

6. Return spring : 10 Nm (1.0 kgf-m, 7.3 lbf-ft) : Do not reuse.

7. Push rod : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
 Brake Control System and Diagnosis: 4A-22

Front Brake Master Cylinder Assembly Removal Installation

and Installation Install the front brake master cylinder in the reverse
BENM23K14106012 order of removal. Pay attention to the following points:
• When installing the master cylinder assembly (1) onto
Removal
the right handlebar (2), align the edge (3) of master
1) Drain brake fluid. (Page 4A-15) cylinder body with the punch mark (4) on the right
2) Place a clean rag underneath the brake hose union handlebar and tighten the front bolt (5) first.
bolt (1) on the master cylinder to catch any spilt
brake fluid. NOTE
3) Remove the brake hose union bolt and disconnect Face the triangle mark (6) forward.
the brake hose.
Tightening torque
4) Disconnect the front brake light switch lead wire
Front brake master cylinder holder bolt (a): 9 N·m
couplers (2).
(0.9 kgf-m, 6.6 lbf-ft)

5, (a)
1
6

1
5, (a)

2 4 3
IH23K1410031-01
IH23K1410033-01
5) Remove the master cylinder bolt and remove the
master cylinder assembly (1).

IG12K1410034-02

“a”: Clearance

IH23K1410032-01
4A-23 Brake Control System and Diagnosis:

• Install the brake hose union bolt and seal washers to 2) Remove the brake lever (1) and brake light switch
brake hose. (2).

NOTE
Do not reuse seal washers.
Replace with the new one. 2

• After the brake hose union has contacted the stopper

(1), tighten the union bolt (2) to the specified torque.
Tightening torque
Brake hose union bolt (a): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)
1
IG12K1410038-01

3) Remove the dust boot (1) and push rod (2).

4) Remove the snap ring (3) with the special tool.

2, (a) Special tool

09900–06108

IH23K1410034-01
1 2
• Bleed air from the brake system. (Page 4A-13) 3

Front Brake Master Cylinder Assembly / Brake IG12K1410039-01

Lever Disassembly and Reassembly 5) Remove the following parts from the master cylinder.
BENM23K14106013
Refer to “Front Brake Master Cylinder Assembly • Piston/cup set (1)
Removal and Installation” (Page 4A-22). • Return spring (2)

Disassembly
1) Remove the reservoir cap (1), plate (2) and
diaphragm (3).

2
1
1 2 3

IG12K1410040-01

IG12K1410037-01
 Brake Control System and Diagnosis: 4A-24

Reassembly • Apply grease to the contact point between push rod

Reassemble the front brake master cylinder and brake and piston/cap set.
lever in the reverse order of disassembly. Pay attention
“A”: Grease 99000–25100 (SUZUKI SILICONE
to the following points:
GREASE)
NOTICE • Set the dust boot (1) to the master cylinder securely.
• Wash the master cylinder components with
new brake fluid before reassembly.
• Do not wipe the brake fluid off after
washing the components.
• When washing the components, use the
specified brake fluid. Never use different
types of fluid or cleaning solvents such as
gasoline, kerosene, etc.
“A”
• Apply brake fluid to the master cylinder 1
bore and all of the master cylinder
components to be inserted into the bore.
IG12K1410042-01

Brake fluid (DOT 3) • When installing the brake light switch, align the
Brake fluid (DOT 4) projection (1) on the switch with the hole (2) in the
master cylinder.
• Tighten the brake light switch mounting screw (3) to
the specified torque.
Tightening torque
Brake light switch screw (a): 1.2 N·m (0.12 kgf-m,
0.90 lbf-ft)

1
3, (a)
I837H1410034-01

• Install a new snap ring (1) with the special tool.

Special tool
09900–06108 2

IG12K1410043-01

1
IG12K1410041-01
4A-25 Brake Control System and Diagnosis:

• Apply grease to the contact point between push rod
and brake lever.
• Apply grease to the brake lever pivot bolt and brake
lever sliding surfaces.
“A”: Grease 99000–25100 (SUZUKI SILICONE
GREASE)
Front Brake Master Cylinder Parts Inspection
BENM23K14106014
Refer to “Front Brake Master Cylinder Assembly / Brake
Lever Disassembly and Reassembly” (Page 4A-23).
Master Cylinder
Inspect the master cylinder bore (1) for any scratches
corrosion or other damage. If any damage is found,
replace it with a new one.

“A”

“A”

IG12K1410044-01 1
• Install the pivot bolt (1) and new lock-nut (2) and then
tighten to the specified torque. IG12K1410046-01

Tightening torque Piston / Cup Set

Brake lever pivot bolt lock-nut (a): 6.0 N·m (0.61 Inspect the piston/cup set surface for any scratches or
kgf-m, 4.45 lbf-ft) other damage. Inspect the primary cup (1) and
secondary cup (2) for wear or damage. If any damage is
found, replace the piston/cup with new one.

1 2
2, (a)

IG12K1410047-01
IH23K5410001-01
 Brake Control System and Diagnosis: 4A-26

Rear Brake Master Cylinder Assembly Components

BENM23K14106015

(a)
12

(b)

10

11

(c)
IH23K1410035-01
4A-27 Brake Control System and Diagnosis:

1. Reservoir cap 7. Brake hose connector : 22.5 Nm (2.29 kgf-m, 16.5 lbf-ft)
2. Ring 8. Piston/Cup set : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
3. Diaphragm 9. Push rod : 17.5 Nm (1.78 kgf-m, 12.9 lbf-ft)
4. Reservoir tank 10. Snap ring : Apply silicone grease.
5. Brake hose 11. Dust boot : Apply brake fluid.

6. Master cylinder 12. Reservoir tank cap guard : Do not reuse.

Rear Brake Master Cylinder Assembly Removal 6) Loosen the lock-nut (1).
and Installation 7) Remove the master cylinder mounting bolts (2) and
BENM23K14106016
hose clamp (3).
Removal 8) Remove the master cylinder with the reservoir (4).
1) Drain brake fluid. (Page 4A-15)
2) Remove the right front footrest guard (1).
3 4
3) Remove the reservoir tank bracket bolt (2).

2
1

IH23K1410043-01

Installation
IK23K4410006-03 Install the rear brake master cylinder in the reverse order
4) Place a clean rag (1) underneath the brake hose of removal. Pay attention to the following points:
union bolt (2) on the master cylinder to catch any • Install hose clamp (1) and tighten the master cylinder
spilt brake fluid. mounting bolts (2) to the specified torque.
5) Remove the brake hose union bolt and disconnect
Tightening torque
the brake hose (3).
Rear brake master cylinder bolt (a): 10 N·m (1.0
kgf-m, 7.3 lbf-ft)
2 • Tighten the lock-nut (3) to the specified torque.
Tightening torque
1 Rear brake master cylinder rod lock-nut (b): 18
N·m (1.8 kgf-m, 13.5 lbf-ft)
3 • Install the brake hose union bolt and seal washers to
the brake hose.

NOTE

IG12K1410068-02
Do not reuse seal washers.
Replace with the new one.

• After the brake hose union has contacted the stopper,

tighten the union bolt (4) to the specified torque.
Tightening torque
Brake hose union bolt (c): 23 N·m (2.3 kgf-m, 17.0
lbf-ft)
 Brake Control System and Diagnosis: 4A-28

1 4, (c) 2
3

2, (a) 1

3, (b)
IG12K1410053-01

5) Pull out the dust boot (1) and remove the snap ring
(2).
Special tool
IH23K1410044-01
09900–06108
• Install the reservoir tank. Refer to “Rear Brake Hose
Routing Diagram (without ABS)” (Page 4A-5).
• Bleed air from the system after installing the master
cylinder. (Page 4A-13)
2
• Adjust the brake pedal height. (Page 4A-12)

Rear Brake Master Cylinder Disassembly and

Reassembly 1
BENM23K14106017
Refer to “Rear Brake Master Cylinder Assembly
Removal and Installation” (Page 4A-27).
IG12K1410054-01
Disassembly
6) Remove the following parts from the master cylinder.
1) Disconnect the reservoir hose (1).
• Push rod (1)
2) Remove the lock-nut (2).
• Piston/cup set (2)

1
2

IG12K1410052-01
IG12K1410055-01
3) Remove the snap ring (1) with the special tool.
Special tool
09900–06108
4) Remove the brake hose connector (2) and O-ring
(3).
4A-29 Brake Control System and Diagnosis:

Reassembly • Apply grease to the lip of the dust boot (1).

Reassemble the rear brake master cylinder in the
“A”: Grease 99000–25100 (SUZUKI SILICONE
reverse order of disassembly. Pay attention to the
GREASE)
following points:
• Set the dust boot to the master cylinder securely.
NOTICE
• Wash the master cylinder components with
new brake fluid before reassembly.
• Do not wipe the brake fluid off after
washing the components. 1
• When washing the components, use the
specified brake fluid. Never use different
types of fluid or cleaning solvents such as
gasoline, kerosene, etc.
• Apply brake fluid to the master cylinder “A”
bore and all of the master cylinder
IG12K1410057-02
components to be inserted into the bore.
• Install a new O-ring (1) to the brake hose connector
Brake fluid (DOT 3) (2).
Brake fluid (DOT 4) • Install a new snap ring (3) with the special tool.
Special tool
09900–06108

2
1

3
IB14J1410051-02

• Apply grease to the push rod end.

“A”: Grease 99000–25100 (SUZUKI SILICONE
GREASE) IG12K1410058-01

• Connect the reservoir hose (1) and set the clamps (2).
• Install a new snap ring (1) with the special tool.
(Page 4A-5)
Special tool
09900–06108
1

1
“A”
2

IG12K1410059-01

IG12K1410056-01
 Brake Control System and Diagnosis: 4A-30

Rear Brake Master Cylinder Parts Inspection Dust Boot

BENM23K14106018 Inspect the dust boot (1) for wear or damage. If any
Refer to “Rear Brake Master Cylinder Disassembly and defects are found, replace it with a new one.
Reassembly” (Page 4A-28).

Master Cylinder
Inspect the master cylinder bore (1) for any scratches or
other damage. If any damage is found, replace the 1
master cylinder with a new one.

IG12K1410062-01

Rear Brake Pedal Components

BENM23K14106019
1

IG12K1410060-01

Piston / Cup Set

Inspect the piston surface for any scratches or other
damage. Inspect the primary cup (1) and secondary cup
(2) for wear or damage. If any damage is found, replace 3
the piston/cup with new ones.

4
2
1
IL23K1410002-01

1 1. Rear brake pedal 4. Cotter pin

2. Rear brake pedal return spring : Apply grease.
2 3. Washer : Do not reuse.

IG12K1410061-01
4A-31 Brake Control System and Diagnosis:

Rear Brake Pedal Removal and Installation 4) Remove footrest bracket bolt (1).
BENM23K14106020
Removal
1) Remove the cotter pin and remove the rear brake
master cylinder pin (1).

IH23K1410047-01

5) Remove footrest bolt (1) and then remove brake

pedal while pull footrest to outside.
IH23K4410021-01

2) Remove the rear brake pedal return spring (1).

1 1

IL23K1410003-01
IH23K1410045-01

3) Remove the rear brake light switch spring (1). Installation

Install the rear brake pedal in the reverse order of
removal. Pay attention to the following points:
• Apply grease to the rear brake pedal shaft.
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

“A”
IL23K1410004-01

IH23K1410046-01
 Brake Control System and Diagnosis: 4A-32

• Use new cotter pins (1). Rear Brake Pedal Inspection

BENM23K14106021
Refer to “Rear Brake Pedal Removal and Installation”
(Page 4A-31).
1 Inspect the brake pedal for wear and damage. If any
defect is found, replace rear brake pedal with new ones.

IG12K1410075-01
IL23K1410005-01

IH23K1410049-01

Specifications
Tightening Torque Specifications
BENM23K14107001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Brake light switch screw (Page 4A-9) /
1.2 0.12 0.90
(Page 4A-24)
Rear brake master cylinder rod lock-nut (Page 4A-12) /
18 1.8 13.5
(Page 4A-27)
Front brake air bleeder valve 8.5 0.86 6.26 (Page 4A-13)
Front reservoir cap screw 1.15 0.11 0.84 (Page 4A-14)
Rear brake air bleeder valve 5.5 0.56 4.05 (Page 4A-15)
Brake hose union bolt (Page 4A-18) /
(Page 4A-19) /
23 2.3 17.0
(Page 4A-23) /
(Page 4A-27)
Rear brake master cylinder bolt (Page 4A-20) /
10 1.0 7.3
(Page 4A-27)
Front brake master cylinder holder bolt 9 0.9 6.6 (Page 4A-22)
Brake lever pivot bolt lock-nut 6.0 0.61 4.45 (Page 4A-25)
4A-33 Brake Control System and Diagnosis:

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Brake Hose Routing Diagram (without ABS)” (Page 4A-1)
“Front Brake Hose Routing Diagram (with ABS)” (Page 4A-3)
“Rear Brake Hose Routing Diagram (without ABS)” (Page 4A-5)
“Rear Brake Hose Routing Diagram (with ABS)” (Page 4A-6)
“Front Brake Master Cylinder Assembly / Brake Lever Components” (Page 4A-21)
“Rear Brake Master Cylinder Assembly Components” (Page 4A-26)
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Recommended Service Material
BENM23K14108001
Material SUZUKI recommended product or Specification Note
Brake fluid DOT 3 — (Page 4A-10) / (Page
4A-13) / (Page 4A-15) /
(Page 4A-16) / (Page
4A-24) / (Page 4A-29)
DOT 4 — (Page 4A-10) / (Page
4A-13) / (Page 4A-15) /
(Page 4A-16) / (Page
4A-24) / (Page 4A-29)
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 4A-31)
SUZUKI SILICONE GREASE P/No.: 99000–25100 (Page 4A-24) / (Page
4A-25) / (Page 4A-29) /
(Page 4A-29)

NOTE
Required service material(s) is also described in:
“Front Brake Master Cylinder Assembly / Brake Lever Components” (Page 4A-21)
“Rear Brake Master Cylinder Assembly Components” (Page 4A-26)
“Rear Brake Pedal Components” (Page 4A-30)

Special Tool
BENM23K14108002
09900–06108
Snap ring pliers (Internal)
(Page 4A-23) /
(Page 4A-24) /
(Page 4A-28) /
(Page 4A-28) /
(Page 4A-29) /
(Page 4A-29)
 Front Brakes: 4B-1

Front Brakes
Brakes

Repair Instructions
Front Brake Components
BENM23K14206001

7 (c)

6 (b)
1
3

8
9
2 (a)
10
11
5
12
8

4
13

18
17
16
14 9 (d)

15
IH23K1420016-01

1. Front brake disc
2. Front brake disc bolt
3. Front brake caliper
4. Brake pad mounting pin
5. Clip
6. Brake air bleeder valve
7. Caliper mounting bolt
8. Rubber boot
10. Pad stopper : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
11. Brake caliper bracket : 8.5 Nm (0.86 kgf-m, 6.26 lbf-ft)
12. Snap ring : 30 Nm (3.0 kgf-m, 22.1 lbf-ft)
13. Spacer : 8.5 Nm (0.87 kgf-m, 6.30 lbf-ft)
14. Brake pad spring : Apply silicone grease to the sliding surface.
15. Brake pad : Apply thread lock to the thread part.
16. Piston : Apply thread lock to the thread part.
17. Dust seal : Apply brake fluid.

9. Brake caliper bracket pin 18. Piston seal : Do not reuse.

4B-2 Front Brakes:

Front Brake Pad Inspection 2) Remove the clip (1).

BENM23K14206002
The extent of brake pad (1) wear can be checked by
observing the grooved limit line “a” on the pads. When
the wear exceeds the grooved limit line, replace the
pads with new ones. (Page 4B-2)

“a”

1
IH23K4420003-01

3) Push out the pad mounting pin (1) gradually pull it

with a pliers (2) and release fitting of the pad
mounting pin ring (3).
“a”
IH23K4420001-01

Front Brake Pad Replacement

BENM23K14206003

NOTE
After replacing the brake pads, pump the
brake lever several times to check for proper
brake operation and then check the brake 1
fluid level. 2

1) Remove the brake caliper (1). 3

IK23K4420001-01

4) Remove the pad mounting pin (1) and brake pads

(2).

NOTE
Do not operate the brake lever while
removing the brake pads.

1
2

IH23K4420002-01

IH23K1420005-01
 Front Brakes: 4B-3

5) Clean up the caliper especially around the caliper
pistons.
6) Push back the caliper pistons into the caliper. At the
time, observe the reservoir level not to exceed the
upper level.
7) Install new brake pads (1) and temporarily new pad
mounting pin (2).
10) Install the brake caliper and tighten the brake caliper
mounting bolts (1) to the specified torque.
Tightening torque
Caliper mounting bolt (a): 30 N·m (3.0 kgf-m,
22.1 lbf-ft)

NOTE
Replace the brake pads as a set.

1, (a)
1

IH23K1420008-01
2
Front Brake Caliper Removal and Installation
BENM23K14206004

Removal
IH23K1420006-01
8) Insert the pad mounting pin gradually tapping it with
the pliers (1) and fit the pad mounting pin ring (2).
1) Drain brake fluid. (Page 4A-15)
2) Place a rag underneath the union bolt on the brake
caliper to catch any spilt brake fluid.
3) Remove the brake hose from the caliper by
removing the union bolt (1) and catch the brake fluid
in a suitable receptacle.
4) Remove the caliper (2) by removing the caliper
mounting bolts.

2
1

1
IH23K1420014-02

9) Install a new clip (1).

2
IH23K1420009-01

IH23K1420003-02
4B-4 Front Brakes:

Installation
1) Install the brake caliper (1).
2) Tighten caliper mounting bolts (2) to the specified
torque.
Tightening torque 2
Caliper mounting bolt (a): 30 N·m (3.0 kgf-m,
22.1 lbf-ft)
3) Install the brake hose union bolt (3) and seal
washers to brake hose. 1

NOTE IG12K1420010-01

Do not reuse seal washers (4). 3) Remove the caliper pistons applying compressed air
Replace with the new one. gradually from the hole for the brake hose.

4) After setting the brake hose union to the stopper, ! WARNING

tighten the union bolt to the specified torque.
Do not apply highly compressed air to the
Tightening torque piston as it is. Place a cloth to prevent the
Brake hose union bolt (b): 23 N·m (2.3 kgf-m, brake piston from jumping-out. Gradually
17.0 lbf-ft) apply compressed air. Do not place your
fingers in front of brake piston while applying
compressed air.

3, (b) 2, (a)

4
1 IG12K1420011-01
IM23K1420001-01

5) Bleed air from the brake system after installing the

4) Remove the dust seals (1) and piston seals (2).
caliper. (Page 4A-13)
6) Check the front wheel speed sensor lead wire is
routing correctly. Refer to “Front Wheel Speed 2
Sensor Routing Diagram” in Section 4E (Page 4E-8)
7) Check the brake fluid leakage referring to “Brake
Hose Inspection” in Section 4A (Page 4A-10) and
brake operation.

Front Brake Caliper Disassembly and

Reassembly 1
BENM23K14206005
Refer to “Front Brake Caliper Removal and Installation”
IG12K1420012-01
(Page 4B-3).
5) Remove the brake air bleeder valve (1) and bleeder
NOTICE valve cap (2).
Take care not to damage piston and caliper
cylinder of front brake caliper.

Disassembly
1) Remove the brake pads. (Page 4B-2)
2) Remove the pad spring (1) and caliper bracket (2).
 Front Brakes: 4B-5

1 2

IG12K1420013-01 IG12K1420015-01

6) Remove the rubber boots (1). 10) If necessary, remove the pad stopper (1).

IG12K1420014-01 IG12K1420016-01

7) Remove the caliper bracket pin (1) and spacer (2).

Reassembly
1) Wash the caliper bores and pistons with specified
1 brake fluid. Particularly wash the dust seal grooves
and piston seal grooves.

NOTICE
• Wash the caliper components with fresh
2 brake fluid before reassembly. Never use
cleaning solvent or gasoline to wash them.
• Do not wipe the brake fluid off after
washing the components.
IF34J1420031-01
• When washing the components, use the
8) Remove the snap ring (1) using the special tool. specified brake fluid. Never use different
Special tool types of fluid or cleaning solvent such as
09900–06107 gasoline, kerosene or the others.

Brake fluid (DOT 3)

Brake fluid (DOT 4)
1

IF34J1420034-01

9) If necessary, remove the brake caliper bracket pin

(1) using a hydraulic press (2) and suitable tool (3).
I649G1420012-02
4B-6 Front Brakes:

2) Apply the brake fluid to new piston seals (1) and new 9) Install the spacer (2) and caliper bracket pin, and
dust seals (2). tighten the caliper bracket pin to the specified torque.
Brake fluid (DOT 3) Tightening torque
Brake fluid (DOT 4) Caliper bracket pin (a): 8.5 N·m (0.86 kgf-m, 6.26
lbf-ft)
3) Install the piston seals and dust seals.

1 , “A ”, (a )

2
1

IF34J1420033-01
I649G1420013-02
10) Install the rubber boots (1).
4) Install the caliper pistons to the brake caliper.
5) If removed, install the pad stopper.
6) If removed, install the brake caliper bracket pin (1)
using a hydraulic press (2) and suitable tool (3).

2
1

3 IG12K1420014-01

11) Install the bleeder valve cap (1) and brake air
bleeder valve, and tighten brake air bleeder valve to
the specified torque.
IG12K1420015-01
Tightening torque
7) Install a new snap ring (1) using the special tool.
Brake air bleeder valve (a): 8.5 N·m (0.86 kgf-m,
Special tool 6.26 lbf-ft)
09900–06107
1

(a)

IG12K1420017-01

IF34J1420032-01 12) Apply grease to the sliding surface of the caliper

8) Apply thread lock to the thread portion of the caliper bracket pins and install the caliper bracket (1).
bracket pin (1).
“A”: Grease 99000–25100 (SUZUKI SILICONE
“A”: Thread lock cement 99000–32030 (THREAD GREASE)
LOCK CEMENT 1303B)
 Front Brakes: 4B-7

13) Install the pad spring pointing the triangle mark (2) Brake Pad Spring
toward the brake disc rotation. Inspect the brake pad spring for damage and excessive
bend. If any defects are found, replace it with a new one.

“A”

IG12K1420018-02

14) Install the brake pads. (Page 4B-2) IF34J1420025-01

Brake Caliper Bracket / Brake Caliper Bracket Pin

Front Brake Caliper Parts Inspection
BENM23K14206006 Inspect the brake caliper bracket and caliper bracket
Refer to “Front Brake Caliper Disassembly and pins for wear and other damage. If any defect is found,
Reassembly” (Page 4B-4). replace them with new ones.

Brake Caliper Cylinder

Inspect the brake caliper cylinder wall for nicks,
scratches or other damage. If any defect is found,
replace the brake caliper with a new one.

IF34J1420026-02

Rubber Boot
Inspect the rubber boots for damage and cracks. If any
defect is found, replace them with new ones.
IG12K1420019-01

Brake Caliper Piston

Inspect the brake caliper piston surfaces for any
scratches or other damage. If any defect is found,
replace them with new ones.

IF34J1420027-01

IF34J1420023-01
4B-8 Front Brakes:

Front Brake Disc Removal and Installation Front Brake Disc Inspection
BENM23K14206007 BENM23K14206008
Removal Brake Disc Thickness
1) Remove front wheel assembly. (Page 2D-3) Check the brake disc for damage or cracks and measure
the thickness using the micrometer.
2) Release front brake disc bolts and then remove front
If the thickness is less than the service limit or if defect is
brake disc (1).
found, replace the brake disc.
Special tool
(A): 09912–66310
Front brake disc thickness
[Limit]: 3.5 mm (0.14 in)

(A)

ID26J1420029-01

Brake Disc Runout

IH23K5420001-01
1) Dismount the front brake pads. (Page 4B-2)
2) Measure the runout using the dial gauge.
Installation Replace the disc if the runout exceeds the service
1) Make sure that the brake disc is clean and free of limit.
any grease. Special tool
2) Install the front brake disc with new brake disc bolts. (A): 09900–20607
09900–20701
NOTE
The stamped mark (1) on the brake disc Front brake disc runout
should face to the outside. [Limit]: 0.30 mm (0.012 in)

Tightening torque
Brake disc bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)
(A)

(a)

ID26J1420030-04

3) Remount the front brake pads. (Page 4B-2)

1
(a)
IH23K1420012-01
 Front Brakes: 4B-9

Specifications
Tightening Torque Specifications
BENM23K14207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Caliper mounting bolt (Page 4B-3) /
30 3.0 22.1
(Page 4B-4)
Brake hose union bolt 23 2.3 17.0 (Page 4B-4)
Caliper bracket pin 8.5 0.86 6.26 (Page 4B-6)
Brake air bleeder valve 8.5 0.86 6.26 (Page 4B-6)
Brake disc bolt 23 2.3 17.0 (Page 4B-8)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Brake Components” (Page 4B-1)
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Recommended Service Material
BENM23K14208001
Material SUZUKI recommended product or Specification Note
Brake fluid DOT 3 — (Page 4B-5) / (Page 4B-
6)
DOT 4 — (Page 4B-5) / (Page 4B-
6)
Grease SUZUKI SILICONE GREASE P/No.: 99000–25100 (Page 4B-6)
Thread lock cement THREAD LOCK CEMENT 1303B P/No.: 99000–32030 (Page 4B-6)

NOTE
Required service material(s) is also described in:
“Front Brake Components” (Page 4B-1)

Special Tool
BENM23K14208002
09900–06107 09900–20607
Snap ring pliers (External) Dial gauge (10 x 0.01 mm)
(Page 4B-5) / (Page 4B-8)
(Page 4B-6)

09900–20701 09912–66310
Dial gauge chuck Micrometer (0 - 25 mm)
(Page 4B-8) (Page 4B-8)
4C-1 Rear Brakes:

Rear Brakes
Brakes

Repair Instructions
Rear Brake Components
BENM23K14306001

3 4 (b)

9
13 6
10
5 (c)

2 (a)

8
11

12
IH23K1430012-01

1. Rear brake disc 8. Pad spring : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
2. Rear brake disc bolt 9. Dust seal : 12.3 Nm (1.25 kgf-m, 9.07 lbf-ft)
3. Rear caliper 10. Piston seal : Apply silicone grease to the sliding surface.
4. Bleeder valve 11. Piston : Apply thread lock to the thread part.
5. Brake pad mounting pin 12. Rear brake pad : Apply brake fluid.

6. O-ring 13. Caliper bracket : Do not reuse.

7. Boot : 23 Nm (2.3 kgf-m, 17.0 lbf-ft)

Rear Brake Pad Inspection

BENM23K14306002
The extent of brake pad (1) wear can be checked by “a”
observing the grooved limit line “a” on the pads. When
the wear exceeds the grooved limit line, replace the
pads with new ones. (Page 4C-2)

1
IH23K4430003-01
 Rear Brakes: 4C-2

Rear Brake Pad Replacement 5) Install a new O-ring (1) to the rear brake pad
BENM23K14306003 mounting pin.
NOTE
After replacing the brake pads, pump the
brake pedal several times to check for proper
brake operation and then check the brake
fluid level.

1) Remove the pad mounting pin (1).

1
2) Remove the brake pads (2).

NOTE
Do not operate the brake pedal while
removing the brake pads.

IH23K1430003-01

6) Tighten the pad mounting pin (1) to the specified

torque.
Tightening torque
Rear brake pad mounting pin (a): 12.3 N·m (1.25
2 kgf-m, 9.07 lbf-ft)

IH23K4430004-01
1. (a)
3) Clean up the caliper especially around the caliper
piston.
4) Install new brake pads.

NOTE
• Check the pads end (1) for proper fit to the IH23K4430006-01
brake caliper bracket (2).
• Replace the brake pads as a set.

1
2
1

IH23K4430005-01
4C-3 Rear Brakes:

Rear Brake Caliper Removal and Installation Installation

BENM23K14306004
1) Install the brake caliper (1) and caliper bracket (2) to
Removal the swingarm (3).
1) Drain brake fluid. (Page 4A-15) 2) Install the brake hose union bolt (4) and new seal
washers to brake hose.
2) Remove the rear wheel. (Page 2D-7)
3) After the brake hose union has contacted the
3) Remove the rear wheel speed sensor lead wire
stopper, tighten the union bolt to the specified
clamp bolt (1).
torque.
Tightening torque
Brake hose union bolt (a): 23 N·m (2.3 kgf-m,
17.0 lbf-ft)

4, (a)
1

2
1
3

IH23K4430007-01

4) Place a rag underneath the union bolt on the brake

caliper to catch any spilt brake fluid.
5) Remove the brake hose from the caliper by
removing the union bolt (1) and catch the brake fluid IH23K1430014-02

in a suitable receptacle. 4) Install the speed sensor lead wire clamp bolt (1).
6) Remove the caliper (2) and caliper bracket. 5) Install the rear wheel. Refer to (Page 2D-7)
6) Bleed air from the brake system. Refer to (Page
4A-13)
7) Check the brake fluid leakage referring to “Brake
Hose Inspection” in Section 4A (Page 4A-10) and
brake operation.
2
Rear Brake Caliper Disassembly and
Reassembly
BENM23K14306005
Refer to “Rear Brake Caliper Removal and Installation”
1 (Page 4C-3).

! CAUTION

IH23K1430005-01
Take care not to damage piston and caliper
cylinder of rear brake caliper.
 Rear Brakes: 4C-4

Disassembly 5) Remove the dust seal (1) and piston seal (2).
1) Remove the caliper bracket (1).

2
1

IG12K1430011-01

Reassembly
Reassemble the caliper in the reverse order of
IH23K1430006-01
disassembly. Pay attention to the following points:
2) Remove the pad spring (1). • Wash the caliper bore and piston with specified brake
fluid. Particularly wash the dust seal groove and
3) Remove the axle insulator (2) and rubber boot (3).
piston seal groove.

3 NOTICE
• Wash the caliper components with fresh
brake fluid before reassembly. Never use
2 cleaning solvent or gasoline to wash them.
1 • Do not wipe the brake fluid off after
washing the components.
• When washing the components, use the
specified brake fluid. Never use different
types of fluid or cleaning solvent such as
IG12K1430009-01 gasoline, kerosene or the others.
4) Remove the caliper piston applying compressed air
gradually from the hole for the brake hose. Brake fluid (DOT 3)
Brake fluid (DOT 4)
! WARNING
Do not apply highly compressed air to the
piston as it is. Place a cloth to prevent the
brake piston from jumping-out. Gradually
apply compressed air. Do not place your
fingers in front of brake piston while applying
compressed air.

I649G1430018-02

• Apply the brake fluid to new piston seal (1) and new
dust seal (2).
Brake fluid (DOT 3)
Brake fluid (DOT 4)

IG12K1430010-01
4C-5 Rear Brakes:

• Install the piston seal and dust seal. Brake Caliper Piston
Inspect the brake caliper piston surface for any
scratches or other damage. If any defects are found,
replace the piston with a new one.

I649G1420013-02

• Apply grease to the slide pins (1).

“A”: Grease 99000–25100 (SUZUKI SILICONE IG12K1430014-01
GREASE)
Brake Pad Mounting Pin
Inspect the brake pad mounting pin for wear and other
damage. If any damage is found, replace the brake pad
mounting pin with a new one.

1, “A”
IH23K1430008-01

Rear Brake Caliper Parts Inspection

BENM23K14306006
Refer to “Rear Brake Caliper Disassembly and
IH23K1430009-01
Reassembly” (Page 4C-3).
Boots
Brake Caliper Cylinder
Inspect the boots for damage and wear. If any defects
Inspect the brake caliper cylinder wall for nicks,
are found, replace them with new ones.
scratches or other damage. If any damage is found,
replace the caliper with a new one.

IG12K1430016-02

IG12K1430013-01
 Rear Brakes: 4C-6

Brake Pad Spring 2) Remove the rear brake disc (1).

Inspect the brake pad springs for damage and excessive
bend. If any defects are found, replace them with new
ones.

IH23K1430016-01

Installation
IH23K1430011-01 1) Make sure that the brake disc (1) is clean and free of
any grease.
Brake Caliper Sliding Pin 2) Install the rear brake disc with the new rear brake
Inspect the brake caliper sliding pin for wear and other disc bolts.
damage. If any damage is found, replace the brake
caliper sliding pin with a new one. NOTE
The stamped mark (2) on the brake disc
should face to the outside.

