Suzuki EN125-2A Service Manual Download Page 1

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SERVICE MANUAL

99500H06100-01E

EN125-2A

Summary of Contents for EN125-2A

Page 1: ...SERVICE MANUAL 99500H06100 01E EN125 2A...

Page 2: ...Prepared by Customer Service Department 1st Ed Aug 2003 Part No 99500H06100 01E Printed in China JIANG MEN DACHANGJIANG GROUP CO LTD...

Page 3: ...ain subject matter of this manual However the EN125 2A machines distributed in your country might differ in minor respects from the standard specification EN125 2A and if they do it is because some mi...

Page 4: ...GROUP INDEX 1 GENERAL INFORMATION 2 3 4 5 6 7 PERIODIC MAINTENANCE AND BREAK IN PROCEDURES ENGINE FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION...

Page 5: ......

Page 6: ...ENERAL INFORMATION CONTENTS SERIAL NUMBER LOCATIONS FUEL AND OIL RECOMMENDATIONS BREAK IN PROCEDURE SPECIAL FEATURE SPECIAL MATERIALS SPECIFICATIONS 1 2 1 2 1 2 1 3 1 4 1 5 1 WARNING CAUTION NOTICE 1...

Page 7: ...ecified lubricant bond or sealant When removing the battery disconnect the negative cable first and then the positive cable When reconnecting the battery connect the positive cable first and then the...

Page 8: ...all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to BREAK IN before subjecting the engine to maximum stresses The future performance and rel...

Page 9: ...ngine r min See Fig 1 2 Closing angle control The introduction of this new electronic timing advance system minimizes fluctuations in the ignition timing and also has improved the timing advance perfo...

Page 10: ...nut Countershaft bearing retainer screws Gearshift cam guide and pawl screws Engine oil pump moun ting screws Pick up coil screws Starter motor securing screws Material SUZUKI SUPER GREASE A 99000 25...

Page 11: ...tarter system Lubrication system Clutch Transmission Gearshift pattern Primary reduction Final reduction Gear ratios Low 2nd Drive chain 3rd 4th Top Four stroke air cooled OHC 1 57 0mm 48 8mm 124cm 9...

Page 12: ...V 3W 12V 3W 12V 3W 12V 2W 12V 5W 12V 2W O 34 1 B T D C above 9 000 r min O 32 B T D C between 4 000 5 000 r min 29 9 B T D C between 6 000 7500 r min O O 12V 35W 35W CHASSIS Telescopic coil spring oil...

Page 13: ...LTS AND NUTS AIR CLEANER ELEMENT VALVE CLEARANCE COMPRESSION PRESSURE SPARK PLUG FUEL HOSE FUEL FILTER ENGINE OIL ENGINE OIL FILTER OIL PRESSURE OIL SUMP FILTER CARBURETOR CLUTCH DRIVE CHAIN BRAKES TI...

Page 14: ...lter Carburetor Clutch Interval ltem Inspect Inspect Inspect Inspect Inspect Clean Change Replace Inspect Inspect Inspect Initial 1 000 km Clean every 3 000 km Inspect Inspect Inspect Inspect Inspect...

Page 15: ...g stem bearings Swing arm bearings Interval ltem Engine oil Engine oil Grease or engine oil Initial and Every 6 000 km Every 12 000 km Engine oil every 1 000 km Grease every 2 years or 20 000 km Greas...

Page 16: ...or level and specific gravity Add distilled water as necessary to keep the surface of the electrolyte above the LOWER LEVEL line but not above the UPPER LEVEL line 09900 28403 Hydrometer Standard spec...

Page 17: ...S AND NUT Inspect initial 1 000 km and Every 4 000 km CYLINDER HEAD NUTS When installing cylinder head cover apply SUZUKI BOND No 1215 to the mating surface of cylinder head Refer to page 3 29 SUZUKI...

Page 18: ...intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption Check and clean the element in the following manner Remove the left frame cover Remove...

Page 19: ...the rotor until the l line on the rotor is aligned with the center of hole on the crankcase Insert the thickness gauge to the valve stem end and the adjusting screw on the rocker arm Remove the right...

Page 20: ...apt to get wet a hotter plug should be used If the standard plug is apt to overheat porcelain is whitish in appearance replace with a colder one NOTE R type spark plug fitted under some of specificati...

Page 21: ...le by center stand Drain the oil by removing the drain plug and filler cap Fit the drain plug securely and add fresh oil through the filler The engine will hold about 1100 ml of oil Use 10W 40 viscosi...

Page 22: ...Before installing on the filter check to be sure that the O ring is properly installed Before putting on the filter cap check to be sure that the filter spring and the O ring are installed correctly R...

Page 23: ...holder before the clutch begins to disengage If the play in the clutch is incorrect adjust it in the following way CLUTCH Inspect initial 1 000 km and Every 4 000 km IDLING ADJUSTMENT NOTE Make this a...

Page 24: ...er pin and loosen the lock nut Adjust the drive chain carefully by tightening the adjuster Loosen the adjuster until the chain has 10 20 mm of sag at the middle between engine and rear sprockets The m...

Page 25: ...ix different types of fluid such as silicone based and petroleum based fluid for refilling the system otherwise serious damage will be caused Do not use any brake fluid taken from old or used or unsea...

Page 26: ...to the caliper bleeder valve and insert the free end of the pipe into a receptacle Squeeze and release the brake lever several times in rapid succession and squeeze the lever fully without releasing i...

Page 27: ...ght cover Be sure to tighten the lock nut securely after setting the bolt 10 mm After adjusting the rear brake height adjust the brake pedal travel First set the pedal at a position for comfortable ri...

