Suzuki DR 125 Service Manual Download Page 123

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5-16 CHASSIS

MASTER CYLINDER REMOVAL AND DISAS-
SEMBLY

• Remove the brake lever cover

• Place a rag underneath the brake hose union bolt

on the

master cylinder to catch any spilt brake fluid. Loosen the
brake hose union bolt and disconnect the brake hose.

• Remove the master cylinder assembly

• Remove the brake lever

NOTE:
Do not loosen the brake lever spring

• Remove the reservoir cap

and diaphragm

• Drain the brake fluid.

Immediately wipe off any brake fluid contacting any
part of the motorcycle. The brake fluid reacts chemi-
cally with paint, plastics, rubber materials, etc., and
will damage them severely.

Summary of Contents for DR 125

Page 1: ...DR Z125 L 9 9 5 0 0 4 1 1 2 5 0 1 E...

Page 2: ...customers of fast and reliable service COPYRIGHT SUZUKI MOTOR CORPORATION 2002 This manual has been prepared on the basis of the latest specifications at the time of publi cation If modifications have...

Page 3: ...isted on the first page of each section to help you find the item and page you need COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit there is an exploded view which provides w...

Page 4: ...cified Measure in voltage range Apply molybdenum oil solution mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 1 Measure in resistance range Apply SUZUKI SUPER GREASE A 99000 25030 For USA...

Page 5: ...03 MODEL 1 4 SERIAL NUMBER LOCATION 1 4 FUEL AND OIL RECOMMENDATION 1 4 FUEL 1 4 ENGINE OIL 1 5 BRAKE FLUID 1 5 FRONT FORK OIL 1 5 BREAK lN PROCEDURES 1 5 INFORMATION LABELS 1 6 SPECIFICATIONS 1 7 DI...

Page 6: ...ust use good judgement and basic mechanical safety principles If you are unsure about how to perform a particular service operation ask a more experienced mechanic for advice GENERAL PRECAUTIONS Prope...

Page 7: ...and case bolts and nuts tighten the larger sizes first Always tighten the bolts and nuts from the inside working out in a crisscross manner Whenever you remove oil seals gaskets packing O rings locki...

Page 8: ...ght side of the steering head pipe The engine serial number 2 is located on the left side of the crankcase These numbers are required especially for registering the machine and ordering spare parts FU...

Page 9: ...necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and reliability of the engine depends on the care and restraint exercised durin...

Page 10: ...AME NO APPLIED SPECIFICATION E 28 E 03 1 Noise label 2 Information label 3 Fuel caution label 4 Manual notice label 5 Warning safety label 6 Certification plate 7 Compliance label DR Z125 L Frame Left...

Page 11: ...e air cooled OHC Number of cylinders 1 Bore 57 0 mm 2 244 in Stroke 48 8 mm 1 921 in Displacement 124 cm 7 6 cu in Compression ratio 9 5 1 Carburetor MIKUNI VM20SS Air cleaner Polyurethane foam elemen...

Page 12: ...ont tire size 70 100 17 40M tube type 70 100 19 42M tube type DR Z125L Rear tire size 90 100 14 49M tube type 90 100 16 52M tube type DR Z125L ELECTRICAL lgnition type Electronic ignition CDl lgnition...

Page 13: ...GENERAL INFORMATION 1 9 COUNTRY AND AREA CODES The following codes stand for the applicable countries and areas CODE COUNTRY OR AREA E 03 E 28 USA Canada...

Page 14: ...SPEED 2 8 FUEL HOSE 2 9 CLUTCH 2 9 ENGINE OIL AND OIL FILTER 2 10 SPARK ARRESTER 2 11 DRIVE CHAIN 2 12 FRONT BRAKE LEVER PLAY DR Z125 2 14 FRONT DISC BRAKE DR Z125L 2 14 REAR BRAKE PEDAL HEIGHT 2 16 B...

Page 15: ...erval months Initially Every Every Item 1 month 6 months 12 months Air cleaner element I I Exhaust pipe bolts and muffler mounting bolts T T T Valve clearance I I I Spark plug I R Spark arrester C Fue...

Page 16: ...low 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 especially wh...

Page 17: ...ve the air cleaner element 2 Separate the polyurethane foam element 3 and element frame 4 Fill a container with a non flammable cleaning solvent Immerse the air cleaner element in the cleaning solvent...

Page 18: ...of periodic inspection 2 when the valve mechanism is serviced and 3 when the camshaft is dis turbed by removing it for servicing Be sure to position the element snugly and correctly so that no incomin...

Page 19: ...210 Valve clearance adjusting driver Valve clearance when cold IN 0 08 0 13 mm 0 003 0 005 in EX 0 13 0 18 mm 0 005 0 007 in CAM CHAIN TENSION ADJUSTER The cam chain is maintained at the proper tensio...

Page 20: ...ire Be sure to clean the car bon deposits off periodically If the center electrode is fairly worn down the spark plug should be replaced and the spark plug gap set to the specifi cation using a thickn...

Page 21: ...in ENGINE IDLE SPEED Adjust the throttle cable play See above Warm up the engine NOTE Make this adjustment when the engine is hot Start the engine turn the throttle stop screw 1 and set the engine idl...

Page 22: ...nspect the fuel hose for damage and fuel leakage If any dam ages are found replace the fuel hoses with a new one CLUTCH Clutch cable play should be 10 15 mm 0 4 0 6 in A as measured at the clutch leve...

Page 23: ...il Use an engine oil that meets API service classifications SF or SG and that has a vis cosity rating of SAE 10W 40 Engine oil drain plug 1 28 N m 2 8 kgf m 20 5 lb ft Make sure that the engine is coo...

Page 24: ...in the engine oil replacement procedure Engine oil capacity Oil change 0 85 L 0 9 0 7 US lmp qt Oil and filter change 0 95 L 1 0 0 8 US lmp qt Engine overhaul 1 1 L 1 2 1 0 US lmp qt SPARK ARRESTER R...

Page 25: ...the drive chain must be replaced CHECKING AND ADJUSTING Remove the rear axle cotter pin 1 Loosen the rear axle nut 2 Tense the drive chain fully by turning both chain adjusters 3 Count out 21 pins 20...

Page 26: ...ve chain tighten the rear axle nut 3 to the specified torque Rear axle nut 45 N m 4 5 kgf m 32 5 lb ft Recheck the chain slack after tightening the axle nut and readjust if necessary Tighten both chai...

Page 27: ...pads as a set otherwise braking performance will be adversely affected Inspect every 6 months Replace every 2 years The brake system is filled with a glycol based brake fluid which is classified DOT 4...

Page 28: ...t the free end of the hose into a receptacle Bleed air from the brake system Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing it Loos...

