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RV125
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RV125 SERVICE MANUAL (99500-31233-01E)
99501-31150-01E
K7
Printed in Japan
K7
DIC120
RV125K7 (07-MODEL)
RV125K7 (07-MODEL)
This manual describes service data, service specifications, troubleshooting for FI system and
servicing procedures which differ from those of the K6 (06-model).
NOTE:
Any differences between the K6 (06-model) and K7 (07-model) in specifications and
service data are indicated with an asterisk mark (*).
Please refer to the K6 (06-model) service manual and service information for details
which are not given in this manual.
CONTENTS
ABBREVIATIONS USED IN THIS MANUAL ....................................................... 3
SPECIFICATIONS (RV125K7) ............................................................................. 4
ENGINE ....................................................................................................... 4
DRIVE TRAIN .............................................................................................. 4
CHASSIS ..................................................................................................... 5
ELECTRICAL .............................................................................................. 5
CAPACITIES ............................................................................................... 5
PERIODIC MAINTENANCE SCHEDULE ............................................................ 6
PERIODIC MAINTENANCE CHART .......................................................... 6
MAINTENANCE AND TUNE-UP PROCEDURES ............................................... 7
THROTTLE CABLE PLAY.......................................................................... 7
FUEL LINE .................................................................................................. 8
SDS CHECK ......................................................................................................... 9
FI SYSTEM DIAGNOSIS .................................................................................... 13
PRECAUTIONS IN SERVICING ............................................................... 13
FI SYSTEM TECHNICAL FEATURES...................................................... 20
ECM TERMINAL ....................................................................................... 29
SELF-DIAGNOSIS FUNCTION................................................................. 30
FAIL-SAFE FUNCTION............................................................................. 32
FI SYSTEM TROUBLESHOOTING .......................................................... 33
SENSORS........................................................................................................... 79
CKP SENSOR INSPECTION .................................................................... 79
CKP SENSOR REMOVAL AND INSTALLATION .................................... 79
IAP/TP/IAT SENSOR INSPECTION ......................................................... 79
ET SENSOR INSPECTION ....................................................................... 79
ET SENSOR REMOVAL AND INSTALLATION ....................................... 80
TO SENSOR INSPECTION....................................................................... 80
TO SENSOR REMOVAL AND INSTALLATION....................................... 81
HO2 SENSOR INSPECTION .................................................................... 81
HO2 SENSOR REMOVAL AND INSTALLATION .................................... 81
RV125K7 (07-MODEL)
RV125K7 (07-MODEL)
CONTENTS
FUEL SYSTEM ..................................................................................................
FUEL TANK ..............................................................................................
FUEL LEVEL INDICATOR CHECK RELAY ............................................
FUEL FILTER ...........................................................................................
THROTTLE BODY....................................................................................
WIRING DIAGRAM ............................................................................................
CABLE AND HOSE ROUTING..........................................................................
SPECIAL TOOLS...............................................................................................
TIGHTENING TORQUE .....................................................................................
SERVICE DATA.................................................................................................
83
83
85
86
87
93
94
97
97
98
CODE
E-02
E-19
COUNTRY or AREA
U.K.
E.U.
RV125K7 (07-MODEL)
A
ABDC
AC
ACL
API
ATDC
A/F
B
BBDC
BTDC
B+
C
CKP Sensor : Crankshaft Position Sensor
(CKPS)
CKT
: Circuit
CLP Switch : Clutch Lever Position Switch
(Clutch Switch)
CO
: Carbon Monoxide
CPU
: Central Processing Unit
D
DC
DMC
DRL
DTC
: Direct Current
: Dealer Mode Coupler
: Daytime Running Light
: Diagnostic Trouble Code
ECT Sensor
ET sensor
FP
FPR
FP Relay
IAP Sensor
IAT Sensor
IG
ISC Valve
L
LCD
LED
LH
M
MAL-Code
Max
MIL
Min
: Malfunction Code
(Diagnostic Code)
: Maximum
: Malfunction Indicator Lamp
(LED)
: Minimum
N
NOx
OHC
: Nitrogen Oxides
P
PCV
: Positive Crankcase
Ventilation (Crankcase Breather)
R
RH
ROM
F
FI
E
ECM
HC
: Hydrocarbons
HO2 Sensor : Heated Oxygen Sensor (HO2S)
: Right Hand
: Read Only Memory
S
SAE
SDS
T
G
GEN
GND
: Generator
: Ground
TO Sensor
TP Sensor
RV125K7 (07-MODEL)
SPECIFICATIONS (RV125K7)
DIMENSIONS AND DRY MASS
Overall length....................................................... 2 140 mm
Overall width ........................................................ 860 mm
Overall height....................................................... 1 120 mm
Wheelbase ........................................................... 1 385 mm
Ground clearance ................................................ 215 mm
Seat height........................................................... 770 mm
Dry mass.............................................................. 118 kg
ENGINE
Type .....................................................................
Number of cylinders .............................................
Bore .....................................................................
Stroke...................................................................
Displacement .......................................................
Compression ratio................................................
Fuel system..........................................................
Air cleaner............................................................
Starter system......................................................
Lubrication system ...............................................
Idle speed ............................................................
DRIVE TRAIN
Clutch...................................................................
Transmission........................................................
Gearshift pattern ..................................................
Primary reduction ratio.........................................
Gear ratios, Low ..................................................
2nd...................................................
3rd....................................................
4th....................................................
5th....................................................
Top...................................................
Final reduction ratio .............................................
Drive chain ...........................................................
RV125K7 (07-MODEL)
CHASSIS
Front suspension.................................................
Rear suspension .................................................
Front suspension stroke......................................
Rear wheel travel ................................................
Caster..................................................................
Trail .....................................................................
Steering angle .....................................................
Turning radius .....................................................
Front brake..........................................................
Rear brake ..........................................................
Front tire size ......................................................
Rear tire size .......................................................
ELECTRICAL
lgnition type .........................................................
lgnition timing ......................................................
Spark plug ...........................................................
Battery.................................................................
Generator ............................................................
Fuse ....................................................................
Headlight .............................................................
Brake light/Taillight..............................................
Position light........................................................
Turn signal light...................................................
Speedometer light ...............................................
Neutral indicator light ..........................................
High beam indicator light.....................................
Turn signal indicator light ....................................
FI indicator light...................................................
Fuel level indicator light.......................................
CAPACITIES
Fuel tank, including reserve ................................
6.5 L
Engine oil, oil change ..........................................
850 ml
filter change .......................................
950 ml
overhaul ............................................. 1 200 ml
These specifications are subject to change without notice.
RV125K7 (07-MODEL)
Interval km
months
1 000
5
4 000
20
I
8 000
40
I
I
R
R
I
I
I
I
I
I
I
R
I
I
Replace every 4 years
R
R
R
I
I
I
I
I
I
Clean and lubricate every 1 000 km
I
I
I
I
Replace every 4 years
I
I
Replace every 2 years
I
I
I
T
T
NOTE:
I = Inspect and clean, adjust, replace or lubricate as necessary; R = Replace; T = Tighten
RV125K7 (07-MODEL)
After the adjustment is completed, check that handlebars movement does not raise the engine idle speed
and that the throttle grip returns smoothly and automatically.
RV125K7 (07-MODEL)
FUEL LINE
Inspect initially at 1 000 km (5 months) and every
4 000 km (20 months) thereafter.