Page 28: ...ck if the brake system is properly adjusted While operating the brake check to see that the extension line from the index mark is within the range on the brake panel If the index mark is outside the r...

Page 29: ...perform steering bearing adjustment as described in page 6 16 of this manual Tightening torque ITEM Handlebars clamp bolts Steering stem head bolts Front fork upper clamp bolt Front fork lower clamp b...

Page 30: ...essary to the specified torque with a torque wrench Tightening torque ITEM Front axle nut Caliper mounting bolt Brake hose union bolt Master cylinder bolt Swing arm pivot nut Rear shock absorber fitti...

Page 31: ...PERIODIC MAINTENANCE AND TUNE UP PROCEDURES 2 18 7 6 6 8 9 B B A...

Page 32: ...URE AND OIL PRESSURE ENGINE REMOVAL AND REMOUNTING UPPER END COMPONENTS DISASSEMBLY UPPER END COMPONENTS INSPECTION AND SERVICING UPPER END COMPONENTS REASSEMBLY LOWER END COMPONENTS DISASSEMBLY LOWER...

Page 33: ...o specified torque values and valves are properly adjusted Have the engine warmed up by idling before testing it Compression gauge 09915 64510 Adapter 09915 63310 Compression pressure Standard Limit 8...

Page 34: ...ake off the right and left frame covers Disconnect the and lead wires of battery ENGINE 3 2 ENGING REMOVAL AND REMOUNTING ENGING REMOVAL CAUTION First disconnect the lead wire Turn the fuel cock lever...

Page 35: ...h lever bolt and adjuster lock nut Take off the breather pipe Loosen the throttle cable adj ster lock nuts and take off the throttle cable u Remove the carburetor by unscrewing the clamp screws Discon...

Page 36: ...ft lever Take off the engine sprocket cover Disconnect the lead wire of starter motor Take off the spark plug cap Take off the drive chain by removing the clip Disconnect the ground wire from the cran...

Page 37: ...rm pivot nut footrest bar bolts and brackets Use both hands and lift the engine from the frame NOTE The engine must be taken out from the right side CAUTION Be careful not to draw out the swing arm pi...

Page 38: ...specified torque Exhaust pipe bolts 9 12 N m 0 9 1 2 kg m Pour 1 35 L of engine oil SAE10W 40 graded SF or SG into the engine after overhauling engine Start up the engine and allow it run for several...

Page 39: ...ine oil NOTE If top end repair only is being performed it is not necessary to remove the engine from the frame As already noted seat fuel tank frame covers etc must be removed Remove magneto cover cap...

Page 40: ...tten camshaft sprocket lock washer Remove camshaft sprocket bolts and detach the camshaft NOTE The cam chain tensioner bolt is to be removed only when disassembling the engine CAUTION Do not drop cams...

Page 41: ...3 9 ENGINE Remove rocker arm shaft set bolts Pull out the rocker arm shafts with pliers Remove cylinder base nuts and cylinder CAUTION If tapping with plastic hammer is necessary do not break the fins...

Page 42: ...ake off the valve cotters from valve stem Tweezers 09916 84510 Take out the valve spring retainer inner spring and outer spring Pull out the valve from the other side Remove oil seal using long nose p...

Page 43: ...16 44910 CAUTION Only oversize valve guide is available as a spare part Place a clean rag over the cylinder base to prevent piston pin circlip from dropping into crankcase and then remove the piston p...

Page 44: ...r head ROCKER ARM SHAFT O D Standard 11 966 11 984 mm Measure diameter of rocker arm shaft ROCKER ARM I D Standard 12 000 12 018 mm When checking the valve rocker arm the inside diameter of the valve...

Page 45: ...09900 20202 H Cam height service limit Intake cam 33 350 mm Exhaust cam 33 000 mm Height H Measure the outside diameter of camshaft journal Replace either the cylinder head set or the cam shaft if th...

Page 46: ...er head Service limit 0 05 mm VALVE FACE WEAR Measure the thickness and if the thickness is found to have been reduced to the limit replace the valve T Service limit 0 5 mm Support the valve with V bl...

Page 47: ...ove check that the face of valve stem end is above the cotter If the valve stem is worn down to the limit when measured with a micrometer replace the valve VALVE STEM WEAR Micrometer 0 25 mm 09900 202...

Page 48: ...after reaming Install valve spring lower seat Be careful not to confuse the lower seat with the spring retainer Lubricate valve stem seal with oil and press fit the seal into position with a finger t...

Page 49: ...tion Valve seat width 0 9 1 1 mm STD W If either requirement is not met correct the seat by servicing it as follows VALVE SEAT SERVICING NOTE The valve seat contact area must be inspected after each c...

Page 50: ...rea O O O If the contact area is too low or too narrow use the 45 cutter to raise and widen the contact area O WARNING Always use extreme caution when handling gasoline NOTE Be sure to adjust the valv...

Page 51: ...R 33 6 mm Standard Spring INNER OUTER 3 77 4 43 kg 26 78 mm 8 86 10 4 kg 29 78 mm CYLINDER DISTORTION Check the gasketed surface of the cylinder for distortion with a straightedge and thickness gauge...

Page 52: ...e crown of the piston Clean the ring grooves similarly PISTON CYLINDER CLEARANCE As a result of the above measurement if the piston to cylinder clearance exceeds the limit shown in the table below rep...

Page 53: ...ring Thickness gauge 09900 20803 Piston ring Service limit 1st 2nd Piston ring groove width Oil 1 01 1 03 mm 1 01 1 03 mm 2 01 2 03 mm PISTON RING FREE END GAP AND PISTON RING END GAP Piston ring free...

Page 54: ...ween these two measurements is more than the limits replace both piston and piston pin Micrometer 0 25 mm 09900 20205 Piston pin bore Service limit 14 030 mm Piston pin O D Service limit 13 980 mm CON...