Page 29: ...12 in REAR BRAKE PEDAL HEIGHT Loosen the lock nut 1 and rotate the adjusting bolt 2 to locate brake pedal 10 mm 0 4 in A below the top face of the footrest Retighten the lock nut 1 to secure the adjus...

Page 30: ...ering should be adjusted properly for smooth turning of handlebars and safe operation Overtight steering prevents smooth turning of the handlebars and too loose steering will cause poor stability Chec...

Page 31: ...increase Therefore main tain the correct tire pressure for good roadability and a longer tire life Cold inflation tire pressure is as follows DR Z125 L SPOKE NIPPLES Make sure that the nipples are ti...

Page 32: ...3 kgf m 16 5 lb ft Muffler connection bolt 2 23 N m 2 3 kgf m 16 5 lb ft Muffler mounting nut and bolt 3 4 23 N m 2 3 kgf m 16 5 lb ft FRONT FORK Inspect the front forks for oil leakage scoring or sc...

Page 33: ...DR Z125L 44 4 4 32 0 5 Handlebar clamp bolt 23 2 3 16 5 6 Front brake master cylinder mounting bolt DR Z125L 10 1 0 7 0 7 Front brake caliper mounting bolt DR Z125L 23 2 3 16 5 8 Brake hose union bol...

Page 34: ...PERIODIC MAINTENANCE 2 21...

Page 35: ...pressure goes below specification check the engine for conditions listed above COMPRESSION TEST PROCEDURE NOTE Before testing the engine for compression pressure make sure that the cylinder head nuts...

Page 36: ...too high Clogged oil passage Combination of the above items OIL PRESSURE TEST PROCEDURE Connect a tachometer to the high tension cord Remove the main oil gallery plug 1 Install the oil pressure gauge...

Page 37: ...EINSTALLATION 3 6 ENGINE DISASSEMBLY 3 9 ENGINE COMPONENTS INSPECTION AND SERVICE 3 18 CYLINDER HEAD COVER 3 18 CYLINDER HEAD 3 20 CAMSHAFT 3 29 CYLINDER 3 30 PISTON AND PISTON PIN 3 31 CRANKSHAFT AND...

Page 38: ...STALLATION Generator cover 3 11 3 54 Generator rotor 3 15 3 49 Generator stator 3 15 3 38 Cam chain 3 15 3 38 PARTS REMOVAL INSTALLATION Kick starter lever 3 9 3 60 Clutch cover 3 12 3 54 Clutch 3 12...

Page 39: ...e fuel tank 4 2 Remove the carburetor 4 5 Drain engine oil 2 10 Disconnect the plug cap Remove the exhaust pipe bolts Remove the muffler connecting bolt 1 and mounting bolts 2 Remove the exhaust pipe...

Page 40: ...that the drive chain has enough slack Remove the engine sprocket 3 NOTE When loosening the engine sprocket bolt depress the brake pedal Remove the clutch release arm 4 along with the clutch cable Dis...

Page 41: ...upper engine mounting bolts and bracket NOTE When removing the upper mounting bolts and nuts support the engine with a jack Remove the swingarm pivot nut and washer Partially remove the swingarm pivo...

Page 42: ...e specified torque NOTE The engine mounting nuts are self locking Once the nuts have been removed they are no longer of any use Tighten the swingarm pivot nut to the specified torque Swingarm pivot nu...

Page 43: ...the engine sprocket bolt to the specified torque Engine sprocket bolt 25 N m 2 5 kgf m 18 0 lb ft NOTE When tightening the engine sprocket bolt depress the brake pedal Install the gearshift cam lever...

Page 44: ...remounting the engine the following adjustments are necessary Clutch lever play 2 9 Throttle cable play 2 8 Engine idle speed 2 8 Drive chain slack 2 13 Pour 1 100 ml 1 2 1 0 US lmp qt of 10W 40 SAE...

Page 45: ...ve the spark plug 09930 10121 Spark plug wrench set KICK STARTER LEVER Remove the kick starter lever Remove the timing inspection plug 1 and generator cover plug 2 Rotate the crankshaft and align the...

Page 46: ...end cap 2 Flatten the lock washer and remove the camshaft sprocket bolts Remove the camshaft 3 and camshaft sprocket 4 Remove the C ring 6 CYLINDER HEAD Remove the cylinder head nuts A Loosen the cyli...

Page 47: ...move the cylinder by removing the nuts NOTE If the cylinder does not come off lightly tap on the finless portion of it with a plastic hammer PISTON Place a clean rag over the cylinder base to prevent...

Page 48: ...crisscross pattern and remove the clutch springs and clutch pressure plate 1 Remove the clutch drive and driven plates Remove the washer 2 bearing 3 clutch push piece 4 and clutch push rod 5 Flatten t...

Page 49: ...IFT Remove the kick starter drive gear 3 and waher Remove the gearshift shaft 4 Remove the pawl lifter 5 and cam guide 6 Remove the gearshift cam driven gear 7 NOTE When removing the cam driven gear 7...

Page 50: ...il pump drive gear nut with the special tool 09930 40113 Rotor holder Remove the oil pump drive gear 3 and primary drive gear 4 Remove the key 5 Remove the snap ring 6 washer 7 and kick starter idle g...

Page 51: ...holder Remove the generator rotor with the special tools 09930 30161 Rotor remover attachment 09930 30102 Sliding shaft GENERATOR STATOR Remove the generator stator 1 CAM CHAIN Remove the generator ro...

Page 52: ...or so that the tool arms are in paral lel with the side of crankcase The crankshaft and transmission components should remain in the left crankcase half When separating the crankcase tap the end of th...

Page 53: ...ENGINE 3 17 Remove the driveshaft and countershaft Remove the gearshift cam stopper 1 CRANKSHAFT Remove the crankshaft with the special tool 09920 13120 Crankcase separator...

Page 54: ...ate and check for distortion with a thickness gauge Check points are shown in Fig Cylinder head cover distortion Service Limit 0 05 mm 0 002 in 09900 20803 Thickness gauge If the distortion exceeds th...

Page 55: ...le the cylinder head cover in the reverse order of dis assembly Pay attention to the following points Apply engine oil to the rocker arm shafts Install the rocker arms 1 wave washers 3 and shafts 2 1...

Page 56: ...alve lifter 09916 14910 Valve lifter attachment Remove the valve cotters 1 from the valve stem 09916 84511 Tweezers Remove the valve spring retainer 2 and inner and outer valve springs 3 4 Identify th...

Page 57: ...03 Thickness gauge VALVE FACE WEAR The thickness of the valve face decreases as the face wears Visually inspect each valve face for wear and replace any valve with an abnormally worn face Measure the...