Tightening torque
Brake disc bolt (a): 23 N·m (2.3 kgf-m, 17.0 lbf-ft)

“A”, (a)

2
IH23K1430015-01

Rear Brake Disc Removal and Installation 1

BENM23K14306007
Refer to “Rear Wheel Assembly Removal and
Installation” in Section 2D (Page 2D-7).
IH23K1430017-01

Removal
1) Remove rear wheel speed sensor rotor (1)

IH23K4430008-01
4C-7 Rear Brakes:

3) Install rear wheel speed sensor rotor (1) and tighten Rear brake disc runout
to the specified torque. [Limit]: 0.30 mm (0.012 in)

NOTE
The stamped mark (2) on rear wheel speed
sensor rotor should face to the outside.
(A)

Tightening torque
Rear wheel speed sensor rotor bolt (a): 6.5 N·m
(0.66 kgf-m, 4.80 lbf-ft)

2 (a) ID26J1430037-04

3) Remount the rear brake pads. (Page 4C-2)

1

IH23K5430001-01

Rear Brake Disc Inspection

BENM23K14306008
Brake Disc Thickness
Check the brake disc for damage or cracks and measure
the thickness using the micrometer.
Replace the brake disc if the thickness is less than the
service limit or if defect is found.
Special tool
(A): 09912–66310
Rear brake disc thickness
[Limit]: 3.5 mm (0.14 in)

(A)

ID26J1430036-01

Brake Disc Runout

1) Dismount the rear brake pads. (Page 4C-2)
2) Measure the runout using the dial gauge.
Replace the disc if the runout exceeds the service
limit.
Special tool
(A): 09900–20607
09900–20701
 Rear Brakes: 4C-8

Specifications
Tightening Torque Specifications
BENM23K14307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Rear brake pad mounting pin 12.3 1.25 9.07 (Page 4C-2)
Brake hose union bolt 23 2.3 17.0 (Page 4C-3)
Brake disc bolt 23 2.3 17.0 (Page 4C-6)
Rear wheel speed sensor rotor bolt 6.5 0.66 4.80 (Page 4C-7)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Rear Brake Components” (Page 4C-1)
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Recommended Service Material
BENM23K14308001
Material SUZUKI recommended product or Specification Note
Brake fluid DOT 3 — (Page 4C-4) / (Page 4C-
4)
DOT 4 — (Page 4C-4) / (Page 4C-
4)
Grease SUZUKI SILICONE GREASE P/No.: 99000–25100 (Page 4C-5)

NOTE
Required service material(s) is also described in:
“Rear Brake Components” (Page 4C-1)

Special Tool
BENM23K14308002
09900–20607 09900–20701
Dial gauge (10 x 0.01 mm) Dial gauge chuck
(Page 4C-7) (Page 4C-7)

09912–66310
Micrometer (0 - 25 mm)
(Page 4C-7)
4E-1 ABS:

ABS
Brakes

Precautions
Precautions for ABS Service
BENM23K14500001
• Battery voltage is always applied to the ABS control
unit. Therefore, disconnect the battery (–) lead wire
before disconnecting the ABS control unit coupler.
• When the ABS control unit coupler is connected, do
not disconnect the sensor coupler(s) with the ignition
switch turned ON. If the sensor coupler is
disconnected with the ignition ON, DTC will be stored
in the ABS control unit.
• The wheel speed sensor cannot be disassembled.
Precautions for Diagnosing Troubles
BENM23K14500002
To ensure that the trouble diagnosis is done accurately
and smoothly, observe the following and follow “ABS
Check” (Page 4E-11).
• The information on the DTCs detected by the ABS
control unit can be checked and cleared using the
special tool.
• If the motorcycle was operated in any of the following
conditions, ABS indicator light may light but this does
not indicate any fault in ABS.
– The motorcycle is stuck in mud, sand, etc.
– Wheel spins while driving.
– Wheels are rotated while the motorcycle is jacked
up.
• Be sure to follow the trouble diagnosis procedure
described in “ABS Check” (Page 4E-11). If the trouble
diagnosis procedure is not followed properly, incorrect
diagnosis may result. (If the incorrect procedure is
performed, other DTC may be stored in the ABS
control unit.)
Precautions for ABS
BENM23K14500003
Refer to “Precautions for Electrical Circuit Service” in
Section 00 (Page 00-2) and “Precautions for ABS
Service” (Page 4E-1).

NOTE
After repairing the trouble, clear the DTC
using special tool. (Page 4E-18)
 ABS: 4E-2

General Description
ABS Description
BENM23K14501001
ABS control unit calculates signals from wheel speed sensor and transmits control signals to HU. HU controls braking
force based on the control signals. This ABS control unit/HU cannot be disassembled.

1 2

3 4

12

5 5

11 11

6 6

13 8

7
10
9

14

15 16
IH23K4450002-01

1. Front brake lever/master cylinder 9. Front wheel speed sensor

2. Rear brake pedal/master cylinder 10. Rear wheel speed sensor
3. Front brake switch 11. Accumulator
4. Rear brake switch 12. HU
5. Inlet valve 13. ABS control unit
6. Outlet valve 14. ABS indicator light
7. Front brake caliper 15. Front system
8. Rear brake caliper 16. Rear system
4E-3 ABS:

ABS Control Unit Calculating Process

In the ABS control unit calculating process, calculation for ABS control and self-diagnosis with fail-safe operation are
carried out. The control unit executes self-diagnosis continuously and, when any malfunction is detected, the unit
cancels the ABS control and returns the brake system to the normal brake. The malfunction is stored as DTC.

Normal calculating process Calculating process when a malfunction occurs

Ignition switch turned to ON

ABS control unit Initialization

Malfunction
Self-diagnosis indicated
(during start up)
No malfunction

Wheel speed sensor signal ABS indicator light

enters lights up

YES
ABS control calculation Is ABS under control ?
NO

Hydraulic unit control signal Prohibition of ABS control Interim ABS control
output

Self-diagnosis (while riding) Diagnostic trouble code

Malfunction memorized
indicated
Correct
I823H3450006-01

Wheel Speed Sensor Description

BENM23K14501002
The wheel speed is detected by the hall IC type wheel speed sensor (1) and sensor ring (2). The wheel speed sensor
is fixed to the body and includes a hall IC (3) having 2 hall elements. As the sensor ring is located on the wheel hub, it
turns along with the wheel. The wheel speed sensor feeds pulse signals in proportion to the wheel speed to ABS
control unit, which then calculates the wheel speed based on such signal information.

1 3 5
IJ31J1452008-02

4. Magnet 5. Magnetic field lines

 ABS: 4E-4

Self-diagnosis Function and ABS Indicator NOTE

Light Description When a malfunction has occurred in the ABS,
BENM23K14501003
The ABS control unit performs the self-diagnosis and connect the special tool to the mode select
can store any electronically detected malfunctions as coupler (2P) to display the diagnostic trouble
diagnostic trouble codes. If a malfunction has occurred, code on the ABS indicator light. (Page 4E-
the indicator light lights up to inform the rider of the 17)
malfunction. The special tool, when connected to the
Special tool
mode select coupler (2P), enables the ABS indicator
(A): 09930–82760
light to display the diagnostic trouble codes.

ABS Indicator Light

The ABS indicator light (1) informs the rider of any ABS (A )
malfunctions. If a malfunction occurred, the ABS
indicator light flashes, during the self-diagnosis, to
indicate the diagnostic trouble code so that the correct
part can be repaired.
• When the ignition switch is turned to ON, the ABS
indicator light lights up even if no malfunction has
occurred, to indicate that the LED is not burnt out. It
will go off after the motorcycle is ridden at more than 5
km/h (3 mile/h). IH23K4450004-01

• If an ABS malfunction has occurred, the ABS indicator

light keeps lighting up.

1
IM23K1450001-12

ABS Operation and ABS Indicator Light

The ABS indicator light (1) shows the ABS operating condition. During normal operation, the ABS indicator light lights
up when the ignition switch is turned to ON and goes off after the motorcycle is ridden at more than 5 km/h (3 mile/h).
If a malfunction has occurred, the ABS indicator light keeps lighting up.
The ABS indicator light goes off when the motorcycle is The ABS is normally activated.
ridden at more than 5 km/h (3 mile/h).
The ABS indicator light keeps lighting up even though the One or more malfunction has been found and ABS
motorcycle is ridden at more than 5 km/h (3 mile/h). activation been hanged up.
The ABS indicator light does not light up when turning the Check the wire harness and combination meter. (Page
ignition switch ON. 4E-14)

1
IM23K1450001-12
4E-5 ABS:

Stored DTCs (Diagnostic Trouble Codes)

The maximum of six DTCs can be recorded. In these records, duplication of the same DTC will not occur. If the system
detects the 7th DTC, it overwrites the record of the oldest DTC.
Check and see if any diagnostic trouble code remains, by actually running the machine to activate ABS and by
carrying out the self-diagnosis after deleting the diagnostic trouble code once the malfunctioned part is repaired.

Fail-safe Function Description

BENM23K14501004
If malfunction occurs in the ABS electric system, this sets valve relay OFF. Consequently, motor relay will be set OFF
and the indicator light ON, and no current will be applied to motor solenoid valve inactivating ABS and turning ABS
indicator light ON. In this case, it functions as the normal brake. However, if malfunctions occurs while ABS is being
activated, when ABS control unit diagnoses that the operation can continue, it will effectuate ABS provisional control
(turning the ABS indicator light ON). Upon the moment when ABS provisional control is over, the valve relay will be set
OFF.
 ABS: 4E-6

Schematic and Routing Diagram

ABS Circuit Diagram
BENM23K14502001

[B] 7

[E] O
T11
[F] W

8
T4 O/W

6
W/R T7 9
11
B/R T14
10

R/B R/Bl
12

Br T2

T1

T9
4
5

[D] 14 15
W/Y T15
[A] 13
B/Y T8 16

9 1
3 17
10 2
11 3
12 4
13 5 [C] Gr/R T3
14 6
2
15 7
16 8
B/W T16
1

[a]

IH23K4450005-01

[A]: ABS control coupler (View: [a]) 3. Regulator/rectifier 11. Front wheel speed sensor
[B]: To brake switch 4. SUB fuse (10 A) 12. ABS indicator light
[C]: To mode select coupler (6P) 5. Ignition switch 13. Rear wheel speed sensor
[D]: To keyless push start control module 6. Main relay (Ignition switch model) / Ignition 14. Pump motor relay
(Keyless start model) solenoid relay (Keyless start model)
[E]: Ignition switch model 7. ABS hydraulic unit / control module assembly 15. Pump motor
[F]: Keyless start model 8. Mode select switch (2P) 16. Solenoid valve relay
1. Battery 9. ABS VALVE fuse (10 A) 17. Solenoid valve
2. MAIN fuse (20 A) 10. ABS MOTOR fuse (15 A)
4E-7 ABS:

Terminal Wire color Circuit Remarks

1 B/R Solenoid valve power supply circuit
2 Br ABS indicator light
3 Gr/R Diagnosis K-line
4 O/W Diagnosis L-line
7 W/R Front wheel speed sensor power supply circuit
8 B/Y Rear wheel speed sensor signal circuit
9 R/Bl Pump motor power supply circuit
O Ignition switch model
11 Ignition switch signal circuit
W Keyless start model
14 B/R Front wheel speed sensor signal circuit
15 W/Y Rear wheel speed sensor power supply circuit
16 B/W Ground
 ABS: 4E-8

Front Wheel Speed Sensor Routing Diagram

BENM23K14502002

[B]

[B] 2
1

[B]

[A]
4

IK23K4450001-02

[A]: After the clamp has contacted the stopper, tighten the bolt. 2. Clamp
: Clamp the marking of the front wheel speed sensor lead wire at
the outside of the front brake hose end as shown in the figure.
[B]: Fix the front wheel speed sensor lead wire sleeve to the clamp firmly. 3. Clamp
: Clamp the front wheel speed sensor lead wire at the upper side of
the front brake pipe protector.
: Cut off the excess tip of the clamp.
1. Clamp 4. Front wheel speed sensor
: Clamp the marking of the front wheel speed sensor lead wire at the
front side of the front brake hose as shown in the figure.
4E-9 ABS:

Rear Wheel Speed Sensor Routing Diagram

BENM23K14502003

2
[C]
1

[A] [B] 7

IK23K4450002-02

[A]: After the stopper of clamp has contacted the rear wheel speed 3. Clamp
sensor, tighten the bolt. : Clamp the marking of the rear wheel speed sensor lead wire at
the outside of the rear brake hose as shown in the figure.
[B]: Fix the rear wheel speed sensor lead wire sleeve to the clamp firmly. 4. Clamp
: Clamp the marking of the rear wheel speed sensor lead wire at
the outside of the brake hose end.
[C]: Pass the rear wheel speed sensor lead wire into the guide. 5. Rear wheel speed sensor lead wire
: Pass the rear wheel speed sensor lead wire inside of the clamp.
1. Clamp 6. Clamp
: Clamp the marking of the rear wheel speed sensor lead wire at the
outside of the rear brake hose end as shown in the figure.
2. Clamp 7. Swingarm
: Clamp the marking of the rear wheel speed sensor lead wire at the
under side of the rear brake hose as shown in the figure.
 ABS: 4E-10

Component Location
ABS Components Location
BENM23K14503001

1 3 8

2 6
7

9
11

10
12

IH23K4450008-01

1. Mode select coupler (6P) 5. ABS VALVE fuse (10 A) 9. Rear wheel speed sensor
2. Mode select coupler (2P) 6. ABS MOTOR fuse (15 A) 10. Rear wheel speed sensor rotor
3. MAIN fuse (20 A) 7. Main relay (Ignition switch model) / Ignition solenoid relay (Keyless start model) 11. Front wheel speed sensor
4. SUB fuse (10 A) 8. ABS control unit/HU 12. Front wheel speed sensor rotor
4E-11 ABS:

Diagnostic Information and Procedures

ABS Check Step 4
BENM23K14504001
Refer to the description after the following general flow Brakes diagnosis
for details of each step. 1) Inspect and repair the ABS. (Page 4E-14)

Step 1 Is the malfunction detected?

Malfunction analysis Yes Repair or replace the malfunction part,
1) Perform “Customer Complaint Analysis” (Page and then go to Step 6.
4E-12).
No Go to Step 5.
2) Perform “Problem Symptom Confirmation” (Page
4E-13). Step 5
3) Perform “DTC Check, Record and Clearance” Intermittent problem check
(Page 4E-13) and recheck DTC. 1) Check for intermittent troubles. (Page 00-2)
Is the same DTC detected again after performing Is the malfunction detected?
the DTC clearance?
Yes Repair or replace the malfunction part,
Yes Inspect and repair referring to the
then go to step 6.
applicable DTC troubleshooting, and then
go to Step 6. No Go to Step 6.
No Go to Step 2. Step 6
Final confirmation test
Step 2
Visual inspection 1) Perform “Final Confirmation Test” (Page 4E-13).
1) Perform “Visual Inspection” (Page 4E-13). Does the trouble recur?
Is there any faulty condition? Yes Go to Step 4.
Yes Repair or replace the malfunction part, No End.
and then go to Step 6.

No Go to Step 3.

Step 3
Riding test
1) Perform “Riding Test” (Page 4E-13).
Is the malfunction detected?

Yes Repair or replace the malfunction part,

and then go to Step 6.

No Go to Step 4.
 ABS: 4E-12

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 a questionnaire form as shown in the following table will facilitate collecting the
information to the point required for the proper analysis and diagnosis.

IE31J1450074-01

NOTE
This form is a standard sample. The form should be modified according to conditions and
characteristic of each market.
4E-13 ABS:

Problem Symptom Confirmation Riding Test

If a symptom in “Customer Questionnaire” is found or
reproduced in the vehicle, confirm the symptom is
problem or not. (This step should be done with the
customer if possible.) Check the ABS indicator light.
(Page 4E-14)
DTC Check, Record and Clearance
Perform “DTC (Diagnostic Trouble Code) Output” (Page
4E-17) procedure, record it and then clear it. (Page
4E-18)
Recheck DTC. (Page 4E-17)
Ride the motorcycle at more than 30 km/h (19 mile/h)
and quickly apply the brakes to check that the ABS
activates correctly.
Final Confirmation Test
Confirm that the problem symptom is not observed any
more and ABS is free from any abnormal conditions. If
what has been repaired is related to the malfunction
DTC, clear the DTC referring to “DTC (Diagnostic
Trouble Code) Deleting” (Page 4E-18) and perform test
riding and confirm that the DTC is not indicated.

NOTE
After deleting the DTC, perform “Riding Test”
(Page 4E-13) and then recheck the DTC.

Visual Inspection
BENM23K14504002
Check the following parts and systems visually.
Inspection Item Referring Section
Connectors of electric wire harness Disconnection, friction “Precautions for Electrical Circuit
Service” in Section 00 (Page 00-2)
Fuses Burning “Precautions for Electrical Circuit
Service” in Section 00 (Page 00-2)
Brake pad Worn “Front Brake Pad Inspection” in
Section 4B (Page 4B-2) and “Rear
Brake Pad Inspection” in Section 4C
(Page 4C-1)
Brake fluid Level, leakage “Brake Fluid Level Check” in Section
4A (Page 4A-10)
ABS indicator light Operation “ABS Indicator Light Inspection” (Page
4E-14)
Tire Pressure “Tire Inspection and Cleaning” in
Section 2D (Page 2D-12)
Type, size “Tire Inspection and Cleaning” in
Section 2D (Page 2D-12)
Damage, wear “Tire Inspection and Cleaning” in
Section 2D (Page 2D-12)
Wheel Runout, play “Wheel / Wheel Axle Inspection” in
Section 2D (Page 2D-10)
Other parts that can be checked visually —

NOTICE
• The standard tire fitted on this motorcycle is 90/80-17M/C (46P) for front and 130/70-17M/C (62P) for
rear. The use of tires other than those specified may cause instability. It is highly recommended to
use a SUZUKI Genuine Tire.
• Replace the tire as a set, otherwise the DTC C1625 (25) may be stored.
 ABS: 4E-14

ABS Symptom Diagnosis

BENM23K14504003

Condition Possible cause Correction / Reference Item

The ABS indicator light
keeps lighting up even
though the motorcycle is
ridden at more than 5 km/
h (3.1 mile/h).
The ABS indicator light
does not light up when
turning the ignition switch
to ON.
Malfunctioning the ABS function.
Malfunctioning the ABS indicator light
circuit.
Malfunctioning the ABS function.
Malfunctioning the ABS indicator light
circuit.
Malfunctioning the combination meter.
Perform the ABS check. (Page 4E-11)
Check the ABS indicator light circuit. (Page
4E-14)
Perform the ABS check. (Page 4E-11)
Check the ABS indicator light circuit. (Page
4E-14)
Check the combination meter. (Page 9C-3)

ABS Indicator Light Inspection Step 3

BENM23K14504004
Wiring Diagram (The ABS indicator light does not light up)
Refer to “ABS Circuit Diagram” (Page 4E-6). 1) Turn the ignition switch OFF.
2) Remove the front seat. (Page 9D-20)
Troubleshooting
3) Remove the stater relay cover and inspect the
Step 1 MAIN fuse (20 A) (1).
1) Check if the ABS indicator light (1) lights up when NOTE
turning the ignition switch ON.
If a fuse is blown, find the cause of the
problem and correct it before replacing the
fuse.

1
IM23K1450001-12

Does the ABS indicator light up?

Yes Go to Step 2.

No Go to Step 3.
IH23K4450009-01

Step 2 Is the MAIN fuse OK?

(The ABS indicator light lights up)
Yes Connect the starter relay coupler, go to
1) Ride the motorcycle at more than 5 km/h (3 mile/ Step 4.
h).
No Replace the MAIN fuse.
Does the ABS indicator light go off?

Yes Normal (No DTC exists)

No • DTC output. (Page 4E-17)

• If DTC can not be output (the ABS
indicator light does not flash), go to
Step 6.
4E-15 ABS:

Step 4 Step 6
1) Disconnect the ABS control unit coupler. (Page (The ABS indicator light does not go off)
4E-37) 1) Turn the ignition switch OFF.
2) Turn the ignition switch ON with the ABS control 2) Remove the front seat. (Page 9D-20)
unit coupler disconnected, measure the voltage 3) Open the fuse box and inspect the SUB fuse (10
between “T2” (Br) and “T16” (B/W) at the coupler. A) (1).

NOTE
If a fuse is blown, find the cause of the
problem and correct it before replacing the
T2 fuse.

T16

IH23K4450010-01 1
Is voltage 7.5 – 9.5 V?

Yes Go to Step 5. IH23K4450012-01

No • Inspect the wire harness. (Faulty Is the SUB fuse OK?

indicator light wire or ground wire)
Yes Go to Step 7.
• Faulty combination meter.
No Replace the SUB fuse.
Step 5
1) Turn the ignition switch OFF. Step 7
2) Check for continuity between “T16” (B/W) at the 1) Remove the main relay (Ignition switch model) /
coupler and body ground. ignition solenoid relay (Keyless start model) (1).
2) Check the main relay (Ignition switch model) /
ignition solenoid relay (Keyless start model).

T16 1

IH23K4450013-01

Is the main relay / ignition solenoid relay OK?

IH23K4450011-01
Yes Install the main relay (Ignition switch
Is continuity indicated?
model) / ignition solenoid relay (Keyless
Yes Replace the ABS control unit/HU. (Page start model), go to Step 8.
4E-37)
No Replace the main relay (Ignition switch
No Inspect the wire harness. (Faulty ground model) / ignition solenoid relay (Keyless
wire) start model).
 ABS: 4E-16

Step 8 Step 10
1) Disconnect the ABS control unit coupler. (Page 1) Turn the ignition switch OFF.
4E-37) 2) Short the mode select coupler (2P) terminals
2) Turn the ignition switch ON with the ABS control using the special tool.
unit coupler disconnected, measure the voltage
Special tool
between “T11” (O) (Ignition switch model) / (W)
(A): 09930–82760
(Keyless start model) terminal and “T16” (B/W)
terminal at the coupler.

(A )

T11

IH23K4450004-01

T16 3) Check for continuity between “T4” (O/W) and

“T16” (B/W) at the coupler.
IH23K4450014-01

Is the voltage 12.0 V or more?

Yes Go to Step 9.

No Inspect the wire harness. (Faulty ignition

wire or ground wire)
T4

Step 9
1) Measure the voltage between “T2” (Br) terminal
and “T16” (B/W) terminal at the coupler.
T16

IH23K4450015-01

Is continuity indicated?
T2
Yes Replace the ABS control unit/HU. (Page
4E-37)

No Inspect the wire harness. (Faulty mode

select coupler wire)

T16

IH23K4450010-01

Is voltage 7.5 – 9.5 V?

Yes Go to Step 10.

No Inspect the wire harness. (Faulty indicator

light wire or ground wire)
4E-17 ABS:

DTC (Diagnostic Trouble Code) Output

BENM23K14504005
NOTE
(A )
• If there is a DTC recorded, the ABS
indicator light repeatedly flashes in a
cyclic manner. (However, when five
minutes have elapsed from the start of
self-diagnosis mode, the output of the DTC
will be interrupted.)
• If no DTC is recorded, the light repeats
flashing for 3.6 seconds in a cyclic
manner. IH23K4450004-01

• In the case that the mode select switch 4) Switch the special tool to ON.
(2P) is turned OFF or the vehicle speed
(both wheels) exceeds 10 km/h (6 mile/h),
the output of DTC will be interrupted.
• Don’t disconnect couplers from ABS HU,
the battery cable from the battery, ABS HU
ground wire harness from the engine or
main fuse before confirming the
malfunction code (self-diagnostic trouble
code) stored in memory. Such
disconnection will erase the memorized
information in ABS HU memory.
I718H1450040-03
• Be sure to read “Precautions for Electrical
Circuit Service” in Section 00 (Page 00-2) 5) Turn the ignition switch ON.
and “Precautions for ABS Service” (Page The ABS indicator light (1) starts flashing to indicate
4E-1) before inspection and observe what the DTC. (Page 4E-21)
is written there.
• After carrying out DTC deleting and ABS
operation check, explain to the customer
that the ABS is operating correctly.
(Page 4E-18)
• DTC can be checked by using the SDS-II or
OBD (for Oceania and Europe model).
Refer to the SDS-II or OBD (for Oceania
and Europe model) operation manual for 1
further details. IM23K1450001-12

6) Turn the ignition switch OFF and disconnect the

1) Turn the ignition switch OFF. special tool.
2) Remove the rear seat. (Page 9D-20) 7) Install the rear seat. (Page 9D-20)
3) Connect the special tool to the mode select coupler
(2P) (1).
Special tool
(A): 09930–82760

IH23K4450016-01
 ABS: 4E-18

Understanding the DTC (Diagnostic Trouble Code)

A two-digit DTC is shown through the flashing pattern of the ABS indicator light. A number between 1 and 9 is
represented by the number of times that the ABS indicator light lights up in interval of 0.4 seconds and the separation
between the tens and ones are indicated by the light staying off for 1.6 seconds. In addition, the separation between
the start code and the DTC is indicated by the light being off for 3.6 seconds. After the start code is displayed, DTCs
appear from the smallest number code.
If no DTC is recorded, the light repeats flashing for 3.6 seconds in a cyclic manner.

Output finish
ON
Mode select switch
OFF
ON

Ignition switch OFF Output start

Code 25
“c”
“f” Code 41
“c” “f”
ON
ABS indicator light OFF
(Malfunction exist)
“a” “b” “e” “b”

“d” “g”
ON
ABS indicator light OFF
(No malfunction exist)
“h”
IE31J1450023-02

“a”: Initial minimum light ON time (About 2 seconds) “e”: Main-sub code interval (1.6 seconds)
“b”: Error code interval (About 3.6 seconds) “f”: Sub code light ON time (0.4 seconds)
“c”: Main code light ON time (0.4 seconds) “g”: Sub code light OFF time (0.4 seconds)
“d”: Main code light OFF time (0.4 seconds) “h”: About 3.6 seconds

DTC (Diagnostic Trouble Code) Deleting 1) Connect the special tool to the mode select coupler
BENM23K14504006 (2P). (Page 4E-17)
NOTE
2) Switch the special tool to ON and turn the ignition
• The previous malfunction history code switch ON.
(Past DTC) still remains stored in the ABS 3) While the DTCs are being output, set the special tool
HU. Therefore, erase the history code to OFF. The DTC deletion mode is started after the
memorized in the ABS HU using special switch is set to OFF.
tool.
• The DTC is memorized in the ABS HU also
when the wire coupler of any sensor is
disconnected. Therefore, when a wire
coupler has been disconnected at the time
of diagnosis, erase the stored malfunction
history code.
• DTC can be checked by using the SDS-II or
OBD (for Oceania and Europe model).
Refer to the SDS-II or OBD (for Oceania
and Europe model) operation manual for I718H1450050-02
further details.
4E-19 ABS:

4) In the DTC deletion mode, switch the special tool from OFF to ON three times within 12.5 seconds, each time
leaving it at ON for more than 1 second.

NOTE
After deleting DTC with the mode select switch in ON position, the system resumes the self-diagnosis
mode again and outputs the DTC.

I718H1450051-02

DTC Deleting Diagram

ON

Ignition switch OFF

DTC indication 1 sec. 1 sec. 1 sec.

OFF
1 2 3
Mode select switch ON

Max. 12.5 seconds

Cleaning start
ON
ABS indicator light OFF
(Malfunction exist)
I823H3450030-01

5) After deleting the DTCs, repeat the code output procedure and make sure that no DTCs remain (the ABS indicator
light no longer flashes).

NOTE
If any DTCs remain, perform the appropriate procedures, then delete the codes. If DTCs are left stored,
confusion may occur and unnecessary repairs may be made.

6) Turn the ignition switch OFF and disconnect the special tool.
7) Install the removed parts.
8) Afterwards, ride the motorcycle at more than 30 km/h (19 mile/h) and quickly apply the brakes to check that the
ABS activates correctly.

ABS Hydraulic Unit Operation Check
BENM23K14504007
NOTE
• A false diagnosis may result if operation
check of the ABS hydraulic unit is
performed without satisfying all of the
specified condition below.
Check that all the following conditions are
met before performing operation check of
the ABS hydraulic unit.
– Battery voltage is 12 V or more.
– No air is trapped in the brake system.
– Brakes do not drag.
– No DTC is stored in ABS hydraulic unit /
control module.
• Operation check must be performed by 2
persons.
1) Turn the ignition switch “OFF”.
2) Remove the seat. (Page 9D-20)
3) Connect the SDS-II tool to mode select coupler (6P)
(1) or OBD tool (for Oceania and Europe model) to
mode select coupler (6P) (1) with special tool (B).
Special tool
(A): 09904–41030
09904–41040
(B): 09904–41051 (for Oceania and Europe
model)
10) After completing the check, close the SDS-II tool and
11) Disconnect the SDS-II tool and install the seat.
B A
(A)
IH23K4450017-01
ABS: 4E-20
4) Jack-up the vehicle until tire can be rotated.
5) Set transmission to neutral position.
6) Turn the ignition switch “ON”, and select “ABS HU
operating” in “Active control” under “ABS” mode of
SDS-II tool or OBD tool (for Oceania and Europe
model).
Refer to Operation Manual of SDS-II or OBD (for
Oceania and Europe model) for further details.
7) Perform the following check with help of another
person.
Apply the brake (lever or pedal) and then select
testing wheel by SDS-II tool or OBD tool (for
Oceania and Europe model) and the wheel should
be turned by another person’s hand. At this time,
check whether the wheel rotates freely due to brake
depressurization.
NOTE
Depressurization by SDS-II or OBD (for
Oceania and Europe model) tool is available
for 5 seconds or other. Refer to tool
operation manual.
IJ31J1452048-01
8) Check all 2-wheels respectively.
9) If any faulty condition is found in Step 6) – 7), replace
ABS hydraulic unit / control module assembly.
turn the ignition switch “OFF”.
(Page 9D-20)
4E-21 ABS:

DTC Table
BENM23K14504008
Indicator
DTC Malfunction cause Reference
status
None Normal ON *1 —
C1625 (25) Wheel speed sensor related malfunction ON (Page 4E-23)
C1635 (35) ABS motor malfunction ON (Page 4E-24)
C1641 (41) Wheel speed sensor signal malfunction (F) *2 ON (Page 4E-25)
C1642 (42) Wheel speed sensor circuit open (F) *2 ON (Page 4E-26)
C1644 (44) Wheel speed sensor signal malfunction (R) *2 ON (Page 4E-28)
C1645 (45) Wheel speed sensor circuit open (R) *2 ON (Page 4E-29)
C1647 (47) Supply voltage (Increased) ON *3 (Page 4E-31)
C1648 (48) Supply voltage (Decreased) ON *3 (Page 4E-31)
C1655 (55) ABS control unit malfunction ON *4 (Page 4E-32)
C1661 (61) ABS solenoid malfunction ON (Page 4E-33)

*1: It goes off after running at more than 5 km/h (3 mile/h).

*2: The wheel speed sensor lead wire is connected to the ABS control unit, but a short-circuit or faulty continuity inside
the ABS control unit caused this DTC to appear, therefore, the ABS control unit/HU assembly must be replaced. An
insufficient wheel speed sensor output voltage is the cause of a malfunction in which the ABS is activated even if the
brakes are not suddenly applied. If this occurs frequently even though the wheel speed sensor is operating correctly,
the ABS control unit/HU assembly should be replaced.
*3: When the voltage resumes the normal level, the ABS indicator light will go off.
*4: These are times that the ABS indicator light does not light up.

NOTE
When disconnecting couplers and turning the ignition switch ON, disconnect the ABS control unit
coupler in order to prevent a DTC from being stored. Each time a resistance is measured, the ignition
switch should be set to OFF.
 ABS: 4E-22

Scan Tool Data

BENM23K14504009
As the data values are standard values estimated on the basis of values obtained from the new vehicles of the
following conditions by using a scan tool, use them as reference values.
• Park vehicle in a flat area.
• Adjust air pressure of all tires to specified value.
• Use new genuine tires and genuine suspension.
• Do not modify suspension.
Even when the vehicle is in good condition, there may be cases where the checked value does not fall within each
specified data range. Therefore, judgment as abnormal should not be made by checking with these data alone.

NOTE
If communication between SDS-II or OBD (for Oceania and Europe model) and ABS control unit is not
possible, perform the following checks:
• Check DIG cable. If necessary, check DIG cable by substituting a known-good DIG cable.
• Check ABS control unit power circuit and ground circuit.

Scan tool data Vehicle condition Condition / Reference value

At stop (Stationary vehicle) 0 km/h (0 mph)
Wheel speed sensor (F)
Turn a wheel Numerical value increases
At stop (Stationary vehicle) 0 km/h (0 mph)
Wheel speed sensor (R)
Turn a wheel Numerical valve increases
IG monitoring voltage Ignition “ON” (Engine stopped) Battery voltage
ABS solenoid Input Voltage open or shorted (F) Ignition “ON” (Engine stopped) Normal
ABS solenoid Output Voltage open or shorted
Ignition “ON” (Engine stopped) Normal
(F)
ABS solenoid Input Voltage open or shorted (R) Ignition “ON” (Engine stopped) Normal
ABS solenoid Output Voltage open or shorted
Ignition “ON” (Engine stopped) Normal
(R)
ABS solenoid valve relay lock Ignition “ON” (Engine stopped) Normal
ABS motor Ignition “ON” (Engine stopped) Normal
ABS motor relay lock (OFF) Ignition “ON” (Engine stopped) Normal
ABS motor relay lock (ON) Ignition “ON” (Engine stopped) Normal
ABS solenoid valve relay Ignition “ON” (Engine stopped) On
ABS solenoid IN/V (F) Ignition “ON” (Engine stopped) Off
ABS solenoid OUT/V (F) Ignition “ON” (Engine stopped) Off
ABS solenoid IN/V (R) Ignition “ON” (Engine stopped) Off
ABS solenoid OUT/V (R) Ignition “ON” (Engine stopped) Off
Service check signal condition Ignition “ON” (Engine stopped) Off
ABS motor Ignition “ON” (Engine stopped) Off
4E-23 ABS:

DTC C1625 (25)

BENM23K14504010
Possible Cause
Wheel Speed Sensor Related Malfunction
Incorrect tire size, poor tire pressure, deformed wheel, wheel spinning, incorrect tooth count,
interference at one or more wheels, permanent bad signal, etc.

Troubleshooting Step 3
Step 1 1) Inspect both wheel speed sensor rotors for
damage and check that no foreign objects are
1) Check that the specified tires are installed.
caught in the rotor openings. (Page 4E-36)
(Page 2D-12)
Are the rotors OK?
Are the tires OK?
Yes Go to Step 4.
Yes Go to Step 2.
No Clean or replace the rotor.
No Use the specified tires.
• Front wheel speed sensor rotor:
Step 2 (Page 4E-35)
1) Make sure the tire pressure for each tire. (Page • Rear wheel speed sensor rotor:
2D-12) (Page 4E-35)
Is the tire pressure for each tire correct?
Step 4
Yes Go to Step 3. 1) Inspect the clearances of the front and rear wheel
speed sensor – sensor rotor using the thickness
No Adjust the tire pressure. gauge. (Page 4E-36)
Are the clearances OK?

