Suzuki UZ125 Owner'S Manual Download Page 65

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6-17

5. Reinstall the air cleaner element in the

reverse order of the removal. Be abso-
lutely sure that the element is securely in
position and is sealing properly.

Air Cleaner Drain Plug

Remove the plug and drain water and oil at
the periodic maintenance interval.

CAUTION

A torn air cleaner element will allow dirt
to enter the engine and can damage the
engine.

Carefully examine the air cleaner ele-
ment for tears during cleaning. Replace
it with a new one if it is torn.

CAUTION

Failure to position the air cleaner ele-
ment properly can allow dirt to bypass
the air cleaner element. This will cause
engine damage.

Be sure to properly install the air cleaner
element.

Summary of Contents for UZ125

Page 1: ...UZ125 OWNER S MANUAL ...

Page 2: ......

Page 3: ...espe cially important that you avoid operating the engine in a manner which could expose the engine parts to excessive heat Please refer to the BREAK IN RUNNING IN section for specific break in recommen dations WARNING CAUTION NOTE Please read this manual and follow its instructions carefully To emphasize special information the words WARNING CAU TION and NOTE carry special meanings and should be ...

Page 4: ...re trained to provide your machine with the best possi ble service with the right tools and equip ment All information illustrations and specifica tions contained in this manual are based on the latest product information available at the time of publication Due to improve ments or other changes there may be some discrepancies in this manual Suzuki reserves the right to make changes at any time Pl...

Page 5: ...8 CONSUMER INFORMATION CONTROLS FUEL AND ENGINE OIL RECOMMENDATION BREAK IN RUNNING IN AND INSPECTION BEFORE RIDING RIDING TIPS INSPECTION AND MAINTENANCE TROUBLESHOOTING MOTORCYCLE CLEANING AND STORAGE PROCEDURE SPECIFICATIONS INDEX ...

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Page 7: ...1 1 1 CONSUMER INFORMATION ACCESSORY INSTALLATION AND PRECAUTION SAFETY TIPS 1 2 MODIFICATION 1 4 SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS 1 4 SERIAL NUMBER LOCATION 1 6 ...

Page 8: ...ist you in selecting quality accessories and installing them cor rectly Use extreme caution when selecting and installing the accessories for your Suzuki We have developed some general guide lines which will aid you when deciding whether and how to equip your motorcycle WARNING Improper accessories or modifications can make your motorcycle unsafe and can lead to an accident Never modify the motorc...

Page 9: ...ol operations Accessories fitted to the handlebars or the front fork area can create serious stability problems This extra weight will cause the motorcycle to be less respon sive to your steering control The weight may also cause oscillations in the front end and lead to instability problems Accessories added to the handlebars or front fork should be as light as possible and kept to a minimum The ...

Page 10: ... aerodynamics and handling of the motorcycle Balance the load between the right and left sides of the motorcycle and fasten it securely MODIFICATION Modification of the motorcycle or removal of original equipment may render the vehicle unsafe or illegal SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS Motorcycle riding is great fun and an excit ing sport Motorcycle riding also requires that some e...

Page 11: ... We suggest that you practice riding your motorcycle in a non traffic situa tion until you are thoroughly familiar with your machine and its controls Remember practice makes perfect KNOW YOUR LIMITS Ride within the boundaries of your own skill at all times Knowing these limits and stay ing within them will help you to avoid acci dents BE EXTRA SAFETY CONSCIOUS ON BAD WEATHER DAYS Riding on bad wea...

Page 12: ...of the motorcyclist Ride defensively Wise motor cyclist uses a strategy of assuming they are invisible to other drivers even in broad day light Wear bright reflecting clothing Turn on the headlight and taillight every time even on a bright sunny day to attract driver s attention Do not ride in another driver s blind spot SERIAL NUMBER LOCATION ...

Page 13: ...r when order ing parts or referring to special service infor mation The frame number 1 is stamped on the frame on left hand side The engine serial number 2 is stamped on the crank case assembly on left hand side Please write down the numbers in the box provided below for your future reference Frame Number Engine Number ...

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Page 15: ...ON OF PARTS 2 2 KEY 2 5 IGNITION SWITCH 2 5 INSTRUMENT PANEL 2 7 LEFT HANDLEBAR 2 8 RIGHT HANDLEBAR 2 11 FUEL TANK CAP 2 13 CHOKE KNOB 2 14 KICK STARTER LEVER 2 15 TRUNK 2 16 HELMET HOLDERS 2 17 HOOK 2 18 CENTRE STAND 2 19 ...

