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SERVICE DATAModel: FL125SDWK9 P-02, 19

4 STROKEVALVE + GUIDE Unit: mm

CAMSHAFT + CYLINDER HEAD Unit: mm

ITEM STANDARD LIMITValve diam. IN. 24.9 – 25.1 —

EX. 21.9 – 22.1 —Valve clearance (when cold) IN. 0.03 – 0.08 —

EX. 0.08 – 0.13 —Valve guide-to-valve stem clearance

IN. 0.010 – 0.037 —EX. 0.030 – 0.057 —

Valve guide I.D. IN. & EX. 5.000 – 5.012 —Valve stem O.D. IN. 4.975 – 4.990 —

EX. 4.955 – 4.970 —Valve stem deflection IN. & EX. — 0.35Valve stem runout IN. & EX. — 0.05Valve head thickness IN. & EX. — 0.5Valve stem end length IN. & EX. — 2.2Valve seat width IN. & EX. 0.9 – 1.1 —Valve head radial runout IN. & EX. — 0.03Valve spring free length IN. & EX. — 32.8Valve spring tension IN. & EX. 110 – 126 N (11.0 – 12.6 kgf)

at length 26.8 mm —

ITEM STANDARD LIMITCam height IN. 27.87 – 27.97 27.57

EX. 27.64 – 27.74 27.34Rocker arm I.D. IN. & EX. 10.003 – 10.018 —Rocker arm shaft O.D. IN. & EX. 9.981 – 9.990 —Cylinder head distortion — 0.05

Date: January 14, 2009

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CYLINDER + PISTON + PISTON RING Unit: mm

CONROD + CRANKSHAFT Unit: mm

OIL PUMP

FIRST CLUTCH Unit: mm

ITEM STANDARD LIMITCompression pressure 750 – 1 200 kPa (7.5 – 12 kgf/cm²) 650 kPa

(6.5 kgf/cm²)Piston-to-cylinder clearance 0.020 – 0.030 0.120Cylinder bore 53.500 – 53.515 53.635Piston diam. 53.475 – 53.490

Measure at 10 mm from the skirt end. 53.355

Cylinder distortion — 0.05Piston ring free end gap 1st R Approx. 5.3 4.2

2nd R Approx. 4.3 3.4Piston ring end gap 1st 0.05 – 0.15 0.50

2nd 0.05 – 0.15 0.50Piston ring-to-groove clearance 1st — 0.180

2nd — 0.150Piston ring groove width 1st 1.01 – 1.03 —

2nd 1.01 – 1.03 —Oil 2.01 – 2.03 —

Piston ring thickness 1st 0.97 – 0.99 —2nd 0.97 – 0.99 —

Piston pin bore I.D. 14.002 – 14.008 14.030Piston pin O.D. 13.996 – 14.000 13.980

ITEM STANDARD LIMITConrod small end I.D. 14.006 – 14.024 14.040Conrod deflection — 3.0Conrod big end side clearance 0.10 – 0.45 1.0Conrod big end width 16.95 – 17.00 —Crank web to web width 41.9 – 42.1 —Crankshaft thrust clearance 0.02 – 0.07 —Crankshaft runout — 0.08

ITEM STANDARD LIMITOil pressure (at 60 °C) 8 – 22 kPa (0.08 – 0.22 kgf/cm²) at 3 000 r/min —

ITEM STANDARD LIMITClutch heel housing I.D. 105.00 – 105.15 105.5Clutch shoe thickness — No grooveClutch engagement 1900 – 2500 r/min —Clutch lock-up 3000 – 3700 r/min —

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GEAR SHIFT CLUTCH Unit: mm

TRANSMISSION + DRIVE CHAIN Unit: mm (Except ratio)

FUEL INJECTOR + ISC VALVE

ITEM STANDARD LIMITClutch release screw 1/8 turn back —Drive plate thickness No. 1, No. 2 2.9 – 3.1 2.6Drive plate claw width No. 1, No. 2 11.80 – 12.00 11.0Driven plate distortion — 0.10Clutch spring free height — 32.0

ITEM STANDARD LIMITPrimary reduction ratio 3.409 (75/22) —Final reduction ratio 2.428 (34/14) —Gear ratios Low 2.909 (32/11) —

2nd 1.785 (25/14) —3rd 1.294 (22/17) —Top 1.052 (20/19) —

Gearshift fork-to-groove clearance No. 1 0.1 – 0.3 0.5No. 2 0.15 – 0.35 0.55

Gearshift fork groove width No. 1 4.5 – 4.6 —No. 2 4.55 – 4.65 —

Gearshift fork thickness No. 1, No. 2 4.3 – 4.4 —Drive chain

Type DID 428——

Links 100 links —20-pitch length — 259

Drive chain slack 15 – 25 —

ITEM SPECIFICATION NOTEFuel injector resistance 1.9 Ω at 20 °CFuel injector voltage (Battery voltage – 1.0 V) or moreISC valve resistance Approx. 35 ΩISC valve voltage Battery voltage