Yes Replace the ABS control unit/HU. (Page

4E-37)

No Adjust the clearance.

 ABS: 4E-24

DTC C1635 (35)

BENM23K14504011
Possible Cause
ABS Motor Malfunction
ABS motor relay circuit open or short, broken fuse for motor relay, ABS motor circuit open or
short, faulty ABS motor relay, faulty ABS motor, faulty ABS control unit, etc.

Wiring Diagram
Refer to “ABS Circuit Diagram” (Page 4E-6).

Troubleshooting
Step 3
Step 1 1) Remove the fuel tank. (Page 1G-8)
1) Turn the ignition switch ON and check that the 2) Check the ABS control unit coupler (1) for loose or
operation sound is heard from the ABS control poor contacts. If OK, then disconnect the ABS
unit. (Page 4E-10) control unit coupler.

Does the ABS motor make any turning noise?

Yes • Faulty HU motor.

• Replace the ABS control unit/HU.
(Page 4E-37)

No Go to Step 2.

Step 2
1) Turn the ignition switch OFF. 1
2) Remove the front seat. (Page 9D-20)
IH23K4450020-01
3) Open the ABS fuse box inspect the ABS MOTOR
3) Measure the voltage between “T9” (R/Bl) and
fuse (15 A) (1).
“T16” (B/W) at the coupler.
NOTE
If a fuse is blown, find the cause of the
problem and correct it before replacing the
fuse.
T9

T16

1
IH23K4450021-01

Is voltage 12.0 V or more?

IH23K4450019-01
Yes Replace the ABS control unit/HU. (Page
Is the ABS MOTOR fuse OK? 4E-37)
Yes Go to Step 3. No Inspect the wire harness. (Faulty motor
power supply wire or ground wire)
No Replace the ABS MOTOR fuse.
4E-25 ABS:

DTC C1641 (41)

BENM23K14504012
Possible Cause
Wheel Speed Sensor Signal Malfunction (F)
Too great air gap, worn or missing teeth, noise, interference between lines, loose contact in wheel speed sensor
connector, wheel speed sensor not securely fastened, input amplifier in ABS control unit failure, etc.

Troubleshooting Step 3
Step 1 1) Check that the front wheel speed sensor (1) is
mounted securely.
1) Inspect the clearance between the front wheel
speed sensor and sensor rotor using the
thickness gauge. (Page 4E-36)
Is the clearance OK? 1

Yes Go to Step 2.

No Adjust the clearance.

Step 2
1) Inspect the front wheel speed sensor rotor for
damage and check that no foreign objects are
caught in the rotor openings. (Page 4E-36) IH23K4450022-01

Is the sensor rotor OK? Is the sensor mounted securely?

Yes Go to Step 3. Yes Go to DTC C1642 (42). (Page 4E-26)

No Clean or replace the sensor rotor. (Page No Tighten the mounting bolt.
4E-35)
 ABS: 4E-26

DTC C1642 (42)

BENM23K14504013
Possible Cause
Wheel Speed Sensor Circuit Open (F)
Wheel speed sensor circuit open or short, loosen contact in wheel speed sensor connector,
input amplifier in ABS control unit failure, etc.

Wiring Diagram
Refer to “ABS Circuit Diagram” (Page 4E-6).

Troubleshooting
Step 2
Step 1 1) Check for continuity between “T7” (W/R) and
ground at the ABS control unit coupler.
1) Turn the ignition switch OFF.
2) Remove the fuel tank. (Page 1G-8)
3) Check the ABS control unit coupler (1) and front
wheel speed sensor coupler (2) for loose or poor
contacts. If OK, then disconnect the ABS control
unit coupler.

T7

2
1 IH23K4450025-01

Is no continuity indicated?

IH23K4450023-01 Yes Go to Step 4.

4) Check for continuity between “T7” (W/R) and No Go to Step 3.
“T14” (B/R) at the ABS control unit coupler.
Step 3
1) Disconnect the front wheel speed sensor coupler.
2) Check for continuity between terminal and ground
at the front wheel speed sensor coupler.

T14
IJ04K1450002-01
T7
Is no continuity indicated?

IH23K4450024-01
Yes Inspect the wire harness. (Faulty W/R
wire)
Is no continuity indicated?
No Faulty front wheel speed sensor. (Page
Yes Go to Step 2. 4E-34)
No • Inspect the wire harness. (Faulty
sensor wire)
• Faulty front wheel speed sensor.
(Page 4E-34)
4E-27 ABS:

Step 4
1) Check for continuity between “T14” (B/R) and
ground at the ABS control unit coupler.

T7

T14
IH23K4450027-01

Is continuity indicated?

Yes Go to Step 7.
IH23K4450026-01

Is no continuity indicated? No Inspect the wire harness. (Faulty W/R

wire)
Yes Go to Step 6.
Step 7
No Go to Step 5.
1) Check for continuity between “T14” (B/R) on the
ABS control unit coupler and B/R wire on the front
Step 5
wheel speed sensor coupler.
1) Disconnect the front wheel speed sensor coupler.
2) Check for continuity between terminal and ground
at the front wheel speed sensor coupler.

IJ04K1450003-01
T14
Is no continuity indicated?

Yes Inspect the wire harness. (Faulty B/R wire)

No Faulty front wheel speed sensor. (Page

IH23K4450028-01
4E-34)
Is continuity indicated?
Step 6
Yes Go to Step 8.
1) Disconnect the front wheel speed sensor coupler.
2) Check for continuity between “T7” (W/R) on the No Inspect the wire harness. (Faulty B/R wire)
ABS control unit coupler and W/R wire on the front
wheel speed sensor coupler. Step 8
1) Measure the front wheel speed sensor current.
Refer to “Wheel Speed Sensor Circuit” under
“Wheel Speed Sensor and Sensor Rotor
Inspection” (Page 4E-36).
Is check result OK?

Yes Replace the ABS control unit/HU. (Page

4E-37)

No Replace front wheel speed sensor.

(Page 4E-34)
 ABS: 4E-28

DTC C1644 (44)

BENM23K14504014
Possible Cause
Wheel Speed Sensor Signal Malfunction (R)
Too great air gap, worn or missing teeth, noise, interference between lines, loose contact in
wheel speed sensor connector, wheel speed sensor not securely fastened, input amplifier in
ABS control unit failure, etc.

Troubleshooting
Step 3
Step 1 1) Check that the rear wheel speed sensor (1) is
mounted securely.
1) Inspect the clearance between the rear wheel
speed sensor and sensor rotor using the
thickness gauge. (Page 4E-36)
1
Is the clearance OK?

Yes Go to Step 2.

No Adjust the clearance.

Step 2
1) Inspect the rear wheel speed sensor rotor for
damage and check that no foreign objects are
caught in the rotor openings. (Page 4E-36) IH23K4450029-01

Is the sensor rotor OK? Is the sensor mounted securely?

Yes Go to Step 3. Yes Go to DTC C1645 (45). (Page 4E-29)

No Clean or replace the sensor rotor. (Page No Tighten the mounting bolt.
4E-35)
4E-29 ABS:

DTC C1645 (45)

BENM23K14504015
Possible Cause
Wheel Speed Sensor Circuit Open (R)
Wheel speed sensor circuit open or short, loosen contact in wheel speed sensor connector,
input amplifier in ABS control unit failure, etc.

Wiring Diagram
Refer to “ABS Circuit Diagram” (Page 4E-6).

Troubleshooting
Step 2
Step 1 1) Check for continuity between “T15” (W/Y) and
ground at the ABS control unit coupler.
1) Turn the ignition switch OFF.
2) Remove the fuel tank. (Page 1G-8)
3) Remove the right front frame cover. (Page 9D-
31)
4) Check the ABS control unit coupler (1) and rear
wheel speed sensor coupler (2) for loose or poor
contacts. If OK, then disconnect the ABS control
unit coupler.

T15

IH23K4450032-01

Is no continuity indicated?
1
2 Yes Go to Step 4.

No Go to Step 3.
IH23K4450030-01

5) Check for continuity between “T15” (W/Y) and Step 3

“T8” (B/Y) at the ABS control unit coupler. 1) Disconnect the rear wheel speed sensor coupler.
2) Check for continuity between terminal and ground
at the rear wheel speed sensor coupler.

IJ04K1450007-01

Is no continuity indicated?
T15
Yes Inspect the wire harness. (Faulty W/Y
T8 wire)
IH23K4450031-01 No Replace the rear wheel speed sensor.
Is no continuity indicated? (Page 4E-34)

Yes Go to Step 2.

No • Inspect the wire harness. (Faulty

sensor wire)
• Faulty rear wheel speed sensor.
(Page 4E-34)
 ABS: 4E-30

Step 4
1) Check for continuity between “T8” (B/Y) and
ground at the ABS control unit coupler.

T15

IH23K4450034-01

Is continuity indicated?
T8
Yes Go to Step 7.
IH23K4450033-01
No Inspect the wire harness. (Faulty W/Y
Is no continuity indicated? wire)
Yes Go to Step 6. Step 7
No Go to Step 5. 1) Check for continuity between “T8” (B/Y) on the
ABS control unit coupler and B/Y wire on the rear
Step 5 wheel speed sensor coupler.
1) Disconnect the rear wheel speed sensor coupler.
2) Check for continuity between terminal and ground
at the rear wheel speed sensor coupler.

IJ04K1450008-01

Is no continuity indicated?

Yes Inspect the wire harness. (Faulty B/Y wire) T8

No Replace the rear wheel speed sensor. IH23K4450035-01

(Page 4E-34) Is continuity indicated?
Step 6 Yes Go to Step 8.
1) Disconnect the rear wheel speed sensor coupler.
No Inspect the wire harness. (Faulty B/Y wire)
2) Check for continuity between “T15” (W/Y) on the
ABS control unit coupler and W/Y wire on the rear Step 8
wheel speed sensor coupler.
1) Measure the rear wheel speed sensor current.
Refer to “Wheel Speed Sensor Current” under
“Wheel Speed Sensor and Sensor Rotor
Inspection” (Page 4E-36).
Is check result OK?

Yes Replace the ABS control unit/HU. (Page

4E-37)

No Replace the rear wheel speed sensor.

(Page 4E-34)
4E-31 ABS:

DTC C1647 (47) / C1648 (48)

BENM23K14504016
Possible Cause
C1647 (47): Supply Voltage (Increased)
C1648 (48): Supply Voltage (Decreased)
• Faulty generator or regulator/rectifier
• Faulty battery
• Faulty ABS control unit
• Faulty wire harness, etc.

Wiring Diagram
Refer to “ABS Circuit Diagram” (Page 4E-6).

Troubleshooting 3) Check the ABS control unit coupler (1) for loose or
poor contacts. If OK, then disconnect the ABS
Step 1 control unit coupler.
1) Turn the ignition switch OFF.
2) Remove the front seat. (Page 9D-20)
3) Measure the voltage between the (+) and (–)
battery terminals.

IH23K4450020-01

4) Install the fuel tank. (Page 1G-8)

5) Start the engine at 5000 r/min with the dimmer
switch set to HI.
IH23K4450036-01 6) Measure the voltage between “T11” (O) (Ignition
Is voltage 12 V or more? switch model) / (W) (Keyless start model) and
“T16” (B/W) at the coupler.
Yes Go to Step 2.

No Charge or replace the battery. (Page 1J-

13)

Step 2
1) Start the engine at 5000 r/min with the dimmer
T11
switch set to HI.
2) Measure the voltage between the (+) and (–)
battery terminals.
Is voltage 14.0 – 15.5 V?
T16
Yes Go to Step 3.

No Inspect the generator and regulator/ IH23K4450014-01

rectifier. (Page 1J-4)
Is voltage 14.0 – 15.5 V?
Step 3 Yes Replace the ABS control unit/HU. (Page
1) Turn the ignition switch OFF. 4E-37)
2) Remove the fuel tank. (Page 1G-8)
No Inspect the wire harness. (Faulty ignition
wire or ground wire)
 ABS: 4E-32

DTC C1655 (55)

BENM23K14504017
Possible Cause
ABS Control Unit Malfunction
Faulty ABS control unit

Troubleshooting
Step 3
Step 1 1) Check that the front and rear wheel speed
sensors (1) are mounted securely.
1) Inspect the clearances of the front and rear wheel
speed sensor – sensor rotor using the thickness
gauge. (Page 4E-36)
Are the clearances OK? 1
1
Yes Go to Step 2.

No Adjust the clearance.

Step 2
1) Inspect both of the wheel speed sensor rotors for
damage and check that no foreign objects are
caught in the rotor openings. (Page 4E-36) IH23K4450037-01

Are the rotors OK? Are the sensors mounted securely?

Yes Go to Step 3. Yes Go to Step 4.

No Clean or replace the rotor. No Tighten the mounting bolts.

• Front wheel speed sensor rotor: Step 4
(Page 4E-35)
1) Delete DTCs (Page 4E-18) and repeat the code
• Rear wheel speed sensor rotor: output procedure. (Page 4E-17)
(Page 4E-35)

IM23K1450002-03

Is the DTC C1655 (55) output again?

Yes Replace the ABS control unit/HU. (Page

4E-37)

No Intermittent trouble.
4E-33 ABS:

DTC C1661 (61)

BENM23K14504018
Possible Cause
ABS Solenoid Malfunction
ABS valve relay circuit open or short, broken fuse for valve relay, faulty ABS valve relay,
interruption of valve, failure output from ABS control unit, etc.

Troubleshooting Step 2
Step 1 1) Remove the fuel tank. (Page 1G-8)
1) Turn the ignition switch OFF. 2) Check the ABS control unit coupler (1) for loose or
poor contacts. If OK, then disconnect the ABS
2) Remove the front seat. (Page 9D-20)
control unit coupler.
3) Open the ABS fuse box and inspect the ABS
VALVE fuse (10 A) (1).

NOTE
If a fuse is blown, find the cause of the
problem and correct it before replacing the
fuse.

IH23K4450020-01

3) Measure the voltage between “T1” (R/B) and

“T16” (B/W) at the coupler.

T1
IH23K4450039-01

Is the ABS VALVE fuse OK?

Yes Go to Step 2.

No Replace the ABS VALVE fuse.

T16

IH23K4450040-01

Is voltage 12.0 V or more?

Yes Replace the ABS control unit/HU. (Page

4E-37)

No Inspect the wire harness. (Faulty solenoid

wire or ground wire)

Repair Instructions
Front Wheel Speed Sensor Removal and
Installation
BENM23K14506001
Removal
1) Turn the ignition switch OFF.
2) Remove the fuel tank. (Page 1G-8)
3) Disconnect the front wheel speed sensor lead wire
coupler (1).
IH23K4450041-01
4) Remove the front wheel speed sensor mounting bolt
(1).
IH23K4450042-01
5) Remove the front wheel speed sensor as shown in
the front wheel speed sensor routing diagram.
(Page 4E-8)
Installation
Install the front wheel speed sensor in the reverse order
of removal. Pay attention to the following points:
• Install the front wheel speed sensor as shown in the
front wheel speed sensor routing diagram. (Page
4E-8)
• Check the clearance between the front wheel speed
sensor and sensor rotor. Refer to “Wheel Speed
Sensor and Sensor Rotor Inspection” (Page 4E-36).
ABS: 4E-34
Rear Wheel Speed Sensor Removal and
Installation
BENM23K14506002
Removal
1) Turn the ignition switch OFF.
2) Remove the right front frame cover. (Page 9D-31)
3) Disconnect the rear wheel speed sensor lead wire
coupler (1).
IH23K4450043-01
4) Remove the rear wheel speed sensor mounting bolt
(1).
IH23K4450044-01
5) Remove the rear wheel speed sensor as shown in
the rear wheel speed sensor routing diagram.
(Page 4E-9)
Installation
Install the rear wheel speed sensor in the reverse order
of removal. Pay attention to the following points:
• Install the rear wheel speed sensor as shown in the
rear wheel speed sensor routing diagram. (Page
4E-9)
• Check the clearance between the rear wheel speed
sensor and sensor rotor. Refer to “Wheel Speed
Sensor and Sensor Rotor Inspection” (Page 4E-36).
4E-35 ABS:

Front Wheel Speed Sensor Rotor Removal and
Installation
BENM23K14506003
Refer to “Front Wheel Assembly Removal and
Installation” in Section 2D (Page 2D-3).
Rear Wheel Speed Sensor Rotor Removal and
Installation
BENM23K14506004
Refer to “Rear Wheel Assembly Removal and
Installation” in Section 2D (Page 2D-7).

NOTICE
• Do not hit the front wheel speed sensor
rotor when dismounting the front wheel.
• Keep any type of magnets (including
magnetic pick-up tools, magnetic
screwdrivers, etc.) away from the wheel
speed sensor or sensor rotor.
NOTICE
• Do not hit the rear wheel speed sensor
rotor when dismounting the rear wheel.
• Keep any type of magnets (including
magnetic pick-up tools, magnetic
screwdrivers, etc.) away from the wheel
speed sensor or sensor rotor.

Removal Removal
1) Remove the front wheel speed sensor rotor (1). 1) Remove the rear wheel speed sensor rotor (1).

1
IH23K4450045-01 IH23K4450047-01

Installation Installation
1) Install the wheel speed sensor rotor as the letters 1) Install the wheel speed sensor rotor as the letters
“46T” face outside. “50T” face outside.
2) Tighten the front wheel speed sensor rotor bolts (1) 2) Tighten the rear wheel speed sensor rotor bolts (1)
to the specified torque. to the specified torque.
Tightening torque Tightening torque
Front wheel speed sensor rotor bolt (a): 6.5 N·m Rear wheel speed sensor rotor bolt (a): 6.5 N·m
(0.66 kgf-m, 4.80 lbf-ft) (0.66 kgf-m, 4.80 lbf-ft)

1, ( a)
1 , (a )

50T

IH23K4450046-02 IH23K4450048-02

3) Check the clearance between the front wheel speed 3) Check the clearance between the rear wheel speed
sensor and sensor rotor. Refer to “Wheel Speed sensor and sensor rotor. Refer to “Wheel Speed
Sensor and Sensor Rotor Inspection” (Page 4E-36). Sensor and Sensor Rotor Inspection” (Page 4E-36).
 ABS: 4E-36

Wheel Speed Sensor and Sensor Rotor Wheel Speed Sensor

Inspection 1) Remove the wheel speed sensor.
BENM23K14506005
Wheel Speed Sensor – Sensor Rotor Clearance • Front: (Page 4E-34)
Check the clearance between the wheel speed sensor • Rear: (Page 4E-34)
(1) and sensor rotor (2) using the thickness gauge. 2) Inspect the wheel speed sensor for damage.
Special tool Clean the sensor if any metal particle or foreign
(A): 09900–20803 material stuck on it.
(B): 09900–20806
Wheel speed sensor – Sensor rotor clearance
Front [Standard]: 0.68 – 1.65 mm (0.0268 – 0.0649 in)
Rear [Standard]: 0.48 – 1.65 mm (0.0189 – 0.0649 in)

[A]
2

( A) , ( B )

IH23K4450051-01
1
3) After finishing the speed sensor inspection, install
the wheel speed sensor.
• Front: (Page 4E-34)
IH23K4450049-01 • Rear: (Page 4E-34)

[B]
Wheel Speed Sensor Current
(A), (B) 1) Disconnect the wheel speed sensor coupler.
• Front: (Page 4E-34)
• Rear: (Page 4E-34)
2) Connect three 1.5 V dry cells (1) in series as shown
and make sure that their total voltage is more than
4.5 V. Measure the current between (+) dry cells
terminal and wheel speed sensor coupler terminal
2 1 (2) as shown in the figure.

IH23K4450050-01 Normal value

5.9 – 16.8 mA
[A]: Front [B]: Rear

A
IH20K1930020-03

3) Install the removed parts.

4E-37 ABS:

Wheel Speed Sensor Rotor 1) Turn the ignition switch OFF.

1) Raise the wheel off the ground and support the 2) Drain the brake fluid. (Page 4A-15)
motorcycle with a jack. 3) Remove the rear brake hose bolt (1).
2) Check that no wheel speed sensor rotor teeth are
broken and that no foreign objects are caught in the
wheel speed sensor. If any defects are found,
replace the wheel speed sensor rotor with a new
one.
• Front: (Page 4E-35)
• Rear: (Page 4E-35)
1

IH23K4450052-01

4) Disconnect the ABS control unit coupler (1).

I718H1450064-02

ABS Control Unit / HU Removal and Installation

BENM23K14506006
Refer to “Fuel Tank Removal and Installation” in Section
1G (Page 1G-8).

Removal

! WARNING
1
When storing the brake fluid, seal the IH23K4450053-01

container completely and keep away from 5) Loosen the flare nuts (1) and disconnect the brake
children. pipes.

NOTICE
• This brake system is filled with an ethylene
glycol-based DOT 4 brake fluid. Do not mix 1
different types of fluid such as silicone-
based or petroleum-based.
• Do not use any brake fluid taken from old,
used or unsealed containers. Never reuse
brake fluid left over from the last servicing 1
or stored for long periods.
• Handle brake fluid with care: the fluid IH23K4450054-01
reacts chemically with paint, plastics, 6) Remove the ABS control unit/HU assembly (1).
rubber materials etc. and will damage then
severely.
1
• The ABS control unit/HU cannot be
disassembled.

IH23K4450055-01
 ABS: 4E-38

7) Remove the ABS control unit/HU (1) from the holder. • Install ABS control unit/HU mounting rubbers (1) to
8) Remove the ABS control unit/HU mounting rubbers the holder (2) and frame (3) as shown in the figure.
(2).
1

1 2

IH23K4450058-01

IH23K4450056-01

2
IH23K4450059-01

IH23K4450057-01 • Make sure to hold the brake pipe when tightening the
flare nut, or it may be misaligned.
Installation • Tighten the brake pipe flare nuts (1) to the specified
Install the ABS control unit/HU in the reverse order of torque.
removal. Pay attention to the following points:
Tightening torque
• Stick the wiring harness cushion (1) on the ABS
Brake pipe flare nut (a): 16 N·m (1.6 kgf-m, 12.0
control unit/HU (2) aligning the vertical edges with the
lbf-ft)
edges of the control unit/HU as shown in the figure.

1, (a)

1, (a)
“a”
2
IH23K4450062-01
IH23K4450060-01
“a”: 3 – 8 mm (0.12 – 0.31 in)
• Bleed air from the brake fluid circuit. (Page 4A-13)
4E-39 ABS:

Specifications
Tightening Torque Specifications
BENM23K14507001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Front wheel speed sensor rotor bolt 6.5 0.66 4.80 (Page 4E-35)
Rear wheel speed sensor rotor bolt 6.5 0.66 4.80 (Page 4E-35)
Brake pipe flare nut 16 1.6 12.0 (Page 4E-38)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Special Tool
BENM23K14508001
09900–20803 09900–20806
Thickness gauge Thickness gauge
(Page 4E-36) (Page 4E-36)

09904–41030 09904–41040
SDS-II set SDS-II (oscilloscope) set
(Page 4E-20) (Page 4E-20)

B A B A

09904–41051 09930–82760
Conversion cable Mode selection switch
(Page 4E-20) (Page 4E-4) /
(Page 4E-16) /
(Page 4E-17)

Section 5
Transmission / Transaxle
CONTENTS
Precautions .................................................5-1
Precautions............................................................. 5-1
Precautions for Transmission / Transaxle............. 5-1
Manual Transmission.............................. 5B-1
Diagnostic Information and Procedures............5B-1
Manual Transmission Symptom Diagnosis ......... 5B-1
Repair Instructions ..............................................5B-2
Transmission Components ................................. 5B-2
Transmission Removal and Installation .............. 5B-3
Transmission Construction.................................. 5B-4
Countershaft Assembly / Driveshaft
Assembly Disassembly and Reassembly ......... 5B-4
Gearshift Fork / Gearshift Cam Inspection.......... 5B-7
Transmission Bearing / Oil Seal Removal and
Installation ......................................................... 5B-8
Transmission Bearing / Oil Seal Inspection ...... 5B-10
GP Switch Inspection ........................................ 5B-10
GP Switch Removal and Installation ................. 5B-11
Gearshift Lever Construction ............................ 5B-12
Gearshift Lever Removal and Installation ......... 5B-12
Gearshift Lever Height Inspection and
Adjustment ...................................................... 5B-13
Gearshift Shaft / Gearshift Cam Plate
Components.................................................... 5B-14
Gearshift Shaft / Gearshift Cam Plate
Removal and Installation................................. 5B-14
Gearshift Linkage Inspection ............................ 5B-16
Gearshift Shaft Oil Seal Removal and
Installation ....................................................... 5B-17
Specifications.....................................................5B-17
Table of Contents 5- i
Tightening Torque Specifications......................5B-17
Special Tools and Equipment ...........................5B-18
Recommended Service Material .......................5B-18
Special Tool ......................................................5B-18
Clutch ....................................................... 5C-1
Precautions...........................................................5C-1
Precautions for Clutch System............................5C-1
Diagnostic Information and Procedures ............5C-1
Clutch System Symptom Diagnosis ....................5C-1
Repair Instructions ..............................................5C-2
Clutch Lever Position Switch Inspection .............5C-2
Clutch Cable Inspection ......................................5C-2
Clutch Cable Play On-Vehicle Inspection and 5
Adjustment ........................................................5C-2
Clutch Cable Removal and Installation ...............5C-3
Clutch Lever Removal and Installation................5C-3
Clutch Components.............................................5C-5
Clutch Removal...................................................5C-6
Clutch Installation................................................5C-8
Clutch Cover Disassembly and Reassembly ....5C-11
Primary Drive Gear Removal and Installation ...5C-12
Clutch Parts Inspection .....................................5C-12
Primary Drive Gear and Primary Driven Gear
Inspection / Selection of Gear .........................5C-14
Specifications .....................................................5C-15
Tightening Torque Specifications......................5C-15
Special Tools and Equipment ...........................5C-15
Recommended Service Material .......................5C-15
Special Tool ......................................................5C-15
5-1 Precautions:

Precautions
Transmission / Transaxle

Precautions
Precautions for Transmission / Transaxle
BENM23K15000001
Refer to “General Precautions” in Section 00 (Page 00-1).
 Manual Transmission: 5B-1

Manual Transmission
Transmission / Transaxle

Diagnostic Information and Procedures

Manual Transmission Symptom Diagnosis
BENM23K15204001

Condition Possible cause Correction / Reference Item

Noisy engine (Noise Worn or rubbing gear. Replace. (Page 5B-4)
seems to come from the Worn countershaft spline. Replace countershaft. (Page 5B-4)
transmission) Worn driveshaft spline. Replace driveshaft. (Page 5B-4)
Worn bearing. Replace. (Page 5B-8)
Transmission will not Broken gearshift cam. Replace. (Page 5B-3)
shift Distorted gearshift fork. Replace. (Page 5B-3)
Worn gearshift pawl. Replace. (Page 5B-14)
Transmission will not Broken gearshift shaft return spring. Replace. (Page 5B-14)
shift back Rubbing or stuck gearshift shaft. Repair or replace. (Page 5B-14)
Worn or distorted gearshift fork. Replace. (Page 5B-3)
Transmission jumps out Worn shifting gears on driveshaft or Replace. (Page 5B-4)
of gear countershaft.
Worn or distorted gearshift fork. Replace. (Page 5B-3)
Weakened gearshift cam stopper spring. Replace. (Page 5B-14)
Worn gearshift cam plate. Replace. (Page 5B-14)
5B-2 Manual Transmission:

Repair Instructions
Transmission Components
BENM23K15206001

3
4

5
9

6
10

11
7
12
13

15 8
(a) 14
16
17

(a)
18
(a)

(a)
19
20

(b)

21 (c)
14
IG12K1520001-03

1. 1st driven gear 8. Oil seal retainer 15. Gearshift fork No.1 : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
2. 5th driven gear 9. Countershaft/1st drive gear 16. Gearshift cam plate : 8.5 Nm (0.87 kgf-m, 6.30 lbf-ft)
3. 4th driven gear 10. 5th drive gear 17. Gearshift cam bearing spacer : 4.0 Nm (0.41 kgf-m, 2.95 lbf-ft)
4. 3rd driven gear 11. 3rd/4th drive gear 18. Gearshift cam : Apply grease.
5. 6th driven gear 12. 6th drive gear 19. GP switch : Apply thread lock to the thread part.
6. 2nd driven gear 13. 2nd drive gear 20. Gearshift cam stopper : Apply engine oil.

7. Driveshaft 14. Gearshift fork shaft 21. Gearshift fork No.2 : Do not reuse.
 Manual Transmission: 5B-3

Transmission Removal and Installation 2) Install the gearshift forks No.1 (1) and No.2 (2).
BENM23K15206002
NOTE
Removal
The gearshift forks No.1 are same parts.
1) Remove the engine assembly. (Page 1D-46)
2) Remove the right crankcase. (Page 1D-50)
3) Remove the kick starter shaft assembly. (Page 1I-
14) 2
4) Remove the gearshift fork shafts (1), gearshift forks
(2) and gearshift cam (3).
1

1 1

2 2 IG12K1520004-01

IG12K1520002-01

5) Remove the driveshaft assembly (1) with the

2
countershaft assembly (2).

1
2
IG12K1520005-01
1
3) Install the gearshift cam (1) so that the two holes (2)
face upward.
4) Engage each gearshift fork end to the gearshift cam
groove.
5) Install the gearshift fork shafts (3).

IG12K1520003-01
NOTE
• After the gearshift fork shafts and gearshift
Installation forks have been fitted, make sure that the
1) Install the driveshaft assembly (1) with the gears engage normally.
countershaft assembly (2). • Set the transmission gears to the neutral
position.

1 3

2 1
IG12K1520003-01

IG12K1520006-01
5B-4 Manual Transmission:

Transmission Construction
BENM23K15206003

IG12K1520057-01

1. Countershaft 2. Driveshaft 3. Snap ring

: Face the sharp edge outside.

Countershaft Assembly / Driveshaft Assembly Countershaft

Disassembly and Reassembly 1) Remove the 2nd drive gear (1) using the special tool,
BENM23K15206004
hydraulic press (2) and suitable tool (3).
Refer to “Transmission Removal and Installation” (Page
5B-3). Special tool
(A): 09913–65850
Disassembly

NOTE 2
Identify the position of each removed part.
Organize the parts in their respective groups 3
(i.e., drive or driven) so that they can be
reinstalled in their original positions. 1

(A)
IG12K1520007-02
 Manual Transmission: 5B-5

2) Remove the 6th drive gear (1) and 3rd/4th drive gear 2) Remove the 1st driven gear bushing (1), washer (2)
(2). and 5th driven gear (3).

1
3

2
1

IG12K1520008-01 IG12K1520012-01

3) Remove the snap ring (1). 3) Remove the snap ring (1).
Special tool Special tool
09900–06107 09900–06107

1 1

IG12K1520009-01 IG12K1520013-01

4) Remove the 5th drive gear (1). 4) Remove the washer (1) and 4th driven gear (2).

1
2
1

IG12K1520010-01 IG12K1520014-01

5) Remove the 3rd driven gear (1).

Driveshaft
1) Remove the washer (1) and 1st driven gear (2).

1
2

IG12K1520015-01

IG12K1520011-01
5B-6 Manual Transmission:

6) Remove the washer (1) and 6th driven gear (2). Reassembly
Reassemble the countershaft and driveshaft in the
reverse order of disassembly. Pay attention to the
2 following point:

NOTE
1
• When reassembling the transmission
gears, attention must be given to the
locations and positions of washers and
snap rings. The cross sectional view
shows the correct position of the gears,
bushings, washers and snap rings. Refer
IG12K1520016-01 to “Transmission Construction” (Page 5B-
7) Remove the washer (1) and 2nd driven gear (2). 4).
• When installing new snap rings, do not
expand the end gap larger than required to
2
slip the snap rings over the shaft.
1 • After installing snap rings, make sure that
they are completely seated in its groove
and securely fitted.
• Before installing the gears, apply engine
oil to each rotating and sliding part.

• When installing a new snap ring (1), pay attention to

its direction. Fit it to the side where the thrust (2) is as
IG12K1520017-01 shown in the illustration.
8) Remove the 2nd driven gear bushing (1) and washer
(2). 2

2 1
1
3

IE31J1520022-02

3. Sharp edge

IG12K1520018-01
 Manual Transmission: 5B-7

Gearshift Fork / Gearshift Cam Inspection Gearshift Fork Thickness

BENM23K15206005 Measure the gearshift fork thickness using the vernier
Refer to “Countershaft Assembly / Driveshaft Assembly calipers.
Disassembly and Reassembly” (Page 5B-4).
Special tool
Gearshift Fork to Groove Clearance (A): 09900–20102
Using a thickness gauge, check the gearshift fork Gearshift fork thickness
clearance in the groove of its gear.
No.1 [Standard]: 4.8 – 4.9 mm (0.189 – 0.192 in)
If the clearance checked is noted to exceed the limit
No.3 [Standard]: 5.3 – 5.4 mm (0.209 – 0.212 in)
specified, replace the fork or its gear, or both.

NOTE
The clearance for each gearshift fork plays
an important role in the smoothness and
positiveness of the shifting action.

Special tool
(A): 09900–20803
Gearshift fork to groove clearance
No.1 [Standard]: 0.1 – 0.3 mm (0.004 – 0.011 in) IE31J1520028-01
[Limit]: 0.5 mm (0.019 in)
No.3 [Standard]: 0.1 – 0.3 mm (0.004 – 0.011 in) Gearshift Cam
[Limit]: 0.5 mm (0.019 in) Inspect the gearshift cam groove for abnormal wear and
damage. If any defects are found, replace the gearshift
cam with a new one.