Page 16: ...2 2 CONTROLS LOCATION OF PARTS 1 Rear brake lever 5 Throttle grip 2 Left handlebar switches 6 Front brake lever 3 Instrument panel 7 Choke knob 4 Right handlebar switches 8 Ignition switch ...

Page 17: ...2 3 9 Helmet holders D Battery and fuse 0 Spark plug E Passenger footrests A Throttle stop screw F Engine oil filter B Air cleaner G Centre stand C Tools H Kick starter lever ...

Page 18: ...2 4 I Fuel tank cap J Engine oil filler cap K Engine oil drain plug ...

Page 19: ... the box provided for your future reference IGNITION SWITCH To open the ignition key hole shutter 1 Match the ignition key head to the square hole on the ignition switch 2 Turn the key clockwise NOTE Apply anti freeze chemicals when atmo spheric temperature becomes less than freezing point to avoid ignition key hole shutter freezing Spray anti corrosion chemicals to the shutter release knob to avo...

Page 20: ...h the key in and turn it to the LOCK position and remove the key All electrical circuits are cut off Seat Lock Release Turn the key counterclockwise to release the seat lock IGNITION L O C K OFF ON SEAT OPEN P U S H SHUT OPEN WARNING Turning the ignition switch to the LOCK position while the motorcycle is moving can be hazardous Moving the motorcycle while the steering is locked can be hazardous Y...

Page 21: ...dicator will flicker quickly to warn the rider of existence of a trouble SPEEDOMETER 2 The speedometer indicates the road speed in kilometers per hour HIGH BEAM INDICATOR LIGHT 3 The blue indicator light will be lit when the headlight high beam is turned on ODOMETER 4 The odometer registers the total distance that the motorcycle has been ridden FUEL METER 5 The E mark indicates the fuel tank is em...

Page 22: ...g the rear brake lever gently towards the grip The brake light will be lit when the lever is squeezed inward DIMMER SWITCH 2 position The headlight low beam and taillight turn on position The headlight high beam and taillight turn on The high beam indicator light also turns on ...

Page 23: ...ancel turn signal opera tion push the switch in HORN SWITCH 4 Press the switch to sound the horn WARNING Failure to use the turn signals and fail ure to turn off the turn signals can be hazardous Other drivers may misjudge your course and this may result in an accident Always use the turn signals when you intend to change lanes or make a turn Be sure to turn off the turn signals after completing t...

Page 24: ...e Lock Use this lock to set and lock the rear brake To lock the rear brake lock squeeze the rear brake lever and engage this lock To release the rear brake lock simply squeeze the lever until the lock lever releases ...

Page 25: ... LEVER 1 The brake is applied by squeezing the front brake lever gently towards the grip The brake light will be lit when the lever is squeezed inward LIGHT SWITCH 2 position Headlight and taillight come on position All lights go off ...

Page 26: ...s controlled by the position of the throttle grip Twist it toward you to increase engine speed Turn it away from you to decrease the engine speed CAUTION To prevent electrical system damage do not operate the starter motor more than five seconds at a time If the engine does not start after several attempts check the fuel supply and igni tion system Refer to the TROUBLE SHOOTING section in this man...

Page 27: ...e fuel tank cap turn it counter clockwise 1 Fuel level 2 Filler neck WARNING Overfilling the fuel tank can cause the fuel to overflow when it expands due to heat from the engine or the sun Spilled fuel can catch on fire Never fill the fuel above the bottom of the filler neck ...

Page 28: ...ine is warm you do not need to use the choke system for starting NOTE Refer to the RIDING TIPS section of this manual for the engine starting proce dure WARNING Fuel and fuel vapor are highly flammable and toxic You can be burned or poi soned when refueling Stop the engine and keep flames sparks and heat sources away Refuel only outdoors or in a well venti lated area Do not smoke Wipe up spills im...

Page 29: ...side of the engine To start the engine place the motor cycle on the centre stand and depress the kick starter lever forcefully WARNING An improperly retracted kick starter lever can interfere with rider control Be sure the kick starter lever is returned to its home position after starting the engine ...

Page 30: ...o not keep heat sensitive items in the trunk since the trunk may get hot Do not keep valuable items in the trunk when leaving the motorcycle unat tended Push down the rear end of the seat if the seat does not unlock with key operation Place helmets as shown or seat may not be completely locked ...