Page 55: ...direction UPPER END COMPONENTS REASSEMBLY OIL RING Top ring and 2nd ring differ in the shape of ring face and the face of top ring is chrome plated whereas that of 2nd ring is not The color of 2nd rin...

Page 56: ...of the piston CYLINDER Fit dowel pins to crankcase and then fit gasket CAUTION To prevent oil leakage do not use the old gasket again always use new one Hold each piston ring with the piston rings pr...

Page 57: ...rings making sure that the close pitch end of each spring goes in first to rest on the head The coil pitch of both the inner and outer springs vary the pitch decreases from top to bottom as shown in t...

Page 58: ...use the old gasket With the head snugly seated on the cylinder secure it by tightening the nuts diagonally Tighten each nut to the torque value specified below Cylinder head nuts tightening torque 8...

Page 59: ...is covering the locating pin Apply THREAD LOCK SUPER 1303B to the bolts and tighten the cam sprocket NOTE Apply grease on the cam sprocket locating pin and install the pin into the camshaft Engage th...

Page 60: ...R ARM AND SHAFT Apply SUZUKI MOLY PASTE to the rocker arms and shafts Place the spring and the wave washer and arm in the exhaust side Place the wave washer and arm in the inlet side After inserting t...

Page 61: ...n the cylinder head cover bolts diagonally and then if everything is satisfactory tighten securely with a torque wrench to the specified torque Tightening torque 9 10 N m 0 9 1 0 kg m Apply engine oil...

Page 62: ...ts and detach magneto cover Loosen and remove the starter motor mounting bolts Take off the starter motor Remove the starter idle gear Remove magneto rotor nut Rotor holder 09930 44511 NOTE Do not all...

Page 63: ...ft 09930 30102 Remove starter clutch gear Remove cam drive chain Remove roller spring and push piece from starter clutch Clamp the rotor with a vise taking care not to damage it and remove the three a...

Page 64: ...m o u n t i n g b o l t s diagonally while holding the primary driven gear and remove clutch pressure plate Conrod holder 09910 20116 After removal of clutch drive and driven plates flatten the lock w...

Page 65: ...ve gear and key OIL PUMP Remove oil pump mounting screws and take off oil pump body NOTE When removing cam driven gear do not lose gear shifting pawl pin and spring OIL PUMP DRIVE GEAR DRIVEN GEAR AND...

Page 66: ...00 06107 NOTE When removing gear position switch do not lose contact and spring Remove gear position switch GEAR POSITION SWITCH ENGINE SPROCKET Flatten the lock washer then remove the sprocket nut by...

Page 67: ...necessary because the gear shifting cam stopper is mounted on the left crankcase half and will be damaged if the transmission components remain in the right half Crankcase separating tool 09920 13120...

Page 68: ...ove gear shifting cam stopper spring Draw out gear shifting fork shafts and take off forks Remove clusters of gears and gear shifting cam CRANKSHAFT Remove crankshaft by using crankshaft rem ver o Cra...

Page 69: ...3 37 ENGINE OIL SEAL AND BEARING Remove retainers oil seals and bearings Oil seal remover Bearing puller 09913 50121 09923 73210 Bearing installer 09940 53311 09924 84510 09913 75820 09913 80112...

Page 70: ...with a thickness gauge Standard Service limit 1 00 mm 0 10 0 45 mm Where the limit is exceeded replace crankshaft assembly or reduce the deflection and the side clearance to within the limit by replac...

Page 71: ...2 6 mm 11 0 mm CLUTCH DRIVEN PLATE Measure each driven plate for distortion with a thickness gauge Replace driven plates which exceed the limit Thickness gauge 09900 20803 Service limit 0 1 mm CLUTCH...

Page 72: ...k the shifting fork clearance in the groove of its gear If the clearance limit is exceeded by any of the three gears determine whether the gear or the gear shifting fork should be replaced by measurin...

Page 73: ...ht to remove any slack then using vernier calipers measure the 20 pitch 21 pins length of cam chain If it measures more than the limits replace the cam chain CRANKCASE BEARING Inspect the play of cran...

Page 74: ...n rebuilding the crankshaft STD width between webs 53 0 0 1 mm LOWER END COMPONENTS REASSEMBLY CRANKSHAFT When mounting the crankshaft in the crankcase it is necessary to pull its left end into the cr...

Page 75: ...d TRANSMISSION CAUTION Never reuse a circlip After a circlip has been removed from a shaft it should be discarded and a new circlip must be installed When installing a new circlip care must be taken n...

Page 76: ...ers and circlips COUNTERSHAFT Press fit 2nd drive gear onto the counter shaft Before reassembling coat the internal face of the 2nd drive gear with THREAD LOCK SUPER 1303B and install it so that the l...

Page 77: ...3 45 ENGINE Fit the gear shifting cam on the crankcase Position the cam as shown in Fig so that the gear shifting fork can be installed easily GEAR SHIFTING CAM AND FORK...

Page 78: ...ey resemble each other very closely in external appearance and configuration Carefully examine the illustration for correct installing positions and directions After cam stopper and gear shifting fork...

Page 79: ...BOND No 1215 99000 31110 uniformly to the fitting surface of the left half of the crankcase and after waiting a few minutes fit the right half on the left half When reassembling the crankcase pay att...

Page 80: ...he gear on the shifting shaft with the center teeth on the shifting driven gear as shown NOTE After the cam driven gear cam guide gear shifting shaft and neutral cam stopper have been fitted confirm t...

Page 81: ...ounting screws NOTE After mounting the oil pump in the crankcase rotate the pump gear by hand to see if it turns smoothly Conrod holder 09910 20116 After checking the oil pump install the oil pump dri...