Replace every 4 years.
Inspect the fuel hoses for damage and fuel leakage. If any
defects are found, replace the fuel hose with a new one.
RV125K7 (07-MODEL)
SDS CHECK
Using SDS, sample the data at the time of new and periodic vehicle inspections.
After saving the sampled data in the computer, file them by model and by user.
The periodically filed data help improve the accuracy of troubleshooting since they can indicate the condition
of vehicle functions that has changed with time.
For example, when a vehicle is brought in for service but the troubleshooting of a failure is not easy, comparing the current data value to the past filed data value at time of normal condition can allow the specific
engine failure to be determined.
Also, in the case of a customer vehicle which is not periodically brought in for service with no past data value
having been saved, if the data value of a good vehicle condition have been already saved as a master
(STD), comparison between the same models helps facilitate the troubleshooting.
Remove the right frame cover. (RV125K3 5-3)
Set up the SDS tools. (Page 39)
09904-41010: SDS set tool
99565-01010-009: CD-ROM Ver. 9
NOTE:
* Before taking the sample of data, check and clear the Past DTC. (Page 40)
* A number of different data under a fixed condition as shown below should be saved and filed as sample.
SAMPLE:
Data sampled from cold starting through warm-up
10
RV125K7 (07-MODEL)
RV125K7 (07-MODEL)
11
12
RV125K7 (07-MODEL)
Example of trouble
Three data; value 1 (current data 1), value 2 (past data 2) and value 3 (past data 3); can be made in comparison by showing them in the graph. Read the change of value by comparing the current data to the past data
that have been saved under the same condition, then you may determine how changes have occurred with
the pass of time and identify what problem is currently occurring.
With DTC not output, if the value of engine temperature is found to be higher than the data saved previously,
the possible cause may probably lie in a sensor circuit opened or ground circuit opened or influence of internal resistance value changes, etc.
No DTC output
RV125K7 (07-MODEL)
FI SYSTEM DIAGNOSIS
PRECAUTIONS IN SERVICING
When handling the component parts or servicing the FI system,
observe the following points for the safety of the system.
ELECTRICAL PARTS
Connector/Coupler
When connecting a connector, be sure to push it in until a
click is felt.
With a lock type coupler, be sure to release the lock when disconnecting, and push in fully to engage the lock when connecting.
When disconnecting the coupler, be sure to hold the coupler
body and do not pull the lead wires.
Inspect each terminal on the connector/coupler for looseness
or bending.
Inspect each terminal for corrosion and contamination.
The terminals must be clean and free of any foreign material
which could impede proper terminal contact.
Inspect each lead wire circuit for poor connection by shaking it
by hand lightly. If any abnormal condition is found, repair or
replace.
1 Coupler
2 Probe
Click
13
14
RV125K7 (07-MODEL)
SWITCH
Never apply grease material to switch contact points to prevent damage.
ECM/VARIOUS SENSORS
Since each component is a high-precision part, great care
should be taken not to apply any sharp impacts during
removal and installation.
INCORRECT
RV125K7 (07-MODEL)
15
INCORRECT
16
RV125K7 (07-MODEL)
*1
1 Sensor
2 ECM
*1 Check for loose connection.
Using a test male terminal, check the female terminals of the
circuit being checked for contact tension.
Check each terminal visually for poor contact (possibly
caused by dirt, corrosion, rust, entry of 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.
*1 Check contact tension by inserting and removing.
*2 Check each terminal for bend
and proper alignment.
Using continuity inspect or voltage check procedure as
described below, inspect the wire harness terminals for open
circuit and poor connection. Locate abnormality, if any.
A Looseness of crimping
B Open
C Thin wire (a few strands left)
*1
*2
RV125K7 (07-MODEL)
Continuity check
Measure resistance across coupler B (between A and C in
the figure).
If no continuity is indicated (infinity or over limit), the circuit is
open between terminals A and C.
1 ECM
Disconnect the coupler B and measure resistance between
couplers A and B.
If no continuity is indicated, the circuit is open between couplers A and B. If continuity is indicated, there is an open circuit between couplers B and C or an abnormality in coupler
B or coupler C.
1 ECM
Voltage check
If voltage is supplied to the circuit being checked, voltage check
can be used as circuit check.
With all connectors/couplers connected and voltage applied
to the circuit being checked, measure voltage between each
terminal and body ground.
5V
5V
0V
5V
17
18
RV125K7 (07-MODEL)
*1
NOTE:
If the circuit to be checked branches to other parts as shown,
disconnect all connectors/couplers of those parts. Otherwise,
diagnosis will be misled.
Measure resistance between terminal at one end of circuit (A
terminal in figure) and body ground. If continuity is indicated,
there is a short circuit to ground between terminals A and C.
5V
1 Other parts
*1 To other parts
Disconnect the connector/coupler included in circuit (coupler
B) and measure resistance between terminal A and body
ground.
If continuity is indicated, the circuit is shorted to the ground
between terminals A and B.
1 ECM
*1 To other parts
*1
RV125K7 (07-MODEL)
19
20
RV125K7 (07-MODEL)
Crankshaft Position
Sensor (CKP Sensor)
Engine speed
signal
Throttle Position
Sensor (TP Sensor)
Various
Sensors
Various signals
Fuel injector
Injection signal
Basic
fuel
injection
time
Compensation
Ultimate
fuel
injection
time
RV125K7 (07-MODEL)
21
ACCELERATION SIGNAL/
DECELERATION SIGNAL
DESCRIPTION
When engine temperature is low, injection time (volume) is
increased.
When intake air temperature signal is low, injection time (volume) is increased.
Air/fuel ratio is compensated to the theoretical ratio from
density of oxygen in exhaust gasses. 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.
At high speed, the injection time (volume) is increased.
When starting engine, additional fuel is injected during
cranking engine.
During acceleration, the fuel injection time (volume) is
increased in accordance with the throttle opening speed and
engine rpm. During deceleration, the fuel injection time (volume) is decreased.
ECM detects this current and compensates the injection
time (volume).
DESCRIPTION
When the motorcycle tips over, the tip-over sensor sends a
signal to the ECM. Then, this signal cuts OFF current supplied to the fuel injector and ignition coil.
The fuel injector stops operation when engine rpm reaches
rev. limit rpm.
22
RV125K7 (07-MODEL)
A ECM
B Tip-over sensor (TOS)
C Heated oxygen sensor (HO2S)
RV125K7 (07-MODEL)
A ECM
F Fuel injector
G ISC valve
23
Neutral switch
HO2 sensor
(HO2S)
Engine temperature
sensor
Tip-over sensor
(TOS)
Side-stand
switch
FI indicator light
ISC valve
Ignition coil
Clutch
switch
Ignition
switch
Starter
relay
Engine
stop Side-stand
switch relay
Starter
button
Fuel injector
Battery
20 A
Regulator/
rectifier
Magneto
24
RV125K7 (07-MODEL)
RV125K7 (07-MODEL)
25
FUEL INJECTOR
The system employs fuel injector (Discharge pump; DCP) that causes injection fuel to be pressurized within
the pump.
The fuel injector pressurizes gravity fed fuel with its plunger and injects the pressurized fuel into the intake
pipe. With the pressure plunger controlled by ECM, necessary volume of fuel is injected at the best timing
for the engine operating condition.