Page 31: ...to the helmet holders and close the seat WARNING Riding with a helmet fastened to the hel met holder can interfere with rider con trol Never carry a helmet fastened to a hel met holder Fix the helmet securely atop the seat if you must carry it ...

Page 32: ...2 18 HOOK This motorcycle is equipped with the hook The hook load capacity is 1 5 kg To use the hook turn the hook and open the hook by turning the upper lever ...

Page 33: ...centre stand To place the motorcycle on the centre stand place your foot on the stand extension and then rock the motorcycle to the rear and upward with the passenger hand rail with your right hand while steadying the handle bars with your left hand ...

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Page 35: ...3 1 3 FUEL AND ENGINE OIL RECOMMENDATION FUEL 3 2 ENGINE OIL AND GEAR OIL 3 2 ...

Page 36: ...ur engine s performance and life Always select good quality SAE 10W 30 engine oil SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W 30 engine oil If SAE 10W 30 engine oil is not available select an alternative according to the following chart CAUTION Spilling gasoline containing alcohol can harm your motorcycle Alcohol can dam age painted surfaces Be careful not to spill any fuel when ...

Page 37: ...AXIMUM THROTTLE OPENING RECOMMENDATION 4 2 VARY THE ENGINE SPEED 4 2 BREAKING IN THE NEW TYRES 4 3 AVOID CONSTANT LOW SPEED 4 3 ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING 4 3 OBSERVE YOUR FIRST AND MOST CRITICAL SERVICE 4 4 INSPECTION BEFORE RIDING 4 4 ...

Page 38: ...e opening recommendation during the break in period VARY THE ENGINE SPEED The engine speed should be varied and not held at a constant speed This allows the parts to be loaded with pressure and then unloaded allowing the parts to cool This aids the mating process of the parts It is essential that some stress be placed on the engine components during break in to ensure this mating process Do not th...

Page 39: ...gine to accelerate freely through the gears without exceeding the recommended maximum limits Do not however use full throttle for the first 1600 km ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING Allow sufficient idling time after warm or cold engine start up before applying load or rev ving the engine This allows time for the lubricating oil to reach all critical engine components WARNING Failure...

Page 40: ...E The 1000 km service should be per formed as outlined in the INSPECTION AND MAINTENANCE section of this Owner s Manual Pay particular attention to the CAUTION and WARNING in that sec tion INSPECTION BEFORE RIDING WARNING Failure to inspect and maintain your motorcycle properly increases the chance of an accident or equipment damage Always perform a pre ride inspection before each ride Refer to th...

Page 41: ...cking the engine stop switch and throttle WHAT TO CHECK CHECK FOR Steering Smoothness No restriction of movement No rattle or looseness Throttle Correct play in the throttle cable Smooth operation and positive return of the throttle grip to the closed position Brakes Brake shoes not to be worn down to the limit line Correct lever play No sponginess Suspensions Smooth movement No oil leakage Fuel E...

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Page 43: ...5 1 5 RIDING TIPS STARTING THE ENGINE 5 2 STARTING OFF 5 4 STOPPING AND PARKING 5 5 ...

Page 44: ...iately after the engine starts return the choke knob halfway and warm up the engine 5 Return the choke knob all the way to its disengaged position NOTE Opening the throttle grip before start ing the engine will make the engine hard to start Do not open the throttle grip before starting WARNING Starting the engine improperly can be hazardous Starting the engine with the centre stand released can mo...

Page 45: ...unning the engine indoors or in a garage can be hazardous Exhaust gas contains carbon monoxide a gas that is colorless and odorless and can cause death or severe injury Only run the engine outdoors where there is fresh air CAUTION Running the engine too long without riding may cause the engine to overheat Overheating can result in damage to internal engine components and discol oration of exhaust ...

Page 46: ...s of your skills your motorcycle and the riding conditions WARNING Removing your hands from the handle bars or feet from the footrests during operation can be hazardous If you remove even one hand or foot from the motorcycle you can reduce your ability to control the motorcycle Always keep both hands on the handle bars and both feet on the footrests of your motorcycle during operation ...

Page 47: ... Sudden side winds which can occur when being passed by larger vehicles at tunnel exits or in hilly areas can upset your control Reduce your speed and be alert to side winds WARNING Inexperienced riders tend to underuti lize the front brake This can cause excessive stopping distance and lead to a collision Using only the front or rear brake can cause skidding and loss of control Apply both brake l...