Page 58: ...e stem deflection Service Limit Intake and exhaust valves 0 35 mm 0 014 in 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand VALVE STEM WEAR Measure the valve stem O D using the micrometer If...

Page 59: ...il the guides after reaming 09916 34550 Valve guide reamer 5 5 mm 09916 34542 Handle VALVE SEAT WIDTH INSPECTION Visually check for valve seat width on each valve face If the valve face has worn abnom...

Page 60: ...ilot N 140 5 5 09916 24900 Valve seat cutter set NOTE Use the solid pilot N 100 5 52 along with the valve seat cutter N 121 and 122 When installing the solid pilot 1 rotate it slightly Seat the pilot...

Page 61: ...the contact area is too high on the valve or if it is too wide use the 15 cutter to lower and narrow the contact area Use the 15 cutter FINAL SEAT CUT If the contact area is too low or too narrow use...

Page 62: ...n replace the valve Valve stem end length Service Limit 2 5 mm 0 10 in VALVE SPRINGS Check the valve springs for proper strength by measuring their free length and also the force required to compress...

Page 63: ...Pay attention to the following points Install each valve spring seat 1 Apply molybdenum oil solution to the valve stem seal and press fit the seal into position by hand MOLYBDENUM OIL Apply molybdenu...

Page 64: ...lifter 09916 14910 Valve lifter attachment 09916 84511 Tweezers INTAKE PIPE When installing the intake pipe apply grease to the O ring 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER G...

Page 65: ...T JOURNAL WEAR Determine whether or not each journal is worn down to the limit by measuring the oil clearance with the camshaft installed in place Measure the clearance using the plastigauge 1 09900...

Page 66: ...e runout using a dial gauge Replace the camshaft if the runout exceeds the limit Camshaft runout Service Limit 0 10 mm 0 004 in 09900 20606 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 21304 V...

Page 67: ...in Piston oversize 0 5 mm 0 02 in 09900 20203 Micrometer 50 75 mm PISTON TO CYLINDER CLEARANCE Subtract the piston diameter from the cylinder bore diameter If the piston to cylinder clearance exceeds...

Page 68: ...soft metal scraper PISTON RING FREE END GAP AND PISTON RING END GAP Measure the piston ring free end gap using a vernier calipers Next fit the piston ring squarely into the cylinder and measure the p...

Page 69: ...e the outside diameter to identify the size PISTON PIN BORE Measure the piston pin bore inside diameter using the caliper gauge and measure the piston pin outside diameter using the micrometer If eith...

Page 70: ...mall end inside diameter using the dial cal ipers If the conrod small end inside diameter exceeds the ser vice limit replace the conrod Conrod small end I D Service Limit 14 040 mm 0 5528 in 09900 206...

Page 71: ...hickness gauge If the clearance exceeds the service limit replace crankshaft assembly or bring the deflection and side clearance into specifi cation by replacing the worn parts e g conrod big end bear...

Page 72: ...he bearing and inner surface of the each gear Never reuse a snap ring After a snap ring has been removed from a shaft it should be dis carded and a new snap ring must be installed When installing a ne...

Page 73: ...the gear surface Press fitted 2nd drive gear onto the countershaft Before reassem bling coat the internal face of the 2nd drive gear with THREAD LOCK SUPER 1303 and install the gears so that the lengt...

Page 74: ...rance is too great the meshed gears may slip apart If the clearance exceeds the specification replace the fork its respective gear or both Gearshift fork to groove clearance Service Limit 0 5 mm 0 02...

Page 75: ...within the service limit replace the clutch plates as a set Clutch driven plate distortion Service Limit 0 10 mm 0 004 in 09900 20803 Thickness gauge CLUTCH SPRING FREE LENGTH Measure the free length...

Page 76: ...e installed cor rectly Applyb engine oil to the O ring 4 and 5 Install the oil filter cap OIL SUMP FILTER REMOVAL Remove the oil sump filter cap 1 Remove the oil sump filter 2 CLEANING AND INSPECTION...

Page 77: ...shaft return spring 3 09900 06107 Snap ring pliers Remove the kick starter shaft 4 kick starter 5 spring 6 and washer 7 1Kick starter lever 2Kick starter drive gear 3Kick starter shaft 4Kick starter...

Page 78: ...unch mark B on the kick starter shaft 2 Insert the kick starter shaft into the crankcase Engage the kick starter 1 to the guide 2 Install the return spring 3 and hook the part C onto the crankcase Tur...

Page 79: ...ties the bearing is defective and must be replaced as follows BEARING REMOVAL Remove the bearing retainers 1 2 Remove the oil seals 3 with the special tool 09913 50121 Oil seal remover Remove the wash...

Page 80: ...ll quantity of SUZUKI SUPER GREASE A to the lip of the oil seal 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Install the oil seal using the special tool 09913 70210 B...

Page 81: ...LOCK 1342 to the bearing retainer screws 99000 32050 THREAD LOCK 1342 CLUTCH RELEASE CAMSHAFT REMOVAL Remove the oil seal retainer 1 Remove the clutch release camshaft 2 REASSEMBLY Install the clutch...

Page 82: ...ls 09910 32812 Crankshaft installer 09910 20116 Conrod holder Apply engine oil to the crankshaft bearings Install the countershaft and driveshaft assemblies Align the pin groove A of gearshift cam sto...

Page 83: ...ft cam as shown so that the gearshift fork shafts can be installed easily Wipe both crankcase mating surfaces with a cleaning solvent Apply SUZUKI BOND 1207B uniformly to the mating surface of the rig...

Page 84: ...a plastic hammer Install the gearshift cam stopper Apply SUZUKI SUPER GREASE A to the O ring of the engine sprocket spacer and the oil seal lip When installing the engine sprocket spacer onto the dri...

Page 85: ...0113 Rotor holder Generator rotor nut 55 N m 5 5 kgf m 40 0 lb ft Install the kick starter idle gear 1 washer 2 and snap ring 3 to the driveshaft 09900 06107 Snap ring pliers PRIMARY DRIVE GEAR Instal...

Page 86: ...tor holder Primary drive gear oil pump drive gear nut 50 N m 5 0 kgf m 36 0 lb ft Bend the lock washer securely OIL PUMP Apply engine oil to the sliding surfaces of the oil pump case outer rotor inner...

Page 87: ...ear assembly Install the pawl lifter 5 and cam guide 6 NOTE Apply a small quantity of THREAD LOCK 1342 to the threads of the screws 99000 32050 THREAD LOCK 1342 GEARSHIFT SHAFT Install the return spri...

Page 88: ...ngaging the primary drive and driven gears turn the pri mary driven gear assembly to the counterclockwise Install the clutch sleeve hub 5 and lock washer 6 1Primary driven gear assembly 2Clutch sleeve...

