Description:
The Suzuki VL125 Intruder is a cruiser-style motorcycle often positioned as an entry-level or mid-size option for riders seeking a relaxed riding experience with classic styling. It typically appeals to riders who appreciate the cruiser aesthetic but may not require the power or size of larger displacement models.
Competitors:
Competes with other 125cc cruisers from brands like Honda (e.g., Shadow 125), Yamaha (e.g., Virago 125/DragStar 125), Kawasaki (e.g., Eliminator 125), and potentially some European offerings in the same displacement class.
Styling:
Classic cruiser styling with low seat height, swept-back handlebars, teardrop fuel tank, and often chrome accents.
Engine Layout:
V-twin engine, providing a characteristic sound and feel associated with larger cruisers.
Accessibility:
Designed to be accessible for newer riders or those seeking an easy-to-manage motorcycle.
Covered Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009
Type:
Service Workshop Repair Manual
Clarity:
Prepared for simplicity, enabling even less experienced technicians or DIY enthusiasts to perform satisfactory after-services.
Compatibility:
Compatible with Windows, Mac, and Linux operating systems, requiring Adobe Reader for viewing.
Engine Mechanical:
Full disassembly, assembly, inspection, repair, tuning, and troubleshooting of engine components, including cylinders, pistons, crankshaft, camshafts, valves, timing, lubrication system, cooling system (if applicable), and related parts.
Fuel System:
Carburetor(s) (identification, adjustment, cleaning, repair), fuel lines, fuel tank, fuel pump (if applicable), fuel filter.
Ignition System:
Ignition timing, spark plugs, ignition coils, CDI unit, troubleshooting.
Transmission Drivetrain:
Gearbox (disassembly, assembly, inspection, repair), clutch (operation, adjustment, replacement), final drive (chain/belt maintenance, lubrication).
Chassis Frame:
Frame inspection, suspension (forks, shock absorbers, linkages), steering system (headstock bearings, handlebars), swingarm.
Braking System:
Front and rear brakes (disc/drum, caliper, master cylinder, brake fluid replacement, bleeding, pad/shoe replacement, component inspection).
Electrical System:
Wiring diagrams, battery, starter motor, generator/alternator, lighting (headlight, taillight, signals), instrumentation, fuses, relays, troubleshooting electrical faults.
Bodywork Fittings:
Body panels, seat removal/installation, fuel tank removal/installation, fenders, exhausts.
Exhaust System:
Inspection, maintenance, and potential repair of the exhaust pipes and mufflers.
Wheels Tires:
Tire inspection, replacement, and wheel bearing maintenance.
Maintenance:
Scheduled maintenance, fluid changes (oil, brake fluid), filter replacements, lubrication, chain adjustment, tire pressure checks.
Troubleshooting:
Systematic diagnosis of common problems and faults, with step-by-step guides and potential causes.
Repair Rebuild:
Detailed instructions for the removal, disassembly, inspection, repair, and reassembly of all major vehicle components.
Adjustments:
Carburetor idle speed and mixture, clutch free play, brake lever free play, chain slack, suspension settings.
Special Tools:
Identification and usage of specialized tools required for specific repair and adjustment procedures.
Component Illustrations:
Detailed illustrations, exploded diagrams, and drawings are provided for clarity during disassembly and reassembly procedures.
Safety Precautions:
Includes special notes, precautions, DANGER, CAUTION, and NOTE remarks to ensure safe working practices and prevent damage to the vehicle or injury to personnel.
Depth:
Comprehensive, covering everything from basic maintenance and adjustments to full engine rebuilds, electrical system diagnostics, and chassis repairs.
Diagnostic Procedures:
Includes specific diagnostic steps for identifying and resolving common mechanical and electrical issues.
Specification Lists:
Contains comprehensive lists of service data, including tightening torques, clearance specifications, and wear limits for various components.
Diagrams Drawings:
Rich in diagrams, exploded views, and drawings that visually guide users through service procedures.
Configuration:
V-twin, four-stroke
Bore X Stroke:
Typically around 42mm x 45mm (exact figures may vary slightly, refer to manual for definitive specs).
Cooling System:
Liquid-cooled (common for this generation of VL125).
Valve Train:
SOHC, 2 valves per cylinder
Horsepower Output:
Around 13-15 hp at 9,000-10,000 rpm (subject to market regulations and specific model tuning; consult manual for official figures).
Torque Output:
Approximate torque figures typically in the range of 10-12 Nm (consult manual for specific figures).
Carburetion:
Twin Mikuni carburetors (e.g., CV type, specific model numbers provided in the manual).
Fuel Capacity:
Approximately 12-14 liters (refer to manual for exact capacity).
Oil Change:
Typically every 3,000-5,000 km or annually, whichever comes first. Specific interval detailed in the manual's periodic maintenance chart.
Spark Plug Replacement:
Recommended replacement at intervals such as 10,000-15,000 km, or as indicated by the manual.
Air Filter Cleaning:
Regular inspection and cleaning/replacement at intervals like 5,000-10,000 km, depending on operating conditions.
Engine Oil:
Refer to the manual for the specific viscosity grade (e.g., 10W-40) and API service classification (e.g., SG or higher) required for the engine oil. Suzuki recommends genuine Suzuki oil or equivalent.
Brake Fluid:
DOT 3 or DOT 4 brake fluid, as specified in the manual, for both front and rear brake systems.
Coolant:
A mixture of ethylene glycol-based antifreeze and distilled water is typically used for liquid-cooled engines. Specific ratio and type detailed in the manual.
Gear Oil:
Refer to the manual for specific gear oil type and viscosity for the transmission and final drive (if separate).
Fork Oil:
Specific type and quantity of fork oil required for front suspension servicing will be detailed in the manual.
Carburetor Gumming:
Potential for carburetor jets to become clogged with fuel residue if the motorcycle sits for extended periods without fuel stabilizer, leading to starting issues or rough idling.
Clutch Slippage:
Wear on clutch plates can lead to slippage, particularly under heavy load or aggressive acceleration. Manual provides inspection and adjustment procedures.
Electrical Connection Corrosion:
In humid or coastal environments, electrical connectors can be prone to corrosion, leading to intermittent electrical faults. Regular inspection and dielectric grease application are recommended.
Chain Maintenance:
Proper chain lubrication and tension adjustment are critical for drivetrain longevity and smooth operation. Neglect can lead to premature wear of the chain, sprockets, and seals.