Operation
When the plunger returns, fuel in the pump chamber enters through IN check valve.
By the ECM signal, the coil is energized causing the plunger to pressurize fuel. This pressurization occurs
after vapor inside the pump chamber has been bled through the pressure valve.
When the pressurization begins, OUT check valve opens and the fuel pressure rises until the injection
nozzle opens.
The volume of fuel injection is controlled by the length of time in which the plunger compresses fuel.
When the ignition switch is turned ON, the discharge pump starts to operate for 2 seconds for purging (initial operation).
Vapor
Coil
IN check valve
Plunger
Fuel
Pressure valve
OUT check valve
Filter
Orifice
Injection
26
RV125K7 (07-MODEL)
FUEL CIRCULATION
From the fuel tank, fuel enters into the fuel injector through the fuel filter. Vapor generated here returns to
the fuel tank.
*2
*2
*1
*1
1
2
3
3-way joint
Fuel filter
Fuel injector
*1
*2
ECM
ECM (Engine Control Module) consists of CPU (Central Processing Unit), memory (ROM/RAM) and IN/OUT section. Signals from various sensors are sent to the input section and then
to CPU. On the basis of information received, CPU performs calculation of necessary amount of fuel injection by means of a
map that is programmed for various engine conditions and
sends operation signal from the output section to fuel injector.
Light load: When the engine load is light, the fuel injection time
(volume) is determined on the basis of intake air
pressure and engine speed.
High load: When the engine load is high, the fuel injection time
(volume) is determined on the basis of throttle valve
opening and engine speed.
ET SENSOR
ET (Engine Temperature) sensor sends the signal of engine
temperature as thermistor ohmic value, which is then detected
by ECM. When the engine temperature is low, the injection volume increases.
The thermistor ohmic value increases with the engine temperature low and it decreases with the temperature high.
RV125K7 (07-MODEL)
TO SENSOR
TO (Tip-Over) sensor detects the vehicle inclination. When the
vehicle tips to more than 65, a signal is sent to ECM. When this
signal continues for more than 4 seconds, ECM interrupts current to fuel injector and ignition coil.
To restart the engine, turn the ignition switch OFF once and then
attempt starting in the normal procedure.
65
IAP/TP/IAT SENSOR
The IAP sensor/TP sensor/IAT sensor are combined into one.
IAP sensor
The value of intake air pressure is converted into an electrical
signal and sent to ECM.
The base fuel injection time (volume) in light load is determined
in accordance with this electrical signal (output signal).
The higher the intake air pressure, the higher the signal voltage
becomes.
TP sensor
TP (Throttle Position) sensor is a sort of variable resistor and
detects the throttle valve opening.
The sensor voltage is translated to throttle opening voltage and
sent to ECM.
The base fuel injection time (volume) in high load is determined
in accordance with this electrical signal (output signal).
The wider the throttle opening, the higher the signal voltage
becomes.
IAT sensor
IAT (Intake Air Temperature) sensor senses the intake air temperature as ohmic value of thermistor and sends it to ECM.
When the intake air temperature is low, the injection volume is
increased.
The thermistor ohmic value increases with the intake air temperature low and decreases with the temperature high.
65
27
28
RV125K7 (07-MODEL)
CKP SENSOR
CKP (Crank position) sensor generates the reference ignition
signal and sends it to ECM.
ECM calculates and determines the injection and ignition timings on the basis of this signal.
HO2 SENSOR
HO2 (Heated Oxygen) sensor is made of zirconia element (platinum plated) which changes output voltage depending on the
oxygen concentration difference between its internal and external surfaces.
The terminal voltage change is dependent on the oxygen concentration in the exhaust gas. This detected voltage value therefore represents the oxygen concentration.
The terminal voltage decreases when the oxygen concentration
is high, and increases when it is low.
NOTE:
As the zirconia element is not conductive below 250 C, HO2
sensor will not function properly until the engine is at normal
operating temperature.
ISC valve
ISC (Idle Speed Control) valve controls the cold engine fast idle
speed as well as warmed engine idle speed.
The air volume is adjusted by opening or closing the bypass port
provided in the throttle port.
By controlling the fuel injection volume and air flow, the idle
speed is maintained at a constant level, eliminating the need of
manual adjustment.
RV125K7 (07-MODEL)
ECM TERMINAL
ECM coupler
TERMINAL
NO.
1
2
3
4
5
6
7
8
9
0
A
B
C
CIRCUIT
Power ground (E0)
ISC valve
Control ground (E1)
Sensor ground (E2)
Power source (+B)
HO2 sensor heater
Clutch switch
Power source for sensors (VCC)
TO sensor (TO)
TERMINAL
NO.
D
E
F
G
H
I
J
K
L
M
N
O
P
CIRCUIT
Ignition coil
FI indicator light
Fuel injector Mode select switch
Fuel injector +
Neutral switch
ET sensor (ET)
IAT sensor (IAT)
TP sensor (TP)
IAP sensor (IAP)
29
30
RV125K7 (07-MODEL)
SELF-DIAGNOSIS FUNCTION
The self-diagnosis function is incorporated in the ECM. The function has two modes, User mode and
Dealer mode. The user can only be notified by the FI indicator light. To check the function of the individual
FI system devices, the dealer mode is provided. In this check, the special tool is necessary to read the code
of the malfunction items.
USER MODE
FI INDICATOR LIGHT
INDICATION
NO
---YES
FI indicator light turns ON.
Engine can start
*1
Engine can not start FI indicator light turns ON
and blinks.
*2
MALFUNCTION
*1
When one of the signals is not received by ECM, the fail-safe
circuit works and injection is not stopped. In this case, FI indicator light is lighted and the motorcycle can run.
*2
The injection signal is stopped, when the crankshaft position
sensor signal, tip-over sensor signal, ignition signal, injector signal or ignition switch signal is not sent to ECM. In this case, FI
indicator light is ON and blinks and the motorcycle can not run.
When the ignition switch is turned ON, FI indicator light is lit for 2
seconds and thereafter remains unlit.
When the ignition switch is turned ON and the engine stop
switch is turned OFF, in this case, the speedometer does not
receive any signal from ECM, and the speedometer does not
light FI indicator light.
If FI indicator light is not lighted when turning the ignition switch
to ON, the FI indicator light does not indicate the trouble code.
It is necessary to check the wiring harness between ECM and
speedometer couplers.
The possible cause of this indication is as follows;
Engine stop switch is in OFF position. Fuse is burnt.
FI indicator bulb is burnt.
FI
RV125K7 (07-MODEL)
31
DEALER MODE
The defective function is memorized in the ECM. Use the special tools coupler to connect to the dealer
mode coupler. The memorized malfunction code is displayed by the flashing pattern of FI indicator light.
Malfunction means that the ECM does not receive normal signal from the devices. These affected devices
are indicated in the code form.
09930-82720: Mode select switch
FI
Before checking DTC (Diagnostic Trouble Code), do not disconnect the ECM lead wire coupler.
If the coupler from the ECM is disconnected, the DTC memory is erased and can not be
checked.
MALFUNCTION
NO
YES
FI INDICATOR LIGHT
INDICATION
OFF
ON and blinks
32
RV125K7 (07-MODEL)
FAIL-SAFE FUNCTION
FI system is provided with fail-safe function to allow the engine to start and the motorcycle to run in a minimum performance necessary even under malfunction condition.