Page 48: ...se wheel skid and loss of control Brake lightly and with care on slippery or irregular surfaces WARNING Following another vehicle too closely can lead to a collision As vehicle speeds increase stopping distance increases progressively Be sure you have a safe stopping dis tance between you and the vehicle in front of you WARNING A hot muffler can burn you The muffler will be hot enough to burn you ...

Page 49: ...ANCE SCHEDULE 6 2 TOOLS 6 6 LUBRICATION POINTS 6 8 BATTERY 6 10 AIR CLEANER 6 14 SPARK PLUG 6 18 FUEL HOSE 6 22 ENGINE OIL 6 22 GEAR OIL 6 29 CARBURETOR 6 30 COOLING FAN FILTER 6 32 BRAKES 6 33 TYRES 6 38 LIGHT BULB REPLACEMENT 6 41 FUSE 6 50 ...

Page 50: ... Steering components suspensions and wheel com ponents are key items and require very spe cial and careful servicing For maximum safety we suggest that you have these items inspected and serviced by your authorized Suzuki dealer WARNING Improper maintenance or failure to per form recommended maintenance increases the chance of an accident or motorcycle damage Always follow the inspection and maint...

Page 51: ...ls consult your SUZUKI dealer WARNING Running the engine indoors or in a garage can be hazardous Exhaust gas contains carbon monoxide a gas that is colorless and odorless and can cause death or severe injury Only run the engine outdoors where there is fresh air CAUTION Using poor quality replacement parts can cause your motorcycle to wear more quickly and may shorten its useful life Use only genui...

Page 52: ...5 20 40 Battery specific gravity of electrolyte I I Air cleaner element I I Replace every 12000 km Exhaust pipe bolts and muffler mounting nut T T Valve clearance I I I Spark plug I R Fuel line I I Engine oil R R R Engine oil filter R R Final gear box oil I Throttle cable play I I I Idle speed I I I PAIR air supply system I I Drive belt I I Brakes I I I ...

Page 53: ...I Inspect and clean adjust replace or lubricate as necessary R Replace T Tighten Interval km 1000 4000 8000 Item months 5 20 40 Tyres I I Steering I I Front forks I Rear suspension I Chassis bolts and nuts T T T ...

Page 54: ...6 6 TOOLS A tool kit is supplied and is located under the seat ...

Page 55: ...nd wrench 10 mm 12 mm 4 Open end wrench 14 mm 17 mm 5 Screwdriver 6 Screwdriver grip 7 Hexagon wrench 4 mm 8 Socket wrench 16 mm 9 Socket wrench 10 mm 12 mm 0 Box wrench handle A Box wrench 12 mm B Box wrench 17 mm C Box wrench 22 mm ...

Page 56: ... motorcycle and also for safe riding It is a good practice to lubricate the motorcycle after a long rough ride or after it gets wet in the rain or after washing it Major lubrication points are indicated as follows CAUTION Lubricating switches can damage the switches Do not apply grease and oil to the switches ...

Page 57: ...6 9 1 Rear brake lever holder 2 Centre stand pivot and spring hook 3 Throttle cable 4 Front brake lever holder Motor oil Grease ...

Page 58: ...tween the MAX and MIN level lines at all times If the solution level is below the MIN limit line add ONLY distilled water up to the MAX limit line NEVER use tap water To remove the battery follow procedure below 1 Remove the foot board cover 1 2 Remove the screw and bolts Remove the maintenance lid 2 ...

Page 59: ...6 11 3 Remove the screw Remove the cooling belt duct 3 from the maintenance lid 2 4 Disconnect the negative terminal first then disconnect the positive ter minal 5 Pull out the battery 4 ...

Page 60: ...rm this service WARNING Battery acid is harmful to eyes skin and clothing If battery acid gets in eyes or comes in contact with skin flush eyes or skin with water and call your physician immedi ately Never add battery acid to your bat tery WARNING Hydrogen gas produced by batteries can explode if exposed to flames or sparks Keep flames and sparks away from the battery Never smoke when working near...

Page 61: ...he charging system and the battery The red lead must go to the positive terminal and the black or black with white tracer lead must go to the nega tive terminal CAUTION Battery acid can damage your motorcy cle s finish Route the battery breather pipe as shown ...

Page 62: ...ng the engine without the air cleaner element in place could allow a flame to spit back from the engine to the air cleaner or could allow dirt to enter the engine This could cause a fire or severe engine damage Never run the engine without the air cleaner element properly installed CAUTION Clean or replace the air cleaner element frequently if the motorcycle is used in dusty wet or muddy condition...