IE31J1520026-01

Gearshift Fork Groove Width

Measure the gearshift fork groove width using the
vernier calipers. IG12K1520019-01

Special tool
(A): 09900–20102
Gearshift fork groove width
No.1 [Standard]: 5.0 – 5.1 mm (0.197 – 0.200 in)
No.3 [Standard]: 5.5 – 5.6 mm (0.217 – 0.220 in)

IE31J1520027-01
5B-8 Manual Transmission:

Transmission Bearing / Oil Seal Removal and Right crankcase

Installation 1) Remove the engine assembly. (Page 1D-46)
BENM23K15206006
Removal 2) Remove the right crankcase. (Page 1D-50)
Left crankcase 3) Remove the bearing retainers (1).
1) Remove the engine assembly. (Page 1D-46)
2) Remove the right crankcase. (Page 1D-50)
3) Remove the kick starter shaft assembly. (Page 1I-
14)
4) Remove the transmission. (Page 5B-3) 1

5) Remove the oil seal retainer (1).

1 IG12K1520023-01

4) Remove the countershaft bearing (1) and driveshaft

bearing (2) using the special tool.
Special tool
(A): 09913–70210

IG12K1520020-01 (A) (A)

6) Remove the driveshaft oil seal (1) using the special
tool.
Special tool
(A): 09913–50121

(A)
1 2

IG12K1520024-01

5) Remove the gearshift cam bearing (1) using the

special tool.

1 Special tool
(A): 09913–70210

IG12K1520021-01
(A)
7) Remove the countershaft bearing (1) and driveshaft
bearing (2) using the special tools.
Special tool
(A): 09921–20240
(B): 09913–70210

(A) (B) 1
IG12K1520058-01

2
1

IG12K1520022-01
 Manual Transmission: 5B-9

Installation 3) Apply grease to the oil seal lip.

Left crankcase “A”: Grease 99000–25011 (SUZUKI SUPER
1) Install a new driveshaft bearing (1) and a new GREASE A)
countershaft bearing (2) using the special tool.

NOTE
The sealed side (3) of the bearings faces
“A”
outside.

Special tool
(A): 09913–70210

IG12K1520028-01
1 2 4) Install the oil seal retainer (1) and tighten its bolts (2)
to the specified torque.
3 3 Tightening torque
Driveshaft oil seal retainer bolt (a): 10 N·m (1.0
kgf-m, 7.3 lbf-ft)

IG12K1520025-01
2, (a)

(A) (A)

1
2
IG12K1520029-02

IG12K1520026-01
Right crankcase
2) Install a new driveshaft oil seal (1) using the special 1) Install a new countershaft bearing (1) and a new
tool. driveshaft bearing (2) using the special tool.

Special tool Special tool

(A): 09913–70210 (A): 09913–70210

(A) (A) (A)

2
1

1
1 “a”
2
IG12K1520027-01 IG12K1520030-01

2. Left crankcase “a”: 0 – 1 mm (0 – 0.04 in)

5B-10 Manual Transmission:

2) Install the gearshift cam bearing (1) using the special GP Switch Inspection
tool. BENM23K15206008
1) GSX R 125 Model
Special tool Remove front fairing. (Page 9D-22)
(A): 09913–70210
GSX S 125 Model
Remove fuel tank side cover. (Page 9D-25)
2) Remove right frame cover. (Page 9D-31)
(A)
3) Disconnect the GP switch lead wire couplers (1).

NOTICE
When disconnecting and connecting the
neutral switch coupler, make sure to turn
“OFF” the ignition switch, or electronic parts
1 may get damaged.
IG12K1520059-01

3) Apply thread lock to the bearing retainer screws (1).

“A”: Thread lock cement 99000–32150 (THREAD
LOCK CEMENT 1322D)
1
4) Install the bearing retainers (2) and tighten its screws
to the specified torque.
Tightening torque
Countershaft bearing retainer screw (a): 8.35
N·m (0.85 kgf-m, 6.15 lbf-ft)
Gearshift cam bearing retainer screw (b): 8.35
N·m (0.85 kgf-m, 6.15 lbf-ft)

IH23K1520001-04

1, “A”, (b) 4) Check the continuity between the B/W wire terminal
and other wire terminal with the transmission in each
position as follows. If any defect is found, replace the
GP switch with a new one.
1, “A”, (a)
Color
B/W W/Y L R/B G/L Y/L Br/R G/R
Position
1st
2 Neutral
IG12K1520031-02 2nd
3rd
Transmission Bearing / Oil Seal Inspection 4th
BENM23K15206007
Refer to “Crankcase Bearing / Oil Seal Inspection” in 5th
Section 1D (Page 1D-55). 6th
IH23K1520002-01
 Manual Transmission: 5B-11

GP Switch Removal and Installation 5) Remove the GP switch (1).

BENM23K15206009
Removal
1) GSX R 125 Model
a) Remove front fairing. (Page 9D-22) 1
b) Remove right frame cover. (Page 9D-31)
GSX S 125 Model
a) Remove fuel tank side cover. (Page 9D-25)
b) Remove right frame cover. (Page 9D-31)
2) Remove the engine sprocket cover. (Page 3A-4)
3) Disconnect the GP switch lead wire couplers (1).
IG12K1520035-01

Installation
Install the GP switch in the reverse order of removal. Pay
1 attention to the following points:
• Install a new O-ring (1) to the GP switch.

IH23K1520001-04

4) Remove the clamp (1) and disconnect the harness

clamps (2) from the frame.

IG12K1520036-02

• Tighten the GP switch mounting bolts (1) to the

specified torque.
Tightening torque
GP switch mounting bolt (a): 4.0 N·m (0.41 kgf-
1 m, 2.95 lbf-ft)

2
1, (a)

IH23K1520006-01

IG12K1520037-01

• Route the GP switch lead wire. Refer to “Wiring

Harness Routing Diagram” in Section 9A (Page 9A-
11).
5B-12 Manual Transmission:

Gearshift Lever Construction

BENM23K15206010

10

“b” “c” 9
6 (a)

7 4

1
8 (a) [A]
8 (a)

9 5

“a” 2
3
IK23K4520001-01

[A]: Apply lithium grease all around 4. Gearshift lever assembly 8. Gearshift link rod nut “a”: 17 mm (0.66 in)
1. Footrest holder bolt 5. Footrest 9. Gearshift link rod “b”: 89°
2. Front footrest bracket left 6. Gearshift link arm bolt 10. Gearshift link joint “c”: 93°
3. Washer 7. Gearshift link arm : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)

Gearshift Lever Removal and Installation

BENM23K15206011
Refer to “Gearshift Lever Construction” (Page 5B-12)

Removal
1) Remove gearshift link arm bolt (1) and footrest
bracket bolt (2). 2
2) Pull out gearshift link arm (3) and footrest bracket(4). 4

IK23K4520002-01
 Manual Transmission: 5B-13

3) Remove gearshift link rod (1) from gearshift lever (2). Gearshift Lever Height Inspection and
Adjustment
NOTE BENM23K15206012

Mark the position of the gearshift lever on the Inspection

footrest bracket (3) before removing the link
arm.
4) Remove footrest holder bolt (3) for remove the
gearshift lever (2).
Inspect and adjust the gearshift lever height in the
following procedures:
1) Inspect the gearshift lever height “a” between the
lever top face and footrest.
Adjust the gearshift lever height if necessary.
Gearshift lever height
[Standard]: 50 – 60 mm (2.0 – 2.3 in)

“a”
1
IK23K4520003-01

Installation
IK23K4520005-01
Install the gearshift lever in the reverse order of removal.
Pay attention to the following points:
Adjustment
• Install the gearshift lever so that the gearshift lever
1) Loosen the lock-nuts (1).
height becomes the specified range. (Page 5B-13)
2) Turn the gearshift link rod (2) until the gearshift lever
• Tighten gear shift link arm bolt (1) to the specified
height is within the specification.
torque.
Gearshift lever height
Tightening torque
[Standard]: 50 – 60 mm (2.0 – 2.3 in)
Gear shift link arm bolt (a): 10 N·m (1.0 kgf-m, 7.3
lbf-ft) 3) Tighten the lock-nuts (1) to the specified torque.
• Tighten footrest bracket bolt lever bolt (2). Tightening torque
Gearshift link rod nut (a): 10 N·m (1.0 kgf-m, 7.3
lbf-ft)

1, (a)
1, (a)

1, (a)

IK23K4520004-02

2
IK23K4520007-01
5B-14 Manual Transmission:

Gearshift Shaft / Gearshift Cam Plate 3) Remove the following parts from the gearshift shaft
Components (1).
BENM23K15206013
• Snap ring (2)
• Washer (3)
5 12
• Spring (4)
4 • Gearshift cam drive plate (5)
3
2 • Gearshift shaft return spring (6)
Special tool
1 09900–06107

2 3
5 4 6

(a) 6
1

7 10
11 4
3
8 9 (b) 2
IK23K4520006-01 5
1. Gearshift shaft
IG12K1520043-01
2. Gearshift cam drive plate
3. Spring 4) Remove the gearshift cam plate bolt (1) and
4. Washer (14x22x1) gearshift cam plate (2).
5. Snap ring
5) Remove the gearshift cam stopper (3).
6. Gearshift stopper
7. Gearshift shaft return spring 6) Remove the gearshift arm stopper (4).
8. Seal (14x22x6)
9. Bolt
2
10. Dust cover
11. Gearshift link arm
1
12. Nut
: 19 Nm (1.9 kgf-m, 14.0 lbf-ft)
: 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
: Apply grease.
: Apply thread lock to the thread part.
: Do not reuse. 4 3

Gearshift Shaft / Gearshift Cam Plate Removal

and Installation IG12K1520044-01

BENM23K15206014 7) Remove the gearshift cam plate pins (1) and

gearshift cam bearing spacer (2).
Removal
1) Remove the clutch cover. (Page 5C-6)
2) Remove the gearshift shaft assembly (1). 1

1 IG12K1520045-02

IG12K1520041-01
 Manual Transmission: 5B-15

Installation 4) Install the gearshift cam plate pins (1) and gearshift
1) Apply a small quantity of thread lock to the gearshift cam bearing spacer (2).
arm stopper (1) and tighten it to the specified torque.
“A”: Thread lock cement 99000–32150 (THREAD
1
LOCK CEMENT 1322D)
Tightening torque
Gearshift arm stopper (a): 19 N·m (1.9 kgf-m,
14.0 lbf-ft)

IG12K1520045-02

5) Check the gearshift cam stopper moves smoothly.

6) Locate the gearshift cam in the neutral position.
7) Install the gearshift cam plate (1).
1, (a) “A”
NOTE
Align the gearshift cam plate pins (2) with the
IG12K1520046-01
gearshift cam plate holes (3).
2) Install the gearshift cam stopper (1), bolt (2), washer
(3) and spring (4).
3) Tighten the gearshift cam stopper bolt to the
specified torque.
3
NOTE 2

Hook the return spring end (5) to the

gearshift cam stopper.

Tightening torque
Gearshift cam stopper bolt (a): 10 N·m (1.0 kgf- 1
m, 7.3 lbf-ft)
IG12K1520050-01

8) Apply a small quantity of thread lock to the gearshift

1 cam plate bolt (1) and tighten it to the specified
torque.
“A”: Thread lock cement 99000–32150 (THREAD
4 LOCK CEMENT 1322D)
Tightening torque
2
Gearshift cam plate bolt (a): 10 N·m (1.0 kgf-m,
7.3 lbf-ft)
3

IG12K1520047-01

1, (a)
“A”

2, (a) IG12K1520051-01

IG12K1520048-01
5B-16 Manual Transmission:

9) Install the gearshift shaft return spring (1).
NOTE
Position the stopper (2) of gearshift arm
between the shaft return spring ends (3).
2
Gearshift Linkage Inspection
BENM23K15206015
Refer to “Gearshift Shaft / Gearshift Cam Plate Removal
and Installation” (Page 5B-14).
Gearshift Shaft
Check the gearshift shaft (1) for bend or wear.
Check the return spring (2) for damage or fatigue.
If any defects are found, replace the defective parts.

1 2

IG12K1520052-01
1
10) Install the following parts.
• New snap ring (1) IG12K1520054-01
• Washer (2)
• Gearshift cam drive plate (3) Gearshift Shaft Oil Seal
Inspect the gearshift shaft oil seal lip (1) for damage or
• Spring (4)
wear. If any defect is found, replace the oil seal with a
new one.
2 1 1

1
3 4 2
IF34J1520028-01

11) Install the gearshift shaft assembly (1).

NOTE IG12K1520055-01

Pinch the gearshift arm stopper (2) with

return spring ends (3).

3
IG12K1520053-01

12) Install the removed parts.

 Manual Transmission: 5B-17

Gearshift Shaft Oil Seal Removal and Installation

Installation 1) Install a new oil seal (1) with the special tool.
BENM23K15206016
Refer to “Gearshift Shaft / Gearshift Cam Plate Removal NOTE
and Installation” (Page 5B-14).
Install the gearshift shaft oil seal to the
Removal specified depth from the left crankcase end.
1) Remove the engine sprocket cover. Refer to “Engine Special tool
Sprocket Removal and Installation” in Section 3A (A): 09913–70210
(Page 3A-4).
2) Apply grease to the oil seal lip.
2) Remove the gearshift shaft. (Page 5B-14)
3) Remove the oil seal (1). “A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

1 2

1, “A”
(A) “a”
IG12K1520055-01
IG12K1520056-02

2. Left crankcase “a”: 0 – 1 mm (0 – 0.03 in)

3) Install the removed parts.

Specifications
Tightening Torque Specifications
BENM23K15207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Driveshaft oil seal retainer bolt 10 1.0 7.3 (Page 5B-9)
Countershaft bearing retainer screw 8.35 0.85 6.15 (Page 5B-10)
Gearshift cam bearing retainer screw 8.35 0.85 6.15 (Page 5B-10)
GP switch mounting bolt 4.0 0.41 2.95 (Page 5B-11)
Gear shift link arm bolt 10 1.0 7.3 (Page 5B-13)
Gearshift link rod nut 10 1.0 7.3 (Page 5B-13)
Gearshift arm stopper 19 1.9 14.0 (Page 5B-15)
Gearshift cam stopper bolt 10 1.0 7.3 (Page 5B-15)
Gearshift cam plate bolt 10 1.0 7.3 (Page 5B-15)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Transmission Components” (Page 5B-2)
“Gearshift Lever Construction” (Page 5B-12)
“Gearshift Shaft / Gearshift Cam Plate Components” (Page 5B-14)
“Fasteners Information” in Section 0C (Page 0C-10)
5B-18 Manual Transmission:

Special Tools and Equipment

Recommended Service Material
BENM23K15208001
Material SUZUKI recommended product or Specification Note
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 5B-9) / (Page 5B-
17)
Thread lock cement THREAD LOCK CEMENT 1322D P/No.: 99000–32150 (Page 5B-10) / (Page
5B-15) / (Page 5B-15)

NOTE
Required service material(s) is also described in:
“Transmission Components” (Page 5B-2)
“Gearshift Shaft / Gearshift Cam Plate Components” (Page 5B-14)

Special Tool
BENM23K15208002
09900–06107 09900–20102
Snap ring pliers (External) Vernier calipers (200 mm)
(Page 5B-5) / (Page 5B-7) /
(Page 5B-5) / (Page 5B-7)
(Page 5B-14)

09900–20803 09913–50121
Thickness gauge Oil seal remover
(Page 5B-7) (Page 5B-8)

09913–65850 09913–70210
Bearing puller Bearing installer set
(Page 5B-4) (Page 5B-8) /
(Page 5B-8) /
(Page 5B-8) /
(Page 5B-9) /
(Page 5B-9) /
(Page 5B-9) /
(Page 5B-10) /
(Page 5B-17)
09921–20240
Bearing remover set
(Page 5B-8)

Clutch
Transmission / Transaxle
Precautions
Precautions for Clutch System
Refer to “General Precautions” in Section 00 (Page 00-1).
Diagnostic Information and Procedures
Clutch System Symptom Diagnosis
Condition Possible cause
Noisy engine (Noise Worn countershaft spline.
seems to come from the Worn clutch sleeve hub spline.
clutch)
Worn clutch plate teeth.
Distorted clutch plates, driven and drive. Replace.
Worn clutch release bearing.
Weakened clutch springs.
Weakened clutch dampers.
Worn or rubbing primary gears.
Clutch slips Clutch cable out of adjustment.
Weakened clutch springs.
Worn or distorted clutch pressure plate. Replace.
Distorted clutch plates, driven and drive. Replace.
Clutch: 5C-1
BENM23K15300001
BENM23K15304001
Correction / Reference Item
Replace countershaft. (Page 5B-4)
Replace clutch sleeve hub.
• Removal: (Page 5C-6)
• Installation: (Page 5C-8)
Replace clutch plate.
• Removal: (Page 5C-6)
• Installation: (Page 5C-8)
• Removal: (Page 5C-6)
• Installation: (Page 5C-8)
Replace.
• Removal: (Page 5C-6)
• Installation: (Page 5C-8)
Replace.
• Removal: (Page 5C-6)
• Installation: (Page 5C-8)
Replace primary driven gear.
• Removal: (Page 5C-6)
• Installation: (Page 5C-8)
Replace.
• Removal: (Page 5C-6)
• Installation: (Page 5C-8)
Adjust. (Page 5C-2)
Replace.
• Removal: (Page 5C-6)
• Installation: (Page 5C-8)
• Removal: (Page 5C-6)
• Installation: (Page 5C-8)
• Removal: (Page 5C-6)
• Installation: (Page 5C-8)
5C-2 Clutch:

Condition Possible cause Correction / Reference Item

Clutch drags Clutch cable out of adjustment. Adjust. (Page 5C-2)
Some clutch springs are weak, while Replace.
others are not. • Removal: (Page 5C-6)
• Installation: (Page 5C-8)
Worn or distorted clutch pressure plate. Replace.
• Removal: (Page 5C-6)
• Installation: (Page 5C-8)
Distorted clutch plates, driven and drive. Replace.
• Removal: (Page 5C-6)
• Installation: (Page 5C-8)

Repair Instructions
Clutch Lever Position Switch Inspection
BENM23K15306001
Clutch Cable Inspection
1) Disconnect clutch lever position switch lead wire BENM23K15306002
coupler (1). Check that clutch lever moves smoothly. If it does not
move smoothly, lubricate clutch cable.

Clutch Cable Play On-Vehicle Inspection and

Adjustment
BENM23K15306003
Inspection
Inspect clutch cable play “a” at the clutch lever end.
Adjust clutch cable play if necessary.
Clutch lever play
[Standard]: 10 – 14 mm (0.4 – 0.5 in)

IL23K3530001-02

2) Inspect clutch lever position switch for continuity with

tester.
“a”
If any defect is found, replace switch with a new one.

Color
B BW
Position IH23K1530002-02
FREE
PUSH Adjustment
IL23K3530002-02 Lever side
3) Connect clutch lever position switch lead wire. 1) Slide clutch lever cover (1).
2) Loosen lock-nut (2) on the lever side, and adjust
clutch cable by turning adjuster (3) to obtain free play
“a” at clutch lever end.
3) After adjustment, tighten the lock nut (2) and slide
back clutch lever cover (1).
 Clutch: 5C-3

1
1
3
3 2
2

IH23K3530006-01
5 4
Engine Side
1) Loosen the lock-nut (1) on the engine side, slide the IH23K5530002-01

cable to obtain free play the clutch cable. 6) Remove clutch cable (1) from clutch cable stopper
2) Tighten the lock-nut (1) after adjustment. (2), and then disconnect clutch cable end (3) from
clutch release arm (4).

1 3
4 1
2

IH23K3530007-03

Clutch Cable Removal and Installation

BENM23K15306004
IH23K5530003-01

Installation
Removal
Install clutch cable in the reverse order of removal. Pay
1) Remove the following parts. attention to the following points:
• GSX R125: Front fairing (Page 9D-22) • Route clutch cable properly. Refer to “Throttle Cable
• GSX S125: Fuel tank side cover (right side) Routing Diagram” in Section 1D (Page 1D-1).
(Page 9D-25) • Adjust clutch cable play. (Page 5C-2)
2) Slide the cover (1) and fully loosen the lock-nut (2).
Clutch Lever Removal and Installation
BENM23K15306005
2
1
Removal
1) Disconnect clutch cable from clutch lever. Refer to
“Clutch Cable Removal and Installation” (Page 5C-
3).
2) Remove clutch lever pivot nut (1) and bolt (2), and
then remove clutch lever (3).

IH23K3530008-02

3) Slide clutch lever cover (1), loosen the lock nut (2).
4) Align lock nut (2), clutch cable adjuster (3) and clutch
lever (4) with the cutaway
5) Disconnect clutch cable end (5) from clutch lever.
5C-4 Clutch:

1 1, (a)

2 2, (b)

IM23K1530003-01 IM23K1530001-01

3) Remove clutch lever holder. Refer to “Handlebar • Adjust clutch cable play. (Page 5C-2)
Removal and Installation” in Section 6B (Page 6B-4).

Installation
Install clutch lever in the reverse order of removal. Pay
attention to the following points:
• Install clutch lever holder securely. Refer to
“Handlebar Removal and Installation” in Section 6B
(Page 6B-4).
• Apply grease to the clutch lever pivot bolt.
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

1, “A”

IM23K1530002-01

• Tighten clutch lever pivot bolt (1) and new clutch lever
pivot nut (2) to the specified torque.
Tightening torque
Clutch lever pivot bolt (a): 6.5 N·m (0.66 kgf-m,
4.80 lbf-ft)
Clutch lever pivot nut (b): 6.5 N·m (0.66 kgf-m,
4.80 lbf-ft)
 Clutch: 5C-5

Clutch Components
BENM23K15306006

(a)

2
4 5
6
7

(b)

10 (c)

13
11
9

12
15

14

13
IH23K1530008-01

1. Clutch release arm 9. Clutch driven plate : 5.0 Nm (0.51 kgf-m, 3.70 lbf-ft)
2. Clutch release camshaft 10. Clutch sleeve hub nut : 75 Nm (7.64 kgf-m, 55.3 lbf-ft)
3. Clutch spring 11. Lock washer : Apply grease.
4. Clutch pressure plate 12. Clutch sleeve hub : Apply engine oil.

5. Circlip 13. Thrust washer : Apply molybdenum oil solution.

6. Bearing 14. Primary driven gear assembly : Do not reuse.

7. Clutch release rack 15. Spacer
8. Clutch drive plate : 10 Nm (1.0 kgf-m, 7.3 lbf-ft)
5C-6 Clutch:

Clutch Removal 8) Remove gasket (1), O-ring (2) and dowel pins (3).
BENM23K15306007
1) Drain engine oil. (Page 1E-5).
2) Drain engine coolant. Refer to “Engine Coolant
Replacement” in Section 1F (Page 1F-5).
3) Remove the following parts. 1

• Front fairing (GSX R125): (Page 9D-22).

• Under cowling (GSX S125): (Page 9D-26).
4) Fully loosen lock-nut (1) and adjuster (2).
5) Remove clutch cable stopper (3) and clutch release 3
arm (4).

2 3
IH23K1530018-02

4 1 9) Remove clutch spring set bolts (1), clutch springs

2
and clutch pressure plate (2).

NOTE
3
Loosen the clutch spring set bolts little by
little and diagonally.

IH23K1530010-01

6) Disconnect radiator outlet hose (1) and bypass hose 1

(2). 2

IH23K1530011-01
IH23K1530019-01
7) Remove clutch cover (1).
10) Remove clutch release rack (1), bearing (2) and
circlip (3) from the clutch pressure plate.

1 2 1

3
IH23K1530017-02

IH23K1530012-02
 Clutch: 5C-7

11) Remove clutch drive plates (1) and driven plates (2). 14) Remove lock washer (1) and clutch sleeve hub (2).

1
1

2
2

IG12K1530019-01

15) Remove thrust washer (1) and primary driven gear

IH23K1530020-01
assembly (2).
12) Flatten lock washer (1).

1
2

IH23K1530022-01

16) Remove spacer (1) and thrust washer (2).

IH23K1530021-01

13) Hold clutch sleeve hub with the special tool and
remove clutch sleeve hub nut (1).
1
Special tool 2
(A): 09920–53740

IG12K1530021-01

(A)
IG12K1530018-01
5C-8 Clutch:

Clutch Installation 5) Install clutch sleeve hub (1), and then install a new
BENM23K15306008 lock washer (2) so that section “A” of lock washer
and section “B” of clutch sleeve hub are aligned.
! WARNING
Primary drive gear and primary driven gear
are combination gear.

Please replace with proper combination.

Refer to “Primary Drive Gear and Primary 1
2
Driven Gear Inspection / Selection of Gear”
(Page 5C-14) for reference / selection of the
gear.

1) Apply molybdenum oil solution to the spacer side of “A” “B”

the thrust washer (1) and outside of the spacer (2).
“A”: Assembly lubrication (Molybdenum oil
solution)
IH23K1530024-01
2) Install the thrust washer and spacer. 6) Apply engine oil to contacting surface and thread
part of clutch sleeve hub nut and install it.
7) Hold clutch sleeve hub with the special tool and
tighten clutch sleeve hub nut (1) to specified torque.
2, “A”
1, “A”
Special tool
(A): 09920–53740
Tightening torque
Clutch sleeve hub nut (a): 75 N·m (7.64 kgf-m,
55.3 lbf-ft)

IG12K1530022-02
(A)
3) Install the primary driven gear assembly (1). 1, (a)
4) Apply molybdenum oil solution to the primary driven
gear assembly side of the thrust washer (2).
“A”: Assembly lubrication (Molybdenum oil
solution)

IG12K1530026-01

2, (a)

IH23K1530023-01
 Clutch: 5C-9

8) Bend the lock washer to lock nut securely. 11) Apply engine oil to the bearing.
9) Apply engine oil to the clutch drive plates and driven 12) Install circlip (1), bearing (2) and clutch release rack
plates. (3) into clutch pressure plate (4).
10) Insert clutch drive plates and driven plates one by
one into the clutch sleeve hub (1) in the prescribed 2 1
order.

3
IH23K1530017-02

13) Install clutch pressure plate (1), clutch springs and

clutch spring set bolts (2).
14) Tighten clutch spring set bolts to specified torque.

NOTE
IH23K1530025-01
Tighten clutch spring set bolts little by little
and diagonally.
2 2

Tightening torque
Clutch spring set bolt (a): 5.0 N·m (0.51 kgf-m,
3.70 lbf-ft)

2, (a)
1

3
IG12K1530028-01

2. Clutch drive plate 3. Clutch driven plate

2, (a)

IH23K1530026-01
5C-10 Clutch:

15) Install a new gasket (1), a new O-ring (2) and dowel 18) Install clutch release arm (1).
pins (3).
NOTE
Remove any play of clutch release camshaft
by turning it clockwise, and then install
clutch release arm to release camshaft within
1 the range “a” shown in the figure.

19) Tighten clutch release arm bolt to specified torque.

Tightening torque
Clutch release arm bolt (a): 10 N·m (1.0 kgf-m,
3 7.3 lbf-ft)

2 3 “a”
IH23K1530018-02

16) Apply engine oil to clutch release rack gear (1) and
face the gear backward.
1

(a)

1 IG12K1530035-01

20) Install clutch cable end (1) to the clutch release arm
(2).
21) Install clutch cable stopper (3) and tighten the bolts
to specified torque.
Tightening torque
IG12K1530032-01 Clutch cable stopper bolt (a): 10 N·m (1.0 kgf-m,
17) Install clutch cover (1) and tighten the bolts to 7.3 lbf-ft)
specified torque.
Tightening torque 3
Clutch cover bolt (a): 10 N·m (1.0 kgf-m, 7.3 lbf- 1
ft)

2
(a) 1
(a)

IH23K3530036-02

22) Install the removed parts.

23) Adjust clutch cable play. (Page 5C-2)
24) Pour engine oil through the oil filler hole. (Page
1E-5)
25) Pour engine coolant to the radiator inlet and bleed
the air trapped in the cooling circuit. (Page 1F-5)
IH23K1530027-01
 Clutch: 5C-11

Clutch Cover Disassembly and Reassembly Reassembly

BENM23K15306009 Reassemble clutch cover component part in reverse
Refer to “Clutch Removal” (Page 5C-6) and “Clutch order of disassembly. Pay attention to the following
Installation” (Page 5C-8). points:
Disassembly • Apply grease to the lip of new oil seals.
1) Remove crankshaft oil seal (2). “A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)
• Install the oil seal until it seats in the clutch cover hole.

“A”
1

IH23K3530039-01

2) Pull out clutch release camshaft oil seal (1) and

washer with clutch release camshaft (2). IH23K3530037-01

2 “A”

IG12K1530037-01
IG12K1530039-01

• After installing clutch release camshaft (1), check

clutch release camshaft operation.

IG12K1530040-01
5C-12 Clutch:

Primary Drive Gear Removal and Installation NOTE

BENM23K15306010
Removal Wipe off engine oil from the drive and driven
plates with a clean rag.
1) Remove the following part:
• Clutch component. “Clutch Removal” (Page 5C-6) Special tool
• Oil pump driven gear and oil pump drive gear. (A): 09900–20102
(Page 1E-8)
Drive plate thickness
2) Remove primary drive gear (1). [Limit]: 2.6 mm (0.10 in)

1 (A)

IE31J1530086-01

Measure the claw width of drive plates with vernier

IJ23K1530002-01
calipers. Replace drive plates that have worn down to
the limit.
3) Remove the key (1).
Special tool
(A): 09900–20102
Drive plate claw width
1
With groove [Limit]: 11.4 mm (0.449 in)
Without groove [Limit]: 11.3 mm (0.445 in)

(A)

IJ23K1530003-01

Installation

! WARNING IE31J1530087-01

Measure each driven plate for distortion with a thickness

Primary drive gear and primary driven gear gauge and surface plate.
are combination gear. Replace driven plates which exceed the limit.

Please replace with proper combination. Special tool

Refer to “Primary Drive Gear and Primary (A): 09900–20803
Driven Gear Inspection / Selection of Gear” Driven plate distortion
(Page 5C-14) for reference / selection of the [Limit]: 0.10 mm (0.004 in)
gear.

Install primary drive gear in the reverse order of removal.

(A)

Clutch Parts Inspection

BENM23K15306011
Refer to “Clutch Removal” (Page 5C-6), “Clutch
Installation” (Page 5C-8) and “Clutch Cover Disassembly
and Reassembly” (Page 5C-11).
IE31J1530088-01
Clutch Drive / Driven Plate
Measure thickness of drive plates with a vernier calipers.
If drive plate thickness is found to have reached the limit,
replace it with a new one.
 Clutch: 5C-13

Clutch Spring Clutch Sleeve Hub / Primary Driven Gear Assembly

Measure free length of each coil spring with a vernier Inspect the slot of clutch sleeve hub (1) and primary
calipers, and compare the length with the specified limit. driven gear assembly (2) for damage or wear caused by
Replace all springs if any spring is not within the limit. clutch plates. If necessary, replace it with a new one.
Inspect springs of primary driven gear assembly for any
Special tool
damages. If necessary, replace primary driven gear
(A): 09900–20102
assembly with a new one.
Clutch spring free length
[Limit]: 30.9 mm (1.22 in) ! WARNING
Primary drive gear and primary driven gear
are combination gear.
(A)
Please replace with proper combination.
Refer to “Primary Drive Gear and Primary
Driven Gear Inspection / Selection of Gear”
(Page 5C-14) for reference / selection of the
gear.

IE31J1530089-01

Clutch Release Bearing

Inspect clutch release bearing (1) for any abnormality, 2
especially cracks. When removing the bearing from 1
clutch, decide whether it can be reused or if it should be
replaced.
Smooth engagement and disengagement of the clutch
depends on the condition of this bearing.

IH23K1530014-01

Clutch Release Camshaft

Inspect clutch release camshaft for wear or bend. If
necessary, replace it with a new one.