ITEM
IAP sensor
TP sensor
IAT sensor
ET sensor
HO2 sensor
ISC valve
FAIL-SAFE MODE
Intake air pressure is fixed to 101
kPa (760 mmHg).
The throttle opening is fixed to full
open position.
Ignition timing is also fixed.
Intake air temperature value is fixed
to 25 C.
Engine temperature value is fixed to
80 C.
Feedback compensation is inhibited.
(Air/fuel ratio is fixed to normal.)
ISC operation is stopped.
STARTING
ABILITY
RUNNING
ABILITY
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
YES
The engine can start and can run even if the above signal 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.
RV125K7 (07-MODEL)
33
FI SYSTEM TROUBLESHOOTING
CUSTOMER COMPLAINT ANALYSIS
Record details of the problem (failure, complaint) and how it occurred as described by the customer. For this
purpose, use of such an inspection form such as below will facilitate collecting information required for
proper analysis and diagnosis.
EXAMPLE: CUSTOMER PROBLEM INSPECTION FORM
User name:
Date of issue:
FI indicator light condition
Model:
Date Reg.
Always ON
Sometimes ON
Mileage:
Always OFF
PROBLEM SYMPTOMS
Poor Driveability
Hesitation on acceleration
Difficult Starting
No cranking
No initial combustion
No combustion
Poor starting at
( cold
warm
Other
VIN:
Date of problem:
Back fire/
always)
Poor Idling
Poor fast Idle
Abnormal idling speed
( High
Low) (
r/min)
Unstable
Hunting (
r/min to
r/min)
Other
OTHERS:
After fire
Lack of power
Surging
Abnormal knocking
Engine rpm jumps briefly
Other
Engine Stall when
Immediately after start
Throttle valve is opened
Throttle valve is closed
Load is applied
Other
Good condition
34
RV125K7 (07-MODEL)
Fair
Cloudy
Hot
Warm
Always
Rain
Snow
Cool
Always
Cold (
Sometimes (
C)
times/
Other
Always
day, month)
Only once
Road
Urban
Suburb
Tarmacadam
Highway
Gravel
Mountainous (
Uphill
Downhill)
Other
Motorcycle condition
Engine condition
Cold
Warming up phase
Motorcycle condition
During driving:
Constant speed
Warmed up
Always
Other at starting
Engine speed (
Accelerating
r/min)
Decelerating
km/h)
Other
NOTE:
The above form is a standard sample. The form should be modified according to conditions and characteristics of each market.
VISUAL INSPECTION
Prior to diagnosis using the mode select switch or SDS, 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 or SDS.
* Engine oil level and leakage (RV125K3 2-10)
* Fuel level and leakage (Page 8 and 84)
* Clogged air cleaner element (RV125K3 2-4)
* Battery condition (RV125K3 6-31)
* Throttle cable play (Page 7)
* Broken fuse
* FI indicator light operation (Page 30)
* Exhaust gas leakage and noise (RV125K3 2-19)
* Each coupler disconnection
RV125K7 (07-MODEL)
SELF-DIAGNOSTIC PROCEDURES
NOTE:
* Do not disconnect the coupler from ECM, battery cable from
battery, ECM ground wire from engine or main fuse before
confirming the DTC (Diagnostic Trouble Code) stored in memory. Such disconnection will erase the memorized information
in ECM memory.
* DTC stored in ECM memory can be checked by the special
tool.
* Before checking DTC, read SELF-DIAGNOSIS FUNCTION
USER MODE and DEALER MODE (Page 30 and 31)
carefully to have good understanding as to what functions are
available and how to use it.
* Be sure to read PRECAUTIONS IN SERVICING (Page 13)
before inspection and observe what is written there.
Remove the right frame cover. (RV125K3 5-3)
Connect the special tool to the dealer mode coupler at the wiring harness.
Turn the special tools switch ON and check the malfunction
code to determine the malfunction part.
09930-82720: Mode select switch
35
36
RV125K7 (07-MODEL)
0.3
0.3
2
0.3
0.3 0.3
0.3
0.3 0.3
0.3
0.3 0.3
ON
FI indicator light
OFF
1.0
3.0
0.3
1.0
0.3
3.0
0.3 0.3
1.0
0.3
(Sec.)
RV125K7 (07-MODEL)
DTC No.
MALFUNCTION PART
REMARKS
None
00
CKP sensor (Page 44)
12
1
37
38
RV125K7 (07-MODEL)
*40
C40 code has no first digit display. For this reason, the interval A between the displays as shown below is
longer than the others.
4.0 sec.
1.0 sec.
4
FI
RV125K7 (07-MODEL)
39
40
RV125K7 (07-MODEL)
RV125K7 (07-MODEL)
41
Click Show data when trouble 1 to display the data. By clicking the drop down button 2, either Failure
#1 or Failure #2 can be selected.
42
RV125K7 (07-MODEL)
13
H
P0105
L
14
H
P0120
L
15
H
P0115
L
21
H
P0110
L
DETECTED
DETECTED FAILURE CONDITION
CHECK FOR
ITEM
NO FAULT
CKP sensor The CKP sensor signal does not reach CKP sensor wiring and mechanECM for 4 sec. or more, after receiving ical parts
CKP sensor, lead wire/coupler
the IAP sensor signal.
connection
IAP sensor
The sensor should produce following IAP sensor, lead wire/coupler
connection
voltage.
0.2 V
sensor voltage < 4.5 V
In other than the above range, 13
(P0105) is indicated.
Sensor voltage is higher than specified IAP sensor circuit open or
value.
shorted to VCC or ground circuit
open
Sensor voltage is lower than specified IAP sensor circuit shorted to
value.
ground or VCC circuit open
TP sensor
The sensor should produce following TP sensor, lead wire/coupler
connection
voltage.
0.3 V
sensor voltage < 4.7 V
In other than the above range, 14
(P0120) is indicated.
Sensor voltage is higher than specified TP sensor circuit shorted to
value.
VCC or ground circuit open
Sensor voltage is lower than specified TP sensor circuit open or
value.
shorted to ground or VCC circuit
open
ET sensor
The sensor voltage should be the fol- ET sensor, lead wire/coupler
connection
lowing.
0.1 V
sensor voltage < 4.7 V
In other than the above range, 15
(P0115) is indicated.
Sensor voltage is higher than specified ECT sensor circuit open or
value.
ground circuit open
Sensor voltage is lower than specified ECT sensor circuit shorted to
value.
ground
IAT sensor
The sensor voltage should be the fol- IAT sensor, lead wire/coupler
connection
lowing.
0.1 V
sensor voltage < 4.6 V
In other than the above range, 21
(P0110) is indicated.
Sensor voltage is higher than specified IAT sensor circuit open or
value.
ground circuit open
Sensor voltage is lower than specified IAT sensor circuit shorted to
value.
ground
RV125K7 (07-MODEL)
DTC No.
23
H
P1651
L
24
DETECTED
DETECTED FAILURE CONDITION
ITEM
TO sensor
The sensor voltage should be the following for 2 sec. and more, after ignition switch is turned ON.
0.2 V
sensor voltage < 4.6 V
In other than the above value, 23
(P1651) is indicated.
Sensor voltage is higher than specified
value.