Page 89: ...piece 3 bearing 4 and washer 5 Install the clutch drive and driven plates one by one into the clutch sleeve hub Install the clutch pressure plate 6 clutch springs and clutch spring mounting bolts Hol...

Page 90: ...o dowel pins and new gasket 1 Tighten the clutch cover bolts and oil filter cap nut securely GENERATOR COVER Install the new gasket 1 Install the generator cover 2 and tighten the bolts securely Insta...

Page 91: ...l the 2nd ring and 1st ring NOTE 1st ring and 2nd ring differ in shape The 1st and 2nd piston rings should be installed with their marks facing up Position the piston ring gaps as shown NOTE Before in...

Page 92: ...LINDER Before installing the cylinder oil the big and small ends of the conrod and also the sliding surface of the piston Install the dowel pins into the crankcase and then install the cylinder gasket...

Page 93: ...pper washer B Short bolt Steel washer C Long bolt Steel washer D Short bolt Copper washer Tighten the cylinder head bolts to the specified torque in a crisscross pattern Cylinder head bolt Initial 10...

Page 94: ...s par allel with mating surface of the cylinder head and cylinder head cover Engage the cam chain on the camshaft sprocket with the locating pin hole B at just past top position NOTE Do not rotate the...

Page 95: ...all the camshaft end cap 1 Clean the mating surfaces of the cylinder head and head cover Install the dowel pins Apply SUZUKI BOND 1216B uniformly to the mating surface of the cylinder head cover and i...

Page 96: ...ll the cam chain tension adjuster to the cylinder and tighten its mounting bolts to the specified torque Cam chain tension adjuster mounting bolt 10 N m 1 0 kgf m 7 0 lb ft Turn the crankshaft normal...

Page 97: ...VAL 4 3 FUEL FILTER INSPECTION AND CLEANING 4 3 FUEL HOSE INSPECTION 4 3 CARBURETOR 4 4 CONSTRUCTION 4 4 SPECIFICATIONS 4 5 I D NO LOCATION 4 5 REMOVAL 4 5 DISASSEMBLY 4 6 CLEANING 4 8 INSPECTION 4 9...

Page 98: ...NK FUEL TANK REMOVAL Remove the frame covers and seat 5 2 Turn the fuel valve to OFF position and disconnect the fuel hose 1 from the fuel valve Remove the fuel tank Gasoline is highly flammable and e...

Page 99: ...e fuel filter is dirty with sediment or rust fuel will not flow smoothly and loss in engine power may result Clean the fuel fil ter with compressed air FUEL HOSE INSPECTION Visually inspect the fuel h...

Page 100: ...t needle 4Starter plunger 5Throttle valve 6Main air jet 7Pilot air jet 8Diaphragm 9Throttle stop screw 0O ring AWasher BSpring CPilot screw DPilot jet ENeedle jet FMain jet holder GPlate HMain jet IVa...

Page 101: ...ose 1 air vent hose 2 and carburetor overflow hose 3 Remove the clamps Remove the carburetor top cap 4 Remove the carburetor ITEM SPECIFICATION E 03 28 Carburetor type MIKUNI VM20SS Bore size 20 0 mm...

Page 102: ...uretor top cap 3 Remove the float chamber body 4 Remove the float assembly 5 by removing the float pin 6 NOTE Remove the float assembly together with the needle valve Remove the needle valve 7 Remove...

Page 103: ...seat 3 Pilot jet Slowly turn the pilot screw 4 in clockwise and count the num ber of turns until the screw is lightly seated Make a note of how many turns were made so the screw cam be reset cor rectl...

Page 104: ...stall the pilot screw to the original factory setting with a new O ring seal Do not attempt to remove the four screws of the car buretor body Some carburetor cleaning chemicals especially dip type soa...

Page 105: ...If the needle is worn as shown in the illustration replace it together with a valve seat Clean the fuel passage of the mixing chamber with compressed air FLOAT HEIGHT ADJUSTMENT To check the float hei...

Page 106: ...ALL CONROD SMALL END BY PASS PRIMARY DRIVEN GEAR SPACER COUNTERSHAFT AND GEARS COUNTERSHAFT LEFT SIDE BEARING OIL SUMP FILTER CAM FACES ROCKER ARM SHAFTS CONROD BIG END BEARING CLUTCH PLATES DRIVESHAF...

Page 107: ...CATION SYSTEM 4 11 OIL PRESSURE 2 23 OIL FILTER 2 10 OIL SUMP FILTER 3 41 NOTE When separating the crankcase wash the oil sump filter with cleaning solvent and then blow compressed air through it to d...

Page 108: ...E CALIPER REASSEMBLY AND REMOUNTING 5 14 BRAKE DISC INSPECTION 5 15 MASTER CYLINDER REMOVAL AND DISASSEMBLY 5 16 MASTER CYLINDER INSPECTION 5 17 MASTER CYLINDER REASSEMBLY AND REMOUNTING 5 17 FRONT FO...

Page 109: ...Remove the bolts A left and right Remove the seat 1 FUEL TANK COVERS Remove the tank covers 1 and 2 FRONT NUMBER PLATE Pull out the fuel vent hose and untie the belt Remove the front number plate 1 F...

Page 110: ...d front axle nut 4 Raise the front wheel off the ground with a jack or wooden block Remove the front wheel with the front brake panel by remov ing the front axle shaft 1Dust seal 2Bearing 3Bearing 4Br...

Page 111: ...IS Remove the front brake panel 1 Remove the brake shoes 2 from the brake panel Remove the brake cam lever bolt and nut Remove the brake cam lever 3 Remove the spring 4 washer 5 O ring 6 and brake cam...

Page 112: ...aring remover set AXLE SHAFT Measure the front axle runout using the dial gauge If the runout exceeds the service limit replace the front axle 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stan...

Page 113: ...new ones REASSEMBLY WHEEL BEARINGS Apply SUZUKI SUPER GREASE A to the bearings before installing 99000 25030 SUZUKI SUPER GREASE A USA 99000 25010 SUZUKI SUPER GREASE A Others Install the wheel beari...

Page 114: ...A USA 99000 25010 SUZUKI SUPER GREASE A Others REMOUNTING Remount the front wheel in the reverse order of removal Pay attention to the following points Align the rib 1 on the left fork leg with the s...

Page 115: ...he front wheel off the ground with a jack or wooden block Remove the front axle shaft and front wheel 1Bearing 2Spacer 3Bearing 4Brake disc 5Front axle AFront axle nut BBrake disc mounting nut ITEM N...

Page 116: ...REMOUNTING Reassemble and remount the front wheel in the reverse order of removal and disassembly Pay attention to the following points WHEEL BEARINGS 5 5 BRAKE DISC Tighten the brake disc nuts to the...