IE31J1140298-01

IH23K1530016-01
5C-14 Clutch:

Primary Drive Gear Primary Drive Gear and Primary Driven Gear
Inspect primary drive gear for wear and damage. If there Inspection / Selection of Gear
is an abnormality, replace it with the new one. BENM23K15306012

! WARNING Inspection
See “Clutch Parts Inspection” (Page 5C-12).
Primary drive gear and primary driven gear
are combination gear. Selection of Gear
Select the combination primary drive gear (1) and
Please replace with proper combination. primary driven gear (2) with the same color.
Refer to “Primary Drive Gear and Primary Combination Primary Drive Gear Primary Driven Gear
Driven Gear Inspection / Selection of Gear” Identification Color Identification Color
(Page 5C-14) for reference / selection of the [A] [B]
gear. Green Green
Pink Pink

[A]
IJ23K1530004-01

IJ23K1530005-01

[A]: Green or Pink

[B]
IJ23K1530006-01

[B]: Green or Pink

 Clutch: 5C-15

Specifications
Tightening Torque Specifications
BENM23K15307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Clutch lever pivot bolt 6.5 0.66 4.80 (Page 5C-4)
Clutch lever pivot nut 6.5 0.66 4.80 (Page 5C-4)
Clutch sleeve hub nut 75 7.64 55.3 (Page 5C-8)
Clutch spring set bolt 5.0 0.51 3.70 (Page 5C-9)
Clutch cover bolt 10 1.0 7.3 (Page 5C-10)
Clutch release arm bolt 10 1.0 7.3 (Page 5C-10)
Clutch cable stopper bolt 10 1.0 7.3 (Page 5C-10)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Clutch Components” (Page 5C-5)
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Recommended Service Material
BENM23K15308001
Material SUZUKI recommended product or Specification Note
Assembly lubrication Molybdenum oil solution — (Page 5C-8) / (Page 5C-
8)
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 5C-4) / (Page 5C-
11)

NOTE
Required service material(s) is also described in:
“Clutch Components” (Page 5C-5)

Special Tool
BENM23K15308002
09900–20102 09900–20803
Vernier calipers (200 mm) Thickness gauge
(Page 5C-12) / (Page 5C-12)
(Page 5C-12) /
(Page 5C-13)

09920–53740
Clutch sleeve hub holder
(Page 5C-7) /
(Page 5C-8)
5C-16 Clutch:

Section 6
Steering
CONTENTS
Precautions .................................................6-1
Precautions............................................................. 6-1
Precautions for Steering ....................................... 6-1
Steering General Diagnosis.................... 6A-1
Diagnostic Information and Procedures............6A-1
Steering Symptom Diagnosis.............................. 6A-1
Steering / Handlebar................................ 6B-1
Repair Instructions ..............................................6B-1
Handlebar Components ...................................... 6B-1
Handlebar Construction ...................................... 6B-2
Handlebar Removal and Installation ................... 6B-4
Handlebar Inspection ........................................ 6B-11
Steering Stem Components .............................. 6B-12
Table of Contents 6- i
Steering On-Vehicle Inspection.........................6B-13
Steering Tension Adjustment ............................6B-13
Steering Stem Upper Bracket Removal and
Installation .......................................................6B-14
Steering Stem Upper Bracket Inspection ..........6B-17
Steering Stem Removal and Installation ...........6B-18
Steering Stem Removal and Installation ...........6B-20
Steering Stem Inspection ..................................6B-23
Steering Stem Bearing Removal and
Installation .......................................................6B-23
Specifications .....................................................6B-25
Tightening Torque Specifications......................6B-25
Special Tools and Equipment ...........................6B-26
Recommended Service Material .......................6B-26
Special Tool ......................................................6B-26
6
6-1 Precautions:

Precautions
Steering

Precautions
Precautions for Steering
BENM23K16000001
Refer to “General Precautions” in Section 00 (Page 00-1).

Steering General Diagnosis
Steering
Diagnostic Information and Procedures
Steering Symptom Diagnosis
Condition Possible cause
Heavy steering Over tightened steering stem nut.
Broken steering stem steel ball/race.
Distorted steering stem.
Not enough pressure in tires.
Wobbly handlebar Loss of balance between right and left
front forks.
Distorted front fork.
Distorted front axle or crooked tire.
Loose steering stem nut.
Worn or incorrect tire.
Incorrect tire pressure.
Worn steering stem steel ball/race.
Steering General Diagnosis: 6A-1
BENM23K16104001
Correction / Reference Item
Adjust. (Page 6B-13)
Replace. (Page 6B-23)
Replace. (Page 6B-18)
Adjust. (Page 2D-12)
Replace fork, adjust fork oil level or replace
fork spring.
• Replace fork: (Page 2B-2)
• Adjust fork oil level or replace fork spring:
(Page 2B-4)
Repair or replace. (Page 2B-2)
Replace. (Page 2D-3)
(Page 2D-13)
Adjust. (Page 6B-13)
Replace. (Page 2D-13)
Adjust. (Page 2D-12)
Replace. (Page 6B-23)
6B-1 Steering / Handlebar:

Steering / Handlebar
Steering

Repair Instructions
Handlebar Components
BENM23K16206001

1
7
5

8
[A ]
10

6 (a)
9

[A ]
GSX R125 Model

GSX S125 Model

IM23K1620001-01

[A]: Apply handle grip glue.
1. Throttle grip
2. Right handle switch
3. Left handle switch
4. Left handlebar grip
5. Right handlebar 10. Handlebar balancer
6. Left handlebar : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
7. Handlebar bolt : Apply water resistant grease EP2.
8. Handlebar nut
9. Handlebar
 Steering / Handlebar: 6B-2

Handlebar Construction
BENM23K16206002
GSX R 125 Model

[A]

(c) [B]

[C] (a)
2
4

5
1 3 1
(b)
(e)

[E]
“a”

(c)

(c) (e)
(d)

[C]

[D]
IM23K1620006-03

[A]: Face the triangle mark forward. 3. Cover clutch lever : 1.2 Nm (0.12 kgf-m, 0.90 lbf-ft)
[B]: Apply handle grip glue. 4. Clutch lever : 6.5 Nm (0.66 kgf-m, 4.80 lbf-ft)
[C]: Tighten the front bolt first. 5. Clutch lever holder : Apply grease to sliding surface.
[D]: Align the punch mark of the right handlebar with the “a”: 2.0 – 3.0 mm (0.08 – 0.11 in) : Apply water resistant grease EP2.
edge of front brake master cylinder holder.
[E]: Align the mating surface of the clutch lever holder with : 10 Nm (1.0 kgf-m, 7.5 lbf-ft) : Do not reuse.
the punch mark of left handlebar.
1. Handlebar balancer : 1.0 Nm (0.10 kgf-m, 0.75 lbf-ft)
2. Front brake lever : 6.0 Nm (0.61 kgf-m, 4.45 lbf-ft)
6B-3 Steering / Handlebar:

GSX S 125 Model

[F]

(f)

[A]

[B]
[C] (a)

1 4 3 1
(b)
[C] (c) (e)

“a”
(a)

[E]

(c)

(d)

(c)
(d)

[D]

IM23K1620007-02

[A]: Face the triangle mark forward. 2. Front brake lever : 1.2 Nm (0.12 kgf-m, 0.90 lbf-ft)
[B]: Apply handle grip glue. 3. Clutch lever : 6.5 Nm (0.66 kgf-m, 4.80 lbf-ft)
[C]: Tighten the front bolt first. 4. Clutch lever holder : 23 Nm (2.34 kgf-m, 16.9 lbf-ft)
[D]: Align the punch mark of the handlebar with the edge of “a”: 2.0 – 3.0 mm (0.08 – 0.11 in) : Apply grease to sliding surface.
front brake master cylinder holder.
[E]: Align the mating surface of the clutch lever holder with : 10 Nm (1.0 kgf-m, 7.5 lbf-ft) : Apply water resistant grease EP2.
the punch mark of handlebar.
[F]: Align the punch mark the handlebar with upper face of : 1.0 Nm (0.10 kgf-m, 0.75 lbf-ft) : Do not reuse.
lower handle holder.
1. Handlebar balancer : 6.0 Nm (0.61 kgf-m, 4.45 lbf-ft)
 Steering / Handlebar: 6B-4

Handlebar Removal and Installation Left side

BENM23K16206003
1) Remove the following parts from the left side of the
Removal handlebar.
GSX R 125 Model a) Handlebar balancer (1)
Right side b) Left handle switch (2)
NOTICE c) Left handlebar grip (3)

Do not turn the front brake master cylinder

upside down.

1) Remove the following parts from the right side of the

handlebar.
a) Handlebar balancer (1)
b) Right handle switch (2)
c) Throttle grip (3) 1
d) Front brake master cylinder assembly (4)

2
3
IM23K1620002-01

4 2) Disconnect the clutch cable from the clutch lever.

3 (Page 5C-3)
3) Remove clutch switch coupler. (Page 5C-2)
1 4) Remove the clutch lever holder bolt (1) for remove
the clutch lever assembly.

2
1

IM23K1620003-01

2) Remove the right handlebar (1).

IM23K1620004-01

IH23K1620004-01
6B-5 Steering / Handlebar:

5) Remove the left handlebar (1). 5) Apply grease to the end of the throttle cables and
cable pulley.
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

“A”

IH23K1620007-01 “A”

Installation
IK23K4620002-01
Right side
6) Install the throttle cable (1) to the throttle grip (2).
1) Install the right handlebar (1) and install the
handlebar bolt (2) and a new handlebar nut (3).
2) Tighten the right handlebar nut to specified torque.
Tightening torque 1
Right handlebar bolt (a): 23 N·m (2.34 kgf-m, 2
16.9 lbf-ft)

IK23K4620003-01
1
7) Insert the projection (1) of the right handle switch
into the hole (2) of the handlebar, and then tighten
the right handle switch screws.
3, (a)
1
IH23K1620008-01

3) Install the front brake master cylinder assembly.

(Page 4A-22)
4) Apply grease onto the handlebars before installing
the throttle grip.
“A”: Grease 99000–25350 (SUZUKI WATER
RESISTANT GREASE EP2) 2

“A” IK23K4620004-01
IE31J1620008-02
 Steering / Handlebar: 6B-6

8) Install the right handlebar balancer (1) and adjust
clearance between the throttle grip and handlebar
balancer as follows.
9) Tighten the handlebar balancer screw (2).
Tightening torque
Handlebar balancer screw (a): 5.5 N·m (0.56 kgf-
m, 4.05 lbf-ft)
3) Install the clutch lever assembly as follows.
a) Match the clutch lever holder (1) with the punch
mark (2) on the handlebar (3).
b) Tighten the clutch lever holder bolt (4) to the
specified torque.
Tightening torque
Clutch lever holder bolt (a): 6.0 N·m (0.61 kgf-m,
4.45 lbf-ft)

“a” 3

1
2
1

2, (a)

IH23K1620012-01
3
“a”: 2.0 – 3.0 mm (0.08 – 0.11 in)
1
4, (a)
10) Install the right rear view mirror.
IM23K1620005-01

Left side 4) Install the clutch cable to the clutch lever. (Page
5C-3)
1) Install the left handlebar (1) and install the handlebar
bolt (2), clutch cable guide (3) and a new handlebar 5) Insert the projection (1) of the left handle switch into
nut (4). the hole (2) of the handlebar, and then tighten the left
handle switch screws.
2) Tighten the left handlebar nut to specified torque.
Tightening torque
Left handlebar bolt (a): 23 N·m (2.34 kgf-m, 16.9
lbf-ft)

3 1
1

2
2, (a)

IM23K1620016-02
IH23K1620013-01
6B-7 Steering / Handlebar:

6) Apply handle grip glue to both the left handlebar (1) Removal
outer surface on which the grip is being fitted and GSX S 125 Model
internal surface of the left handlebar grip (2) evenly. 1) Remove the following parts from the right side of the
“A”: Adhesive (Handle grip glue) handlebar.
a) Rear view mirror (1)
b) Handlebar balancer (2)
c) Right handle switch (3)
d) Throttle grip (4)
e) Front brake master cylinder assembly (5)

5
1 2
IE31J1620012-01

7) Install the left handlebar balancer (1) and adjust

clearance between the left grip and handlebar
balancer as follows.
8) Tighten the handlebar balancer screw (2).
3 4
Tightening torque
Handlebar balancer screw (a): 5.5 N·m (0.56 kgf-
m, 4.05 lbf-ft)

IH23K2620031-01

“a” 2) Remove the following parts from the left side of the
handlebar.
a) Rear view mirror (1)
b) Handlebar balancer (2)
c) Left handle switch (3)
d) Left handlebar grip (4)
2, (a)

IH23K1620016-01

“a”: 2.0 – 3.0 mm (0.08 – 0.11 in)

1
9) Install the left rear view mirror.
2

4
3
IM23K1620012-01
 Steering / Handlebar: 6B-8

3) Disconnect the clutch cable from the clutch lever. Installation

(Page 5C-3)
4) Remove clutch switch coupler. (Page 5C-2)
5) Remove the clutch lever holder bolt (1) for remove
the clutch lever assembly.
1) Install the handlebar (1) and install the handlebar
bolt (2).
2) Tighten the handlebar bolt to specified torque.
Tightening torque
Handlebar holder clamp bolt (a): 23 N·m (2.34
kgf-m, 16.9 lbf-ft)

2, (a)
1

IM23K1620013-01

6) Remove handlebar holder clamp bolt and then

remove handlebar (1).

1 IH23K2620006-01

Right side
1) Install the front brake master cylinder assembly.
(Page 4A-22)
2) Apply grease onto the handlebars before installing
the throttle grip.
“A”: Grease 99000–25350 (SUZUKI WATER
RESISTANT GREASE EP2)

IH23K2620004-01 “A”
IE31J1620008-02
6B-9 Steering / Handlebar:

3) Apply grease to the end of the throttle cables and 5) Insert the projection (1) of the right handle switch
cable pulley. into the hole (2) of the handlebar, and then tighten
the right handle switch screws.
“A”: Grease 99000–25011 (SUZUKI SUPER
GREASE A)

“A” 1

2
“A”

IH23K2620018-01

4) Install the throttle cable (1) to the throttle grip (2). IH23K2620020-01

6) Install the right handlebar balancer (1) and adjust

2 clearance between the throttle grip and handlebar
1 balancer as follows.
7) Tighten the handlebar balancer screw (2).
Tightening torque
Handlebar balancer screw (a): 5.5 N·m (0.56 kgf-
m, 4.05 lbf-ft)

“a”

IH23K2620019-01

2, (a)

IH23K1620012-01

“a”: 2.0 – 3.0 mm (0.08 – 0.11 in)

 Steering / Handlebar: 6B-10

8) Install the rear view mirror (1) and tightening the rear 2) Install the clutch cable to the clutch lever. (Page
view mirror bolt (2). 5C-3)
3) Insert the projection (1) of the left handle switch into
the hole (2) of the handlebar, and then tighten the left
handle switch screws.
1

IH23K2620005-02

Left side 2
1) Install the clutch lever assembly as follows.
a) Match mating surface of clutch lever holder (1)
with the punch mark (2) on the handlebar (3).
b) Tighten the clutch lever holder bolt (4) to the
specified torque. IM23K1620016-02

4) Apply handle grip glue to both the left handlebar (1)

3
outer surface on which the grip is being fitted and
internal surface of the left handlebar grip (2) evenly.
“A”: Adhesive (Handle grip glue)

2 1

IE31J1620012-01
3
1
4, (a)
IM23K1620014-01

Tightening torque
Clutch lever holder bolt (a): 6.0 N·m (0.61 kgf-m,
4.45 lbf-ft)
6B-11 Steering / Handlebar:

5) Install the left handlebar balancer (1) and adjust Handlebar Inspection
clearance between the left grip and handlebar BENM23K16206004

balancer as follows. GSX R 125 Model

Refer to “Handlebar Removal and Installation” (Page 6B-
6) Tighten the handlebar balancer screw (2). 4).
Tightening torque Inspect the handlebars for distortion and damage.
Handlebar balancer screw (a): 5.5 N·m (0.56 kgf- If any defect is found, replace the handlebar with a new
m, 4.05 lbf-ft) one.

“a”

IM23K1620015-01
2, (a)
GSX S 125 Model
Refer to “Handlebar Removal and Installation” (Page 6B-
1
4).
Inspect the handlebars for distortion and damage.
IH23K1620016-01
If any defect is found, replace the handlebar with a new
one.
“a”: 2.0 – 3.0 mm (0.08 – 0.11 in)

7) Install the rear view mirror (1) and tightening the rear
view mirror bolt (2).

IH23K2620007-01
2

IH23K2620005-02
 Steering / Handlebar: 6B-12

Steering Stem Components

BENM23K16206005

GSX S125

(a) 13

1 (b)

14

2
(a)

GSX R125

1 (b)

(a)

3 (c)

4
5
12
6

11 7

8
(a)
9

10
IM23K1620009-01
6B-13 Steering / Handlebar:

1. Steering stem head nut
2. Steering stem upper bracket
3. Steering stem nut
4. Dust cover
5. Steering stem upper steel ball outer race
6. Steering stem upper steel ball
7. Steering stem upper steel ball inner race
8. Steering stem lower steel ball inner race
9. Steering stem lower steel ball
10. Steering stem lower steel ball outer race
11. Steering stem lower bracket
12. Steering lock plate
13. Handle holder bolt
14. Handle upper holder
: 23 Nm (2.3 kgf-m, 17.0 lbf-ft)
: 30 Nm (3.1 kgf-m, 22.5 lbf-ft)
: 20 Nm (2.0 kgf-m, 15.0 lbf-ft) → turn
counterclockwise 1/4 → 5.0 Nm (0.51 kgf-m,
3.70 lbf-ft)
: Apply grease.
: Do not reuse.

Steering On-Vehicle Inspection GSX S 125 Model

BENM23K16206006
Steering should be adjusted properly for smooth turning
of handlebars and safe running. Overtightened steering
prevents smooth turning of the handlebars and loose
steering will cause poor stability.
1) Check that there is no play in the front fork.
a) Support the motorcycle with its front wheel off
the ground, grasp the bottoms of the front forks
and move the forks back-and-forth to check
there is no play in the stem bearings.

IH23K2620009-01

2) If play is found, readjust the steering. (Page 6B-

13)

Steering Tension Adjustment

BENM23K16206007
1) By supporting the motorcycle with a jack, lift the front
wheel until it is off the ground 20 – 30 mm (0.8 – 1.2
in).
2) Check to make sure that the cables and wire
harnesses are properly routed.
IH23K1620020-01
3) With the front wheel in the straight ahead state, hitch
b) With the front wheel on the ground and applying the spring scale (special tool) on one handlebar grip
the front brake(s), move the handlebar back- end as shown in the figure and read the graduation
and-forth and up-and-down to check there is no when the handlebars start moving.
play in the stem bearings.
GSX R 125 Model Special tool
(A): 09940–92720
Steering tension initial force
[Standard]: 2 – 5 N (0.20 – 0.51 kgf, 0.45 – 1.12 lbf)

(A)

ID26J1620028-01
IH23K1620021-01
 Steering / Handlebar: 6B-14

4) Do the same on the other grip end.
5) If the initial force reading on the scale when the
handlebar starts turning is either too heavy or too
light, adjust the tension until it satisfies the
specification as follows.
a) First, loosen the front fork upper clamp bolts and
steering stem head nut, and then adjust the
steering stem nut by loosening or tightening it.
Special tool
(A): 09910–60620
GSX R 125 Model
b) Tighten the steering stem head nut, front fork
upper clamp bolts to the specified torque, and
recheck the initial force with the spring scale
according to the previously described procedure.
Tightening torque
Steering stem head nut: 30 N·m (3.1 kgf-m,
22.5 lbf-ft)
Front fork upper clamp bolt: 23 N·m (2.34
kgf-m, 16.9 lbf-ft)
c) If the initial force is found within the specified
range, then hold the front fork outer tube legs,
move them back-and-forth and make sure that
the steering is not loose.

IH23K1620039-01

IK23K4620008-01

GSX S 125 Model

Steering Stem Upper Bracket Removal and
Installation
BENM23K16206008

Removal
GSX R 125 Model

NOTE
Do not turn the front brake master cylinder
upside down.
(A) 1) Support the motorcycle with stand.
2) Remove the headlight assembly. (Page 9B-2)
3) Disconnect the clutch cable from the clutch lever.
IH23K2620010-01 (Page 5C-3)
6B-15 Steering / Handlebar:

4) Remove the front brake master cylinder assembly 7) Loosen the front fork lower clamp bolts (1), and then
(1) and disconnect the front brake light switch remove the steering stem head nut (2), washer (3)
couplers (2). and steering stem upper bracket assembly (4).

1
2

4
1
1

IK23K4620009-01
IH23K1620023-01

GSX S 125 Model

NOTE
Do not turn the front brake master cylinder
upside down.

1) Support the motorcycle with center stand.

2) Remove the headlight assembly. (Page 9B-2)
3) Disconnect the clutch cable from the clutch lever.
(Page 5C-3)
2 4) Remove the front brake master cylinder assembly
(1) and disconnect the front brake light switch
couplers (2).
IH23K1620041-02

5) Disconnect the following lead wire couplers.

• Left handle switch
• Clutch lever position switch 1
• Ignition switch
• Right handle switch
6) Remove the left handlebar (1) and right handlebar
(2).

2
IH23K2620011-01
1

IH23K1620024-02
 Steering / Handlebar: 6B-16

7) Loosen the front fork lower clamp bolts (1), and then
remove the steering stem head nut (2), washer (3)
and steering stem upper bracket assembly (4).

4 2
2
3

1
1
IH23K2620012-01

5) Disconnect the following lead wire couplers.

• Left handle switch (1)
• Clutch lever position switch (2)
• Right handle switch (3) IH23K2620015-01

Installation
1) Install the steering stem upper bracket assembly (1),
washer (2) and steering stem head nut (3).
2) Tighten the steering stem head nut and front fork
upper clamp bolts (4) to the specified torque.
Tightening torque
Steering stem head nut (a): 30 N·m (3.1 kgf-m,
1 22.5 lbf-ft)
2 Front fork upper clamp bolt (b): 23 N·m (2.34
3 kgf-m, 16.9 lbf-ft)
IH23K2620013-01

6) Remove the handlebar (1). 1

3, (a)
1 2

4, (b) 4, (b)

IH23K2620016-01

IH23K2620014-02
6B-17 Steering / Handlebar:

3) Install the handlebar (1) and handlebar holder clamp Steering Stem Upper Bracket Inspection
and then tighten handlebar holder clamp bolts to BENM23K16206009

specified torque. Refer to “Handlebar Removal and GSX R 125 Model

Installation” (Page 6B-4). Refer to “Steering Stem Upper Bracket Removal and
Installation” (Page 6B-14).
Inspect the steering stem upper bracket for damage.
1 If any damage is found, replace the steering stem upper
bracket with a new one.

IH23K2620014-02

4) Connect front brake light switch couplers (1) and IM23K1620010-01

install the front brake master cylinder assembly.

Refer to “Front Brake Master Cylinder Assembly
Removal and Installation” in Section 4A (Page 4A-
22).
GSX S 125 Model
Refer to “Steering Stem Upper Bracket Removal and
Installation” (Page 6B-14).
Inspect the steering stem upper bracket for damage.
If any damage is found, replace the steering stem upper
bracket with a new one.

IH23K2620017-01

5) Install the headlight assembly. (Page 9B-2)

6) Adjust the clutch cable play. (Page 5C-2) IH23K2620024-01
 Steering / Handlebar: 6B-18

Steering Stem Removal and Installation 6) Remove the dust cover (1) and steering stem upper
BENM23K16206010 steel ball outer race (2).
GSX R 125 Model

Removal
1) Remove the front forks. (Page 2B-2) 1 2
2) Remove the right and left handlebars. (Page 6B-
14)
3) Remove the steering stem head nut (1) and washer
(2), and then remove the steering stem upper
bracket assembly (3).

3 IK23K4620012-01

7) Remove the steering stem upper (1) and lower (2)

steel balls.
1
2 Number of steel ball
Upper 23 pieces
Lower 28 pieces

IK23K4620010-01

4) While holding the steering stem lower bracket,

remove the steering stem nut (1) using the special 1 2
tool.
Special tool
(A): 09940–14920
5) Remove the steering stem lower bracket.

IK23K4620013-01

(A)

IK23K4620011-02
6B-19 Steering / Handlebar:

Installation 4) Set the steering stem lower bracket to the frame.

1) Apply grease to the steering stem upper and lower 5) Install the steering stem nut (1) as shown below.
inner races. a) Tighten the steering stem nut to 20 Nm (2.0 kgf-
“A”: Grease 99000–25011 (SUZUKI SUPER m, 15.0 lbf-ft) with the special tools.
GREASE A) b) Loosen the steering stem nut 1/4 turn “a”.
c) Tighten the steering stem nut to 5.0 Nm (0.51
“A” kgf-m, 3.70 lbf-ft) with the special tools.
Special tool
(A): 09940–14920
Tightening torque
Steering stem nut (a): 20 Nm (2.0 kgf-m, 15.0
lbf-ft) → turn counterclockwise 1/4 → 5.0 Nm
“A” (0.51 kgf-m, 3.70 lbf-ft)
IE29J1620043-01

2) Install new steering stem upper (1) and lower (2)

steel balls.

Number of steel ball

Upper 23 pieces
Lower 28 pieces (A)

1, (a)

1 2

IK23K4620016-02

“a”

IK23K4620014-01

3) Install a new steering stem upper steel ball outer

race (1) and a new dust cover (2).

IF40J2620007-01

1 2

IK23K4620015-01
 Steering / Handlebar: 6B-20

6) Turn the steering stem (1) quickly to the left and right 12) Pass the cables correctly and install the headlight
more than three times to seat the stem properly. housing brace. Refer to “Throttle Cable Routing
Diagram” in Section 1D (Page 1D-1).
13) Check the steering tension. (Page 6B-13)

Steering Stem Removal and Installation

BENM23K16206011
1 GSX S 125 Model

Removal
1) Remove the front forks. (Page 2B-2)
2) Remove handlebar (1) and steering stem upper
bracket (2). (Page 6B-14)

1
IH23K1620035-01

7) In this condition, check that the steering stem can

turn smoothly without rattle and stiffness. If there is a 2
rattle or heavy movement, readjust the tightness by
the stem nut.

NOTE
This adjustment may vary depending on the
motorcycle individually.

8) Install the front forks (4), handle bar (5), steering lock
plate (6), steering stem upper bracket (1), washer (2)
and steering stem head nut (3) temporarily. IH23K2620025-01

9) Tighten the steering stem head nut to the specified 3) While holding the steering stem lower bracket,
torque. remove the steering stem nut (1) using the special
tool.
Tightening torque
Steering stem head nut (a): 30 N·m (3.1 kgf-m, Special tool
22.5 lbf-ft) (A): 09940–14920
4) Remove the steering stem lower bracket.

5
1
5

3, (a) (A)
2

6
4 1

IH23K1620044-01

10) Install the handlebars. (Page 6B-14)

IK23K4620011-02
11) Install the front forks in proper position. (Page 2B-
2)
6B-21 Steering / Handlebar:

5) Remove the dust cover (1) and steering stem upper Installation
steel ball outer race (2). 1) Apply grease to the steering stem upper and lower
inner races.
“A”: Grease 99000–25011 (SUZUKI SUPER
1 2 GREASE A)

“A”

“A”
IE29J1620043-01

IH23K2620026-02 2) Install new steering stem upper (1) and lower (2)
6) Remove the steering stem upper (1) and lower (2) steel balls.
steel balls.
Number of steel ball
Number of steel ball Upper 23 pieces
Upper 23 pieces Lower 28 pieces
Lower 28 pieces

1 2
1 2

IH23K2620027-02

IH23K2620027-02 3) Install a new steering stem upper steel ball outer

race (1) and a new dust cover (2).

1 2

IH23K2620026-02
 Steering / Handlebar: 6B-22

4) Set the steering stem lower bracket to the frame.
5) Install the steering stem nut (1) as shown below.
a) Tighten the steering stem nut to 20 Nm (2.0 kgf-
m, 15.0 lbf-ft) with the special tools.
b) Loosen the steering stem nut 1/4 turn “a”.
c) Tighten the steering stem nut to 5.0 Nm (0.51
kgf-m, 3.70 lbf-ft) with the special tools.
Special tool
(A): 09940–14920
Tightening torque
Steering stem nut (a): 20 Nm (2.0 kgf-m, 15.0
lbf-ft) → turn counterclockwise 1/4 → 5.0 Nm
(0.51 kgf-m, 3.70 lbf-ft)
(A)
7) In this condition, check that the steering stem can
turn smoothly without rattle and stiffness. If there is a
rattle or heavy movement, readjust the tightness by
the stem nut.
NOTE
This adjustment may vary depending on the
motorcycle individually.
8) Install the front forks (1) in proper position. (Page
2B-2)
9) Install the steering lock plate (2), steering stem
upper bracket (3), washer (4) and steering stem
head nut (5) temporarily.
10) Install the handlebars (6). (Page 6B-14)
11) Tighten the steering stem head nut to the specified
torque.
Tightening torque
Steering stem head nut (a): 30 N·m (3.1 kgf-m,
22.5 lbf-ft)

1, (a)

3 1 1
IK23K4620016-02
5, (a) 4

“a”
2

IH23K2620029-01

12) Pass the cables correctly and install the headlight

housing brace. Refer to “Throttle Cable Routing
Diagram” in Section 1D (Page 1D-1).
IF40J2620007-01
13) Check the steering tension. (Page 6B-13)
6) Turn the steering stem (1) quickly to the left and right
more than three times to seat the stem properly.

IH23K2620028-01
6B-23 Steering / Handlebar:

Steering Stem Inspection Steering Stem Bearing Removal and Installation

BENM23K16206012 BENM23K16206013
Refer to “Steering Stem Removal and Installation” (Page
6B-18). Removal
Inspect the removed parts for the following 1) Remove the dust cover, steering stem upper steel
abnormalities: ball outer race and steering stem upper/lower steel
• Distortion of the steering stem balls. (Page 6B-18)
• Steering stem steel ball wear or damage 2) Remove the steering stem lower steel ball outer race
• Abnormal bearing noise using a chisel.
• Steering stem steel ball race wear or damage
If any abnormal points are found, replace defective parts
with new ones.

I649G1620033-02

3) Drive out the steering stem upper and lower steel

ball inner races using a suitable bar.

IK23K4620017-02

GSX R125

IE29J1620050-01

GSX S125

IM23K1620011-01
 Steering / Handlebar: 6B-24

Installation
1) Press in new steering stem upper / lower steel ball
inner races using the special tool.
Special tool
(A): 09941–34513

(A)

IF34J1620041-01

2) Press in a new steering stem lower steel ball outer

race using the special tool.
Special tool
(A): 09941–74911

(A)

IF34J1620043-01

3) Apply grease to the steering stem upper/lower steel

ball races, and then install new steering stem upper/
lower steel balls and the steering stem lower bracket
to the frame. (Page 6B-18)
6B-25 Steering / Handlebar:

Specifications
Tightening Torque Specifications
BENM23K16207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Right handlebar bolt 23 2.34 16.9 (Page 6B-5)
Handlebar balancer screw (Page 6B-6) /
(Page 6B-7) /
5.5 0.56 4.05
(Page 6B-9) /
(Page 6B-11)
Left handlebar bolt 23 2.34 16.9 (Page 6B-6)
Clutch lever holder bolt (Page 6B-6) /
6.0 0.61 4.45
(Page 6B-10)
Handlebar holder clamp bolt 23 2.34 16.9 (Page 6B-8)
Steering stem head nut (Page 6B-14) /
(Page 6B-16) /
30 3.1 22.5
(Page 6B-20) /
(Page 6B-22)
Front fork upper clamp bolt (Page 6B-14) /
23 2.34 16.9
(Page 6B-16)
Steering stem nut 20 Nm (2.0 kgf-m, 15.0 lbf-ft) → turn (Page 6B-19) /
counterclockwise 1/4 → 5.0 Nm (0.51 kgf- (Page 6B-22)
m, 3.70 lbf-ft)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Handlebar Components” (Page 6B-1)
“Handlebar Construction” (Page 6B-2)
“Steering Stem Components” (Page 6B-12)
“Fasteners Information” in Section 0C (Page 0C-10)
 Steering / Handlebar: 6B-26

Special Tools and Equipment

Recommended Service Material
BENM23K16208001
Material SUZUKI recommended product or Specification Note
Adhesive Handle grip glue — (Page 6B-7) / (Page 6B-
10)
Grease SUZUKI SUPER GREASE A P/No.: 99000–25011 (Page 6B-5) / (Page 6B-
9) / (Page 6B-19) /
(Page 6B-21)
SUZUKI WATER RESISTANT P/No.: 99000–25350 (Page 6B-5) / (Page 6B-
GREASE EP2 8)

NOTE
Required service material(s) is also described in:
“Handlebar Components” (Page 6B-1)
“Handlebar Construction” (Page 6B-2)
“Steering Stem Components” (Page 6B-12)

Special Tool
BENM23K16208002
09910–60620 09940–14920
Adjustable wrench Steering stem nut socket
wrench
(Page 6B-14) (Page 6B-18) /
(Page 6B-19) /
(Page 6B-20) /
(Page 6B-22)
09940–92720 09941–34513
Spring scale (400 - 1000 g) Bearing installer set
(Page 6B-13) (Page 6B-24)

09941–74911
Steering stem bearing
installer
(Page 6B-24)
6B-27 Steering / Handlebar:

Section 9
Body and Accessories
CONTENTS
Precautions .................................................9-1
Precautions............................................................. 9-1
Precautions for Electrical System ......................... 9-1
Component Location ............................................. 9-1
Electrical Components Location ........................... 9-1
Wiring Systems........................................ 9A-1
General Description .............................................9A-1
Abbreviations ...................................................... 9A-1
Wire / Connector Color Symbols......................... 9A-1
How to Read Terminal Nos. ................................ 9A-2
Schematic and Routing Diagram........................9A-3
Wiring Diagram ................................................... 9A-3
Wiring Harness Routing Diagram...................... 9A-11
Component Location .........................................9A-15
Electrical Components Location ....................... 9A-15
Lighting Systems..................................... 9B-1
Precautions...........................................................9B-1
Precautions for Lighting Systems ....................... 9B-1
Diagnostic Information and Procedures............9B-1
Headlight Symptom Diagnosis ............................ 9B-1
Turn Signal Light Symptom Diagnosis ................ 9B-1
Rear Brake Light Symptom Diagnosis ................ 9B-1
Repair Instructions ..............................................9B-2
Headlight Construction........................................ 9B-2
Headlight Removal and Installation .................... 9B-2
Headlight LED / Position Light LED
Replacement ..................................................... 9B-4
Headlight Beam Adjustment ............................... 9B-4
Rear Lighting System Construction..................... 9B-4
Rear Brake Light / Rear Turn Signal Light /
License Plate Light Components ...................... 9B-5
Rear Brake Light Removal and Installation......... 9B-6
Rear Brake Light Bulb Replacement................... 9B-8
License Plate Light Removal and Installation ..... 9B-8
Front Turn Signal Light Removal and
Installation ......................................................... 9B-9
Rear Turn Signal Light Removal and
Installation ....................................................... 9B-10
Turn Signal Bulb Replacement ......................... 9B-11
Turn Signal Relay Inspection ............................ 9B-11
Turn Signal Relay Removal and Installation ..... 9B-12
Turn Signal Switch Inspection........................... 9B-12
Table of Contents 9- i
Dimmer Switch Inspection.................................9B-13
Passing Switch Inspection ................................9B-13
Hazard Switch Inspection (If Equipped) ............9B-14
Specifications .....................................................9B-15
Tightening Torque Specifications......................9B-15
Combination Meter / Fuel Meter / Horn.. 9C-1
General Description .............................................9C-1
Combination Meter System Description..............9C-1
Diagnostic Information and Procedures ............9C-2
Combination Meter Symptom Diagnosis.............9C-2
Horn Symptom Diagnosis ...................................9C-2
Repair Instructions ..............................................9C-2
Combination Meter Construction.........................9C-2
Combination Meter On-Vehicle Inspection..........9C-3
Combination Meter Removal and Installation .....9C-3
Speedometer On-Vehicle Inspection ..................9C-5
Fuel Level Indicator Inspection ...........................9C-5
Fuel Level Gauge Inspection ..............................9C-6
ECT Sensor Removal and Installation ................9C-6
Horn Inspection ...................................................9C-6
Horn Removal and Installation ............................9C-7
Specifications .......................................................9C-7
Tightening Torque Specifications........................9C-7
Exterior Parts ........................................... 9D-1
Repair Instructions ..............................................9D-1
Seat Lock Construction .......................................9D-1
Headlight Housing Construction..........................9D-2
Front Fairing Construction (GSX R 125
Model) ...............................................................9D-6 9
Fuel Tank Side Cover and Under Cowling
Construction ......................................................9D-8
Front Fairing Cushion Construction ..................9D-10
Frame Cover and Rear Fender Construction....9D-12
Front Fender Construction ................................9D-13
Fuel Tank Construction .....................................9D-14
Fuel Tank Cover Cushion Construction ............9D-16
Body Cowling Cushion Construction.................9D-18
Meter Panel Cushion Construction ...................9D-19
Fastener Removal and Installation....................9D-20
Seat Removal and Installation ..........................9D-20
Front Fairing Assembly Removal and
Installation .......................................................9D-22
Front Fairing Disassembly and Reassembly.....9D-24
9-ii Table of Contents
Fuel Tank Side Cover Assembly Removal
and Installation ................................................9D-25
Fuel Tank Side Cover Disassembly and
Reassembly ....................................................9D-25
Under Cowling Removal and Installation ..........9D-26
Under Cowling Disassembly and Reassembly ..9D-27
Fuel Tank Cover Removal and Installation .......9D-27
Windscreen Removal and Installation...............9D-28
Body Cowling Removal and Installation............9D-29
Meter Panel Removal and Installation ..............9D-30
Frame Cover Removal and Installation.............9D-31
Front Fender Removal and Installation .............9D-31
Rear Fender Rear Removal and Installation.....9D-32
Rear Fender Front Removal and Installation ....9D-33
Specifications.....................................................9D-33
Tightening Torque Specifications......................9D-33
Body Structure......................................... 9E-1
Repair Instructions ..............................................9E-1
Frame Construction.............................................9E-1
Front Footrest Construction ................................9E-3
Front Footrest Removal and Installation .............9E-4
Pillion Footrest Construction ...............................9E-4
Pillion Footrest Removal and Installation ............9E-5
Side-stand Construction......................................9E-5
Side-stand Removal and Installation...................9E-5
Center Stand Construction (If equipped).............9E-6
Center Stand Removal and Installation...............9E-6
Specifications .......................................................9E-7
Tightening Torque Specifications........................9E-7
Special Tools and Equipment .............................9E-7
Recommended Service Material .........................9E-7
 Precautions: 9-1

Precautions
Body and Accessories

Precautions
Precautions for Electrical System
BENM23K19000001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions for Electrical Circuit Service” in Section 00
(Page 00-2).

