2003-2006 Suzuki RV125 VanVan Service Manual (128 Pages)
RV125 VanVan technical guide detailing engine, carburetor, brakes, and suspension service. Covers MIKUNI BS26 tuning, spark plug gap 0.7-0.8mm, and complete chassis adjustment procedures.
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Sample pages from the 2003-2006 Suzuki RV125 VanVan Service Manual (128 Pages) manual
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Models Covered & Key Technical Specifications
Suzuki RV125 VanVan — 2003–2006 Technical Service Archive | VanVan Series Repository.
- Nominal Fastening Values: Engine displacement reaches 125 cm³ (7.6 cu in) is calibrated to the four-stroke air-cooled OHC architecture Benchmarks.
- Principal Threaded Fastener Data: For optimal engine operation, 9.2:1 compression ratio is designed for maximum combustion chamber pressure Range.
- Rated System Fill: Front fork suspension stroke provides 110 mm (4.3 in) maximum suspension travel displacement Sequences.
- Technical Power Framework: The spark plug electrode is calibrated to 0.7–0.8 mm (0.028–0.031 in) gap spacing Baseline.
- Standard Throughput Data: Fuel system volume establishes 7.5 L (2.0 US gal / 1.6 imp gal) including 1.8 L reserve capacity Requirements.
- Defined Output Density: Charging voltage reaches 14.0–15.5 V at 5,000 r/min regulated output Threshold.
Professional Workshop Service Manual & Technical Specifications
Verified Technical Field Manual: Motorcycle 2003-2006 Suzuki RV125 VanVan Standards-Vault
Technical-Domain: Suzuki RV125 VanVan (2003–2006 models K3, K4, K5, K6) // Machine-Range: Four-stroke single-cylinder air-cooled engine system logic // Unit-Designations: 125 cc displacement, 57.0 mm bore, 48.8 mm stroke, electronic ignition.
| Document Role | Coverage | Availability |
|---|---|---|
| General Information and Specifications | Operating envelope (0–40 °C), spark plug gap data (0.7–0.8 mm), fuel tank capacity (7.5 L with 1.8 L reserve), charging voltage (14.0–15.5 V at 5,000 r/min) | Complete specifications provided |
| Periodic Maintenance and Service Schedules | Inspection intervals, lubrication points, air cleaner element cleaning, valve clearance reference data, brake system maintenance, tire and wheel service | Documented maintenance intervals at 1,000 km, 4,000 km, 8,000 km, and monthly checks |
| Engine Systems and Components | Engine removal/installation procedures, cylinder head cover, camshaft, pistons, crankshaft, transmission components, clutch assembly, electrical generator and ignition systems | Full disassembly and reassembly sequences included |
Major sections focus on engine and transmission systems, detailing front brake hydraulic components, addressing chassis suspension and steering geometry, covering rear brake and wheel assembly information, and documenting electrical charging and ignition system diagnostics. The manual provides detailed specifications for valve clearance reference data, includes torque specifications for engine mounting bolts to ensure proper assembly stress control, presents brake fluid specifications and bleeding procedures, and delivers comprehensive wiring diagrams and cable routing information.
The documentation addresses inspection guidelines for front wheel bearings, suspension stroke measurements (110 mm front fork travel, 136 mm rear wheel travel), and tire pressure specifications for solo and dual riding conditions (125 kPa cold inflation pressure). Assembly instructions are detailed for carburetor heater installation, PAIR system hose routing, and fuel tank mounting procedures. Hydraulic schematics are included for engine lubrication system flow through oil filters, galleries, and bearing surfaces. Steering component information is provided for steering stem nut torque values, upper and lower bearing races, and handlebar clamp positioning. Inspection guidelines are provided for crankshaft runout (0.08 mm service limit), camshaft journal oil clearance (0.150 mm service limit), and brake disc thickness (3.5 mm service limit).
The manual documents torque specifications for the clutch sleeve hub assembly to ensure proper assembly stress control, covering primary drive gear installation, generator rotor retention, and transmission component fastening procedures throughout the engine reassembly sequence.
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