Page 82: ...ENGINE 3 50 CLUTCH Install the clutch camshaft by positi ning the face to right side Install the oil seal by using the 17 mm socket o Tighten the oil seal retainer screw 1 5 mm 2 0 mm...

Page 83: ...of the spacer Tighten clutch sleeve hub nut using the special tool to the specified torque Clutch sleeve hub holder 09920 53710 Tightening torque 30 50 N m 3 0 5 0 kg m Be sure to lock the nut by firm...

Page 84: ...t When reassembling the clutch cover fit a gasket to correctly position as shown in Fig CAUTION Do not use the old gasket to prevent oil leakage OIL SUMP FILTER Wash the sump filter with cleaning solv...

Page 85: ...ghten with specified torque 15 20 N m 1 5 2 0 kg m MAGNETO ROTOR Fit key in the key slot on the crankshaft Install the magneto rotor Apply a small quantity of THREAD LOCK SUPER to the threaded parts o...

Page 86: ...UTION Always replace the driveshaft oil seal with a new one every disassembly to prevent oil leakage Also grease the oil seal lip On installation refer to Fig for correct position and direction Replac...

Page 87: ...e sprocket nut to the specified torque and bend up the washer 80 100 N m 8 0 10 0 kg m Rotor and Sprocket holder GEAR POSITION SWITCH Install gear position switch THREAD LOCK SUPER 1303B 99000 32030 A...

Page 88: ...FUEL AND LUBRICATION SYSTEM CONTENTS 4 1 4 2 4 6 4 FUEL COCK CARBURETOR LUBRICATION SYSTEM...

Page 89: ...nscrew the fuel cock securing bolts and take off the fuel cock assembly CLEANING Rust from the fuel tank tends to build up in the filter which when the filter has been neglected for a long period inhi...

Page 90: ...8 turn out 1 25 0 5 1 0 4DH41 2nd P 0 390 Needle jet N J Pilot jet P J Starter jet G S Pilot screw P S Pilot air jet P A J Throttle cable play Jet needle J N Carburetor type Bore size I D No Idle r mi...

Page 91: ...the carburetor top cover by unscrewing the cover screws REMOVAL AND DISASSEMBLY Remove the float chamber body by unscrewing the two screws Loosen the fitting screw and remove the float 4 3 FUEL AND LU...

Page 92: ...worn beyond the permissible limits similar trouble will occur Conversely if the needle sticks the gasoline will not flow into the float chamber Clean the float chamber and float parts with gasoline If...

Page 93: ...m Remount the carburetor by reversing the sequence of removal steps and following adjustments and inspection are necessary after remounting the carburetor REMOUNTING Throttle cable play adjustment Thr...

Page 94: ...CAM FACE ROCKER ARM SHAFT CAM CHAIM CONROD SMALL END CYLINDER WALL CONROD BIG END BEARING CLUTCH RELEASE CAM DRIVESHAFT BEARING DRIVESHAFT AND GEARS CONTERSHAFT BEARING COUNTERSHAFT AND GEARS PRIMARY...

Page 95: ...4 7 FUEL AND LUBRICATION SYSTEM...

Page 96: ...CHASSIS CONTENTS 5 1 5 6 5 12 5 21 5 27 5 35 5 FRONT WHEEL FRONT FORK STEERING STEM FRONT BRAKE REAR WHEEL AND REAR BRAKE REAR SWING ARM...

Page 97: ...3 6 5 2 1 5 2 5 A B Support the machine by center stand and jack or block REMOVAL AND DISASSEMBLY Pull out the cotter pin and remove the axle nut Draw out the axle shaft and take off the wheel NOTE Do...

Page 98: ...ings inner race by hand while fixing it in the wheel hub Rotate the inner race by hand to inspect whether abnormal noise occurs or rotating smoothly Replace the bearing if there is something unusual A...

Page 99: ...e new lock washers Make sure that the brake disc is clean and free of any greasy matter After securing it in place by tightening its bolts be sure to lock with specified torque BRAKE DISC Tightening t...

Page 100: ...CHASSIS 5 4 FRONT FORK Tightening torque Item N m 15 30 20 26 kg m 1 5 3 0 2 0 2 6 A B Remove the front wheel See page 5 1 Remove the two bolts and dismount the front caliper REMOVAL AND DISASSEMBLY...

Page 101: ...olts and take off the front fender Remove the two screws and take off the head light Remove the two bolts and take off the head light housing Disconnect the couplers and lead wires Remove the lead wir...

Page 102: ...tion switch Refer to page 3 4 and Disconnect the clutch inner cable from the clutch lever Take off the throttle cable by removing the right handle switch assy Remove the brake hose clamp bolt Remove t...

Page 103: ...he front fork cap bolts to facilitate later disassembly Loosen the front fork lower clamp bolts NOTE Slightly loosen the front fork cap bolts to facilitate later disassembly Remove the brackets of hea...

Page 104: ...eral times to remove the oil Hold the fork inverted for a few minutes Remove damper rod bolt by using the special tools and 8mm hexagon wrench T handle 09940 34520 Attachment D 09940 34561 Remove the...

Page 105: ...ool Oil seal remover 09913 50121 CAUTION The oil seal removed should be replaced with a new one INSPECTION DAMPER ROD RING Inspect the damper rod ring for wear and damage INNER TUBE AND OUTER TUBE Ins...

Page 106: ...oval and also carry out the following steps DAMPER ROD BOLT SUZUKI BOND NO 4 99100 31110 THREAD LOCK CEMENT 99000 32040 T handle 09940 34520 Attachment D 09940 34561 Tightening torque 20 26 N m 2 0 2...