Component Location
Electrical Components Location
BENM23K19003001
Refer to “Electrical Components Location” in Section 0A (Page 0A-6).
9A-1 Wiring Systems:

Wiring Systems
Body and Accessories

General Description
Abbreviations
BENM23K19101001
Refer to “Abbreviations” in Section 0A (Page 0A-1) for general abbreviations.

Wire / Connector Color Symbols

BENM23K19101002
Refer to “Wire Color Symbols” in Section 0A (Page 0A-3).
 Wiring Systems: 9A-2

How to Read Terminal Nos.

BENM23K19101003
The connector shape and terminal layout shown in this manual are those when viewed from “Z” in the illustration.

NOTE
• Molded terminal numbers that are different from the above can be found on some connectors in rare
cases.
• These molded numbers are not applied in this manual.

View Z

Male terminal A40

4 3 2 1
Z
8 7 6 5

(View Z)
Female terminal D18
1 2 3 4 View Z’
5 6 7 8
(View Z’)
Terminal No. Z’

IE31J1910901-02
9A-3 Wiring Systems:

Schematic and Routing Diagram

Wiring Diagram
BENM23K19102001
GSX R 125 Model (For Europe / Korea)

HAZARD SWITCH HANDLE - SW, R

(If Equipped) ENG-STOP START SW FRONT - BRAKE
ON OFF OFF
OFF RUN PUSH ON

SPEEDOMETER HARN
SP01 0.3 P SP01 0.3 P SP01 0.3 P
SPD
TA01 0.3 BG TA01 0.3 BG TA01 0.3 BG
TACO
MB01 0.3 WY
STOP - LAMP, SW
MB01 0.3 WY MB01 0.3 WY SIDE-STAND, SW
GP – 1
MC01 0.3 RB MC01 0.3 RB MC01 0.3 RB O WB
GP – 2 ON ON TURN - RELAY
MD01 0.3 GL MD01 0.3 GL MD01 0.3 GL OFF OFF
GP – 3

OW
OB

YG
BL

Sb

Lg

B
ME01 0.3 YL ME01 0.3 YL ME01 0.3 YL
GP – 4

WB
O
MF01 0.3 BrR MF01 0.3 BrR MF01 0.3 BrR

BW
B L

O
GP – 5
MG01 0.3 GR MG01 0.3 GR MG01 0.3 GR
GP – 6
MA01 0.5 L MA01 0.5 L MA01 0.5 L
NEUTRAL

ED04 0.75 OW

BB01 0.75 OB

BC01 0.75 YG
NS01 0.5 Br

KB02 0.5 WB

KB01 0.5 WB
SS01 0.3 OW

TR02 0.5 Sb

TR01 0.5 LB
ED04 0.5 Lg
ABS

BA04 0.5 O

BA05 0.5 O

BA12 0.5 O
CC29 0.3 B

SB05 0.5 V
SR01 0.3 OB SR01 0.3 OB LE04 0.3 BL
HI – BEAM (–)
RA01 0.5 LgR NS01 0.5 Br NS01 0.5 WL
HI – BEAM (+)
TE01 0.3 Dg TE01 0.3 Dg TE01 0.3 GL
TECH
SB01 0.3 V SB01 0.3 V SB01 0.3 V
TURN – L
CD01 0.5 BW CD01 0.5 BW CD01 0.5 BW
GND
SC01 0.3 Lg SC01 0.3 Lg SC01 0.5 Lg
TURN – R 1
BB01 0.3 O BB01 0.3 O BB01 0.5 O
ILLUMI
FB01 0.3 YB FB01 0.3 YB FP01 0.5 YB
FUEL
BD01 0.75 OW BD01 0.75 OW BD01 1.25 OW
IG (+)
AB01 0.5 R AB01 0.5 R BE02 0.5 W
+BATT 2

3
HARN
4

EA01 0.5 YW EA01 0.5 YW EA01 0.5 YW

5
LF01 0.5 YB LF01 0.5 YB LF01 0.5 YB

LE01 0.5 BL LE01 0.5 BL LE01 0.5 BL

PL02 0.75 Br PL02 0.75 Br PL02 0.75 Br

CC01 0.5 BW CC01 0.5 BW CC01 1.25 BW

RA01 0.5 LgR

HARN
HEAD - LAMP 8

F - TURN, L 9

SB01 0.5 V
B 10
CC11 0.5 BW
BW 11

12

F - TURN, R 13
SC01 0.5 Lg
Lg 14

CC12 0.5 BW
BW 15

16

17

18

19

20

21

22

23

24

25

26

27

EB01 0.5 WR

ED04 0.5 BBr

CC18 0.75 BW

EC01 0.5 Dg
CC07 0.3 BW
FA01 0.75 B

NA03 0.3 R

SP01 0.3 P

BD01 1.25 OW

BD02 1.25 OW

EF01 0.75 OR
FD01 1.25 YB

FD01 1.25 YB
CC26 0.5 BW

CC27 0.5 BW

CC06 0.5 BW

EB01 0.5 WR

EA01 0.5 YW
PL01 0.75 Br

BB02 0.5 OB
FU01 0.5 YW
BE01 1.25 W
EF04 0.5 OR

BA01 1.25 O

AB01 1.25 R

CC01 1.25 B
LE03 0.5 BL
DA01 0.75 BW

FA01 0.75 B
BA10 0.5 O
MF01 0.3 BrR

RS01 0.5 B
MB01 0.3 WY

LD01 0.3 B
CC16 0.3 BW

MG01 0.3 GR
MC01 0.3 RB

MD01 0.3 GL

IG01 0.5 G
BA01 1.25 O

ME01 0.3 YL
CL01 0.5 BY

TR01 0.5 LB
LE03 0.5 BL

DA01 1.25 L

SC03 0.5 Lg

DA01 1.25 L
LF01 0.5 YB

MA01 0.5 L
SB03 0.5 V
GND
OUT
B

Vcc

G
Y
SP - SENSOR
BATTERY
CHARGE
BrR

EARTH
WY
BW

GR
GL
RB

YL

LED-K

LED-A
V-OUT
L
BW
YW
BL
BG

Sb
Lg
W
B

FAN MOTOR
B

HORN N MAIN FAN

1 P REG & REC
2
LOCK RELAY - BOX
3
4 OFF MAGNETO
5 ON
6
Br Gr O R
ON ON HI + L
GPS
OFF OFF LO PUSH PUSH IGNITION - SW
CLUTCH–SW DIMMER HORN R
PASS
TURN SIGNAL
HANDLE – SW, L

IM23K1910901-01
 5
1

4
3
2

7
6

11
10

23
22
18

20
13

27
26
25
24
21
19
17
16
15
14
12
BB04 0.75 OB

CC28 0.5 BW KA01 0.75 WL

IG-COIL
KL01 0.5 B

EF02 0.5 OR

IG01 0.5 G NA02 0.3 R

IG RELAY - BOX
FF01 0.3 Br
P
ED03 0.3 BBr

FUEL-CUT, SENSOR
EC01 0.5 Dg
N+

STARTER - MOTOR
NA01 0.5 R
VCC
HA01 0.3 WP
VTA
BB06 0.75 OB GA01 0.3 GB
PM
ST01 0.5 BY FF01 0.3 Br

STARTER - RELAY
DON

1
AB01 1.25 R ET01 0.3 BL
THW
IA01 0.3 G
THA

1. MAIN (20A)
ED01 0.5 BBr
E2
OA01 0.3 BO
OX
SD01 0.5 GrR
SDL
AB04 1.25 R TS01 0.5 WR
TS/KEY

1
BE01 1.25 W CL01 0.5 BY
CLT
AB03 1.25 R SS01 0.3 OW
SS

2. FAN (10A)
1. SUB (10A)
EF01 0.75 OR TA01 0.3 BG

FUSE - BOX
TACO
TE01 0.3 GL
TECH
MA02 0.3 L
NT

AT
CC01 1.25 B SP01 0.5 P
BW SPD
US01 0.3 WG
ECU

SOL2
AC01 1.25 R
R

12 V

BATTERY
BB01 0.75 OB
+B
BE03 0.75 W
BATT
TS02 0.3 B
ECU SOLP
LA01 0.3 GW
INJ
FC01 0.5 YR
FP
CC24 0.5 B KA01 0.75 WL
GND IG

ANS - L RLY
EF03 0.5 B FU01 0.5 YW
BATT FAR

KEYLESS-UNIT
RS01 0.5 B BC01 0.75 YG
REQ - SW STA
LD01 0.3 B ST01 0.5 BY
LED STM
BD03 0.5 B WH01 0.3 YR
IG - SW ISC1A
KL01 0.5 B WM01 0.3 Lg
IG - SO IS1B
WK01 0.3 Sb
ANS - R IS2A
WN01 0.3 BLg
IS2B
CC08 0.5 BW
E1
ED05 0.3 BBr CC09 0.5 BW
BW E03
OA01 0.3 BO
B

O2-SNSR
FP01 0.5 YB

CC01 0.5 BW

ED02 0.3 BBr BB05 0.75 OB

M

ET01 0.3 BL FC01 0.5 YR

FUEL - PUMP

W. T. SNSR
BB03 0.75 OB US01 0.3 WG
PL01 0.75 Br

KB01 0.5 WB
CC03 0.5 BW
SB01 0.5 V

LA01 0.3 GW BB09 0.5 OB

PL04 0.3 Br
SC01 0.5 Lg

CC13 0.3 BW
CC14 0.5 BW
CC15 0.5 BW

INJECTER
SOLENOID

BB07 0.5 OB
Gr

BW

WB

NA01 0.5 R

HA01 0.3 WP TS01 0.5 WR

B

Lg
BW

TPS
BW

Gr

BW
TS

GA01 0.3 GB
MAP
R - TURN, L

R - TURN, R

MAQS
REAR - COMB

IA01 0.3 G SD01 0.5 GrR

AT
LICENSE - LAMP

ED01 0.5 BBr CC05 0.3 BW

WN01 0.3 BLg

IS2A (D)
WK01 0.3 Sb
IS2B (C)
WM01 0.3 Lg

ISC
IS1B (B)
WH01 0.3 YR
IS1A (A)
VT01 0.75 RL
UBMR

WSOF
AC01 1.25 R BF01 0.5 O
WAUIN1
RR01 0.5 RB FB01 0.5 BR
B

WSOR
AC02 1.25 R FV01 0.5 WR
FVW
W

ABSOFF /BLS
RT01 0.75 RL FB01 0.5 BR
WSSF

1. ABS VALVE (10A)

2. ABS MOTOR (15A)
ABS FUSE - BOX
RV01 0.5 WY
WSPR
RB01 0.5 BY BW01 0.75 BW
B

GND
RV01 0.5 WY VR01 0.5 RB
RVW
W

UBVR
ABS-CONT

NS01 0.5 WL
NABSSLAMP
SR01 0.5 GrR
DIAGK
XC01 0.5 OW XC01 0.5 OW
DIAGL
CC21 0.5 BW
CAN1M
SHORT-C

CAN1P
FV01 0.5 WR
WSPF
RB01 0.5 BY
WSSR
RT01 0.75 RL VT01 0.75 RL

BA11 0.5 O BF01 0.5 O

Wiring Systems:

CC20 0.75 BW BW01 0.75 BW

RR01 0.5 RB VR01 0.5 RB

SD02 0.5 GrR SR01 0.5 GrR

ABS-SHORT, C

IM23K1910902-01
9A-4
9A-5 Wiring Systems:

GSX R 125 Model (For Australia)

HAZARD SWITCH HANDLE - SW, R

(If Equipped) ENG-STOP START SW FRONT - BRAKE
ON OFF OFF
OFF RUN PUSH ON

SPEEDOMETER HARN
SP01 0.3 P SP01 0.3 P SP01 0.3 P
SPD
TA01 0.3 BG TA01 0.3 BG TA01 0.3 BG
TACO
MB01 0.3 WY
STOP - LAMP, SW
MB01 0.3 WY MB01 0.3 WY SIDE-STAND, SW
GP – 1
MC01 0.3 RB MC01 0.3 RB MC01 0.3 RB O WB
GP – 2 ON ON TURN - RELAY
MD01 0.3 GL MD01 0.3 GL MD01 0.3 GL OFF OFF
GP – 3

OW
OB

YG
DIODE

BL

Sb

Lg

B
ME01 0.3 YL ME01 0.3 YL ME01 0.3 YL
GP – 4

WB
O
MF01 0.3 BrR MF01 0.3 BrR MF01 0.3 BrR

BW
B L

O
GP – 5
MG01 0.3 GR MG01 0.3 GR MG01 0.3 GR
GP – 6
MA01 0.5 L MA01 0.5 L MA01 0.5 L
NEUTRAL

ED04 0.75 OW

BB01 0.75 OB

BC01 0.75 YG
NS01 0.5 Br

KB02 0.5 WB

KB01 0.5 WB
SS01 0.3 OW

TR02 0.5 Sb

TR01 0.5 LB
ED04 0.5 Lg

TR01 0.5 LB

TU01 0.5 Sb
ABS

BA04 0.5 O

BA05 0.5 O

BA12 0.5 O
CC29 0.3 B

SB05 0.5 V
SR01 0.3 OB SR01 0.3 OB LE04 0.3 BL
HI – BEAM (–)
RA01 0.5 LgR NS01 0.5 Br NS01 0.5 WL
HI – BEAM (+)
TE01 0.3 Dg TE01 0.3 Dg TE01 0.3 GL
TECH
SB01 0.3 V SB01 0.3 V SB01 0.3 V
TURN – L
CD01 0.5 BW CD01 0.5 BW CD01 0.5 BW
GND
SC01 0.3 Lg SC01 0.3 Lg SC01 0.3 Lg
TURN – R 1
BB01 0.3 O BB01 0.3 O BB01 0.3 O
ILLUMI
FB01 0.3 YB FB01 0.3 YB FP01 0.3 YB
FUEL
BD01 0.75 OW BD01 0.75 OW BD01 0.75 OW
IG (+)
AB01 0.5 R AB01 0.5 R BE02 0.5 W
+BATT 2

3
HARN
4

EA01 0.5 YW EA01 0.5 YW EA01 0.5 YW

5
LF01 0.5 YB LF01 0.5 YB LF01 0.5 YB

LE01 0.5 BL LE01 0.5 BL LE01 0.5 BL

PL02 0.75 Br PL02 0.75 Br PL02 0.75 Br

CC01 0.5 BW CC01 0.5 BW CC01 1.25 BW

RA01 0.5 LgR

HARN
HEAD - LAMP 8

F - TURN, L 9

SB01 0.5 V
B 10
CC11 0.5 BW
BW 11

12

F - TURN, R 13
SC01 0.5 Lg
Lg 14

CC12 0.5 BW
BW 15

16

17

18

19

20

21

22

23

24

25

26

27

EB01 0.5 WR

ED04 0.5 BBr

CC18 0.75 BW

EC01 0.5 Dg
CC07 0.3 BW
FA01 0.75 B

NA03 0.3 R

SP01 0.3 P

BD01 1.25 OW

BD02 1.25 OW

EF01 0.75 OR
FD01 1.25 YB

FD01 1.25 YB
CC26 0.5 BW

CC27 0.5 BW

CC06 0.5 BW

EB01 0.5 WR

EA01 0.5 YW
PL01 0.75 Br

BB02 0.5 OB
FU01 0.5 YW
BE01 1.25 W
EF04 0.5 OR

BA01 1.25 O

AB01 1.25 R

CC01 1.25 B
LE03 0.5 BL
DA01 1.25 BW

FA01 0.75 B
BA10 0.5 O
MF01 0.3 BrR

RS01 0.5 B
MB01 0.3 WY

LD01 0.3 B
CC16 0.3 BW

MG01 0.3 GR
MC01 0.3 RB

MD01 0.3 GL

IG01 0.5 G
BA01 1.25 O

ME01 0.3 YL
CL01 0.5 BY

TU01 0.5 LB
LE03 0.5 BL

DA01 1.25 L

SC03 0.5 Lg

DA01 1.25 L
LF01 0.5 YB

MA01 0.5 L
SB03 0.5 V
GND
OUT
B

Vcc

G
Y
SP - SENSOR
BATTERY
CHARGE
BrR

EARTH
WY
BW

GR
GL
RB

YL

LED-K

LED-A
V-OUT
L
BW
YW
BL
BG

Sb
Lg
W
B

FAN MOTOR
B

HORN N MAIN FAN

1 P REG & REC
2
LOCK RELAY - BOX
3
4 OFF MAGNETO
5 ON
6
Br Gr O R
ON ON HI + L
GPS
OFF OFF LO PUSH PUSH IGNITION - SW
CLUTCH–SW DIMMER HORN R
PASS
TURN SIGNAL
HANDLE – SW, L

IM23K1910903-01
 5
1

4
3
2

7
6

11
10

23
22
18

20
13

27
26
25
24
21
19
17
16
15
14
12
BB04 0.75 OB

CC28 0.5 BW KA01 0.75 WL

IG-COIL
KL01 0.5 B

EF02 0.5 OR

IG01 0.5 G NA02 0.3 R

IG RELAY - BOX
FF01 0.3 Br
P
ED03 0.3 BBr
FUEL-CUT, SENSOR

EC01 0.5 Dg
N+

STARTER - MOTOR
NA01 0.5 R
VCC
HA01 0.3 WP
VTA
BB06 0.75 OB GA01 0.3 GB
PM
ST01 0.5 BY FF01 0.3 Br

STARTER - RELAY
DON

1
AB01 1.25 R ET01 0.3 BL
THW
IA01 0.3 G
THA

1. MAIN (20A)
ED01 0.5 BBr
E2
OA01 0.3 BO
OX
SD01 0.5 GrR
SDL
AB04 1.25 R TS01 0.5 WR
TS/KEY

1
BE01 1.25 W CL01 0.5 BY
CLT
AB03 1.25 R SS01 0.3 OW
SS

2. FAN (10A)
1. SUB (10A)
EF01 0.75 OR TA01 0.3 BG

FUSE - BOX
TACO
TE01 0.3 GL
TECH
MA02 0.3 L
NT

AT
CC01 1.25 B SP01 0.3 P
BW SPD
US01 0.3 WG
ECU

SOL2
AC01 1.25 R
R

12 V

BATTERY
BB01 0.75 OB
+B
BE03 0.75 W
BATT
TS02 0.3 B
ECU SOLP
LA01 0.3 GW
INJ
FC01 0.5 YR
FP
CC24 0.5 B KA01 0.75 WL
GND IG
SB04 0.5 B
ANS - L RLY
EF03 0.5 B FU01 0.5 YW
BATT FAR

KEYLESS-UNIT
RS01 0.5 B BC01 0.75 YG
REQ - SW STA
LD01 0.3 B ST01 0.5 BY
LED STM
BD03 0.5 B WH01 0.3 YR
IG - SW ISC1A
KL01 0.5 B WM01 0.3 Lg
IG - SO IS1B
SC04 0.5 B WK01 0.3 Sb
ANS - R IS2A
WN01 0.3 BLg
IS2B
CC08 0.5 BW
E1
ED05 0.3 BBr CC09 0.5 BW
BW E03
OA01 0.3 BO
B

O2-SNSR
FP01 0.5 YB

CC01 0.5 BW

ED02 0.3 BBr BB05 0.75 OB

M

ET01 0.3 BL FC01 0.5 YR

FUEL - PUMP

W. T. SNSR
BB03 0.75 OB US01 0.3 WG
PL01 0.75 Br

KB01 0.5 WB
CC03 0.5 BW
SB01 0.5 V

LA01 0.3 GW BB09 0.5 OB

PL04 0.3 Br
SC01 0.5 Lg

CC13 0.3 BW
CC14 0.5 BW
CC15 0.5 BW

INJECTER
SOLENOID

BB07 0.75 OB
Gr

BW

WB

NA01 0.5 R

HA01 0.3 WP TS01 0.5 WR

B

Lg
BW

TPS
BW

Gr

BW
TS

GA01 0.3 GB
MAP
R - TURN, L

R - TURN, R

MAQS
REAR - COMB

IA01 0.3 G SD01 0.5 GrR

AT
LICENSE - LAMP

ED01 0.5 BBr CC05 0.3 BW

WN01 0.3 BLg

IS2A (D)
WK01 0.3 Sb
IS2B (C)
WM01 0.3 Lg

ISC
IS1B (B)
WH01 0.3 YR
IS1A (A)
VT01 0.75 RL
UBMR

WSOF
AC01 1.25 R BF01 0.5 O
WAUIN1
RR01 0.5 RB FB01 0.5 BR
B

WSOR
AC02 1.25 R FV01 0.5 WR
FVW
W

ABSOFF /BLS
RT01 0.75 RL FB01 0.5 BR
WSSF

1. ABS VALVE (10A)

2. ABS MOTOR (15A)
ABS FUSE - BOX
RV01 0.5 WY
WSPR
RB01 0.5 BY BW01 0.75 BW
B

GND
RV01 0.5 WY VR01 0.5 RB
RVW
W

UBVR
ABS-CONT

NS01 0.5 WL
NABSSLAMP
SR01 0.5 GrR
DIAGK
XC01 0.5 OW XC01 0.5 OW
DIAGL
CC21 0.5 BW
CAN1M
SHORT-C

CAN1P
FV01 0.5 WR
WSPF
RB01 0.5 BY
WSSR
RT01 0.75 RL VT01 0.75 RL

BA11 0.5 O BF01 0.5 O

Wiring Systems:

CC20 0.75 BW BW01 0.75 BW

RR01 0.5 RB VR01 0.5 RB

SD02 0.5 GrR SR01 0.5 GrR

IM23K1910904-01 ABS-SHORT, C
9A-6
9A-7 Wiring Systems:

GSX R 125 Model (For Saudi Arabia)

HAZARD SWITCH HANDLE - SW, R

(If Equipped) ENG-STOP START SW FRONT - BRAKE
ON OFF OFF
OFF RUN PUSH ON

SPEEDOMETER HARN
SP01 0.3 P SP01 0.3 P SP01 0.3 P
SPD
TA01 0.3 BG TA01 0.3 BG TA01 0.3 BG
TACO
MB01 0.3 WY
STOP - LAMP, SW
MB01 0.3 WY MB01 0.3 WY SIDE-STAND, SW
GP – 1
MC01 0.3 RB MC01 0.3 RB MC01 0.3 RB O WB
GP – 2 ON ON TURN - RELAY
MD01 0.3 GL MD01 0.3 GL MD01 0.3 GL OFF OFF
GP – 3

OW
OB

YG
BL

Sb

Lg

B
ME01 0.3 YL ME01 0.3 YL ME01 0.3 YL
GP – 4

WB
O
MF01 0.3 BrR MF01 0.3 BrR MF01 0.3 BrR

BW
B L

O
GP – 5
MG01 0.3 GR MG01 0.3 GR MG01 0.3 GR
GP – 6
MA01 0.5 L MA01 0.5 L MA01 0.5 L
NEUTRAL

ED04 0.75 OW

BB01 0.75 OB
NS01 0.5 Br

KB02 0.5 WB

KB01 0.5 WB
SS01 0.3 OW

BC01 0.5 YG
TR02 0.5 Sb

TR01 0.5 LB
ED04 0.5 Lg
ABS

BA04 0.5 O

BA05 0.5 O

BA12 0.5 O
CC29 0.3 B

SB05 0.5 V
SR01 0.3 OB SR01 0.3 OB LE04 0.3 BL
HI – BEAM (–)
RA01 0.5 LgR NS01 0.5 Br NS01 0.5 WL
HI – BEAM (+)
TE01 0.3 Dg TE01 0.3 Dg TE01 0.3 GL
TECH
SB01 0.3 V SB01 0.3 V SB01 0.5 V
TURN – L
CD01 0.5 BW CD01 0.5 BW CD01 0.5 BW
GND
SC01 0.3 Lg SC01 0.3 Lg SC01 0.3 Lg
TURN – R 1
BB01 0.3 O BB01 0.3 O BB01 0.3 O
ILLUMI
FB01 0.3 YB FB01 0.3 YB FP01 0.3 YB
FUEL
BD01 0.75 OW BD01 0.75 OW BD01 0.75 OW
IG (+)
AB01 0.5 R AB01 0.5 R BE02 0.5 W
+BATT 2

3
HARN
4

EA01 0.5 YW EA01 0.5 YW EA01 0.5 YW

5
LF01 0.5 YB LF01 0.5 YB LF01 0.5 YB

LE01 0.5 BL LE01 0.5 BL LE01 0.5 BL

PL02 0.75 Br PL02 0.75 Br PL02 0.75 Br

CC01 0.5 BW CC01 0.5 BW CC01 1.25 BW

RA01 0.5 LgR

HARN
HEAD - LAMP 8

F - TURN, L 9

SB01 0.5 V
B 10
CC11 0.5 BW
BW 11

12

F - TURN, R 13
SC01 0.5 Lg
Lg 14

CC12 0.5 BW
BW 15

16

17

18

19

20

21

22

23

24

EB01 0.5 WR

ED04 0.5 BBr

CC18 0.75 BW

EC01 0.5 Dg
CC07 0.3 BW
FA01 0.75 B

NA03 0.3 R

SP01 0.3 P

BD02 1.25 OW
BD02 1.25 OW

BD01 1.25 OW

EF01 0.75 OR

FD01 1.25 YB
FD01 1.25 YB

CC06 0.5 BW

EB01 0.5 WR

EA01 0.5 YW
BB02 0.5 OB
FU01 0.5 YW
BE01 1.25 W
AT01 0.5 PW

BA01 1.25 O

AB01 1.25 R

CC01 1.25 B
LE03 0.5 BL
DA01 1.25 BW

FA01 0.75 B
MF01 0.3 BrR
MB01 0.3 WY

BA10 0.5 O
CC16 0.3 BW

MG01 0.3 GR
MC01 0.3 RB

MD01 0.3 GL

PL01 0.75 Br
BA01 1.25 O

ME01 0.3 YL
CL01 0.5 BY

TR01 0.5 LB
LE03 0.5 BL

DA01 1.25 L

SC03 0.5 Lg

DA01 1.25 L
LF01 0.5 YB

MA01 0.5 L
SB03 0.5 V
GND
OUT
B

Vcc

G
Y
SP - SENSOR BATTERY
CHARGE
BrR

EARTH
WY
BW

GR
GL
RB

YL

LED-K

LED-A
V-OUT
L
BW
YW
BL
BG

Sb
Lg
W
B

FAN MOTOR
B

HORN N P MAIN FAN

1 REG & REC
LOCK
2
3 OFF RELAY - BOX
4 ON
MAGNETO
5
6 Br Gr O R P
ON ON HI + L
GPS
OFF OFF LO PUSH PUSH
R
CLUTCH–SW PASS DIMMER HORN IGNITION–SW
TURN SIGNAL
HANDLE – SW, L

IM23K1910905-01
 5
1

4
3
2

7
6

11
10

22
21
17

19
13

23
20
18
16
15
14
12

24
BB04 0.75 OB

KA01 0.75 WL

IG-COIL
NA02 0.3 R

FF01 0.3 Br
P
ED03 0.3 BBr
FUEL-CUT, SENSOR

EC01 0.5 Dg
N+

STARTER - MOTOR
NA01 0.5 R
VCC
HA01 0.3 WP
VTA
BB06 0.75 OB GA01 0.3 GB
PM
ST01 0.5 BY FF01 0.3 Br

STARTER - RELAY
DON

1
AB01 1.25 R ET01 0.3 BL
THW
IA01 0.3 G
THA

1. MAIN (20A)
ED01 0.5 BBr
E2
OA01 0.3 BO
OX
SD01 0.5 GrR
SDL
AB04 1.25 R TS01 0.5 WR
TS/KEY

1
BE01 1.25 W CL01 0.5 BY
CLT
AB03 1.25 R SS01 0.3 OW
SS

2. FAN (10A)
1. SUB (10A)
EF01 0.75 OR TA01 0.3 BG

FUSE - BOX
TACO
TE01 0.3 GL
TECH
MA02 0.3 L
NT
AT01 0.5 PW
AT
CC01 1.25 B SP02 0.3 P
BW SPD
US01 0.3 WG
ECU

SOL2
AC01 1.25 R
R

12 V

BATTERY
BB01 0.75 OB
+B
BE03 0.75 W
BATT

SOLP
LA01 0.3 GW
INJ
FC01 0.5 YR
FP
KA01 0.75 WL
IG

RLY
FU01 0.5 YW
FAR
BC01 0.75 YG
STA
ST01 0.5 BY
STM
WH01 0.3 YR
ISC1A
WM01 0.3 Lg
IS1B
WK01 0.3 Sb
IS2A
WN01 0.3 BLg
IS2B
CC08 0.5 BW
E1
ED05 0.3 BBr CC09 0.5 BW
BW E03
OA01 0.3 BO
B

O2-SNSR
FP01 0.5 YB

CC01 0.5 BW

ED02 0.3 BBr BB05 0.75 OB

M

ET01 0.3 BL FC01 0.5 YR

FUEL - PUMP

W. T. SNSR
BB03 0.75 OB US01 0.3 WG
PL01 0.75 Br

KB01 0.5 WB
CC03 0.5 BW
SB01 0.5 V

LA01 0.3 GW BB09 0.5 OB

PL04 0.3 Br
SC01 0.5 Lg

CC13 0.3 BW
CC14 0.5 BW
CC15 0.5 BW

INJECTER
SOLENOID

BB07 0.5 OB
Gr

BW

WB

NA01 0.5 R

HA01 0.3 WP TS01 0.5 WR

B

Lg
BW

TPS
BW

Gr

BW
TS

GA01 0.3 GB
MAP
R - TURN, L

R - TURN, R

MAQS
REAR - COMB

IA01 0.3 G SD01 0.5 GrR

AT
LICENSE - LAMP

ED01 0.5 BBr CC05 0.3 BW

WN01 0.3 BLg

IS2A (D)
WK01 0.3 Sb
IS2B (C)
WM01 0.3 Lg

ISC
IS1B (B)
WH01 0.3 YR
IS1A (A)
VT01 0.75a RL
UBMR

WSOF
AC01 1.25 R BF01 0.5 O
WAUIN1
RR01 0.5 RB FB01 0.5 BR
B

WSOR
AC02 1.25 R FV01 0.5 WR
FVW
W

ABSOFF /BLS
RT01 0.75 RL FB01 0.5 BR
WSSF

1. ABS VALVE (10A)

2. ABS MOTOR (15A)
ABS FUSE - BOX
RV01 0.5 WY
WSPR
RB01 0.5 BY BW01 0.75 BW
B

GND
RV01 0.5 WY VR01 0.5 RB
RVW
W

UBVR
ABS-CONT

NS01 0.5 WL
NABSSLAMP
SR01 0.5 GrR
DIAGK
XC01 0.5 OW XC01 0.5 OW
DIAGL
CC21 0.5 BW
CAN1M
SHORT-C

CAN1P
FV01 0.5 WR
WSPF
RB01 0.5 BY
WSSR
RT01 0.75 RL VT01 0.75 RL

BA11 0.5 O BF01 0.5 O

Wiring Systems:

