Suzuki DR 125, Service Manual

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SERVICING INFORMATION 7-3
Complaint Symptom and possible causes Remedy
Engine is noisy. Excessive valve chatter
1. Excessive valve clearance.
2. Weak or broken valve spring.
3. Worn camshaft.
4. Worn or burnt camshaft journal.
Noise seems to come from the piston
1. Worn piston.
2. Worn cylinder.
3. Carbon build-up in combustion chamber.
4. Worn piston pin or piston pin bore.
5. Worn piston ring or ring groove.
Noise seems to come from the cam chain
1. Stretched cam chain.
2. Worn cam chain sprocket.
3. Improperly working cam chain tensioner.
Noise seems to come from the clutch
1. Worn crankshaft spline.
2. Worn clutch hub spline.
3. Worn clutch plate teeth.
4. Distorted clutch plate.
5. Weak clutch damper.
6. Weak clutch spring.
Noise seems to come from the crankshaft
1. Ratting bearing.
2. Worn or burnt crank pin bearing.
3. Worn or burnt journal bearing.
Noise seems to come from transmission
1. Worn or rubbing gear.
2. Worn countershaft 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 chain and
sprockets.
Repair or replace.
Replace countershaft.
Replace clutch hub.
Replace clutch plate.
Replace.
Replace primary driven gear.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace countershaft.
Replace driveshaft.
Replace.
Replace.
Clutch slips. 1. Clutch cable out of adjustment.
2. Weak or broken clutch spring.
3. Worn or distorted clutch pressure plate.
4. Distorted clutch plate. Adjust.
Replace.
Replace.
Replace.
Clutch drags. 1. Clutch out of adjustment.
2. Some clutch springs are weak, while others are not.
3. Worn or distorted clutch pressure plate.
4. Distorted clutch plate. Adjust.
Replace.
Replace.
Replace.
Transmission will not
shift. 1. Broken gearshift cam.
2. Distorted gearshift fork.
3. Worn gearshift pawl. Replace.
Replace.
Replace.
Transfer will not shift
or shift back. 1. Broken gearshift shaft return spring.
2. Rubbing or stuck gearshift shaft.
3. Worn or distorted gearshift fork. Replace.
Repair or replace.
Replace.