Page 117: ...therwise serious damage to the brake system will result Do not use any brake fluid taken from old used or unsealed containers Do not reuse brake fluid left over from the last servicing or which has be...

Page 118: ...caliper mounting bolts to the specified torque Brake caliper mounting bolt 23 N m 2 3 kgf m 16 5 lb ft NOTE After replacing the brake pads pump the brake lever a few times to check for proper brake o...

Page 119: ...Close the air bleeder valve and disconnect a clear hose Fill the reservoir with new brake fluid to the upper end of the inspection window Air bleeder valve 7 5 N m 0 75 kgf m 5 5 lb ft BRAKE CALIPER...

Page 120: ...BRAKE CALIPER Inspect each brake caliper cylinder wall for nicks scratches or other damage If any damages are found replace the brake cal iper with a new one BRAKE CALIPER PISTON Inspect the brake cal...

Page 121: ...d dust seal 2 as shown BRAKE CALIPER HOLDER Apply SUZUKI SILICON GREASE to the brake caliper holder 99000 25100 SUZUKI SILICONE GREASE Install the spring 3 Wash the brake caliper components with new b...

Page 122: ...asure the thickness using the micrometer If any damages are found or if the thickness is less than the service limit replace the brake disc with a new one 09900 20205 Micrometer 0 25 mm Brake disc thi...

Page 123: ...ake hose union bolt and disconnect the brake hose Remove the master cylinder assembly 3 Remove the brake lever 4 NOTE Do not loosen the brake lever spring 5 Remove the reservoir cap 6 and diaphragm 7...

Page 124: ...r damage If any damages are found replace the master cylinder with a new one PISTON AND RUBBER PARTS Inspect the piston surface primary secondary cup and dust seal boot for any scratches wear or damag...

Page 125: ...0 lb ft Install the brake lever cover Adjust the brake lever play 2 16 Wash the master cylinder components with new brake fluid before reassembly Do not wipe the brake fluid off after washing the com...

Page 126: ...ts Pull down the front fork assembly 1O ring 2Front fork spring 3Damper rod 4Inner tube 5Slide metal 6Oil seal stopper ring 7Oil seal 8Oil seal retainer 9Outer tube slide metal 0Oil lock piece AOuter...

Page 127: ...nd spring Invert the fork and stroke it several times to drain out the fork oil Under this condition inverted condition hold the fork for a few minutes Remove the damper rod bolt 1 Remove the damper r...

Page 128: ...be Remove the oil lock piece 1 Remove the oil seal 2 oil seal retainer 3 outer tube antifric tion metal 4 and inner tube antifriction metal 5 The outer and inner tube s antifriction metals must be rep...

Page 129: ...remount the front fork in the reverse order of removal and disassembly Pay attention to the following points ANTIFRICTION METALS OIL SEAL AND DUST SEAL Hold the inner tube vertically clean the metal g...

Page 130: ...the specified torque Damper rod bolt 20 N m 2 0 kgf m 14 5 lb ft FORK OIL Pour the specified fork oil into the inner tube Front fork oil capacity each leg 172 ml 4 3 4 5 US lmp oz 99000 99001 SS8 SUZ...

Page 131: ...e Front fork cap bolt 23 N m 2 3 kgf m 16 5 lb ft Install the boot Tighten the upper clamp bolt 1 to the specified torque Tighten the lower clamp bolt 2 to the specified torque Front fork upper clamp...

Page 132: ...aster cylinder and brake caliper DR Z125L Remove the front forks 5 19 Remove the bolt 1 1Steering stem upper bracket 2Steering stem nut 3Dust seal 4Steering stem upper bearing 5Steering stem lower bea...

Page 133: ...e steering stem upper bracket 5 by removing the steering stem head nut Remove the steering stem nut 6 by using the special tool 09940 14930 Steering stem nut socket wrench Remove the steering stem low...

Page 134: ...and lower bearing races by using the special tools 09941 54911 Bearing outer race remover 09941 74911 Steering bearing remover REASSEMBLY AND REMOUNTING Reassemble and remount the steering stem in th...

Page 135: ...2 of a turn A NOTE This adjustment will vary from motorcycle to motorcycle Install the front forks 5 24 Tighten the steering stem head nut to the specified torque Steering stem head nut 90 N m 9 0 kg...

Page 136: ...hers Set the clutch lever holder to match its mating face to the punched mark 2 on the handlebars Install the engine stop button 3 Set the front brake lever to match its mating face to the punched mar...

Page 137: ...tment and installing the handlebars rock the front wheel assembly forward and backward to ensure that there is no play and that the procedure was accomplished correctly Finally check to make sure that...

Page 138: ...und with a jack or wooden block Remove the rear axle 5 Disengage the drive chain from the rear sprocket Remove the rear wheel together with the rear brake panel 1Rear axle 2Dust seal 3Rear sprocket 4B...

Page 139: ...5 32 CHASSIS Remove the rear brake panel 1 Remove the rear sprocket 2 Remove the brake shoes 3 from the brake panel Remove the brake cam lever 4 Remove the washer 5 O ring 6 and brake camshaft 7...

Page 140: ...ocket and drive chain REASSEMBLY AND REMOUNING Reassemble and remount the rear wheel and rear brake in the reverse order of removal and disassembly Pay attention to the following points WHEEL BEARINGS...

Page 141: ...hten the rear axle nut to the specified torgue Rear axle nut 45 N m 4 5 kgf m 32 5 lb ft Install the new cotter pin Adjust the drive chain slack after installing the rear wheel 2 12 Adjust the rear br...

Page 142: ...m 5Drive chain case 6Chain buffer 7Chain guide ARear shock absorber mounting bolt BRear shock absorber mounting nut CSwingarm pivot nut DCushion lever bolt Front ECushion lever nut Center FCushion rod...

Page 143: ...ve the right frame cover 5 2 Remove the rear shock absorber upper mounting bolt 2 Remove the cushion lever nut 3 and bolt Remove the swingarm pivot nut 4 and shaft Remove the swingarm assembly Remove...

Page 144: ...and cushion rod Inspect the spacers for any flaws or other damage If any dam ages are found replace the spacers with new ones SWINGARM BUSHING Remove the dust seals 09913 50121 Oil seal remover Insert...

Page 145: ...er 09930 30102 Sliding shaft SWINGARM Inspect the swingarm for damage If any damages are found replace the swingarm with a new one NEEDLE BEARINGS Remove the dust seals 09913 50121 Oil seal remover Re...

Page 146: ...cessive play replace the bearing with new ones Remove the needle bearings by using the special tools 09923 73210 Bearing remover 09930 30102 Sliding shaft CHAIN BUFFER Inspect the chain buffer for dam...