Page 63: ...6 15 Follow the procedure below to remove the air cleaner element 1 Open the seat Remove the trunk with the seat 1 by removing the bolts and screws 2 Remove the screws Remove the air cleaner cover 2 ...

Page 64: ...hose to blow the dust from the air cleaner element NOTE Always apply air pressure to the inside of the air cleaner element only If you apply air pressure to the outside dirt will be forced into the pores of the element restrict ing the air flow through the element ...

Page 65: ...he periodic maintenance interval CAUTION A torn air cleaner element will allow dirt to enter the engine and can damage the engine Carefully examine the air cleaner ele ment for tears during cleaning Replace it with a new one if it is torn CAUTION Failure to position the air cleaner ele ment properly can allow dirt to bypass the air cleaner element This will cause engine damage Be sure to properly ...

Page 66: ... spark plug follow the proce dure below 1 Remove the spark plug maintenance lid 1 2 Remove the maintenance lid 2 by refer ring to the BATTERY section 3 Disconnect the spark plug cap 4 Remove the spark plug with a spark plug wrench ...

Page 67: ...lor tells you whether or not the standard spark plug is suitable for your type of usage A normal operating spark plug should be very light brown in color 0 6 0 7 mm CAUTION An improper spark plug may have an incorrect fit or heat range for your engine This may cause severe engine damage which will not be covered under warranty Use one of the spark plugs listed or equivalent Consult your Suzuki dea...

Page 68: ... interference with your motorcycle ignition system resulting in motorcycle performance problems Use rec ommended spark plugs NGK REMARKS CR6HSA Standard CR7HSA If the standard plug is very white or glazed in appearance replace with this plug CHAMPION REMARKS P RZ9HC Standard P RZ8HC If the standard plug is very white or glazed in appearance replace with this plug ...

Page 69: ...sing the old spark plug tighten it with a wrench about 1 8 turn past finger tight CAUTION A crossthreaded or overtightened spark plug will damage the aluminum threads of the cylinder head Follow the procedure below to tighten the spark plug properly CAUTION Dirt can damage your engine if it enters an open spark plug hole Cover the spark plug hole whenever the spark plug is removed ...

Page 70: ...ne life depends much on the selection of a quality oil and the periodic changing of the oil Daily oil level checks and periodic changes are two of the most impor tant maintenance items to be performed ENGINE OIL LEVEL CHECK Check the engine oil level with the engine oil dipstick The dipstick comes out together with the oil filler cap as shown The level on the dipstick should be between the L Low a...

Page 71: ...er hole upper edge WARNING Exhaust pipe and muffler are hot enough to burn you Wait until the exhaust pipe and muffler are cool enough to touch with bare hands before removing the oil filler cap CAUTION The engine oil level must be between the L Low line and F Full line or engine damage may occur Check the oil level with the dipstick with the motorcycle held vertically on level ground before each ...

Page 72: ...terval The engine oil should be changed when the engine is hot so that the engine oil will drain thoroughly from the engine The procedure is as follows 1 Place the motorcycle on the centre stand 2 Remove the engine oil filler cap 1 3 Place a drain pan under the drain plug 2 4 Remove the drain plug 2 and drain out the engine oil ...

Page 73: ...th bare hands before draining oil WARNING New and used oil can be hazardous Children and pets may be harmed by swallowing new or used oil Repeated prolonged contact with used engine oil may cause skin cancer Brief contact with used oil may irritate skin Keep new and used oil away from chil dren and pets Wear a long sleeve shirt and water proof gloves Wash with soap if oil contacts your skin ...

Page 74: ...6 26 5 Remove the three bolts 3 holding the fil ter cap 4 in place 6 Replace the engine oil filter 5 with a new one ...

Page 75: ...time the engine oil filter element is replaced CAUTION Using an oil filter with the wrong design can cause engine damage Use a genuine SUZUKI oil filter for your motorcycle CAUTION Failure to insert the new element cor rectly can damage the engine No oil flow will result if the element is inserted backwards Insert the open end of the new oil filter element into the engine ...

Page 76: ... oil will be required when changing oil only without replacing the oil filter 10 Tighten the oil filler cap 11 Start the engine and allow it to idle for a few minutes 12 Check the oil level according to Oil Level Check procedure NOTE Check to see that no oil is leaking from the oil filter cover CAUTION Engine damage may occur if you use oil that does not meet Suzuki s specifica tions Use the oil s...