CC20 0.75 BW BW01 0.75 BW

RR01 0.5 RB VR01 0.5 RB

SD02 0.5 GrR SR01 0.5 GrR

IM23K1910906-01 ABS-SHORT, C
9A-8
 NA03 0.3 R
VCC
SP01 0.5 P
OUT

ON
OFF
CC07 0.3 BW
GND

Lg

SP–SENSOR
BW
BW
F–TURN, L

F–TURN, R

CLUTCH–SW
CC18 0.75 BW
B

HEAD–LAMP
FA01 0.75 B
L

ON
SC01
CC11
SB01

CC12

OFF
FANMOTOR
LF01

PL02
LE01

0.5
0.5
0.5
EA01

0.5
RA01
CC02

Lg
0.5

PASS
0.5
0.5

0.5
0.5

BW

BW
0.75
CL01 0.5 BY

YB

BL
B

Br
YW

BW

LgR
W

HI
LO
LE03 0.5 BL
BG
BA01 1.25 L
BL

DIMMER
9A-9 Wiring Systems:

SC03 0.5 Lg
Lg
LF01 0.5 YB

+
YW

PUSH

HANDLE–SW, L
TR01 0.5 Sb
Sb

HORN
DA01 1.25 BW BE02 0.5 W
BW +BATT
SB03 0.5 V BD02 0.75 OW
B IG (+)

R
FP01 0.5 YB

PUSH
FUEL
BA07 0.5 O
ILLUMI
SC02 0.3 Lg
TURN–R

TURNSIGNAL
DA01 1.25 O CC17 0.5 BW
GND
CC04 1.25 L SB02 0.3 V
TURN–L

HORN
TE01 0.3 GL
TECH
RA01 0.5 LgR

6
5
4
3
2
1
N
HI–BEAM (+)
CC16 0.3 BW LE04 0.3 BL
BW HI–BEAM (–)
MA01 0.5 L NS01 0.5 Br
L ABS
MB01 0.3 WY MA01 0.5 L
WY NEUTRAL
SPEEDOMETER

MC01 0.3 RB MG01 0.3 GR

RB GP–6

GPS
MD01 0.3 GL MF01 0.3 BrR
GL GP–5
GSX S 125 Model (For Europe / Australia / Korea)

ME01 0.3 YL ME01 0.3 YL

YL GP–4
MF01 0.3 BrR MD01 0.3 GL
BrR GP–3
MG01 0.3 GR MC01 0.3 RB
GR GP–2
MB01 0.3 WY
GP–1
TA01 0.3 BG
TACO

P
SP02 0.3 P

ON
OFF
SPD

LOCK
PL01 0.75 Br
ON

Br

Br
OFF

BA08 0.5 O
Gr

Gr
ON
OFF

BD02 0.75 OW
SS01 0.3 OW
(If Equipped)

O
HAZARD SWITCH

BD01 0.75 OW CC22 0.3 BW

O
SWITCH

IGNITION–SW
BW
FD01 1.25 YB
SIDE–STAND

R
R
OFF
RUN

AT01 0.5 PW
SB05 0.5 V

P
P BL
TR02 0.5 Sb
ENG–STOP

IGNITION–SW
Sb
CC06 0.5 BW SC05 0.5 Lg
Lg
BD03 0.75 OW BD01 0.75 OW
OB
PUSH
START

BA01 1.25 O

MAIN
BB01 0.75 OB
OW
BE01 1.25 W BC01 0.75 YG
YG
BA04 0.5 O
B
HANDLE–SW, R

FU01 0.5 YW
ON

KB01 0.5 WB
OFF

RELAY–BOX
BB02 0.5 OB

EF01 0.75 OR

FAN
FRONT–BRAKE

FA01 0.75 B
ON
OFF

EB01 0.5 WR BA05 0.5 O

CHARGE
O

O
AB01 1.25 R KB02 0.5 WB
BATTERY
WB
WB

FD01 1.25 YB
V – OUT
STOP–LAMP, SW

LE01 0.5 BL
LED – K
EA01 0.5 YW BA02 0.5 O

REG & REC

LED – A
B

CC01 1.25 BW TR01 0.5 Sb

L

EARTH
TURN–RELAY

EB01 0.5 WR
Y
EC01 0.5 Dg
B

MAGNETO
ED04 0.5 BBr BB04 0.75 OB
G
KA01 0.75 WL
IG–COIL

25
4
3
2
1

9
8
7
6
5

11

24
23
22
21
20
19
18
17
16
15
14
13
12
10

IM23K1910907-01
 9
8
7
6
5
4
3
2
1

11

25
24
23
22
21
20
19
18
17
16
15
14
13
12
10
NA02 0.3 R

FF01 0.3 Br
P
ED03 0.3 BBr

STARTER–MOTOR
FUEL–CUT, SNSR
BB06 0.75 OB EC01 0.5 Dg
N+
ST01 0.5 BY NA01 0.5 R

STARTER–RELAY
VCC

1
AB01 1.25 R HA01 0.3 WP
VTA
CA01 0.3 GB
PM

1: MAIN 20A
FF01 0.3 Br
DON
ET01 0.3 BL
THW
IA01 0.3 G
THA
AB04 1.25 R ED01 0.5 BBr
E2

1
BE01 1.25 W OA01 0.3 BO
OX

2. FAN (10A)
1. SUB (10A)
AB03 1.25 R SD01 0.5 GrR
SDL

2
EF01 0.75 OR TS01 0.5 WR

FUSE–BOX
TS/KEY
CL01 0.5 BY
CLT
SS01 0.3 OW
SS
TA01 0.3 BG
TACO
CC01 1.25 BW TE01 0.3 GL
BW TECH
MA02 0.3 L
NT
AC01 1.25 R AT01 0.5 PW

12 V
R AT

BATTERY
SP01 0.5 P
SPD
US01 0.3 WG
ECU

SOL2

BB01 0.75 OB
+B
AB05 0.5 R
BATT

SOLP
LA01 0.3 GW
INJ
FC01 0.5 YR
FP
KA01 0.75 WL
IG

RLY
FU01 0.5 YW
FAR
BC01 0.75 YG
STA
ST01 0.5 BY
STM
WH01 0.3 YR
ISC1A
WM01 0.3 Lg
IS1B
ED05 0.3 BBr WK01 0.3 Sb
BW IS2A
OA01 0.3 BO WN01 0.3 BLg
B IS2B

O2–SNSR
CC08 0.5 BW
E1
CC09 0.5 BW
E03
ED02 0.3 BBr

ET01 0.3 BL FP10 0.5 YB

CC10 0.5 BW

W.T. SNSR
BB05 0.75 OB

BB03 0.75 OB FC01 0.5 YR

FUEL–PUMP

LA01 0.3 GW

INJECTER
US01 0.5 WG
PL01

KB01
CC03

NA01 0.5 R BB09 0.75 OB

PL04
CC14
CC15

SC01
0.5
0.5
SB01

CC13
0.75

HA01 0.3 WP
SOLENOID

0.3
0.5
0.5

0.5
0.5

0.3
Br

TPS
WB
BW

GA01 0.3 GB BB07 0.75 OB

V

Br
Lg

BW
BW

MAP

BW
IA01 0.3 G

MAQS
AT
ED01 0.5 BBr TS01 0.5 WR
Gr

WB
BW
TS

WN01 0.3 BLg SD01 0.5 GrR

Lg
B

BW
BW

Gr

BW
IS2A (D)
WK01 0.3 Sb CC05 0.3 BW
IS2B (C)
R–TURN, R
REAR–COMB
R–TURN, L

WM01 0.3 Lg

ISC
IS1B (B)
LICENSE–LAMP

WH01 0.3 YR
IS1A (A)

AC01 1.25 R

1
RR01 0.5 RB VT01 0.75 RL
UBMR
AC02 1.25 R
WSOF

2
RT01 0.75 RL BF01 0.5 O
WAUIN1

1. ABS VALVE (10A)

ABS FUSE–BOX
2. ABS MOTOR (15A)
WSOR

ABSOFF/BLS
FB01 0.5 BR FB01 0.5 BR
B

WSSF
FV01 0.5 WR RV01 0.5 WY
FVW
W

WSPR
BW01 0.75 BW
GND
VR01 0.5 RB
UBVR
RB01 0.5 BY NS01 0.5 Br
ABS–CONT

NABSSLAMP
RV01 0.5 WY SR01 0.5 GrR
RVW
W

DIAGK
XC01 0.5 OW
DIAGL

CAN1M
XC01 0.5 OW
CAN1P
CC21 0.5 BW FV01 0.5 WR
WSPF
RB01 0.5 BY
SHORT–C

WSSR
RT01 0.75 RL VT01 0.75 RL

BA06 0.5 O BF06 0.5 O

Wiring Systems:

CC20 0.75 BW BW01 0.75 BW

RR01 0.5 RB VR01 0.5 RB

SD02 0.5 GrR SR01 0.5 GrR

ABS–SHORT, C

IM23K1910908-01
9A-10
9A-11 Wiring Systems:

Wiring Harness Routing Diagram

BENM23K19102002

[L]
[V] [U] [S]

10
[P] 12

[T]
[K] 8
14 12
[Q]
[M]
[J]
[R] 11 9 [O]

13 [N] [I] 9

Front ward
7 6

Sect U - U’

1 5
[C]
Front [H]
[D] [A] [B]
Ward
4 [G]
U
2 3
U’
Sect V - V’
V’ V [F]

[E]

IK23K4910901-01

[A]: After fixed clamp touch to the upper side bracket [S]: Fuel cut sensor branch goes between turn-relay and air cleaner
[B]: Insert clamp (insert frontward hole) [T]: Fuel cut sensor is face the ‘UP’ mark upward
[C]: Goes upside throttle cables [U]: Set fuel cut sensor branch to the air cleaner ditch after mount the fuel cut
sensor
[D]: Insert clamp [V]: Put relay holder between air cleaner and seat bracket.
Holder must be touched with rounded edge of bracket.
[E]: Speed sensor branch 1. Frame
• Goes between starter motor and engine mounting portion
• Goes under magneto lead and GPS lead
[F]: Rectifier & regulator branch goes rear-side of air cleaner mounting 2. Main wire harness
portion and bottom branch goes between rib and rectifier &
regulator
[G]: Rectifier & regulator goes upper side of mating face of air cleaner 3. Fan motor lead
[H]: Clamping position is between rear-fender rib 4. Canister purge no. 2 hose (if equipped)
[I]: Starter motor relay branch goes outside of body 5. Reserve tank inlet hose
[J]: Fuse branch under starter motor lead and starter motor relay 6. Magneto lead
[K]: Rectifier & regulator branch under air cleaner duct 7. Gear position lead
[L]: Rectifier & regulator branch pass inside starter motor lead 8. Battery
[M]: Relay box branch goes front side of air cleaner duct 9. Terminal plus battery
[N]: Rectifier & regulator branch goes inside of air cleaner rib 10. Motor starter lead wire
[O]: Put terminal license plat light and rear turn signal 11. TO sensor
[P]: All branch goes inside of starter motor and battery minus lead 12. Relay holder
[Q]: Fuel tank branch is put on the air cleaner guide before fuel tank 13. Air cleaner
mount
[R]: GPS branch goes behind of fuel pump branch 14. Seat bracket
 Wiring Systems: 9A-12

9 10

12

13

4 3 1
[A]

14

11

6 5

[B]

[C]

[J]

[G]

[E]
[F]
[D]
8
[H] [I]

IK23K4910902-02

[A]: Hose goes over the wires 3. Ignition coil lead

[B]: Magneto and gear position lead wire goes between keyless unit
and bracket
[C]: Starter motor lead wire and battery minus lead wire go over the
bridge tube
[D]: Stop lamp switch lead goes under the frame
[E]: Stop lamp switch lead to the brake hose
[F]: Speed sensor branch goes inside of the starter motor lead and
battery minus lead
[G]: Wire harness no. 2 branch goes bracket front
[H]: After connected boots covered vertically and opening face under
side
[I]: Set connectors into PVC boot
[J]: Speed meter branch goes under the brace
1. Ignition coil connector upside
2. Ignition coil connector bottom
4. Left & right handle switch, ignition switch and clutch switch connectors:
After connected tie the wires and set clamp
5. Battery minus lead under main wiring harness
6. Stop lamp switch, magneto, gear position switch, keyless unit
7. Starter motor lead and battery minus lead
: Tie on the blue tape and between the brackets cut surplus. Cut end turn
inside
8. O2 sensor connector insert front side hole
9. Keyless indicator (if equipped)
10. Plate
11. Ignition switch
: Ignition switch connectors go under plate
12. Request switch (if equipped)
13. Solenoid (if equipped)
14. Steering lock
9A-13 Wiring Systems:

[C]
[A]

[B]

1
3

1 6 5

2
IK23K4910903-01

[A]: Side stand switch lead between two of boss and magneto cover 3. Clamp:
• Harness
• Magneto lead
• Stop light switch lead
• Side stand switch lead
[B]: Side stand switch lead and gear position sensor lead between magneto cover and fixed by 4. Clamp:
engine sprocket • Gear position sensor lead
• Magneto lead
• Stop light switch lead
Set lock outside of frame, surplus to bottom
[C]: Lead wires between bracket and keyless unit 5. Clamp:
• Gear position sensor lead
• Magneto lead
• Stop light switch lead
1. Engine sprocket cover 6. Side stand switch (if equipped)
2. Magneto side cover
 Wiring Systems: 9A-14

GSX S 125 Model

2 1
3 3

4
[A]
[B]

7
5

6
8

[C]

[D]

IH23K2910903-02

[A]: Insert the clamp to the INNER hole the brace after connected the 3. Front turn signal assembly
terminals.
[B]: Insert the clamp to the OUTER hole the brace after connected the 4. Right handle switch coupler: After connected boots covered vertically and
terminals. opening face under side
[C]: Route main harness right-side of throttle cable. 5. Left handle switch coupler: After connected boots covered vertically and
opening face under side
[D]: Insert clamp 6. Headlight coupler
7. Clutch switch
1. Speedometer: After connected connector, fit the boot to the 8. Clamp
speedometer certainly
2. Headlight housing brace 9. Throttle cable assembly
9A-15 Wiring Systems:

With ABS

“A” “B” [B]

Detail “A”

1
3
[A]

[C] [D]

[E] 2 “C”

Detail “C” Detail “B”

IH23K4910908-01

[A]: Pass front wheel speed sensor coupler rear side of the radiator. [E]: True up the ABS / Hydraulic control unit
edges of the cushion.
[B]: Connect ABS power supply connector under air-cleaner intake tube. 1. ABS / Hydraulic control unit.
[C]: MAQS branch goes inside of the rear ABS pipe. 2. ABS / Hydraulic control unit coupler.
[D]: ABS branch goes rear side of the canister drain hose. 3. Cushion.

Component Location
Electrical Components Location
BENM23K19103001
Refer to “Electrical Components Location” in Section 0A (Page 0A-6).
 Lighting Systems: 9B-1

Lighting Systems
Body and Accessories

Precautions
Precautions for Lighting Systems
BENM23K19200001
NOTICE
• When you touch the bulb with your bare hands, clean the bulb with a cloth moistened with alcohol
or soap water to prevent premature bulb failure.
• Do not use the bulb of a wattage other than specification.
• To avoid damage to the LED, do not connect the headlight LO circuit to the battery or 12 V power
source directly.

Diagnostic Information and Procedures

Headlight Symptom Diagnosis
BENM23K19204001

Condition Possible cause Correction / Reference Item

Low beam does not light Faulty regulator/rectifier. Replace regulator/rectifier. (Page 1J-10)
up Faulty LED. Replace headlight assembly. (Page 9B-2)
Faulty wiring or ground. Repair wiring. (Page 9A-3)
Faulty dimmer switch. Check dimmer switch. (Page 9B-13)
High beam does not light Faulty regulator/rectifier. Replace regulator/rectifier. (Page 1J-10)
up Faulty LED. Replace headlight assembly. (Page 9B-2)
Faulty wiring or ground. Repair wiring. (Page 9A-3)
Faulty dimmer switch. Check dimmer switch. (Page 9B-13)

Turn Signal Light Symptom Diagnosis

BENM23K19204002

Condition Possible cause Correction / Reference Item

Flash rate high or one Bulb blown.
side only flashes Incorrect bulb.
Faulty turn signal relay.
Open circuit or high resistance between
turn signal switch and non lighting bulb.
Flash rate low Supply voltage low or high resistance.
Faulty turn signal relay.
Replace bulb. (Page 9B-8)
Replace bulb. (Page 9B-8)
Check turn signal relay. (Page 9B-11)
Repair wiring. (Page 9A-3)
Check charging system. (Page 1J-4)
Repair wiring. (Page 9A-3)
Check turn signal relay. (Page 9B-11)

Rear Brake Light Symptom Diagnosis

BENM23K19204003

Condition Possible cause Correction / Reference Item

All lights do not light up Faulty wiring or grounding.
Tail light do not light up Bulb blown.
Faulty wiring or grounding.
Brake light do not light up Faulty front brake light switch.
Faulty rear brake light switch.
Faulty wiring or grounding.
Faulty brake light bulb.
Brake light stay on Faulty front brake light switch.
Faulty rear brake light switch.
Faulty wiring or grounding.
Repair wiring. (Page 9A-3)
Replace bulb. (Page 9B-8)
Repair wiring. (Page 9A-3)
Check front brake light switch. (Page 4A-9)
Check rear brake light switch. (Page 4A-9)
Repair wiring. (Page 9A-3)
Replace bulb. (Page 9B-8)
Check front brake light switch. (Page 4A-9)
Check rear brake light switch. (Page 4A-9)
Repair wiring. (Page 9A-3)
9B-2 Lighting Systems:

Repair Instructions
Headlight Construction
BENM23K19206001
Refer to “Headlight Housing Construction” in Section 9D
(Page 9D-2).

Headlight Removal and Installation

BENM23K19206002

Removal
GSX R 125 Model
1) Disconnect the battery (–) lead wire. Refer to
“Battery Removal and Installation” in Section 1J
(Page 1J-13).
2) Remove body cowling. Refer to “Body Cowling
Removal and Installation” in Section 9D (Page 9D- IH23K1920003-02

29). 5) Pull to the front for remove the headlight (1).

3) Remove headlight coupler (1).

IH23K1920004-02
IH23K1920001-01

4) Remove the headlight brace bolts. GSX S 125 Model

1) Disconnect the battery (–) lead wire. Refer to
“Battery Removal and Installation” in Section 1J
(Page 1J-13).
2) Remove meter cover. Refer to “Combination Meter
Removal and Installation” in Section 9C (Page 9C-
3).
3) Remove front turn signal light coupler. Refer to
“Front Turn Signal Light Removal and Installation”
(Page 9B-9).

IH23K1920002-02
 Lighting Systems: 9B-3

4) Remove license plate bracket (1). 7) Release headlight (1) from headlight brace cushion
(2) and then remove headlight.
1

IH23K2920004-01
IH23K2920001-01

5) Remove the headlight brace bolts. Installation

Installation is in the reverse order of removal. Pay
attention to the following points:

GSX R 125 Model

• Tighten the headlight brace bolts (1) to the specified
torque.
Tightening torque
Headlight brace bolt (a): 2.0 N·m (0.20 kgf-m, 1.47
lbf-ft)

(a)

IH23K2920002-01

6) Remove the headlight coupler (1).

IH23K5920001-01

IH23K2920003-01
9B-4 Lighting Systems:

Headlight LED / Position Light LED

Replacement
BENM23K19206003
NOTE 1

If LED operation is abnormal, replace the

headlight assembly with a new one. (Page
9B-2)

Headlight Beam Adjustment

BENM23K19206004
1) Using screwdriver, rotate headlight adjust bolt (1)
counterclockwise or clockwise to adjust headlight
vertical beam.
IH23K1920005-01

Rear Lighting System Construction

BENM23K19206005

10
5 2

(a)
3
(a)

4
2
8

11

[B]
7 6 [A]

[C]
1

IH23K1920006-02

[A]: Insert protector tube in the hole of rear fender brace. 6. Rear fender brace
[B]: Set protector tube attached to clamp. 7. Protector tube
[C]: Pass the license plate light lead wire and turn signal lead wire into protector tube in the hole 8. Rear fender front cover
of rear fender brace.
1. Rear brake light 9. Rear reflector
2. Rear turn signal light 10. Rear turn signal plate
3. License plate light 11. Rear brake light cushion
: Affix the cushion along the line of rear comb.
4. Frame : 2.0 Nm (0.20 kgf-m, 1.47 lbf-ft)
5. Rear fender
 Lighting Systems: 9B-5

Rear Brake Light / Rear Turn Signal Light / License Plate Light Components
BENM23K19206006

(a)

4
6
3

(a)

IH23K1920007-03
9B-6 Lighting Systems:

11

16

15

13
14
12
15

13
10 11

16
14

10 12

15

15

IK23K4920001-01

1. Rear brake light lens and housing 7. License plate light 13. Rear turn signal plate
2. Bulb (12V21/5W) 8. Rubber 14. Gasket
3. Rear brake light socket 9. Rear reflector 15. Screw
4. Tube breath 10. Rear turn signal lens 16. Rear turn signal socket
5. Protector tube 11. Rear turn signal housing
6. Rear brake light cushion 12. Bulb (12V10W)

Rear Brake Light Removal and Installation

BENM23K19206007

Removal
1) Remove rear fender rear. (Page 9D-32) 1

2) Remove right and left frame cover and frame center

cover. (Page 9D-31)
3) Cut rear brake light lead wire clamp (1) and then
disconnect rear brake light lead wire coupler (2).

IH23K1920009-01
 Lighting Systems: 9B-7

4) Remove rear fender front cover screws (1) and rear Installation
brake light screws upper (3) and then pull out rear Install the combination light in the reverse order of
fender front cover (2) and rear brake light. removal.
Pay attention to the following point:
2 • Tighten the rear fender front screws (1) to the
specified torque.

IH23K1920010-02 1, (a)

3, (a)
IH23K1920013-02

Tightening torque
Rear fender front screw (a): 2.0 N·m (0.20 kgf-m,
1.47 lbf-ft)
• Tighten the rear brake light screws upper (3) to the
specified torque.
Tightening torque
Rear combination light screw (a): 2.0 N·m (0.20 kgf-
m, 1.47 lbf-ft)

3, (a)

IH23K1920011-04

5) Remove rear brake light screw and then remove rear

brake light (1) from rear fender front cover (2).

IH23K1920011-04

IH23K1920012-02
9B-8 Lighting Systems:

Rear Brake Light Bulb Replacement License Plate Light Removal and Installation
BENM23K19206008 BENM23K19206009
1) Open rear seat. (Page 9D-20)
Removal
2) Turn rear brake light socket (1) counterclockwise
and remove it. 1) Remove rear fender rear. (Page 9D-32)
2) Remove rear fender brace (1).

IH23K1920014-02 IH23K1920015-01
3) Push in on the bulb (1), twisting it to the left, and pull 3) Remove license plate light screws.
it out

1
IH23K1920028-01

IH23K1920016-01

4) Pull out license plate light (1) for remove.

IH23K1920017-01
 Lighting Systems: 9B-9

Installation Front Turn Signal Light Removal and

Install license plate light in the reverse order of removal. Installation
Pay attention to the following points: BENM23K19206010
Removal
• Tighten the license plate light screws (1) to the
GSX R 125 Model
specified torque.
1) Remove front fairing. (Page 9D-22)
• Pass the license plate light lead wire (2) into the
protector tube (3) in the rear fender brace hole (4). 2) Remove front turn signal plate (1).

Tightening torque
License plate light screw (a): 2.0 N·m (0.20 kgf-m, 1
1.47 lbf-ft)

1, (a)

IH23K1920022-01

3) Remove front turn signal light assembly (1).

IH23K1920018-02

2
IH23K1920023-03

GSX S 125 Model

1) Remove meter cover bolt.

3
IH23K1920019-01

NOTICE
Be careful not to bent, twist, or damage the
license plate light lead wire when you pass
into protector tube in the rear fender brace
hole.

NOTE
License plate light is assembly.
If LED operation is abnormal, replace the
license plate light assembly with a new one.
IH23K2920006-01
9B-10 Lighting Systems:

2) Remove front turn signal couplers (1) and remove Rear Turn Signal Light Removal and Installation
meter cover. BENM23K19206011

Removal
1) Remove rear fender rear. (Page 9D-32)
1 2) Remove rear fender brace (1).

IH23K2920005-02

3) Remove front turn signal plate (1).

IH23K1920015-01
1
3) Remove rear turn signal plate (1).

IH23K2920007-01

4) Remove front turn signal light assembly (1).

IH23K1920020-01

4) Remove rear turn signal assembly (1).

IH23K2920008-01

Installation
Install rear turn signal in the reverse order of removal.

IH23K1920021-01
 Lighting Systems: 9B-11

Installation 3) Push in on the bulb (1), twisting it to the left, and pull
Install rear turn signal in the reverse order of removal. it out for replacement.

Turn Signal Bulb Replacement

BENM23K19206012
1) Remove turn signal light screws and then pull out
turn signal lens (1).

IH23K1920026-03

1
1

IH23K1920024-02

2) Remove turn signal bulb holder screw (1).

IH23K1920027-01

4) To fit replacement bulb, push it in and twist to the

right while pushing.

NOTICE
Over-tightening the screws when reinstalling
1 the lens may cause the lens to crack.
Tighten the screws only until they are snug.

Turn Signal Relay Inspection

BENM23K19206013
Refer to “Electrical Components Location” in Section 0A
IH23K1920025-02
(Page 0A-6).

NOTE
Make sure that the battery is fully charged.

Before removing the turn signal relay, check the

operation of the turn signal light.
If the turn signal light does not illuminate, inspect the
bulb, turn signal switch and circuit connection.
If the bulb, turn signal switch and circuit connection are
OK, the turn signal relay may be faulty. In this case,
replace the turn signal relay with a new one. (Page 9B-
12)
9B-12 Lighting Systems:

Turn Signal Relay Removal and Installation

BENM23K19206014
Removal Color
Lg Lbl B
Position
1) Remove frame cover. (Page 9D-31)
L
2) Remove fuel tank. (Page 1G-8) PUSH
3) Disconnect the coupler (1) and remove the turn R
signal relay (2). I944H1920039-01

5) After finishing the turn signal switch inspection,

install the removed parts.

2
GSX S 125 Model
1) Remove headlight assembly. “Headlight Removal
and Installation” (Page 9B-2)
2) Disconnect the left handle switch coupler (1).

1
1

IH23K1920029-02

Installation
Install the turn signal relay in the reverse order of
removal. Pay attention to the following point:
• Install the starter relay with the clamp. Refer to
“Electrical Components Location” in Section 9A (Page IH23K2920009-03
9A-15)“Wiring Harness Routing Diagram” in Section 3) Inspect the turn signal switch for continuity with a
9A (Page 9A-11). circuit tester. If any abnormality is found, replace the
left handle switch with a new one. Refer to
Turn Signal Switch Inspection “Handlebar Removal and Installation” in Section 6B
BENM23K19206015 (Page 6B-4).
GSX R 125 Model
1) Remove frame cover. (Page 9D-31)
Color
2) Remove fuel tank. (Page 1G-8) Lg Lbl B
Position
3) Disconnect the left handle switch coupler (1). L
PUSH
R
I944H1920039-01

4) After finishing the turn signal switch inspection,

install the removed parts.
1

IH23K1920030-02

4) Inspect the turn signal switch for continuity with a

circuit tester. If any abnormality is found, replace the
left handle switch with a new one. Refer to
“Handlebar Removal and Installation” in Section 6B
(Page 6B-4).
 Lighting Systems: 9B-13

Dimmer Switch Inspection 3) Inspect the dimmer switch for continuity with a circuit
BENM23K19206016 tester.
GSX R 125 Model If any abnormality is found, replace the left handle
1) Remove fuel tank. (Page 1G-8) switch with a new one. Refer to “Handlebar Removal
2) Disconnect the left handle switch coupler (1). and Installation” in Section 6B (Page 6B-4).

Color
YW Y W BG
Position
HI
LO
1 IH23K1920031-03

4) After finishing the dimmer switch inspection, reinstall

the removed parts.

Passing Switch Inspection

BENM23K19206017
GSX R 125 Model
1) Remove fuel tank. (Page 1G-8)
IH23K1920030-02
2) Disconnect the left handle switch coupler (1).
3) Inspect the dimmer switch for continuity with a circuit
tester.
If any abnormality is found, replace the left handle
switch with a new one. Refer to “Handlebar Removal
and Installation” in Section 6B (Page 6B-4).
1
Color
YW Y W BG
Position
HI
LO
IH23K1920031-03

4) After finishing the dimmer switch inspection, reinstall

the removed parts.
IH23K1920030-02
GSX S 125 Model 3) Inspect the passing switch for continuity with a circuit
1) Remove headlight assembly. “Headlight Removal tester. If any abnormality is found, replace the left
and Installation” (Page 9B-2) handle switch with a new one. Refer to “Handlebar
2) Disconnect the left handle switch coupler (1). Removal and Installation” in Section 6B (Page 6B-4).

Color
W BG Y
Position
FREE
1 PUSH
IH23K1920032-02

4) After finishing the passing switch inspection, reinstall

the removed parts.

IH23K2920009-03
9B-14 Lighting Systems:

GSX S 125 Model

1) Remove headlight assembly. “Headlight Removal Color
BL Lb Lg
and Installation” (Page 9B-2) Position
2) Disconnect the left handle switch coupler (1). OFF
ON
IL23K3920001-02

4) After finishing the hazard switch inspection, reinstall

the removed parts.
1
GSX S 125 Model
1) Remove headlight assembly. “Headlight Removal
and Installation” (Page 9B-2)
2) Disconnect the right handle switch coupler (1).

IH23K2920009-03

3) Inspect the passing switch for continuity with a circuit

tester. If any abnormality is found, replace the left
handle switch with a new one. Refer to “Handlebar
Removal and Installation” in Section 6B (Page 6B-4). 1

Color
W BG Y
Position
FREE
PUSH
IH23K1920032-02
IH23K2190001-01
4) After finishing the passing switch inspection, reinstall
the removed parts. 3) Inspect the hazard switch for continuity with a circuit
tester. If any abnormality is found, replace the right
handle switch with a new one. Refer to “Handlebar
Hazard Switch Inspection (If Equipped)
BENM23K19206018 Removal and Installation” in Section 6B (Page 6B-4).
GSX R 125 Model
1) Remove fuel tank. (Page 1G-8) Color
BL Lb Lg
Position
2) Disconnect the right handle switch coupler (1).
OFF
ON
IL23K3920001-02

4) After finishing the hazard switch inspection, reinstall

the removed parts.
1

IH23K1190003-02

3) Inspect the hazard switch for continuity with a circuit

tester. If any abnormality is found, replace the right
handle switch with a new one. Refer to “Handlebar
Removal and Installation” in Section 6B (Page 6B-4).
 Lighting Systems: 9B-15

Specifications
Tightening Torque Specifications
BENM23K19207001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Headlight brace bolt 2.0 0.20 1.47 (Page 9B-3)
Rear fender front screw 2.0 0.20 1.47 (Page 9B-7)
Rear combination light screw 2.0 0.20 1.47 (Page 9B-7)
License plate light screw 2.0 0.20 1.47 (Page 9B-9)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Rear Lighting System Construction” (Page 9B-4)
“Fasteners Information” in Section 0C (Page 0C-10)
9C-1 Combination Meter / Fuel Meter / Horn:

Combination Meter / Fuel Meter / Horn

Body and Accessories

General Description
Combination Meter System Description
BENM23K19301001
This combination meter mainly consists of the LCD (Liquid Crystal Display) and LED (Light Emitting Diode).
The LCD indicates Fuel level indicator (4), Clock (5), Odo / Trip A / Trip B (6), Speed (7), Engine RPM indicator (8) and
Gear position indicator (9) respectively.
LED is used for the illumination light and each indicator light.
LED is maintenance free. LED consumes less power and is more resistant to vibration compared to conventional light
bulbs.

2 5 8 9 4

12 12

15
11

14
10

13
16

3 7 1
6
IM23K1930001-01

1. Adjust switch 11. LED (Engine RPM indicator light) 15. LED (MIL)
2. Tachometer 12. LED (Turn signal indicator light) 16. ABS
3. Select switch 13. LED (Hi beam indicator light)
10. LED (Neutral indicator light) 14. LED (ECT indicator light)
 Combination Meter / Fuel Meter / Horn: 9C-2

Diagnostic Information and Procedures

Combination Meter Symptom Diagnosis
BENM23K19304001
1) Check the combination meter power and ground circuit.