Sensor voltage is lower than specified
value.
Ignition
signal
P0351
Fuel injector
32
P0201
ISC valve
40
P0505
42
P1650
44
P0130
44
P0135
Ignition
switch
HO2 sensor
43
CHECK FOR
TO sensor, lead wire/coupler
connection
44
RV125K7 (07-MODEL)
Bl
Bl
B/Br
CKP
E2
To regulator/rectifier
Generator
INSPECTION
Step 1
1) Turn the ignition switch OFF.
2) Remove the seat. (RV125K3 5-3)
3) Check the CKP sensor coupler 1 for loose or poor contacts.
If OK, then measure the CKP sensor resistance.
RV125K7 (07-MODEL)
Go to step 2.
Replace the CKP sensor with a new one.
6) After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
Step 2
1) Crank the engine a few seconds with the starter motor, and
measure the CKP sensor peak voltage at the coupler.
2) Repeat the above test procedure a few times and measure
the highest peak voltage.
CKP sensor peak voltage: 2.0 V and more
(+ G - Bl)
1 Peak volt adaptor
09900-25008: Multi-circuit tester set
Tester knob indication: Voltage ()
45
46
RV125K7 (07-MODEL)
YES
NO
2
ECM coupler (Harness side)
RV125K7 (07-MODEL)
DETECTED CONDITION
IAP sensor voltage is not within the following range.
0.2 V
Sensor voltage < 4.5 V
NOTE:
Note that atmospheric pressure varies
depending on weather conditions as
well as altitude.
Take that into consideration when
inspecting voltage.
P0105
Sensor voltage is higher than specified
H
value.
Sensor voltage is lower than specified
L
value.
POSSIBLE CAUSE
Clogged vacuum passage between throttle body
and IAP sensor.
Air being drawn from vacuum passage between
throttle body and IAP sensor.
IAP sensor circuit open or shorted to ground.
IAP sensor malfunction.
ECM malfunction.
ECM
IAP sensor
G/B
IAP
B/Br
E2
VCC
NOTE:
IAP sensor is incorporated in the TP sensor/IAT sensor.
INSPECTION
Step 1 (When indicating 13:)
1) Turn the ignition switch OFF.
2) Check the IAP sensor coupler 1 for loose or poor contacts.
If OK, then measure the IAP sensor input voltage.
47
48
3)
4)
5)
6)
RV125K7 (07-MODEL)
1
V
Go to Step 2.
Loose or poor contacts on the ECM coupler
(terminal 9 or 4).
Open or short circuit in the R wire or B/Br wire.
RV125K7 (07-MODEL)
Go to Step 2.
G/B wire shorted to VCC, or B/Br wire open.
8) After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
Step 1 (When indicating P0105-L:)
1) Turn the ignition switch OFF.
2) Check the IAP sensor coupler 1 for loose or poor contacts.
If OK, then check the IAP sensor lead wire continuity.
49
50
RV125K7 (07-MODEL)
9) After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
RV125K7 (07-MODEL)
Step 2
1) Connect the IAP sensor coupler and ECM coupler.
2) Insert the needle pointed probes to the lead wire coupler.
3) Start the engine at idle speed and measure the IAP sensor
output voltage (between G/B and B/Br wires).
2
V
YES
NO
2
ECM coupler (Harness side)
51
52
RV125K7 (07-MODEL)
POSSIBLE CAUSE
TP sensor maladjusted
TP sensor circuit open or short
TP sensor malfunction
ECM malfunction
ECM
TP sensor
E2
B/Br
P
TP sensor
VCC
NOTE:
TP sensor is incorporated in the IAP sensor/IAT sensor.
INSPECTION
Step 1 (When indicating 14:)
1) Turn the ignition switch to OFF.
2) Check the TP sensor coupler 1 for loose or poor contacts.
If OK, then measure the TP sensor input voltage.
RV125K7 (07-MODEL)
3)
4)
5)
6)
1
V
Go to Step 2.
Loose or poor contacts on the ECM coupler
(terminal 9 or 4).
Open or short circuit in the R wire or B/Br wire.
53
54
RV125K7 (07-MODEL)
Go to Step 2.
P wire shorted to VCC, or B/Br wire open
8) After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
Step 1 (When indicating P0120-L:)
1) Turn the ignition switch OFF.
2) Check the TP sensor coupler 1 for loose or poor contacts.
If OK, then check the TP sensor lead wire continuity.
RV125K7 (07-MODEL)
9) After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
55
56
RV125K7 (07-MODEL)
Step 2
1) Connect the TP sensor coupler.
2) Turn the ignition switch ON.
3) Measure the TP sensor output voltage (between + P and B/Br) by turning the throttle grip.
3
V
YES
NO
3
ECM coupler (Harness side)
RV125K7 (07-MODEL)
POSSIBLE CAUSE
ET sensor circuit open or short
ET sensor malfunction
ECM malfunction
ET sensor circuit open or ground circuit open
ECM
ET sensor
ET
B/Br
E2
INSPECTION
Step 1 (When indicating 15:)
1) Turn the ignition switch OFF.
2) Check the ET sensor coupler 1 for loose or poor contacts.
If OK, then measure the ET sensor voltage at the coupler.
Go to Step 2.
Loose or poor contacts on the ECM coupler
(terminal K or 4).
Open or short circuit in the O wire or B/Br wire
57
58
RV125K7 (07-MODEL)
Go to Step 2.
O or B/Br wire open
6) After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
RV125K7 (07-MODEL)
Go to Step 2.
O wire shorted to ground
If wire is OK, go to Step 2.
5) After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
59
60
RV125K7 (07-MODEL)
Step 2
1) Turn the ignition switch OFF.
2) Disconnect the ET sensor coupler.
3) Measure the ET sensor resistance between B wires.
YES
NO
Resistance
Approx. 13.0 k
Approx. 6.2 k
Approx. 1.7 k
Approx. 1.0 k
2
ECM coupler (Harness side)
RV125K7 (07-MODEL)
POSSIBLE CAUSE
IAT sensor circuit open or short.
IAT sensor malfunction.
ECM malfunction.
IAT sensor circuit open or ground circuit open.
ECM
IAT sensor
Dg
IAT
B/Br
E2
VCC
NOTE:
IAT sensor is incorporated in the IAP sensor/TP sensor.
INSPECTION
Step 1 (When indicating 21:)
1) Turn the ignition switch OFF.
2) Check the IAT sensor coupler 1 for loose or poor contacts.
If OK, then measure the IAT sensor voltage at the wire side
coupler.
3) Disconnect the IAT sensor coupler and turn the ignition switch
ON.
61
62
RV125K7 (07-MODEL)
1
V
Go to Step 2.
Loose or poor contacts on the ECM coupler
(Terminal L or 4).
Open or short circuit in the Dg wire or B/Br wire.
Go to Step 2.
Dg wire or B/Br wire open
6) After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
RV125K7 (07-MODEL)
1
?
5) Connect the IAT sensor coupler and turn the ignition switch
ON.
6) Measure the voltage between Dg wire A and ground.
IAT sensor output voltage: Approx. 2.5 V at 23 C
Approx. 1.8 V at 40 C
(+ Dg - Ground)
09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
Tester knob indication: Voltage ()
Are the continuity and voltage OK?
YES
NO
Go to Step 2.