Page 77: ...Remove the oil level plug 2 and inspect the oil level If the level is below the level hole add oil until it flows out from the level hole 4 Tighten the oil level plug 2 NOTE If oil is dirty with sludge or used for a long period drain the oil by removing the drain plug 3 and pour fresh oil through the oil level hole ...

Page 78: ...y periodically IDLE SPEED ADJUSTMENT 1 Start up the engine and let the engine run until it warms up fully 2 After engine warms up turn the throttle stop screw 1 located on the carburetor in or out so that engine may run at 1400 1600 r min Use a commercially avail able screwdriver to turn the throttle stop screw THROTTLE CABLE ADJUSTMENT 2 0 4 0 mm Measure the throttle cable play by turning the thr...

Page 79: ...rect play 3 After adjusting the play tighten the lock nut 1 WARNING Inadequate throttle cable play can cause engine speed to rise suddenly when you turn the handlebars This can lead to loss of rider control Adjust the throttle cable play so that engine idle speed does not rise due to handlebar movement ...

Page 80: ...ng fan filter is located on the left side of crankcase assembly Clean the cool ing fan filter every 3000 km Follow the procedure below to remove the cooling fan filter 1 Remove the screws 1 and cover 2 2 Remove the cooling fan filter 3 ...

Page 81: ...ENT 1 Measure the front brake lever play at the brake lever end The play should be 15 25 mm 2 If adjustment is necessary turning the front brake adjusting nut 1 clockwise will increase the distance WARNING Brakes are items of personal safety and should always be maintained in proper adjustment ...

Page 82: ...e following 1 Check if the brake system is properly adjusted Index mark Range Fig A The extension line of the index mark is within the range 2 While fully applying the brake check to see that the extension line of the index mark is within the range on the brake panel as shown in the Fig A Index mark Range Fig B The extension line of the index mark is out of the range ...

Page 83: ...crease your chance of having an acci dent Inspect brake shoe wear before each use Ask your SUZUKI dealer to replace brake shoes if the shoes are worn to the limit WARNING Too much play in the rear brake lever can cause poor braking performance and may lead to an accident Too little play may force brake shoes to rub against the drum at all times causing damage to the shoes and the drum Follow the s...

Page 84: ...if necessary as follows 1 Turn the rear brake adjusting nut 1 clockwise or counterclockwise to obtain the specified play Turning the adjusting nut clockwise will decrease the play 2 After adjusting the play check that there is no dragging when turning rear wheel with the wheel off the ground and that there is enough clearance between the rear brake lever and grip when the lever is tightly squeezed...

Page 85: ...limit indicator on the rear brake To check wear of the brake lining perform the following Fig A Indicator Limit mark Rear brake Fig A Indicator is within the limit mark 1 Check if the brake system is properly adjusted 2 While operating the brake check if the Indicator is as shown in Fig A ...

Page 86: ...r motorcycle Replace a tyre when worn to the speci fied limit or if you find damage such as cuts or cracks Always use the size and type of tyres specified in this owner s manual Read this section of owner s manual carefully WARNING Failure to perform break in of the tyres could cause tyre slip and loss of control Use extra care when riding on new tyres Perform proper break in of the tyres referrin...

Page 87: ...ure should only be checked and adjusted before riding since riding will heat up the tyres and lead to higher inflation pressure readings Cold Tyre Inflation Pressure Under inflated tyres make smooth cornering difficult and can result in rapid tyre wear Over inflated tyres have a smaller amount of tyre in contact with the road which can con tribute to skidding and loss of control SOLO RIDING DUAL R...

Page 88: ...le changing motorcycle handling characteristics Check tyre conditions each day before you ride Replace tyres if tyres show visual evi dence of damage such as cracks or cuts or if tread depth is less than 1 6 mm front 1 6 mm rear Whenever you replace a tyre use a tyre of the size and type listed below If you use a different size or type of tyre vehicle handling may be adversely affected possibly re...

Page 89: ... a bulb WARNING An improperly repaired installed or bal anced tyre can cause loss of control or shorten tyre life Ask your SUZUKI dealer or a qualified mechanic to perform tyre repair replacement and balancing because proper tools and experience are required Install tyres according to the rotation direction shown by arrows on the side wall of each tyre CAUTION Using a light bulb with the wrong wat...

Page 90: ...6 42 HEADLIGHT To replace the headlight bulb follow the pro cedure below 1 Remove the mirrors 2 Remove the screws 3 Remove the front cover with the head lamp assembly 1 ...