Page 107: ...K OIL 10 Capacity each leg Hold the front fork vertical and adjust thefork oil level with the special tool NOTE When adjusting oil level remove the fork spring and compress the inner tube fully Forl o...

Page 108: ...ork assembly align the top of inner tube to the upper surface of the steering stem head Tighten the upper and lower clamp bolt to the specified torque Tightening torque Tightening torque Tighten the s...

Page 109: ...Item REMOVAL AND DISASSEMBLY Remove the front wheel See page 5 1 Remove the front fork See page 5 4 Remove the steering stem nut and draw out steering stem NOTE Hold the steering stem by hand to prev...

Page 110: ...nd lower steel balls Number of balls Upper Lower 22pcs 18pcs Remove the outer race fitted on the steering stem This be done with a chisel Draw out the two inner races fitted to the top and bottom ends...

Page 111: ...el balls Distortion of steering stem REASSEMBLY Reassemble and remount the steering stem in the reverse order of disa sse mbly and removal and also carry out the following steps INNER RACES Press in t...

Page 112: ...he upper and lower inner races when installing the steel balls Number of balls Upper Lower 22pcs 18pcs STEERING STEM NUT Steering nut socket wrench Turn the steering stem right ang left lock to lock f...

Page 113: ...and back ward to ensure that there is no play and that the procedure was accomplished correctly Finally check to be sure that the steering stem moves freely from left to right with its own weight If...

Page 114: ...N m 5 8 7 9 25 kg m 0 5 0 8 0 7 0 9 2 5 0 A B C CHASSIS 5 18 Tightening turque Item FRONT BRAKE...

Page 115: ...caliper mounting bolts to the specified torque Tightening torque N m 2 5 0 kg m NOTE Push in the piston and piston holder all the way to the caliper when remounting the caliper BRAKE PAD REPLACEMENT...

Page 116: ...receptacle Refer to page 2 13 Loosen the two pins of caliper Remove the caliper mounting bolts and take off the caliper CAUTION Do not operate the brake lever while dismounting the caliper Remove the...

Page 117: ...e 5 21 CHASSIS INSPECTION CALIPER CYLINDER PISTON Inspect the piston surface for any scratches or damage RUBBER PARTS Inspect the each rubber part for damage and wear BRAKE DISC Measure the disc thick...

Page 118: ...of disassembly and removal and also carry out the following steps CAUTION Wash the caliper components with fresh brake fluid before reassembly Never use cleaning solvent or gasoline to wash them Appl...

Page 119: ...gm Drain brake fluid MASTER CYLINDER REMOVAL AND DISASSEMBLY CAUTION Immediately and completely wipe off any brake fluid contacting any part of the motorcycle The fluid reacts chemically with paint pl...

Page 120: ...reassembly Never use cleaning solvent or gasoline to wash them Apply brake fluid to the cylinder bore and all internal parts before inserting into the bore Reassemble and remount the master cylinder i...

Page 121: ...ing torque Item N m 50 80 5 8 18 28 kg m 5 0 8 0 0 5 0 8 1 8 2 8 A B C Support the machine by the center stand Remove the rear brake adjuster nut and disconnect the brake rod Pull off the cotter pin a...

Page 122: ...raw out the axle shaft and take off the chain from rear sprocket Take off the rear wheel and separate the brake panel from the wheel Flatten the washers and remove the four nuts Separate the rear spro...

Page 123: ...CHASSIS Remove the bearing and retainer from the mounting drum Remove the cushion from the wheel NOTE Removing the left side bearing first makes the job easier Remove the right and left side wheel bea...

Page 124: ...CHASSIS 5 28 Take off the brake shoes REAR BRAKE Remove the cam lever nut and bolt Pull off the brake cam washer O ring and cam lever...

Page 125: ...normal noise occurs and it rotates smoothly Replace the bearing if there are any defects Service limit 0 25 mm AXLE SHAFT Using the special tools check the axle shaft for runout and replace it if the...

Page 126: ...t is exceeded by the wear noted replace the drum The value of this limit is indicated inside the drum Service limit 130 7 mm CAUTION Replace the brake shoes as a set otherwise braking performance will...

Page 127: ...o carry out the following steps Apply grease to the bearings before installing Install the wheel bearings by using the special tool NOTE First install the wheel bearing for right side Bearing installe...

Page 128: ...m Apply grease to the brake cam BRAKE CAM SUZUKI SUPER GREASE A 99000 25010 WARNING Be careful not to apply too much grease to the brake cam If grease gets on the lining brake slippage will result Ins...

Page 129: ...R SWING ARM Tightening torque Item N m 50 80 10 15 kg m 5 8 0 0 1 0 1 5 A B Remove the rear wheel See page 5 25 Remove the rear shock absorber units and take off the shock absorber units REMOVAL AND D...

Page 130: ...ff the chain case Remove the swing arm pivot nut and draw out the shaft Remove the swing arm Pull off the cotter pin and remove the nut and bolt Remove the torque link Remove the chain buffer Remove t...

Page 131: ...ide shaft 09930 30102 INSPECTION BUSHING Inspect the bushing for wear and damage SWING ARM PIVOT SHAFT Using a dial gauge check the pivot shaft for runout and replace it if the runout exceeds the limi...

Page 132: ...and removal and also carry out the following steps SWING ARM BUSHINGS Force fit the bushings into the swing arm by using the special tool Bearing installer set 09924 84510 SPACER AND DUST SEAL COVER...

Page 133: ...ELECTRICAL SYSTEM CONTENTS 6 1 6 5 6 9 6 12 6 13 6 13 6 16 6 IGNITION SYSTEM CHARGING SYSTEM STARTER SYSTEM COMBINATION METER LIGHTS SWITCHES BATTERY...