Page 147: ...SEMBLY AND REMOUNTING Reassemble and remount the rear swingarm and suspension in the reverse order of removal and disassembly Pay attention to the following points SWINGARM BUSHING Apply SUZUKI SUPER...

Page 148: ...d by using the special tool and suitable socket wrench 09924 84521 Bearing installer REAR SUSPENSION Tighten the cushion lever and rod nuts to the specified torque Cushion lever nut CTR 80 N m 8 0 kgf...

Page 149: ...USPENSION SETTING REAR SHOCK ABSORBER SPRING SETTING Turn the adjuster 1 to obtain the spring length A of 269 4 mm 10 6 in Tighten the lock ring 2 to the specified torque Rear shock absorber lock ring...

Page 150: ...a vice Make a hole with a drill The rear shock absorber unit contains high pressure nitrogen gas Mishandling can cause explosion Keep away from fire and heat High gas pressure caused by heat can cause...

Page 151: ...RICAL SYSTEM CAUTIONS IN SERVICING 6 2 CONNECTORS 6 2 COUPLERS 6 2 CLAMPS 6 2 SEMI CONDUCTOR EQUIPPED PARTS 6 2 WIRING PROCEDURE 6 2 USING THE MULTI CIRCUIT TESTER 6 3 IGNITION SYSTEM 6 4 DESCRIPTION...

Page 152: ...r be sure to hold the coupler do not pull the lead wires Inspect each terminal on the coupler for looseness or bends Inspect each terminal for corrosion and contamination CLAMPS Refer to the WIRE CABL...

Page 153: ...r If the voltage and current values are not known begin mea suring in the highest range When measuring the resistance make sure no voltage is applied If voltage is applied the tester will be damaged A...

Page 154: ...LECTRICAL SYSTEM IGNITION SYSTEM DESCRIPTION The ignition system is shown in the diagram below TROUBLESHOOTING G B B Y B W B Bl B B R G B B Y B W B Bl B B R Generator Engine stop switch Spark plug CDI...

Page 155: ...peak voltage using the multi circuit tester in the following procedure Connect the multi circuit tester with the peak voltage adaptor as follows Ignition coil Black White terminal Ground White Blue te...

Page 156: ...pect the igni tion coil IGNITION COIL RESISTANCE Remove the fuel tank 4 2 Disconnect the spark plug cap Disconnect the ignition coil lead wire coupler 1 and then remove the ignition oil Measure the ig...

Page 157: ...for a few times and then measure the pick up coil peak voltage Repeat the above procedure a few times and measure the highest pick up coil peak voltage Pick up coil peak voltage More than 2 0 V Tester...

Page 158: ...etween the two lead wires using the multi circuit tester If the resistance is not within the specified value replace the stator coil with a new one Also check that the generator core is insulated Stat...

Page 159: ...7 8 WIRING DIAGRAM 7 9 WIRE CABLE AND HOSE ROUTING 7 10 WIRE ROUTING 7 10 CABLE ROUTING 7 12 FRONT BRAKE HOSE ROUTING 7 13 FUEL HOSE AND FUEL TANK MOUNTING 7 14 SIDE STAND SET UP 7 15 CARBURETOR INSTA...

Page 160: ...tension cord 7 Defective generator 8 Defective CDI unit No fuel reaching the carburetor 1 Clogged fuel tank vent hose 2 Clogged or defective fuel valve 3 Defective carburetor needle valve 4 Clogged fu...

Page 161: ...ershaft spline 3 Worn driveshaft spline 4 Worn or rubbing primary gear 5 Worn bearing Adjust Replace Replace Replace Replace Replace Clean Replace Replace Replace cam chain and sprockets Replace cam c...

Page 162: ...Low float chamber fuel level 10 Dirty air cleaner element 11 Clogged fuel hose resulting in inadequate fuel supply to carburetor Replace Replace Regap or replace Adjust Replace CDI unit Replace Replac...

Page 163: ...Clean Tighten adjust or replace gas ket Tighten or replace defective part Adjust Idling or low speed trouble 1 Clogged or loose pilot jet 2 Clogged or loose pilot air jet 3 Air leaking from carbureto...

Page 164: ...just Front suspension too stiff 1 Excessively viscous fork oil 2 Excessive fork oil 3 Improper suspension setting Replace Check level and drain Adjust Front suspension too noisy 1 Insufficient fork oi...

Page 165: ...e pad surface 2 Tilted brake pad 3 Damaged wheel bearing 4 Worn brake pad 5 Foreign material in brake fluid 6 Clogged return port of master cylinder 7 Loose front or rear axle nut Clean surface with s...

Page 166: ...4 Dirty air cleaner element 5 Incorrect spark plug cold type Adjust carburetor Adjust carburetor Change Clean or replace Change to standard spark plug Spark plug quickly becomes fouled with oil or ca...

Page 167: ...SERVICING INFORMATION 7 9 WIRING DIAGRAM...

Page 168: ...HOSE ROUTING WIRE ROUTING Throttle cable Front brake cable Clutch cable Engine stop switch lead wire Clamp CDI unit Clamp Clamp Clamp Clamp Throttle cable Engine stop switch lead wire Clutch cable Fa...

Page 169: ...SERVICING INFORMATION 7 11 Generator lead wire 5 N m 0 5 kgf m 3 7 lb ft 55 N m 5 5 kgf m 40 lb ft 90...

Page 170: ...7 12 SERVICING INFORMATION CABLE ROUTING Front brake cable Front brake cable Clamp Clamp Wire harness Face the circlip end down Clutch cable Clutch cable Throttle cable Steering stem upper bracket...

Page 171: ...SERVICING INFORMATION 7 13 Brake hose Brake hose guide Clamp 1 mm 0 04 in Brake hose Clamp After the brake hose union has contacted the stopper tighten the union bolt FRONT BRAKE HOSE ROUTING...

Page 172: ...NG INFORMATION Fuel valve Face the clamp end down Face the clamp end outside 4 4 N m 0 44 kgf m 3 0 lb ft Frame Cut the clamp end after tightening Face the clamp end to the right FUEL HOSE AND FUEL TA...

Page 173: ...SERVICING INFORMATION 7 15 55 N m 5 5 kgf m 40 0 lb ft 50 N m 5 0 kgf m 36 0 lb ft SIDE STAND SET UP...

Page 174: ...to the right side Air vent hose Breather hose Air vent hose carburetor overflow hose VIEW A Pass the air vent hose between the frame and engine cover Clamp Clamp A A Air vent hose Breather hose Genera...

Page 175: ...eter 50 75 mm 09900 20205 Micrometer 0 25 mm 09900 20508 Cylinder gauge set 09900 20605 Dial calipers 1 100 mm 10 34 mm 09900 20607 Dial gauge 1 100 mm 09900 20701 Magnetic stand 09900 20803 Thickness...