Dg wire shorted to ground
If wire is OK, go to Step 2.
7) After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
1
V
63
64
RV125K7 (07-MODEL)
Step 2
1) Turn the ignition switch OFF.
2) Measure the IAT sensor resistance.
YES
NO
2
ECM coupler (Harness side)
RV125K7 (07-MODEL)
65
POSSIBLE CAUSE
TO sensor circuit open or short
TO sensor malfunction
ECM malfunction
TO sensor circuit shorted to VCC or ground circuit
open
TO sensor circuit open or shorted to ground or
VCC circuit open
ECM
TO sensor
VCC
Br/W
TOS
B/Br
E2
INSPECTION
Go to Step 2.
Replace the TO sensor with a new one.
66
RV125K7 (07-MODEL)
Go to Step 2.
Br/W wire shorted to VCC, or B/Br wire open.
9) After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
RV125K7 (07-MODEL)
Go to Step 2.
R or Br/W wire open, or Br/W wire shorted to
ground.
10)After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
67
68
RV125K7 (07-MODEL)
Step 2
1) Connect the TO sensor coupler and ECM coupler.
2) Insert the needle pointed probes to the lead wire coupler.
3) Turn the ignition switch ON.
4) Measure the voltage between Br/W and B/Br wires.
2
V
2
V
65
YES
NO
3
ECM coupler (Harness side)
RV125K7 (07-MODEL)
POSSIBLE CAUSE
Fuel injector circuit open or short
Fuel injector malfunction
ECM malfunction
ECM
Fuel injector
R/W
Fuel injector
W/Bl
Fuel injector
INSPECTION
Step 1
1) Turn the ignition switch OFF.
2) Check the fuel injector coupler 1 for loose or poor contacts.
If OK, then measure the fuel injector resistance.
3) Disconnect the fuel injector coupler.
69
70
RV125K7 (07-MODEL)
Go to Step 2.
Replace the fuel injector with a new one.
(Page 88)
6) After repairing the trouble, clear the DTC using the SDS tool.
(Page 40)
Step 2
1) Turn the ignition switch ON.
2) Measure the fuel injector voltage between R/W wire and
ground.
2
V
YES
NO
2
ECM coupler (Harness side)
RV125K7 (07-MODEL)
DETECTED CONDITION
When the ISC operation voltage
remains at 1.0 V or lower continuously
for 2 sec. or longer.
Idle speed is higher than the normal
condition.
POSSIBLE CAUSE
ISC valve circuit open or shorted to ground
ISC valve malfunction
ECM malfunction
ECM
Ignition SW
ISC
Y/R
20 A
To regulator/rectifier
B/O
Battery
ISC valve
INSPECTION
Step 1
1) Turn the ignition switch OFF.
2) Check the ISC valve coupler 1 for loose or poor contacts.
If OK, then check the ISC valve resistance.
3) Disconnect the ISC valve coupler.
71
72
RV125K7 (07-MODEL)
Go to Step 2.
Replace the ISC valve with a new one.
(Page 88)
6) After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
Step 2
1) Turn the ignition switch ON.
2) Measure the ISC valve voltage between B/O wire and ground.
2
V
2
ECM coupler (Harness side)
YES
NO
RV125K7 (07-MODEL)
Check 2
1) Click the button 1 and decrease the Spec 2 to 1 000 rpm
slowly.
2) Check that the Desired idle speed 3 is nearly equal to the
Spec 2. At the same time, check that the air volume of the
ISC duty decreases.
3) Click the button 4 and increase the Spec 2 slowly.
4) Check that the Desired idle speed 3 is nearly equal to the
Spec 2. Also, check that the air volume 5 of the ISC duty
increases.
73
74
RV125K7 (07-MODEL)
Check 3
1) Click the button 1 and increase the Spec 2 to 1 300 rpm
slowly.
2) Check that the Desired idle speed 3 is nearly equal to the
Spec 2. Also, check that the air volume 4 of the ISC duty
increases.
Check 4
1) Increase the Spec 1 to 1 900 rpm.
2) Check that the Desired idle speed 2 is approx. 1 900 rpm.
3) Check that the Engine speed 3 is close to 1 900 rpm.
NOTE:
Be careful not to increase the Spec to more than 3 000 rpm, or
the Engine speed may reach the upper limit.
If the ISC valve does not function properly, replace the ISC valve (Page 88) or inspect the ISC valve
(Page 91).
RV125K7 (07-MODEL)
44
(P0135)
DETECTED CONDITION
HO2 sensor output voltage is not input
to ECM during engine operation and
running condition.
(Sensor voltage < 0.60 V)
The heater can not operate so that
heater operation voltage is not supply to
the oxygen heater circuit.
POSSIBLE CAUSE
HO2 sensor circuit open or shorted to ground.
Fuel system malfunction.
ECM malfunction.
Battery voltage supply to the HO2 sensor.
ECM
HO2S
W/G
HO2. H
Ignition
switch
B/O
To side-stand
switch
W
B/Br
W
B
Gr
E2
HO2 sensor
INSPECTION
75
76
RV125K7 (07-MODEL)
10)After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
Step 2 (When indicating 44/P0130:)
1) Connect the ECM coupler and HO2 sensor coupler.
2) Warm up the engine enough.
3) Measure the HO2 sensor output voltage between W/G wire
and B/Br wire, when idling condition.
HO2 sensor output voltage at idle speed:
0.3 1.0 V (+ W/G - B/Br)
4) If OK, measure the HO2 sensor output voltage while holding
the engine speed at 5 000 r/min.
HO2 sensor output voltage at 5 000 r/min:
0.6 V and more (+ W/G - B/Br)
09900-25008: Multi-circuit tester set
09900-25009: Needle pointed probe set
Tester knob indication: Voltage ()
RV125K7 (07-MODEL)
YES
NO
2
ECM coupler (Harness side)
4) Disconnect the HO2 sensor coupler and measure the resistance between terminals.
NOTE:
* Temperature of the sensor affects resistance value largely.
* Make sure that the sensor heater is at correct temperature.
HO2 heater resistance: 6.5 8.9 at 23 C
(W W)
09900-25008: Multi-circuit tester set
Tester knob indication: Resistance ()
Is the voltage OK?
YES
NO
Go to Step 2.
Replace the HO2 sensor with a new one.
5) After repairing the trouble, clear the DTC using SDS tool.
(Page 40)
77
78
RV125K7 (07-MODEL)
YES
NO
2
ECM coupler (Harness side)
RV125K7 (07-MODEL)
SENSORS
CKP SENSOR INSPECTION
The crankshaft position sensor is installed in the generator
cover. (Page 44)
ET SENSOR INSPECTION
The engine temperature sensor is installed in the cylinder.
(Page 57)
79
80
RV125K7 (07-MODEL)
If the ET sensor ohmic value does not change in the proportion indicated, replace it with a new one.
Engine temperature sensor specification
Temperature
20 C
40 C
80 C
100 C
Resistance
Approx. 13.0 k
Approx. 6.2 k
Approx. 1.7 k
Approx. 1.0 k
TO SENSOR INSPECTION
The tip-over sensor is located between the tool box and rear
fender. (Page 65)
RV125K7 (07-MODEL)
NOTE:
When installing the TO sensor, the arrow mark A must be
pointed upward.