Page 91: ...ct the socket 2 and remove the rubber cap 3 5 Unhook the bulb holder spring 4 and pull out the bulb 5 CAUTION Oil from your skin may damage the head light bulb or shorten its life Grasp the new bulb with a clean cloth ...

Page 92: ...t beam can be adjusted verti cally if necessary To adjust the beam move the adjuster bolt 1 forward or backward BRAKE LIGHT TAILLIGHT To replace the brake light taillight bulb follow the procedure below 1 Remove the lens by removing the screws 1 ...

Page 93: ...it to the left and pull it out 3 To fit the replacement bulb push it in and turn it to the right while pushing CAUTION Overtightening the screws when rein stalling the lens may cause the lens to crack Tighten the screws only until they are snug ...

Page 94: ...6 46 FRONT TURN SIGNAL LIGHT To replace the front turn signal light bulb fol low the procedure below 1 Remove the screws and the lens 2 Turn the socket counterclockwise and remove it ...

Page 95: ...shing REAR TURN SIGNAL LIGHT To replace the rear turn signal light bulb fol low the procedure below 1 Remove the screw 1 2 Insert the screwdriver between the cover and lens to unhook the lens hook 3 Take off the lens CAUTION Overtightening the screws when rein stalling the lens may cause the lens to crack Tighten the screws only until they are snug ...

Page 96: ...it to the left and pull it out 5 To fit the replacement bulb push it in and turn it to the right while pushing CAUTION Overtightening the screws when rein stalling the lens may cause the lens to crack Tighten the screws only until they are snug ...

Page 97: ...6 49 LICENSE PLATE LIGHT To replace the license plate light bulb follow the procedure below 1 Turn the license plate lens assembly counterclockwise and remove it 2 Pull off the bulb from the socket ...

Page 98: ...ny elec trical system fails to operate then the fuse must be checked To check the fuse remove the right frame cover A 10A spare fuse is provided in the vinyl case CAUTION Installing a fuse of incorrect rating or using aluminum foil or wire instead of a fuse may seriously damage the electrical system Always replace a blown fuse with a fuse of the same type and rating If the new fuse blows in a shor...

Page 99: ...7 1 7 TROUBLESHOOTING FUEL SUPPLY CHECK 7 2 IGNITION SYSTEM CHECK 7 4 ENGINE STALLING 7 4 ...

Page 100: ...rburetor a Loosen the drain screw located under the carburetor Drain fuel from the car buretor into a container CAUTION Failure to troubleshoot a problem cor rectly can damage your motorcycle Improper repairs or adjustments may damage the motorcycle instead of fixing it Such damage may not be covered under warranty If you are not sure about the proper action consult your Suzuki dealer or a qualifi...

Page 101: ...3 If fuel is reaching the carburetor ignition system should be checked next WARNING Fuel and fuel vapor are highly flammable and toxic You can be burned or poi soned when handling fuel When draining the carburetor Stop the engine and keep flames sparks and heat sources away Drain fuel only outdoors or in a well ventilated area Do not smoke Wipe up spills immediately Avoid breathing fuel vapor Keep...

Page 102: ... plug gap If there is no spark consult your Suzuki dealer for repairs ENGINE STALLING 1 Check the fuel supply in the fuel tank 2 Check the ignition system for intermittent spark 3 Check the idle speed WARNING Performing the spark test improperly can cause a high voltage electrical shock or an explosion Avoid performing this check if you are not familiar with this procedure or if you have a heart c...

Page 103: ...8 1 8 MOTORCYCLE CLEANING AND STORAGE PROCEDURE MOTORCYCLE CLEANING 8 2 STORAGE PROCEDURE 8 4 PROCEDURE DURING STORAGE 8 6 PROCEDURE FOR RETURNING TO SERVICE 8 6 ...

Page 104: ...ft cloth The sponge or cloth should be frequently soaked in the soap solution NOTE Avoid spraying or allowing water to flow over the following places Ignition switch Spark plug Fuel tank cap Carburetor 3 Once the dirt has been completely removed rinse off the detergent with running water 4 After rinsing wipe off the motorcycle with a wet chamois or cloth and allow it to dry in the shade CAUTION Cl...

Page 105: ... Cleaning For extended life of your motorcycle lubri cate according to LUBRICATION POINTS section Follow the procedures in the INSPECTION BEFORE RIDING section to check your motorcycle for any problems that may have arisen during your last ride WARNING Wet brakes can cause poor braking per formance and may lead to an accident Avoid a possible accident by expecting longer stopping distances after w...