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FI SENSORS

THROTTLE BODY

ITEM SPECIFICATION NOTECKP sensor resistance 180 – 280 ΩCKP sensor peak voltage 2.0 V (When cranking) or more + Bl/Y – - G/WIAP sensor input voltage 4.5 – 5.5 VIAP sensor output voltage Approx. 2.0 – 3.5 V at idle speed + G/B – - Br/BTP sensor input voltage 4.5 – 5.5 VTP sensor output voltage Closed Approx. 0.7 V

+ P – - Br/BOpened Approx. 3.9 V

IAT sensor input voltage 4.5 – 5.5 VIAT sensor output voltage 1.8 – 3.1 V at 20 °CIAT sensor resistance Approx. 2.56 kΩ at 20 °C/1.20 kΩ at 40 °CET sensor input voltage 4.5 – 5.5 VET sensor resistance Approx. 6.2 – 13 kΩ at 20 – 40 °CTO sensor resistance 16.5 – 22.3 kΩTO sensor voltage Normal 0.4 – 1.4 V

+ Bl/W – - Br/BLeaning 65° 3.7 – 4.4 V

HO2 sensor output voltage 0.3 – 1.0 V at idle speed+ W/G – - Br/B

0.6 V or more at 5 000 r/minHO2 sensor resistance 6.5 – 8.9 Ω at 23 °C W – W

ITEM SPECIFICATIONI.D. No. 16HABore size 24 mmFast idle r/min. 1 800 – 1 650 r/min at 0 – 20 °CIdle r/min. 1 500 ± 100 r/min/Warmed engineThrottle cable play 2.0 – 4.0 mm

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ELECTRICAL Unit: mm

WATTAGE Unit: W

ITEM SPECIFICATION NOTESpark plug Type NGK: CR6HSA

DENSO: U20FSR-UGap 0.6 – 0.7

Spark performance 8.0 mm or more at 1 atm.Ignition coil resistance Primary 2 – 5 Ω + Terminal –

- Terminal

Secondary 25 – 40 kΩ Plug cap –- Terminal

Ignition coil primary peak voltage 150 V or more +: B/W –-: W/Bl

Generator coil resistance 0.2 – 1.2 Ω +: Y – -: YGenerator coil no-load voltage (when engine is cold) 50 V or more at 5 000 r/min

Starter motor brush length 7 3.5Charging output 13.5 – 15.2 V at 5 000 r/minStarter relay resistance 9 – 11 ΩBattery Type

designation FTZ5L-BS

Capacity 12 V 16.2 kC (4.5 Ah)/10 HRFuse size 15 A

ITEM SPECIFICATIONHeadlight HI 35

LO 35Position/Parking light 5Brake light/Taillight 21/5License plate light 5Turn signal light 21Speedometer light 1.7High beam indicator light 1.7Turn signal indicator light 1.7Gear position indicator light 1.7 × 4Neutral indicator light 1.7FI indicator light 1.7

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BRAKE + WHEEL Unit: mm

SUSPENSION Unit: mm

ITEM STANDARD LIMITRear brake pedal height 11 —Rear brake pedal free travel 20 – 30 —Rear brake drum I.D. — 110.7Front brake disc thickness 4.0 ± 0.2 3.5Front brake disc runout — 0.30Master cylinder bore 12.700 – 12.743 —Master cylinder piston diam. 12.657 – 12.684 —Brake caliper cylinder bore 27.000 – 27.050 —Brake caliper piston diam. 26.918 – 26.968 —Brake fluid type DOT 4 —Wheel rim runout Axial — 2.0

Radial — 2.0Wheel axle runout Front — 0.25

Rear — 0.25Wheel rim size Front 17 × 1.40 —

Rear 17 × 1.60 —

ITEM STANDARD LIMITFront fork stroke 90 —Front fork spring free length 296.6 290Front fork oil level (without spring, inner tube fully compressed) 107 —

Front fork oil type SUZUKI FORK OIL SS-08 or equivalent fork oil —Front fork oil capacity (each leg) 51 ml —Front fork inner tube diam. 26 —Rear wheel travel 77 —Swingarm pivot shaft runout — 0.6

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TIRE

FUEL + OIL

ITEM STANDARD LIMITCold inflation tire pressure (Solo riding) Front 175 kPa

(1.75 kgf/cm²) —

Rear 200 kPa(2.00 kgf/cm²) —

Cold inflation tire pressure (Dual riding)

Front 175 kPa(1.75 kgf/cm²) —

Rear 280 kPa(2.80 kgf/cm²) —

Tire size Front 70/90-17 M/C 38P —Rear 80/90-17 M/C 50P —

Tire type Front IRC: NF35 —Rear IRC: NR75 —

Tire tread depth Front — 1.6Rear — 2.0

ITEM SPECIFICATION NOTEFuel type Gasoline used should be graded 91 octane or

higher. An unleaded gasoline is recommended.Fuel tank capacity 4.3 LEngine oil type SAE 10W-40, API SF/SG or SH/SJ with JASO MAEngine oil capacity Change 800 ml

Filter change 900 mlOverhaul 1 000 ml