Page 134: ...nition timing point and current flows through the primary side of the ignition coil A high voltage current is induced in secondary windings of the ignition coil resulting in strong spark between the s...

Page 135: ...ox 0 5_2 0 NOTE When mounting the stator on the magneto cover apply a small quantity of THREAD LOCK 1342 to the threaded parts of screws 99000 32050 THREAD LOCK 1342 Using the pocket tester Rx1 range...

Page 136: ...tro tester 09900 28106 STD Spark performance 8 mm Check the ignition coil with pocket tester Pocket tester 09900 25002 Ignition coil resistance Primary Secondary O W W Approx 3 5 5 4 Plug cap O W Appr...

Page 137: ...e follow ing is observed Connect probe of SUZUKI Pocket Tester x1 range with Green lead wire on the ignitor side and probe with Blue lead wire Next connect probe with Blue lead wire on the ignitor sid...

Page 138: ...turned into DC current then it charges the battery Function of Regulator While the engine r min is low and the generated voltage of AC generator is lower than the adjusted voltage of regulator the re...

Page 139: ...ductive to the direction from point to point Namely at the state of this the current generated from the AC generator gets through SCR without charging the battery and returns to AC generator again At...

Page 140: ...hat the battery is full charged condition STD charging output 13 5V 16 0V at 5 000r min Pocket tester 09900 25002 AC GENERATOR NO LOAD PERFORMANCE Disconnect the three lead wires from the AC generator...

Page 141: ...wires in the following table If the resistance checked is incorrect replace the regulator rectifier Pocket tester 09900 25002 Unit Probe of tester Probe of tester R R B B B B B B B W B W 7 8 7 8 7 8...

Page 142: ...ight handlebar switch box energizes the relay causing the contact points to close which connects the starter motor to the battery The motor draws about 80 amperes to start the engine STARTER MOTOR REM...

Page 143: ...similar fine emery paper when it is dirty After polishing it wipe the commutator with a clean dry cloth ARMATURE COIL Using a pocket tester check the coil for open and ground by placing probe pins on...

Page 144: ...OCK 1342 to starter motor securing screws 99000 32050 THREAD LOCK 1342 Disconnect lead wire of the starter motor at starter relay Turn on the ignition switch inspect the continuity between the termina...

Page 145: ...ocket tester check the continuity be tween lead wires in following diagram If the continuity measured is incorrect replace the respective part INSPECTION Pocket tester 09900 25002 NOTE When making thi...

Page 146: ...LIGHT TAIL BRAKE LIGHT Inspect each switch for continuity with the pocket tester referring to the chart If it is found any abnormality replace the respective switch as sembly with new one SWITCHES Po...

Page 147: ...TEM 6 14 LIGHTING SWITCH ENGINE KILL SWITCH STARTER SWITCH FRONT BRAKE LIGHT SWITCH Gr O Y W O O W O W Y G OFF O W B OFF ON 3 1 2 DIMMER SWITCH TURN SIGNAL LIGHT SWITCH HORN SWITCH G B W OFF Y W W Y B...

Page 148: ...ue Light green Orange Red Pink Light blue White Yellow B Br G Gr L Lg O R P Sb W Y Br R G L O W R B W B B W W Y Y B Y G Y L Y W Black with White tracer Brown with Red tracer Green with Blue tracer Ora...

Page 149: ...m charging current 0 7 A Charging time Confirmation for date of manufacture Servicing The charging time for a new battery is determined by the number of months that have elapsed since the date of manu...

Page 150: ...meniscus curved up portion of electrolyte surface as shown in figure Check the reading as corrected to 20 C with chart to determine the recharging time in hours by constant current charging at a char...

Page 151: ...sulfation Replace the battery with new one in such a case When a battery is left for a long term without using it is apt to be subject to sulfation When the motorcycle is not used for more than 1 mont...

Page 152: ...SERVICING INFORMATION CONTENTS 7 1 7 7 7 12 7 14 7 22 7 23 7 TROUBLESHOOTING SPECIAL TOOLS TIGHTENING TORQUE SERVICE DATA WIRE AND CABLE ROUTING WIRING DIAGRAM...

Page 153: ...lean or replace Clean and dry Replace Replace Replace Replace Clean Clean or replace Replace Clean or replace Clean or replace 1 Fouled spark plug 2 Defective pick up coil 3 Defective ignitor unit 4 C...

Page 154: ...s 3 Weakened stopper pawl spring on gearshift cam 4 Worn gearshift pawl 1 Valve clearance out of adjustment 2 Poor seating of valves 3 Defective valve guides 4 Worn rocker arm or arm shaft 5 Defective...

Page 155: ...ess adjust and replace gasket Check and adjust 1 Needle valve is worn or damaged 2 Spring in needle valve is broken 3 Float is not working properly 4 Foreign matter has adhered to needle valve 1 Start...

Page 156: ...battery 5 Defective cell plates in the battery or loosely connected 1 Internal short circuit in the battery 2 Resistor element in the regulator rectifier damaged or defective 3 Regulator rectifier po...

Page 157: ...The battery left unused for too long in cold climate recharged at sulfation cient or its too low 1 Dirty container tap and sides 2 Impurities in the electrolyte or elec too high trolyte S G is Replac...

Page 158: ...worn down 4 Top much play on brake lever or pedal 5 Linings worn down Refill to level mark Bleed air out Replace Adjust Replace 1 Leakage of brake fluid from hydraulic system 2 Worn pads 3 Oil adhesi...

Page 159: ...40113 Snap ring pliers opening type Snap ring pliers closing type Impact driver set Vernier calipers 150 mm Micrometer 25 50 mm Micrometer 50 75 mm Micrometer 0 25 mm Cylinder gauge set Dial gauge 1 1...