Page 176: ...chment 09916 21111 Valve seat cutter set 09916 24450 Solid pilot N 100 5 52 09916 24480 Solid pilot N 140 5 5 09916 24900 Valve seat cutter set 09916 34542 Reamer handle 9916 34550 Valve guide reamer...

Page 177: ...09925 18011 Steering bearing installer 09930 10121 Spark plug wrench set 09930 30102 Sliding shaft 09930 40113 Rotor holder 09940 14930 Steering stem nut socket wrench 09940 52861 Front fork oil seal...

Page 178: ...40 0 Clutch sleeve hub nut 50 5 0 36 0 Cam chain tension adjuster mounting bolt 10 1 0 7 0 Engine oil drain plug 28 2 8 20 5 Crankcase bolt 10 1 0 7 0 Engine mounting nut 40 4 0 29 0 Engine mounting b...

Page 179: ...g bolt DR Z125L 23 2 3 16 5 Front brake hose union bolt DR Z125L 23 2 3 16 5 Air bleeder valve DR Z125L 7 5 0 75 5 5 Brake disc mounting nut DR Z125L 8 5 0 85 6 0 Front footrest bolt 55 5 5 40 0 Brake...

Page 180: ...l or 4 marked bolt 7 marked bolt N m kgf m lb ft N m kgf m lb ft 4 1 5 0 15 1 0 2 3 0 23 1 5 5 3 0 3 2 0 4 5 0 45 3 0 6 5 5 0 55 4 0 10 1 0 7 0 8 13 1 3 9 5 23 2 3 16 5 10 29 2 9 21 0 50 5 0 36 0 12 4...

Page 181: ...2161 Valve stem O D IN 5 475 5 490 0 2156 0 2161 EX 5 455 5 470 0 2148 0 2154 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 02 Valve stem e...

Page 182: ...0 032 0 066 0 0013 0 0026 0 150 0 0059 Camshaft journal holder I D IN EX 22 012 22 025 0 8666 0 8671 Camshaft journal O D IN EX 21 959 21 980 0 8645 0 8654 Camshaft runout IN EX 0 10 0 004 Rocker arm...

Page 183: ...56 880 2 2394 Cylinder distortion 0 05 0 002 Piston ring free end gap 1st R Approx 7 0 0 28 5 6 0 22 2nd R Approx 8 5 0 33 6 8 0 27 Piston ring end gap 1st 0 10 0 25 0 004 0 010 0 5 0 02 2nd 0 10 0 2...

Page 184: ...dth 15 95 16 00 0 628 0 630 Crank web to web width 53 0 0 1 2 09 0 004 Crankshaft runout 0 08 0 003 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 15 kPa 0 15 kgf cm2 2 1 psi Below 35 kPa 0 35 k...

Page 185: ...30 0 004 0 012 0 50 0 02 Shift fork groove width No 1 5 0 5 1 0 196 0 201 No 2 5 5 5 6 0 217 0 224 Shift fork thickness No 1 4 8 4 9 0 189 0 193 No 2 5 3 5 4 0 209 0 213 Countershaft length Low to 2n...

Page 186: ...2 0 4 0 mm 0 08 0 16 in ITEM SPECIFICATION NOTE Spark plug Type DENSO X24ESR U NGK DR8EA Gap 0 6 0 8 mm 0 024 0 031 in Spark performance Over 8 mm 0 3 in at 1 atm Ignition coil resistance Primary 0 1...

Page 187: ...00 11 043 0 4331 0 4348 Master cylinder piston diam Front 10 957 10 984 0 4314 0 4324 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Brake caliper piston diam Front 30 150 30 200 1 1870...

Page 188: ...m pivot shaft runout 0 6 0 02 COLD INFLATION TIRE PRESSURE kPa kgf cm2 psi FRONT 100 1 0 14 REAR 100 1 0 14 ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octane or 9...

Page 189: ...fer from those of the DR Z125 LK3 03 MODEL NOTE Any differences between the DR Z125 LK3 03 model and DR Z125 LK4 04 model DR Z125 LK5 05 model in specifications and service data are indicated with an...

Page 190: ...14 3rd 1 368 26 19 4th 1 095 23 21 Top 0 923 24 26 Final reduction ratio 3 642 51 14 4 071 57 14 Large wheel Drive chain D I D 428HG 122 links D I D 428HG 130 links Large wheel CHASSIS Front suspensi...

Page 191: ...2165 0 2170 Valve stem O D IN 5 475 5 490 0 2156 0 2161 EX 5 455 5 470 0 2148 0 2154 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 014 Valv...

Page 192: ...ance IN EX 0 032 0 066 0 0013 0 0026 0 150 0 0059 Camshaft journal holder I D IN EX 22 012 22 025 0 8666 0 8671 Camshaft journal O D IN EX 21 959 21 980 0 8645 0 8654 Camshaft runout IN EX 0 10 0 004...

Page 193: ...e skirt end 56 880 2 2394 Cylinder distortion 0 05 0 002 Piston ring free end gap 1st R Approx 7 0 0 28 5 6 0 22 2nd R Approx 8 5 0 33 6 8 0 27 Piston ring end gap 1st 0 10 0 25 0 004 0 010 0 5 0 02 2...

Page 194: ...d big end width 15 95 16 00 0 628 0 630 Crank web to web width 53 0 0 1 2 09 0 004 Crankshaft runout 0 08 0 003 ITEM STANDARD LIMIT Oil pressure at 60 C 140 F Above 15 kPa 0 15 kgf cm2 2 1 psi Below 3...

Page 195: ...e 0 10 0 30 0 004 0 012 0 50 0 02 Shift fork groove width No 1 5 0 5 1 0 196 0 201 No 2 5 5 5 6 0 217 0 224 Shift fork thickness No 1 4 8 4 9 0 189 0 193 No 2 5 3 5 4 0 209 0 213 Countershaft length L...

Page 196: ...ttle cable play 2 0 4 0 mm 0 08 0 16 in ITEM SPECIFICATION NOTE Spark plug Type DENSO X24ESR U NGK DR8EA Gap 0 6 0 8 mm 0 024 0 031 in Spark performance Over 8 mm 0 3 in at 1 atm Ignition coil resista...

Page 197: ...ont 11 000 11 043 0 4331 0 4348 Master cylinder piston diam Front 10 957 10 984 0 4314 0 4324 Brake caliper cylinder bore Front 30 230 30 306 1 1902 1 1931 Brake caliper piston diam Front 30 150 30 20...