Page 106: ...and on a firm flat surface where it will not fall over Turn the handlebars all the way to the left and lock the steering and remove the ignition key FUEL 1 Fill the fuel tank to the top with fuel 2 Drain the carburetor or run the engine for a few minutes until the stabilized gaso line fills the carburetor WARNING Fuel and fuel vapor are highly flammable and toxic You can be burned or poi soned whe...

Page 107: ...otorcycle NOTE Be sure to remove the negative ter minal first then remove the positive termi nal 2 Clean the outside of the battery with a mild detergent and remove any corro sion from the terminals and wiring har ness connections 3 Store the battery in a room above freez ing TYRE Inflate the tyres to the normal specifications EXTERNAL Spray all vinyl and rubber parts with rub ber preservative Spr...

Page 108: ...to connect the positive terminal first then connect the neg ative terminal Remove the spark plug Turn the engine a few times by putting the transmission in top gear and turning the rear wheel Reinstall the spark plug Drain the engine oil thoroughly Replace the oil filter with a new one and pour fresh oil as outlined in this manual Adjust the pressure of tyres as described in the TYRE section Lubri...

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Page 110: ...m Wheelbase 1250 mm Ground clearance 160 mm ENGINE Type Four stroke air cooled OHC Number of cylinder 1 Bore 53 5 mm Stroke 55 2 mm Displacement 124 cm3 Compression ratio 9 6 1 Carburetor VM18 single Air cleaner Non woven fabric element Starter system Electric and Primary kick Lubrication system Wet sump ...

Page 111: ... 576 42 17 46 15 Drive system V belt drive CHASSIS Front suspension Telescopic coil spring oil damped Rear suspension Swingarm type coil spring oil damped Steering angle 45 right left Caster 26 Trail 82 mm Turning radius 1 95 m Front brake Drum brake Rear brake Drum brake Front tyre size 90 100 10 53J tube type Rear tyre size 90 100 10 53J tube type ...

Page 112: ...rator Single phase A C generator Fuse 10A Headlight 12V 35 35W Brake light Taillight 12V 21 5W Turn signal light 12V 10W 2 License plate light 12V 5W High beam indicator light 12V 1 7W Turn signal indicator light 12V 1 7W 2 CAPACITIES Fuel tank 6 0 L Engine oil oil change 900 ml with filter change 1000 ml overhaul 1050 ml ...

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Page 114: ...PEED 4 3 B BATTERY 6 10 BRAKES 6 33 BREAKING IN THE NEW TIRES 4 3 C CARBURETOR 6 30 CENTRE STAND 2 19 CHOKE KNOB 2 14 COOLING FAN FILTER 6 32 E ENGINE OIL 6 22 ENGINE OIL AND GEAR OIL 3 2 ENGINE STALLING 7 4 F FUEL 3 2 FUEL HOSE 6 22 FUEL SUPPLY CHECK 7 2 FUEL TANK CAP 2 13 FUSE 6 50 G GEAR OIL 6 29 GEARSHIFT LEVER 2 15 H HELMET HOLDERS 2 17 HOOK 2 18 ...

Page 115: ... 15 L LEFT HANDLEBAR 2 8 LIGHT BULB REPLACEMENT 6 41 LOCATION OF PARTS 2 2 LUBRICATION POINTS 6 8 M MAINTENANCE SCHEDULE 6 2 MAXIMUM THROTTLE OPENING RECOMMENDATION 4 2 MODIFICATION 1 4 MOTORCYCLE CLEANING 8 2 O OBSERVE YOUR FIRST AND MOST CRITICAL SERVICE 4 4 P PROCEDURE DURING STORAGE 8 6 PROCEDURE FOR RETURNING TO SERVICE 8 6 ...

Page 116: ...MENDATION FOR MOTORCYCLE RIDERS 1 4 SERIAL NUMBER LOCATION 1 6 SPARK PLUG 6 18 STARTING OFF 5 4 STARTING THE ENGINE 5 2 STOPPING AND PARKING 5 5 STORAGE PROCEDURE 8 4 T TOOLS 6 6 TRUNK 2 16 TYRES 6 38 V VARY THE ENGINE SPEED 4 2 Total page 112 ...

Page 117: ...K8 Printed in India Part No 99011 33G50 01A September 2007 EN TK Village Kherki Badshahapur N H 8 Link Road Gurgaon Haryana SUZUKI MOTORCYCLE INDIA PRIVATE LIMITED ...

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