Page 160: ...11 09940 34520 09940 34561 09940 50112 09940 53311 09941 34513 09943 74111 Rotor holder Steering stem nut socket wrench T handle Attachment D Fork oil seal installer Bearing installer Steering race in...

Page 161: ...7 9 SERVICING INFORMATION 10 13 11 14 12 15 16 21 18 22 19 17 23 20 24...

Page 162: ...SERVICING INFORMATION 7 10 27 25 28 26 29 30 37 33 31 38 34 35 32 39 36...

Page 163: ...7 11 SERVICING INFORMATION 40 43 41 44 45 46 49 47 48 42...

Page 164: ...ear nut Clutch sleeve hub nut Engine oil drain plug Engine sprocket nut Engine mounting bolt 8 mm Diam 80 mm length Engine mounting bolt 8 mm Diam the others Exhaust pipe clamp nut Muffler clamp bolt...

Page 165: ...nt brake caliper mounting bolt Front brake hose union bolt Front brake bleeder valve Front brake disc bolt Swing arm pivot nut Front footrest bolt Rear torque link nut Front and Rear Rear shock absorb...

Page 166: ...IN EX IN EX IN EX INNER OUTER INNER OUTER 25 5 22 5 0 04 0 07 0 13 0 18 5 000 5 012 4 975 4 990 4 955 4 970 0 9 1 1 3 77 4 43 kg at length 26 78 mm 8 86 10 4 kg at length 29 78 mm 0 05 0 5 2 0 03 31 2...

Page 167: ...rt end 2 800 kPa 8 0 kg cm 0 120 57 085 56 880 0 05 2 Unit mm ITEM STANDARD LIMIT 5 6 4 8 0 50 0 50 0 180 0 150 14 030 13 980 Approx 7 2 Approx 5 8 0 20 0 32 0 20 0 32 1 01 1 03 1 01 1 03 2 01 2 03 0...

Page 168: ...3 0 0 1 14 040 3 0 1 00 0 05 OIL PUMP ITEM STANDARD LIMIT Oil pump reduction ratio Oil pressure at 60OC 140 F O 2 000 30 15 Above 10 kPa 0 1 kg cm Below 30 kPa 0 3 kg cm at 3000 r min 2 2 CLUTCH Unit...

Page 169: ...clearance Shift fork groove width Shift fork thickness Countershaft length Low to 2nd Drive chain Drive chain sag 3 470 59 17 3 214 45 14 3 000 33 11 1 857 26 14 1 368 26 19 1 143 24 21 0 957 22 23 5...

Page 170: ...50 r min 29 0 5 110 0 6 4DH41 2nd P 0 390 12 5 37 5 PRE SET 2 5 8 turn out 1 25 0 5 1 0 Carburetor type Bore size I D No Idle r min Flat height Main jet M J Main air jet M A J Jet needle J N Needle j...

Page 171: ...harging Y Y 0 5 2 0 Approx Pick up L G 120 200 Approx Generator no load voltage Generator coil resistance More than 70V AC at 5000 r min Starter relay resistance Approx 3 4 Battery Fuse 13 5 16 0V at...

Page 172: ...aster cylinder piston diam Brake caliper cylinder bore Brake caliper piston diam Brake drum I D Brake lining thickness Wheel axle runout Tire size Tire tread depth 20 30 10 4 0 0 2 12 700 12 743 12 65...

Page 173: ...l type and grade Engine oil capacity Filter change 1150 ml Overhaul 1350 ml Front fork oil type Front fork oil capacity each leg Gasoline used should be graded 90 97 oc tane or higher An unleaded or l...

Page 174: ...ead wire Ground wire Reg rec Starter motor lead wire Starter motor lead wire Starter relay Battery terminal Battery Fuse 15A Wiring harness Gear position indicator Starter motor lead wire Clamp Horn W...

Page 175: ...S HANDLE SW R START ENGINE KILL FUEL GAUGE IGNITION COIL IGNITER REG REC R BRAKE SW TURN RELAY REAR TURN R REAR COMB LAMP REAR TURN L FUSE BOX R R 10A 15A FUSE BOX BATTERY ENGINE EARTH FRAME EARTH STA...

Page 176: ...EN125HU SUPPLEMENTARY SERVICE MANUAL...

Page 177: ...Prepared by October 2004 Part No 99501 38140 01E Printed in China JIANGMEN DACHANGJIANG GROUP CO LTD...

Page 178: ...in minor respects from the standard specifications of EN125HU and if they do it is because some minor modifications which are of no consequence in most cases as far as servicing is concerned has to be...

Page 179: ...MODIFICATIONS MADE ON THE BASIS OF EN125 2A rear goods rack engine outer appearance front brake oil tank canceled fuel filter canceled front wheel rear wheel kick starter added carburetor front brake...

Page 180: ...GROUP INDEX 1 2 3 4 5 FRONT WHEEL AND FRONT BRAKE REAR WHEEL AND REAR BRAKE CARBURETOR KICK STARTER WIRING DIAGRAM...

Page 181: ......

Page 182: ...1 5 1 5 1 5 1 6 1 6 1 7 1 7 FRONT WHEEL AND FRONT BRAKE FRONT WHEEL INSPECTION REFITTING FRONT WHEEL ASSEMBLY DETAIL DRAWING DISMANTLING OF PARTS FRONT BRAKE WHEEL BEARING FRONT WHEEL AXLE WHEEL RIM...

Page 183: ...AIL DRAWING DISMANTLING OF PARTS FRONT WHEEL Loosen and dismantle front wheel axle nut Pull out front wheel axle Support motorcycle with center stand or a jack Remove speedometer cable and front brake...