Condition Possible cause Correction / Reference Item

Speedometer does not Faulty speed sensor Check speed sensor. (Page 1C-13)
operate Faulty speedometer Check speedometer. (Page 9C-5)
Faulty speed sensor circuit Repair circuit. (Page 9A-3)
Fuel level indicator does Faulty fuel level gauge Check fuel level gauge. (Page 9C-6)
not operate Faulty fuel level indicator Check fuel level indicator. (Page 9C-5)
Faulty fuel level gauge circuit Repair circuit. (Page 9A-3)

Horn Symptom Diagnosis

BENM23K19304002

Condition Possible cause Correction / Reference Item

Horn does not operate Faulty horn switch Check horn switch. (Page 9C-6)
Faulty wiring or ground Repair circuit. (Page 9A-3)
Faulty horn Check horn. (Page 9C-6)

Repair Instructions
Combination Meter Construction
BENM23K19306001
GSX R 125 Model

2
1

5
4

[A]

3 (a)

IH23K1930001-01

[A]: Fit the coupler boot to the speedometer until it reaches bottom of the meter case. 4. Meter cushion
1. Meter panel 5. Combination meter washer
2. Combination meter : 2.0 Nm (0.20 kgf-m, 1.47 lbf-ft)
3. Combination meter screw
9C-3 Combination Meter / Fuel Meter / Horn:

GSX S 125 Model

2
1

5
4

[A]

3 (a)
IH23K2930001-02

[A]: Fit the coupler boot to the speedometer until it reaches bottom of the meter case. 4. Meter cushion
1. Headlamp housing bracket 5. Combination meter washer
2. Combination meter : 2.0 Nm (0.20 kgf-m, 1.47 lbf-ft)
3. Combination meter screw

Combination Meter On-Vehicle Inspection Combination Meter Removal and Installation

BENM23K19306002 BENM23K19306003
Check that the LEDs (MIL (1) and ECT indicator light (2)) GSX R 125 Model
immediately light up when the ignition switch is turned to 1) Remove body cowling. (Page 9D-29)
ON.
2) Remove meter panel. (Page 9D-30)
Check that other LEDs (Hi beam indicator light (3),
Neutral indicator light (4) and Turn signal indicator lights 3) Remove meter panel screws.
(5)) light up/go off by operating the gearshift lever,
dimmer and turn signal switches.
If abnormal condition is found, replace the combination
meter unit with a new one after checking its wire
harness/coupler. (Page 9C-3)

5 5

1
mph
2

3
4

IM23K1930002-01

IH23K1930002-01
 Combination Meter / Fuel Meter / Horn: 9C-4

4) Pull up speedometer (1) for remove. 3) Remove combination meter coupler (1).

1
1

IH23K2930002-01
IH23K1930003-01
4) Remove combination meter screw (1) and then pull
up combination meter (2) for remove.
GSX S 125 Model
1) Remove meter cover bolt.

IH23K2930003-01

IH23K2920006-01 Installation
2) Remove front turn signal couplers (1) and remove Installation is in the reverse order of removal. Pay
meter cover. attention to the following point:
• Check that combination meter cushion are installed
correctly (1).
• Tighten the combination meter screw (2) to the
1 specified torque.
Tightening torque
Combination meter screw (a): 2.0 N·m (0.20 kgf-m,
1.47 lbf-ft)

IH23K2920005-02
9C-5 Combination Meter / Fuel Meter / Horn:

2, (a)

IH23K2930004-01

IH23K6930001-01
Speedometer On-Vehicle Inspection 4) Turn the ignition switch ON.
BENM23K19306004
If the speedometer, odometer or tripmeter does not 5) Check the display of fuel level indicator (LCD)
function properly, inspect the speed sensor and coupler referring to the following table.
connections. If the speed sensor and coupler If any defect is found, replace the combination meter
connections are OK, replace the combination meter unit with a new one. (Page 9C-3)
with a new one. (Page 9C-3)
NOTE

Fuel Level Indicator Inspection It takes approx. 40 seconds for the fuel level
BENM23K19306005 indicator to indicate the fuel level.
1) Remove fuel tank. (Page 1G-8)
2) Disconnect fuel level gauge coupler (1).
Resistance Fuel level indicator

176.0 – 204.0 Ω
Flicker

130.5 – 149.5 Ω

IH23K4930003-02

3) Connect a variable resistor (1) between the Y/B and 92.5 – 107.5 Ω
B/W lead wires from the wire harness side.

54.5 – 65.5 Ω

21.0 – 29.0 Ω

IG12K1930007-01
 Combination Meter / Fuel Meter / Horn: 9C-6

6) After finishing the fuel level indicator inspection,

reinstall the removed parts.

Fuel Level Gauge Inspection

BENM23K19306006 1
Refer to “Fuel Level Gauge Inspection” in Section 1G
(Page 1G-13).

ECT Sensor Removal and Installation

BENM23K19306007
Refer to “ECT Sensor Removal and Installation” in
Section 1C (Page 1C-7).

Horn Inspection IH23K2920009-03

BENM23K19306008 4) Inspect the horn switch for continuity with a circuit

Horn Switch Inspection tester.
GSX R 125 Model If any defect is found, replace the left handle switch
1) Remove fuel tank. (Page 1G-8) with a new one.
2) Disconnect the left handle switch lead wire coupler
(1). Color
BL BW
Position

PUSH
IH23K1930008-01

5) After finishing the horn switch inspection, reinstall

1 the removed parts.

Horn Inspection
1) Disconnect the horn couplers. Refer to “Horn
Removal and Installation” (Page 9C-7).
2) Connect a 12 V battery to terminal (1) and terminal
(2). If the sound is not heard from the horn, replace
the horn with a new one.
IH23K1920030-02

3) Inspect the horn switch for continuity with a circuit

tester.
If any defect is found, replace the left handle switch
with a new one.

Color
BL BW
Position
1
PUSH
IH23K1930008-01
2
4) After finishing the horn switch inspection, reinstall
the removed parts.
IH23K1930009-02
GSX S 125 Model
1) Remove meter cover. Refer to “Combination Meter
Removal and Installation” (Page 9C-3)
2) Remove headlight assembly. Refer to “Headlight
Removal and Installation” in Section 9B (Page 9B-2)
3) Disconnect the left handle switch lead wire coupler
(1).
9C-7 Combination Meter / Fuel Meter / Horn:

Horn Removal and Installation

BENM23K19306009 2
Removal
1) GSX R125 Model
Remove front fairing. (Page 9D-22)
GSX S125 Model
Remove fuel tank side cover. (Page 9D-25)
2) Disconnect the horn couplers (1).
3) Remove the horn (2).

IH23K1930007-01

Installation
Install the horn in the reverse order of removal.

Specifications
Tightening Torque Specifications
BENM23K19307001
Tightening torque
Fastening part Note
Nm kgf-m lbf-ft
Combination meter screw 2.0 0.20 1.47 (Page 9C-4)

Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Combination Meter Construction” (Page 9C-2)
“Fasteners Information” in Section 0C (Page 0C-10)
 Exterior Parts: 9D-1

Exterior Parts
Body and Accessories

Repair Instructions
Seat Lock Construction
BENM23K19406001

[B]

View A
6 (a)

[A]

[C]
5 (a)

IH23K1940001-02

[A]: Insert the protrusion of the seat lock guide into the hole of the frame. 2. Seat lock plate no.2 6. Bolt
[B]: Align the rib of seat lock and groove of each part. 3. Seat lock assembly : 8.8 Nm (0.89 kgf-m, 6.49 lbf-ft)
[C]: Align the hole of the frame and the slit of the seat lock guide. 4. Seat lock guard
1. Seat lock plate no.1 5. Screw
9D-2 Exterior Parts:

Headlight Housing Construction

BENM23K19406002
GSX R 125 Model

NOTE
Symbols such as [a] – [a] indicate a connection between 2 points.

7 7

8 10 (b)

[a]
11 [b]
[a]
[b]
2

1
(a)

12
5
(a)
(a)

4 (a) 9
6

10 (c)

IH23K5940007-01
 Exterior Parts: 9D-3

1. Body cowling 6. Front license bracket 11. Screw

2. Combination meter 7. Rear view mirror 12. Cowling brace lower washer
3. Meter panel 8. Windscreen : 8.8 Nm (0.89 kgf-m, 6.49 lbf-ft)
4. Headlight 9. Cushion : 4.0 Nm (0.40 kgf-m, 2.95 lbf-ft)
5. Cowling lower brace 10. Screw : 2.0 Nm (0.20 kgf-m, 1.47 lbf-ft)
9D-4 Exterior Parts:

GSX S 125 Model

NOTE
Symbols such as [a] – [a] indicate a connection between 2 points.

6
10 (c) 8 10 (c)
9
7
4 9

1
1 9
10 (b)

1 To Upper
Bracket
2

10 (b) To Under
Bracket

11 (a) 11 (a)

9
10 (b)

IH23K2940001-03
 Exterior Parts: 9D-5

1. Headlight housing 6. Front license bracket 11. Bolt

2. Combination meter 7. Front turn signal light : 8.8 Nm (0.89 kgf-m, 6.49 lbf-ft)
3. Handlebar 8. Cover meter : 2.0 Nm (0.20 kgf-m, 1.47 lbf-ft)
4. Headlight 9. Cushion : 4.0 Nm (0.40 kgf-m, 2.95 lbf-ft)
5. Headlight housing brace 10. Screw
9D-6 Exterior Parts:

Front Fairing Construction (GSX R 125 Model)

BENM23K19406003
NOTE
Symbols such as [a] – [a] indicate a connection between 2 points.

IH23K1940003-02
 Exterior Parts: 9D-7

15
20 (a)

20 (a)

14

20 (a)

20 (a)

10
19 (b)

20 (a)
13

8 6
9 20 (a)
12
11
20 (a)
7
20 (a)

5
IH23K1940004-01

1. Fuel tank center cover 9. Right inner cowling 17. Clip

2. Fuel tank lid 10. Right side upper cowling 18. Screw
3. Radiator 11. Right side lower cowling 19. Screw
4. Fuel tank 12. Fairing brace 20. Screw
5. Left inner cowling 13. Fairing brace cushion 21. Bolt
6. Left side upper cowling 14. Right side middle cowling : 2.0 Nm (0.20 kgf-m, 1.47 lbf-ft)
7. Left side lower cowling 15. Left side middle cowling : 8.4 Nm (0.85 kgf-m, 6.19 lbf-ft)
8. Fairing cushion 16. Lower center cowling
9D-8 Exterior Parts:

Fuel Tank Side Cover and Under Cowling Construction

BENM23K19406004
NOTE
Symbols such as [a] - [a] indicate a connection between 2 points.

19 (c)

19 (c)

1 2

12

(c) 19

(c) 20
(c) 19

20 (c)

20 (c)

IH23K2940002-01
 Exterior Parts: 9D-9

(a)

(a)
(a)

(b) 18
(a)

(a)

18 (b)

(a)
17

IH23K2940003-02

1. Fuel tank center cover 10. Right side frame front cover 19. Screw fuel tank side cover
2. Fuel tank lid 11. Right side frame front lower cover 20. Screw under cowling
3. Radiator 12. Under cowling brace 21. Left side under cowling
4. Fuel tank 13. Frame cover bracket 22. Right side under cowling
5. Left side frame front inner cover 14. Left side frame front middle cover : 2.0 Nm (0.20 kgf-m, 1.47 lbf-ft)
6. Left side frame front cover 15. Right side frame front middle cover : 8.8 Nm (0.89 kgf-m, 6.49 lbf-ft)
7. Left side frame front lower cover 16. Under center cowling : 8.4 Nm (0.85 kgf-m, 6.19 lbf-ft)
8. Cushion 17. Fastener
9. Right side frame front inner cover 18. Bolt
9D-10 Exterior Parts:

Front Fairing Cushion Construction

BENM23K19406005

1
[D]

[B]

“a”
[A]
“a”
B “a”
C
B B-B
C
A-A
C-C
D A

D A
“b”

D-D

“a”
F

F “b”
“b”
E-E E F-F

2 [D]

[C]

IH23K1940053-01

[A]: Left side upper cowling
[B]: Right side middle cowling
[C]: Left side lower cowling
D]: Adhere cushion along the mark off
Exterior Parts: 9D-11
1. Middle cowling cushion
: Before sticking the heat shield, remove oil, dust and paint residue
from the sticking surface. Press the cushion after sticking.
2. Lower cowling cushion
: Before sticking the heat shield, remove oil, dust and paint residue
from the sticking surface. Press the cushion after sticking.
“a”: 0.5 mm (0.39 in)
“b”: 1.0 mm (0.12 in)
9D-12 Exterior Parts:

Frame Cover and Rear Fender Construction

BENM23K19406006
NOTE
Symbols such as [a] – [a] indicate a connection between 2 points.

15 (c) 13 (a)

13 (a)

15 (c)

2 4

“A”

3 (b) 14

(b) 14 9

14 (b)

11
(b) 14
8
14 (b)

5
“A”
6

16 (a)

10

(b) 14
1

(d) 18

(d) 17
(a) 16 12
16 (a)

IK23K4940010-01
 Exterior Parts: 9D-13

1. Rear fender front 9. Left frame cover 17. Bolt (M6: Long)
2. Right frame cover 10. Rear fender brace 18. Bolt (M6: Short)
3. Right frame front cover 11. Cushion : 2.0 Nm (0.20 kgf-m, 1.47 lbf-ft)
4. Frame upper center cover 12. Clip : 6.3 Nm (0.64 kgf-m, 4.64 lbf-ft)
5. Rear fender rear 13. Screw : 4.0 Nm (0.40 kgf-m, 2.95 lbf-ft)
6. Rear inner fender 14. Screw : 8.4 Nm (0.85 kgf-m, 6.19 lbf-ft)
7. Rear fender extension 15. Screw
8. Left frame front cover 16. Screw

Front Fender Construction

BENM23K19406007

7 9

10

2
8
5
10 4 (a)

5
2
6
3 (a) 10

7
IH23K6940001-01

1. Front fender 4. Front fender rear screw 7. Front side reflector (if equipped) 10. Nut
2. Front fender cushion 5. Front fender spacer 8. Front side bracket (left side) : 8.4 Nm (0.85 kgf-m, 6.19 lbf-ft)
3. Front fender front screw 6. Front fender washer 9. Front side bracket (right side)
9D-14 Exterior Parts:

Fuel Tank Construction

BENM23K19406008
GSX R 125 Model

4
3 (c)

6 (a)

8 9 (b)

1
10
(b) (b)

IM23K1170001-02

1. Fuel tank 6. Fuel tank cover screw : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
2. Fuel filler cap 7. Cushion : 10.0 Nm (1.0 kgf-m, 7.37 lbf-ft)
3. Fuel filler cap bolt 8. Clip : 3.0 Nm (0.30 kgf-m, 2.21 lbf-ft)
4. Fuel tank center cover 9. Bolt
5. Fuel tank cover 10. Washer
 Exterior Parts: 9D-15

GSX S 125 Model

4
3 (c)

6 (a)

8 9 (b)

1
10
(b)
(b)

5
7

IM23K1170002-02

1. Fuel tank 6. Fuel tank cover screw : 5.5 Nm (0.56 kgf-m, 4.05 lbf-ft)
2. Fuel filler cap 7. Cushion : 10.0 Nm (1.0 kgf-m, 7.37 lbf-ft)
3. Fuel filler cap bolt 8. Clip : 3.0 Nm (0.30 kgf-m, 2.21 lbf-ft)
4. Fuel tank center cover 9. Bolt
5. Fuel tank cover 10. Frame front inner cover bracket
9D-16 Exterior Parts:

Fuel Tank Cover Cushion Construction

BENM23K19406009
GSX R 125 Model

“a” “b”
[A]
A
2

A-A
A

1
IM23K1940001-01

[A]: Start to stick cushion from this position 3. Fuel tank fastener
: Stick on cover match with mark off line
[B]: Stick on cover match with mark off line “a”: 24 mm (0 – 0.157 in)
1. Fuel tank cover “b”: 3 mm (–0.118 – 0.039 in)
2. Fuel tank cover cushion
: Before sticking the cushion, remove oil, dust and paint residue from the sticking surface.
Press the cushion after sticking.
 Exterior Parts: 9D-17

GSX S 125 Model

[A]
“a” “b”
A
2
A-A

2
3

1
IM23K1940002-01

[A]: Start to stick cushion from this position 3. Fuel tank fastener
: Stick on cover match with mark off line
[B]: Stick on cover match with mark off line “a”: 24 mm (0 – 0.157 in)
1. Fuel tank cover “b”: 3 mm (–0.118 – 0.039 in)
2. Fuel tank cover cushion
: Before sticking the cushion, remove oil, dust and paint residue from the sticking surface.
Press the cushion after sticking.
9D-18 Exterior Parts:

Body Cowling Cushion Construction

BENM23K19406010

A
4

[A]

[B]

2
A-A

[C]

IH23K1940009-01
 Exterior Parts: 9D-19

[A]: Adhere cushion along the mark off 2. Headlamp

[B]: Do not ride on R-End 3. Headlamp cover cushion
[C]: Affix the cushion on comply with an edge setting the edge to the 4. Body cowling cushion: Before sticking the cushion, remove oil, dust
housing notch and paint residue from the sticking surface. Press the cushion after
sticking.
1. Body cowling 5. Meter panel cushion: Before sticking the cushion, remove oil, dust and
paint residue from the sticking surface. Press the cushion after sticking.

Meter Panel Cushion Construction

BENM23K19406011

[A]
[A]

[B]

IH23K1940052-01

[A]: Adhere cushion along the mark off 2. Meter panel

[B]: Fit it until the coupler boots reaches the bottom of meter case 3. Speedometer cushion
1: Meter panel cushion: Before sticking the cushion, remove oil, dust and paint residue from
the sticking surface. Press the cushion after sticking.
9D-20 Exterior Parts:

Fastener Removal and Installation Seat Removal and Installation

BENM23K19406012 BENM23K19406013
Removal Front Seat
1) Depress the head of fastener center piece (1). Removal
2) Pull out the fastener (2). 1) Lift up the rear end of seat and remove the bolts (1).

2 1

ID26J1940192-01

Installation
IK23K4940001-01
1) Let the center piece stick out toward the head so that
the claws (1) closes. 2) Raise the rear end of seat and slide it backward.
2) Insert the fastener into the installation hole.

NOTE
To prevent the claws from damage, insert the
fastener all the way into the installation hole.

IK23K4940002-01

ID26J1940160-01

3) Push in the head of center piece until it becomes

flush with the fastener outside face.

I649G1940007-02
 Exterior Parts: 9D-21

Installation Keyless start model:

Slide the seat hook into the seat look retainer on the • Set main switch (1) in the “ACC” position and then
frame and tighten the bolts securely. remove the main switch (1).
! WARNING
Failure to install the seat properly could allow
the seat to move and cause loss of rider
control.

Faster the seat securely in its proper

position.

1
IK23K4940006-01

NOTICE
Remove main switch except “ACC” position
can make damage in the keyless start
system.
IK23K4940003-01

Make sure remove ignition key in the “ACC”

Rear Seat position.
Removal
1) Ignition key model: • Insert main switch knob key (1) into the lock and
Unlock the rear seat with the ignition key (1). turn it clockwise.

IK23K4940005-01

IK23K4940004-01
9D-22 Exterior Parts:

2) Raise the front end of seat and slide its backward.
Front Fairing Assembly Removal and
Installation
BENM23K19406014
NOTE
The instructions given here for removing and
installing the front fairing are for the left side.
Use the same procedures for the right side
because most of the procedures are the
same for both right and left.
Additional explanations are given only when
different procedures are used between the
right and the left.

Removal
1) Remove the cowling side upper screw.

IK23K4940007-01

Installation
Slide the seat hook into the seat hook retainers and push
down firmly until the seat snaps into the locked position.

! WARNING
Failure to install the seat properly could allow
the seat to move and cause loss of rider
control.

Faster the seat securely in its proper

position.

IH23K1940017-01

2) Remove inner side cowling bolt and cowling lower

center screw.

IK23K4940008-01 IH23K1940018-02
 Exterior Parts: 9D-23

5) Remove front turn light lead wire couplers (1).

IH23K1940019-02

3) Remove cowling side lower screw. IH23K1940022-02

6) Pull it outward to remove front fairing.

IH23K1940020-02

4) Remove cowling side middle screw. IH23K1940023-02

Installation
Install front fairing in reverse order of removal.

IH23K1940021-02
9D-24 Exterior Parts:

Front Fairing Disassembly and Reassembly 4) Remove cowling side middle screw.
BENM23K19406015
Disassembly
1) Remove front fairing assembly. Refer to “Front
Fairing Assembly Removal and Installation” (Page
9D-22)
2) Remove fasteners (1) and screws (2).

1
IH23K1940028-04

2 5) Release claws and then remove cowling side middle

in order of “1” → “2”.

“1”
IH23K1940024-01
“2”
3) Release 3 claws by pulling inner cowling for remove
inner cowling.

IH23K1940029-03

6) Remove under cowling screw.

IH23K1940025-01

IH23K1940026-01
 Exterior Parts: 9D-25

7) Release claws in order of “1” → “2” to remove under 2) Release cushion by pulling out fuel tank side cover
cowling. bolt and then remove fuel tank side cover assembly.

“1”
“2”

IH23K2940007-01
IH23K1940027-02

Reassembly
Assembly front fairing reverse order of disassembly.
Fuel Tank Side Cover Assembly Removal and
Installation
BENM23K19406016
NOTE
The instructions given here for removing and
installing the fuel tank side cover are for the
left side. Use the same procedures for the
right side because most of the procedure are
the same for both right and left. Additional
explanations are given only when different
procedures are used between the right and
the left.
Removal
1) Remove fuel tank side cover assembly bolt.
Installation
Install fuel tank side cover assembly in reverse order of
removal.
Fuel Tank Side Cover Disassembly and
Reassembly
BENM23K19406017
NOTE
The instructions given here for removing and
installing the fuel tank side cover are for the
right side. Use the same procedures for the
left side because most of the procedures are
the same for both right and left. Additional
explanations are given only when different
procedures are used between the right and
the left.
Disassembly
1) Remove fuel tank side cover assembly. “Fuel Tank
Side Cover Assembly Removal and Installation”
(Page 9D-25)
2) Remove frame front inner cover (1).

IH23K2940006-01

IH23K2940009-01
9D-26 Exterior Parts:

3) Release claws in order “1” → “2” and then remove Reassembly

frame front inner cover. Assembly fuel tank side cover in reverse order of
disassembly.

Under Cowling Removal and Installation

BENM23K19406018
NOTE
The instructions given here for removing and
installing the under cowling are for the right
“2” side. Use the same procedures for the left
side because most of the procedures are the
“1” same for both right and left.
Additional explanations are given only when
different procedures are used between the
right and the left.

Removal
Remove under cowling bolt and then remove under
cowling assembly (1).
IH23K2940008-01

4) Remove frame front middle cover (1).

1 1
1

IH23K2940012-01

Installation
Install the under cowling assembly in the reverse order
of removal.
IH23K2940010-01

5) Release claws in order “1” → “2” and then remove

frame front middle cover.

“1”

“2”
IH23K2940011-01
 Exterior Parts: 9D-27

Under Cowling Disassembly and Reassembly
BENM23K19406019
Disassembly
1) Remove under cowling assembly. Refer to “Under
Cowling Removal and Installation” (Page 9D-26)
2) Remove under cowling assembly screw (1) and
fastener (2).
1 2) Remove frame cover bolt (1).
Fuel Tank Cover Removal and Installation
BENM23K19406020
Removal
1) GSX R 125 Model: Remove front fairing. Refer to
“Front Fairing Assembly Removal and Installation”
(Page 9D-22)
GSX S 125 Model: Remove fuel tank side cover
assembly. Refer to “Fuel Tank Side Cover Assembly
Removal and Installation” (Page 9D-25)

2
IH23K2940013-01

3) Release claws and disassembly under cowling

assembly. IH23K1940055-01

3) Remove fuel tank cover bolts and fasteners.

GSX R 125 Model

IH23K2940014-01

Reassembly IH23K1940054-02

Assembly fuel tank side cover in reverse order of

disassembly.
9D-28 Exterior Parts:

GSX S 125 Model 5) If necessary, remove fuel tank center cover (1).

IH23K1940057-02

NOTICE

IH23K2940015-01
For keyless start model, be careful not to
break keyless indicator lead wire.
4) While pulling frame cover (1) remove fuel tank cover
(2) in order of “1” → “2”.
Please make sure disconnect keyless
GSX R 125 Model
indicator lead wire coupler before you
“2” remove fuel tank center cover (1).

2
Installation
“1” Install fuel tank cover in the reverse order of removal.

Windscreen Removal and Installation

BENM23K19406021
Removal
1 Remove the windscreen with release the screws.

IH23K1940056-01

GSX S 125 Model

“1”
“2”

IH23K1940030-02

Installation
Install the windscreen in the reverse order of removal.
2

IH23K2940016-01
 Exterior Parts: 9D-29

Body Cowling Removal and Installation

BENM23K19406022
Removal
1) Remove front fairing. Refer to “Front Fairing
Assembly Removal and Installation” (Page 9D-22)

IH23K1940034-02

4) Remove headlamp coupler (1).

IH23K1940031-02

2) Remove rear view mirror bolts.

IH23K1940035-02
IH23K1940032-03
5) Pull ahead to remove body cowling from meter
3) Remove panel meter screws. panel.

IH23K1940033-02

IH23K1940036-02
9D-30 Exterior Parts:

Installation 4) Remove speedometer coupler (1).

Install the body cowling in the reverse order of removal.
Pay attention to the following point:
• Before installing body cowling, check that the cushion
(1) are installed correctly.

IH23K1940038-02
IH23K1940040-02
5) Remove meter panel by pulling upward through the
steering.
Meter Panel Removal and Installation
BENM23K19406023
Removal
1) Remove front fairing. Refer to “Front Fairing
Assembly Removal and Installation” (Page 9D-22)
2) Remove body cowling. Refer to “Body Cowling
Removal and Installation” (Page 9D-29).
3) Release meter panel hook (1).

IH23K1940039-02

Installation
Install the meter panel in the reverse order of removal.
Pay attention to the following point:
• Before installing meter panel, check that cushion are
installed correctly. Refer to “Meter Panel Cushion
Construction” (Page 9D-19)
IH23K1940037-02
 Exterior Parts: 9D-31

Frame Cover Removal and Installation 5) If necessary, remove frame upper center cover (1).
BENM23K19406024
NOTE
The instructions given here for removing and
1
installing the under cowling are for the left
side. Use the same procedures for the right
side because most of the procedures are the
same for both right and left.
Additional explanations are given only when
different procedures are used between the
right and the left.

Removal
1) Remove front fairing. Refer to “Front Fairing
Assembly Removal and Installation” (Page 9D-22)
2) Remove front and rear seat. Refer to “Seat Removal IH23K1940044-01
and Installation” (Page 9D-20)
3) Remove screws and then remove front frame cover Installation
(1) in order of “1” → “2”. Install the frame cover in the reverse order of removal.

Front Fender Removal and Installation

BENM23K19406025
1 1 Refer to “Front Fender Construction” (Page 9D-13)

Removal
“1”
1) Remove front wheel assembly. Refer to (Page 2D-
3)
“2” 2) Remove brake hose clamp bolt (1), front fender bolt
(2) and front side reflector bolt (3) and then remove
front fender (4).

1
IH23K1940041-01

4) Remove screws (1), fasteners (2), and then remove

2
frame upper cover (3) in order “1” → “2”.
3
1
2
3
“1”

2
“2”
IK23K4940009-02

Installation
Install the front fender in the reverse order of removal.

IH23K1940042-01
9D-32 Exterior Parts:

Rear Fender Rear Removal and Installation 5) Remove rear fender rear (1).
BENM23K19406026
Removal
1) Remove the following parts.
a) Front fairing: (Page 9D-22)
b) Frame cover: (Page 9D-31)
2) Remove rear fender extension (1).

IH23K1940047-02

1 6) If necessary, remove rear fender brace (1).

1
IH23K1940043-01

3) Disconnect ECM coupler (1) and remove ECM (2)

and ECM holder (3).

IH23K1940048-01

NOTICE
1 Be careful not to bent, twist, or damage the
license plate and rear turn signal lead wire
when you remove or install rear fender brace.

Installation
IH23K5940005-01 Install rear fender rear in the reverse order of removal.
4) Disconnect license plate light lead wire coupler (1)
and rear turn signal lead wire couplers (2).

IH23K5940006-01
 Exterior Parts: 9D-33

Rear Fender Front Removal and Installation 6) Disconnect TO sensor (1) and turn signal relay (2)
BENM23K19406027 from rear fender front.
Removal
1) Remove the following parts.
a) Front fairing: (Page 9D-22) 2
b) Frame cover: (Page 9D-31)
c) Rear fender rear: (Page 9D-32)
2) Remove rear brake light. (Page 9B-6)
3) Remove battery. (Page 1J-13)
4) Remove ECM. (Page 1C-2) 1
5) Disconnect fuse box (1).

1
IH23K1940050-01

7) Remove rear fender front (1).

IH23K1940049-01

IK23K4940011-01

Installation
Install the rear fender front in the reverse order of
removal.

Specifications
Tightening Torque Specifications
BENM23K19407001
Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Seat Lock Construction” (Page 9D-1)
“Headlight Housing Construction” (Page 9D-2)
“Front Fairing Construction (GSX R 125 Model)” (Page 9D-6)
“Fuel Tank Side Cover and Under Cowling Construction” (Page 9D-8)
“Frame Cover and Rear Fender Construction” (Page 9D-12)
“Front Fender Construction” (Page 9D-13)
“Fuel Tank Construction” (Page 9D-14)
“Fasteners Information” in Section 0C (Page 0C-10)
9E-1 Body Structure:

Body Structure
Body and Accessories

Repair Instructions
Frame Construction
BENM23K19506001
GSX R 125 Model

IH23K1950007-02
 Body Structure: 9E-2

1. Frame

GSX S 125 Model

IK23K4950004-01

1. Frame
9E-3 Body Structure:

Front Footrest Construction

BENM23K19506002

15 17

16

8 7
13
9
14

12

3
(a) 10 2

5 6
IK23K4950001-01
 Body Structure: 9E-4

1. Front footrest
2. Rear brake pedal
3. Front footrest bar
4. Front footrest bracket
5. Front footrest pin
6. E-ring
7. Rear brake pedal return spring
8. Rear brake pedal return spring plate
9. Rear brake light switch spring
10. Bank sensor bolt
11. Rear brake master cylinder pin
12. Rear brake master cylinder washer
13. Rear brake master cylinder cotter pin
14. Rear brake pedal cotter pin
15. Stop lamp switch
16. Rear brake master cylinder
17. Rear brake reservoir tank
: 18 Nm (1.83 kgf-m, 13.2 lbf-ft)
: Apply grease to sliding surface.
: Do not reuse.

Front Footrest Removal and Installation

BENM23K19506003
Refer to “Front Footrest Construction” (Page 9E-3).

Pillion Footrest Construction

BENM23K19506004

8 (a)

7 1

4 6
5

3
IK23K4950002-01

1. Pillion footrest bracket 5. Pillion footrest ball : 18 Nm (1.83 kgf-m, 13.3 lbf-ft)
2. Pillion footrest bar 6. Pillion footrest plate : Apply grease to sliding surface.
3. E-ring 7. Pillion footrest pin : Do not reuse.
4. Pillion footrest spring 8. Pillion footrest bracket bolt
9E-5 Body Structure:

Pillion Footrest Removal and Installation

BENM23K19506005
Refer to “Pillion Footrest Construction” (Page 9E-4).

Side-stand Construction
BENM23K19506006

5 (a)

[A]

4 (b)

1
2
3

[B]

IL23K3950001-01

[A]: Long arm 3. Side stand inner spring : 7.5 Nm (0.76 kgf-m, 5.53 lbf-ft)
: Keep assembling direction of return : For installation direction of the side stand inner
spring as shown. spring, refer to the illustration.
[B]: Short arm 4. Side stand bolt : Apply grease to sliding surface.
: Keep assembling direction of return
spring as shown.
1. Side stand 5. Side stand nut
2. Side stand outer spring : 40 Nm (4.07 kgf-m, 29.5 lbf-ft)
: For installation direction of the side stand
outer spring, refer to the illustration.

Side-stand Removal and Installation

BENM23K19506007
Refer to “Side-stand Construction” (Page 9E-5).
 Body Structure: 9E-6

Center Stand Construction (If equipped)

BENM23K19506008

[B]
2

5
3 4
[A]

IH23K1950005-01

[A]: Short arm 3. Center stand spring : Apply grease to sliding surface.
: Keep assembling direction of return : For installation direction of the center stand spring,
spring as shown. refer to the illustration.
[B]: Long arm 4. Center stand cushion : Do not reuse.
: Keep assembling direction of return
spring as shown.
1. Center stand 5. Center stand cotter pin
2. Center stand shaft 6. Washer

Center Stand Removal and Installation

BENM23K19506009
Refer to “Center Stand Construction (If equipped)” (Page 9E-6).

NOTE
Support the motorcycle securely with a jack.
9E-7 Body Structure:

Specifications
Tightening Torque Specifications
BENM23K19507001
Reference:
For the tightening torques of fasteners not specified in this page, refer to:
“Front Footrest Construction” (Page 9E-3)
“Pillion Footrest Construction” (Page 9E-4)
“Side-stand Construction” (Page 9E-5)
“Fasteners Information” in Section 0C (Page 0C-10)

Special Tools and Equipment

Recommended Service Material
BENM23K19508001
NOTE
Required service material(s) is also described in:
“Front Footrest Construction” (Page 9E-3)
“Pillion Footrest Construction” (Page 9E-4)
“Side-stand Construction” (Page 9E-5)
“Center Stand Construction (If equipped)” (Page 9E-6)