81
82
RV125K7 (07-MODEL)
RV125K7 (07-MODEL)
FUEL SYSTEM
FUEL TANK
REMOVAL
83
84
RV125K7 (07-MODEL)
INSPECTION
Inlet tube filter
Inspect the inlet tube filter for clogging or any damage.
If necessary, clean the inlet tube filter using compressed air.
B/W
Y/B
Immerse the fuel level switch into kerosen 1 and make sure
that the bulb goes off. If not, replace the fuel level switch with
a new one.
B/W
Y/B
RV125K7 (07-MODEL)
INSTALLATION
Installation is in the reverse order of removal. Pay attention to
the following point:
INSPECTION
First check the insulation between A and B terminals with
tester. Then apply 12 V to C and D terminals, + to C and to D, and check the continuity between A and B.
If there is no continuity, replace the fuel level indicator check
relay with a new one.
09900-25008: Multi-circuit tester set
Tester knob indication: Continuity test ()
85
86
RV125K7 (07-MODEL)
FUEL FILTER
REMOVAL
Place a rag under the hose joint and disconnect the fuel
hoses.
Remove the fuel filter 1.
INSPECTION
When gosoline is poured lightly to the fuel filter from the port
1, the gasoline should flow out through the port 3 smoothly.
Also, check for clogging from the port 2 to 3.
If any defects are found, replace the fuel filter with a new one.
INSTALLATION
Installation is in the reverse order of removal. Pay attention to
the following point:
Rout the fuel hoses properly. (Page 95)
RV125K7 (07-MODEL)
THROTTLE BODY
CONSTRUCTION
1
2
3
4
Return pipe
Upper cushion
O-ring
Fuel injector
5
6
7
A
Cushion seal
ISC valve
Throttle body
ISC valve screw
ITEM
A
Nm
2
kgf-m
0.2
87
88
RV125K7 (07-MODEL)
RV125K7 (07-MODEL)
89
90
RV125K7 (07-MODEL)
RV125K7 (07-MODEL)
INSPECTION
Check following items for any damage or clogging.
* O-ring
* Throttle valve
* Injector cushion seal
ISC valve
Remove the O-ring.
Visually inspect the ISC valve for wear, damage or carbon
deposit, replace it with a new one if necessary.
NOTE:
The ISC valve can be checked without removing it.
(Page 91)
If the resistance is not within the standard range, replace the
ISC valve with a new one.
91
92
RV125K7 (07-MODEL)
22.5
0 mm
0 mm
B/W
Y/B
Y/B
Y/B
B/W
W/B
B/W
B/W
HORN
B/G
HORN BUTTON
PUSH
Br
B/W
Br
B/W
POSITION LIGHT
B/W
B/W
HEADLIGHT
Lg
B/W
Lg
B/W
B/W
Y/B
HAZARD
SWITCH
OFF
ON
TURN SIGNAL
SWITCH
L
PUSH
R
B/R
O
O/W
B/O
O/B
O/B
O/R
Y/G
Y/G
B/Bl
W/B
CLUTCH LEVER
POSITION SWITCH
DIMMER
SWITCH FREE
HI
LO
O/W
BW
R/B
O/Y
O/Y
Br
O
O
O/B
R
R
NEUTRAL
SWITCH
Gr
O
Bl
TURN SIGNAL/
SIDE-STAND RELAY
Br
Br
Lbl
B/W
Lg
Lg
Lg
Bl/B
Lbl
B/W
Lbl
OFF
ON
GENERATOR
CKP
SENSOR
REGULATOR/
RECTIFIER
B/W
STARTER
MOTOR
G/B
P
Y/B
STARTER
RELAY
1 . MAIN 20A
Bl
Y/G
Bl/B
B/O
B
SIDE-STAND
SWITCH
REAR BRAKE
SWITCH
PUSH
FREE
O/Y
R
IGNITION
COIL
W/Bl
W/R
R/W
BATTERY
ECM
IGNITION SWITCH
B/G
DIODE
B
O
Y/B
W/B
B/W
B/W
O/Bl
Y/B
B/Y
ON
C
OFF
LOCK
P
TP/IAP/IAT
SENSOR
W/G
R
OFF
ON
Br/W
G/B
FRONT BRAKE
SWITCH
Dg
B/Br
O/Bl
Bl
G
Bl
B/W
G
Bl
G
B/W
B/Br
Bl
O
B
B
W/B
O
B
W/B
Gr
B/W
B/W
W
Y/R
Y/B
ISC
VALVE
B/O
PUSH
B/W
B/Br
TO
SENSOR
HO2
FUEL
INJECTOR SENSOR
B/W
R/W
SPEEDOMETER
Y/R
W/Bl
CHECK RELAY
B/O
W
R
B/Br
OFF
RUN
B/Br
ET
SENSOR
B/Br
B
Bl
Br/W
W
W/G
B
Gr
B/O
O
B
FUEL GAUGE
W/B
W/B
B
B/W
B
B/W
Gr
B/W
Br
B/W
BRAKE LIGHT/TAILLIGHT
Lg
B/W
RV125K7 (07-MODEL)
WIRING DIAGRAM
93
B/W
W/R
Gr
B/O
Dg
Bl
94
RV125K7 (07-MODEL)
*1
*2
0 mm
*3
0 mm
*7
*4
*5
*6
1
2
3
4
5 Harness
*1
*2
RV125K7 (07-MODEL)
HOSE ROUTING
UPPER
LH
UPPER
RH
LH
RH
45
*1
*3
*2
45
*1
RH
LH
*4
*4
30 35
*1
22.5
*1
*4
*5
*1
*5
95
96
RV125K7 (07-MODEL)
*1
*2
4.4 N.m
(0.44 kgf-m)
1 Frame
2 Cushion
3 Fuel tank joint
RV125K7 (07-MODEL)
SPECIAL TOOLS
09900-25008
Multi-circuit tester
set
09900-25009
Needle pointed
probe set
09904-41010
SDS set tool
09930-82720
Mode select switch
99565-01010-009
CD-ROM Ver. 9
NOTE:
When order the special tool, please confirm whether it is available or not.
TIGHTENING TORQUE
ITEM
ET sensor
HO2 sensor
ISC valve screw
Nm
9
25
2
kgf-m
0.9
2.5
0.2
97
98
RV125K7 (07-MODEL)
SERVICE DATA
VALVE + GUIDE
ITEM
Valve diam.
Valve clearance (when cold)
Valve guide to valve stem
clearance
Valve guide I.D.
Valve stem O.D.
Valve stem deflection
Valve stem runout
Valve head thickness
Valve stem end length
Valve seat width
Valve head radial runout
Valve spring free length
(IN. & EX.)
Valve spring tension
(IN. & EX.)
IN.
EX.
IN.
EX.
IN.
EX.
IN. & EX.
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
INNER
OUTER
INNER
OUTER
STANDARD
25.5
22.5
0.03 0.08
0.13 0.18
0.010 0.037
0.030 0.057
5.000 5.012
4.975 4.990
4.955 4.970
0.9 1.1
38.1 43.9 N
(3.9 4.4 kgf)
at length 26.78 mm
89.6 103 N
(9.1 10.5 kgf)
at length 29.78 mm
IN.
EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
IN. & EX.