Page 198: ...wingarm pivot shaft runout 0 6 0 02 COLD INFLATION TIRE PRESSURE kPa kgf cm2 psi FRONT 100 1 0 14 REAR 105 1 0 14 ITEM SPECIFICATION NOTE Fuel type Use only unleaded gasoline of at least 87 pump octan...

Page 199: ...rake caliper mounting bolt DR Z125L 23 2 3 16 5 Front brake hose union bolt DR Z125L 23 2 3 16 5 Air bleeder valve DR Z125L 7 5 0 75 5 5 Brake disc mounting nut DR Z125L 8 5 0 85 6 0 Front footrest bo...

Page 200: ...K4 04 model DR Z125 LK5 05 model NOTE Any differences between the DR Z125 LK4 04 model DR Z125 LK5 05 model and DR Z125 LK6 06 model DR Z125 LK7 07 model in specifications and service data are indicat...

Page 201: ...14 3rd 1 368 26 19 4th 1 095 23 21 Top 0 923 24 26 Final reduction ratio 3 642 51 14 4 071 57 14 Large wheel Drive chain D I D 428HG 122 links D I D 428HG 130 links Large wheel CHASSIS Front suspensi...

Page 202: ...2165 0 2170 Valve stem O D IN 5 475 5 490 0 2156 0 2161 EX 5 455 5 470 0 2148 0 2154 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 014 Valv...

Page 203: ...0 002 Cylinder head cover distortion 0 05 0 002 ITEM STANDARD LIMIT Compression pressure 1 200 1 600 kPa 12 16 kgf cm2 171 228 psi 1 000 kPa 10 kgf cm2 142 psi Piston to cylinder clearance 0 020 0 03...

Page 204: ...14 040 0 5528 Conrod deflection 3 0 0 12 Conrod big end side clearance 0 10 0 45 0 004 0 018 1 0 0 04 Conrod big end width 15 95 16 00 0 628 0 630 Crank web to web width 53 0 0 1 2 09 0 004 Crankshaf...

Page 205: ...2 5 5 5 6 0 217 0 224 Shift fork thickness No 1 4 8 4 9 0 189 0 193 No 2 5 3 5 4 0 209 0 213 Countershaft length Low to 2nd Drive chain Type D I D 428HG Links DR Z125 122 DR Z125L 130 20 pitch length...

Page 206: ...play DR Z125 0 1 0 3 0 004 0 012 Front brake cable play DR Z125 15 25 0 6 1 0 Rear brake pedal free travel 20 30 0 8 1 2 Rear brake pedal height 10 0 0 4 0 Brake drum I D Front DR Z125 110 7 4 36 Rea...

Page 207: ...ar 4 0 0 16 ITEM STANDARD SPECIFICATION LIMIT Front fork stroke 180 7 1 Front fork spring free length 599 1 23 59 587 23 1 Front fork oil level 173 6 8 Front fork oil type SUZUKI FORK OIL SS 08 10 or...

Page 208: ...MTBE Methyl Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corro sion inhibitor is permissible Fuel tank capacity including reserve 6 6 L 1 7 1 5 US...

Page 209: ...TE Any differences between the DR Z125 LK6 06 model DR Z125 LK7 07 model and DR Z125 LK8 08 model in specifications and service data are indicated with an asterisk mark Please refer to the chapter 1 t...

Page 210: ...8 26 19 4th 1 095 23 21 Top 0 923 24 26 Final reduction ratio 3 642 51 14 4 071 57 14 Large wheel Drive chain D I D 428HG 122 links D I D 428HG 130 links Large wheel CHASSIS Front suspension Telescopi...

Page 211: ...Valve stem O D IN 5 475 5 490 0 2156 0 2161 EX 5 455 5 470 0 2148 0 2154 Valve stem deflection IN EX 0 35 0 014 Valve stem runout IN EX 0 05 0 002 Valve head thickness IN EX 0 5 0 014 Valve stem end l...

Page 212: ...der head cover distortion 0 05 0 002 ITEM STANDARD LIMIT Compression pressure 1 200 1 600 kPa 12 16 kgf cm2 171 228 psi 1 000 kPa 10 kgf cm2 142 psi Piston to cylinder clearance 0 020 0 030 0 0008 0 0...

Page 213: ...28 Conrod deflection 3 0 0 12 Conrod big end side clearance 0 10 0 45 0 004 0 018 1 0 0 04 Conrod big end width 15 95 16 00 0 628 0 630 Crank web to web width 53 0 0 1 2 09 0 004 Crankshaft runout 0 0...

Page 214: ...217 0 224 Shift fork thickness No 1 4 8 4 9 0 189 0 193 No 2 5 3 5 4 0 209 0 213 Countershaft length Low to 2nd Drive chain Type D I D 428HG Links DR Z125 122 DR Z125L 130 20 pitch length 259 0 10 20...

Page 215: ...5 0 1 0 3 0 004 0 012 Front brake cable play DR Z125 15 25 0 6 1 0 Rear brake pedal free travel 20 30 0 8 1 2 Rear brake pedal height 10 0 0 4 0 Brake drum I D Front DR Z125 110 7 4 36 Rear 110 7 4 36...

Page 216: ...ITEM STANDARD SPECIFICATION LIMIT Front fork stroke 180 7 1 Front fork spring free length 599 1 23 59 587 23 1 Front fork oil level 173 6 8 Front fork oil type SUZUKI FORK OIL SS 08 10 or an equivalen...

Page 217: ...Tertiary Butyl Ether less than 10 ethanol or less than 5 methanol with appropriate cosolvents and corro sion inhibitor is permissible Fuel tank capacity including reserve 4 8 L 1 3 1 1 US lmp gal rese...

Page 218: ...mounting bolt DR Z125L 23 2 3 16 5 Front brake hose union bolt DR Z125L 23 2 3 16 5 Air bleeder valve DR Z125L 7 5 0 75 5 5 Brake disc mounting nut DR Z125L 8 5 0 85 6 0 Front footrest bolt 55 5 5 40...

Page 219: ...DR Z125 LK8 08 MODEL 10 11 CABLE ROUTING Front brake cable Front brake cable Clamp Clamp Wire harness Face the circlip end down Clutch cable Clutch cable Throttle cable Steering stem upper bracket...

Page 220: ...DEL FUEL HOSE AND FUEL TANK INSTALLATION Fuel tank Frame Clamp Clamp Fuel tank cushion Fuel valve Fuel hose Face the tip of clamp to lower Face the tip of clamp to outside Face the tip of clamp to out...

Page 221: ...Prepared by 6th Ed May 2008 May 2008 1st Ed March 2002 Part No 99500 41125 01E Printed in Japan 228...

Page 222: ...Printed in Japan K3 K4 K5 K6 K7 K8...

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Suzuki DR 125, Service Manual

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Summary of Contents for DR 125

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