Page 184: ...move dust boot and oil seal Pull out right and left bearings of front wheel Remove the brake shoes Dismantle brake cam lever bolt Tightening torque 5 8N m 0 5 0 8kg m FRONT WHEEL AND FRONT BRAKE FRONT...

Page 185: ...09913 50121 1 3 Remove the brake cam lever Remove the oil seal with special tool Remove the spring collar with special tool Remove the speedometer drive gear unit Spring collar clipper 09900 06107 FR...

Page 186: ...ECTION WHEEL BEARING Fix wheel hub and inspect with hand the play of bearing inner collar Rotate the inner collar with hand to see if there is any abnormal noise and if rotation is easy Replace bearin...

Page 187: ...ng of wheel bearing Replacement of bearing reduces run out In case of failure in reducing run out by replacing bearing adjust spoke tension In case adjustment of spoke tension fails in reducing run ou...

Page 188: ...nce will be adversely affected Service limit 1 5mm BRAKE DRUM Measure the brake drum I D to determine the extent of wear and if the limit is exceeded by the wear noted replace the drum The value of th...

Page 189: ...heel in the reverse order of disassembly and removal and also carry out the following steps WHEEL BEARING Bearing fitting tools 09924 84510 Apply lubricating grease to bearing SUZUKI super lubricating...

Page 190: ...REAR WHEEL DETAIL DRAWING REAR WHEEL REAR SPROCKET REAR BRAKE WHEEL BEARING REAR WHEEL AXLE WHEEL RIM SPOKE NIPPLE TIRE BRAKE SHOE BRAKE DRUM REAR SPROCKET REAR SPROCKET SHOCK ABSORBING BLOCK BRAKE W...

Page 191: ...WHEEL Support motorcycle with center stand Screw out rear brake adjusting nut and dismantle rear brake lever Pull out split pin and dismantle torsion bar tightening nut Loosen the nut and bolt on the...

Page 192: ...te the rear wheel and drive sprocket REAR WHEEL AND REAR BRAKE REAR SPROCKET Remove the wheel bearings by using the special tool in the following procedures Insert the adapter in to the wheel bearing...

Page 193: ...the brake camshaft gasket O ring and camshaft swing arm INSPECTIONS Wheel bearing Rear wheel axle Wheel rim Spoke nipple Tire Brake shoe Brake drum see pages 1 4 see pages 1 5 see pages 1 5 see pages...

Page 194: ...rear brake in an order reversed to that of dismantling and separating paying attention to the following steps BRAKE Install brake cam lever as shown in the figure Note When refitting brake shoe apply...

Page 195: ...wing bolts and nuts at specified torques N m Kg m 10 15 18 28 5 8 50 80 Torsion bar tightening nut Sprocket nut Brake cam lever nut Rear wheel axle nut tightening 1 0 1 5 1 8 2 8 0 5 0 8 5 8 REAR WHEE...

Page 196: ...OR DISMANTLING AND SEPARATING INSPECTION AND FITTING REFITTING CARBURETOR STRUCTURE DRAWING DISMANTLING CARBURETOR FLOAT PIN VALVE FLOAT HEIGHT INSPECTION AND ADJUSTMENT MAIN NOZZLE NEEDLE VALVE 3 1 3...

Page 197: ...Idle speed r min Float level Main jet M J Main air jet M A J Jet needle J N Item MIKUNI 20 4 VM22 405 1450 50r min 21 8mm 92 5 1 0 5EJ50 2 Specification Specification Item Needle jet Idle speed jet Tr...

Page 198: ...nd drain gasoline in carburetor Warning Handle gasoline with care as it is inflammable and explosive Note There is no fuel filter on carburetor oil inlet tube in this model Remove the top cap Remove t...

Page 199: ...ismantle main jet needle jet and remove holder Dismantle pilot jet Dismantle pilot screw remove spring gasket and O ring Dismantle screw and spring Caution Handle with care when fitting and dismantlin...

Page 200: ...3 4 Remove the throttle cable clamp from throttle valve Remove the needle jet Dismantle top cap unit Remove the starter unit CARBURETOR...

Page 201: ...needle wear is as shown in the figure replace it together with valve seat INSPECTION AND ADJUSTMENT OF FLOAT HEIGHT Please float valve at its place and inspect its height Float height 21 8 1 0mm In ca...

Page 202: ...3 6 Fit needle valve in throttle valve as shown in the figure REFITTING Fit other parts of carburetor in the reverse order of removal CARBURETOR...

Page 203: ......

Page 204: ...4 KICK STARTER KICK STARTER DISMANTLING KICK STARTER INSPECTION REFITTING 4 1 4 1 4 3 4 3 CONTENTS...

Page 205: ...bolt and remove the kick starter Remove the clutch cover Remove the kick starting gear washer and kick starting gear Dismantle bolts remove kick starting guide plate and limiting plate Remove kick st...

Page 206: ...der unit piston unit and separating right and left crankcases Refer to EN125 2A SERVICE MANUAL 99500H06100 01E Remove from inside the right side crankcase kick starting bush clip kick starting bush an...

Page 207: ...ight crankcase and then fit ratchet When fitting ratchet fit spring and washer on the marked side of ratchet turn ratchet counterclockwise and clip ratchet pawl on the limiting stopper When fitting cl...

Page 208: ...B BW PA01 CA06 BA06 GA01 YB BW WB O WB O EA02 LA01 OW W MS01 LA01 EA01 CA07 L W OW BW Y Y Y BW R MC01 MB01 MA01 CA10 AB02 0 75 0 75 0 75 1 25 1 25 Y Y Y BW R O WB GA02 BA07 O WB BA05 FA01 O Sb BW LG W...

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Suzuki EN125-2A, Service Manual

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