STANDARD
33.720 33.760
33.310 33.357
0.032 0.066
22.012 22.025
21.959 21.980
12.000 12.018
11.977 11.995
Unit: mm
LIMIT
0.35
0.05
0.5
1.7
0.03
31.3
33.6
Unit: mm
LIMIT
33.420
33.010
0.150
0.10
0.05
0.05
RV125K7 (07-MODEL)
STANDARD
1 100 1 500 kPa
(11 15 kgf/cm2)
0.040 0.050
57.000 57.015
56.955 56.970
Measure at 8 mm from the skirt end.
1st
R
Approx. 7.2
2nd
R
Approx. 5.0
1st
0.20 0.32
2nd
0.20 0.32
1st
2nd
1st
1.01 1.03
2nd
1.01 1.03
Oil
2.01 2.03
1st
0.970 0.990
2nd
0.970 0.990
14.002 14.008
13.992 14.000
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod deflection
Conrod big end side clearance
Conrod big end width
Crank web to web width
Crankshaft runout
STANDARD
14.006 14.014
0.10 0.45
15.95 16.00
53.0 0.1
99
Unit: mm
LIMIT
800 kPa
(8.0 kgf/cm2)
0.120
57.090
56.880
0.05
5.8
4.0
0.7
0.7
0.18
0.15
14.030
13.980
Unit: mm
LIMIT
14.040
3.0
1.0
0.08
OIL PUMP
ITEM
Oil pressure (at 60 C)
STANDARD
Above 15 kPa (0.15 kgf/cm2)
Below 35 kPa (0.35 kgf/cm2)
at 3 000 r/min
CLUTCH
ITEM
Clutch lever play
Drive plate thickness
Drive plate claw width
Driven plate distortion
Clutch spring free length
STANDARD
10 15
2.95 3.15
11.8 12.0
32.6
LIMIT
Unit: mm
LIMIT
2.65
11.5
0.10
31.0
100
RV125K7 (07-MODEL)
Low
2nd
3rd
4th
5th
Top
Shift fork to groove clearance
Shift fork groove width
Shift fork thickness
Countershaft length
(Low to 2nd)
Drive chain
No. 1
No. 2
No. 1
No. 2
STANDARD
3.470 (59/17)
3.500 (49/14)
3.000 (33/11)
1.857 (26/14)
1.368 (26/19)
1.095 (23/21)
0.923 (24/26)
0.833 (20/24)
0.10 0.30
5.0 5.1
5.5 5.6
4.8 4.9
5.3 5.4
0.50
88.0 +0.1
-0
DID 428
134
259.0
15 25
20
(between footrest top and gearshift lever top)
Type
Links
20-pitch
length
SPECIFICATION
1.9 at 20 C
(Battery voltage 1.0 V) and more
Approx. 35
Battery voltage
NOTE
RV125K7 (07-MODEL)
101
* FI SENSORS
ITEM
CKP sensor resistance
CKP sensor peak voltage
IAP sensor input voltage
IAP sensor output voltage
TP sensor input voltage
TP sensor output voltage
IAT sensor input voltage
IAT sensor output voltage
IAT sensor resistance
ET sensor input voltage
ET sensor resistance
TO sensor resistance
TO sensor voltage
HO2 sensor output voltage
HO2 sensor resistance
SPECIFICATION
172 288
2.0 V (When cranking) and more
4.5 5.5 V
Approx. 2.0 3.5 V at idle speed
4.5 5.5 V
Closed
Approx. 0.7 V
Opened
Approx. 3.9 V
4.5 5.5 V
Approx. 2.5 V at 23 C/1.8 V at 40 C
Approx. 2.56 k at 20 C/1.20 k at 40 C
4.5 5.5 V
Approx. 5 13 k at 20 40 C
16.5 22.3 k
Normal
0.4 1.4 V
Leaning 65
3.7 4.4 V
0.3 1.0 V at idle speed
0.6 V and more at 5 000 r/min
6.5 8.9 at 23 C
* THROTTLE BODY
ITEM
I.D. No.
Bore size
Fast idle r/min.
Idle r/min.
Throttle cable play
SPECIFICATION
13G0
26 mm
1 800 r/min at -20 0 C
1 650 r/min at 0 20 C
1 600 r/min at 20 60 C
1 500 100 r/min/Warmed engine
2.0 4.0 mm
NOTE
+ G - BI
+ G/B - B/Br
+P
- B/Br
+ Br/W
- B/Br
+ W/G
- B/Br
WW
102
RV125K7 (07-MODEL)
ELECTRICAL
ITEM
Spark plug
SPECIFICATION
DENSO: U24ESR-N
NGK: CR8E
0.7 0.8 mm
Over 8 mm at 1 atm.
1.6 2.7
Type
Gap
Spark performance
Ignition coil resistance
Primary
Secondary
18 26 k
0.4 0.8
NOTE
+ tap - tap
Plug cap
+ tap
YY
Ground Y
+: B, -:
Ground
WATTAGE
Unit: W
ITEM
Headlight
Position light
Brake light/Taillight
Turn signal light
Speedometer light
Turn signal indicator light
High beam indicator light
Neutral indicator light
FI indicator light
Fuel level indicator light
HI
LO
STANDARD/SPECIFICATION
E-02
E-19
60
55
5
4
21/5
21
1.7
3.4
1.7
3.4
3.4
RV125K7 (07-MODEL)
BRAKE + WHEEL
ITEM
Rear brake pedal free travel
Rear brake pedal height
Brake drum I.D.
Brake disc thickness
Brake disc runout
Master cylinder bore
Master cylinder piston diam.
Brake caliper cylinder bore
Brake caliper piston diam.
Brake fluid type
Wheel rim runout
Wheel axle runout
Wheel rim size
Tire size
Tire tread depth
Front
Rear
Front
Rear
Front
Rear
STANDARD/SPECIFICATION
20 30
5 15
4.0 0.2
12.700 12.743
12.657 12.684
30.230 30.306
30.150 30.200
DOT 4
18 M/C MT 2.50
14 M/C MT 4.50
130/80-18 M/C 66P
180/80-14 M/C 78P
Unit: mm
LIMIT
110.7
3.5
0.30
2.0
2.0
0.25
0.25
4.0
4.0
STANDARD/SPECIFICATION
110
382.9
171
SUZUKI FORK OIL #10 or an equivalent fork oil
230 ml
136
Unit: mm
LIMIT
375
0.6
Rear
Front
Front
Front
Front
Front
Front
Axial
Radial
Front
Rear
SUSPENSION
ITEM
Front fork stroke
Front fork spring free length
Front fork oil level
Front fork oil type
Front fork oil capacity (each leg)
Rear wheel travel
Swingarm pivot shaft runout
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
(SOLO AND DUAL RIDING)
FRONT
REAR
103
kPa
kgf/cm2
125
125
1.25
1.25
104
RV125K7 (07-MODEL)
FUEL + OIL
ITEM
Fuel type
SPECIFICATION
Gasoline used should be graded 91 octane or
higher. An unleaded gasoline type is recommended.
6.5 L
SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Change
850 ml
Filter change
950 ml
Overhaul
1 200 ml
NOTE
Prepared by
September, 2006
Part No. 99501-31150-01E
Printed in Japan
104
4 mm
RV125
USE THIS MANUAL WITH:
RV125 SERVICE MANUAL (99500-31233-01E)
99501-31150-01E
K7
Printed in Japan
K7
DIC120