Suzuki DR 125 User manual

DR-Z125/L

99500-41125-01E

GROUP INDEX

GENERAL INFORMATION

1

PERIODIC MAINTENANCE

2

ENGINE

3

FUEL AND LUBRICATION

SYSTEM

4

CHASSIS

5

ELECTRICAL SYSTEM

6

SERVICING INFORMATION

7

DR-Z125/LK4 (’04-MODEL)

DR-Z125/LK5 (’05-MODEL)

8

DR-Z125/LK6 (’06-MODEL)

DR-Z125/LK7 (’07-MODEL)

9

DR-Z125/LK8 (’08-MODEL)

10

FOREWORD

This manual contains an introductory description on

the SUZUKI DR-Z125/L and procedures for its

inspection/service and overhaul of its main compo-

nents.

Other information considered as generally known is

not included.

Read the GENERAL INFORMATION section to

familiarize yourself with the motorcycle and its main-

tenance. Use this section as well as other sections

to use as a guide for proper inspection and service.

This manual will help you know the motorcycle bet-

ter so that you can assure your customers of fast

and reliable service.



* This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modifications have been made since

then, differences may exist between the con-

tent of this manual and the actual motorcycle.

* Illustrations in this manual are used to show

the basic principles of operation and work

procedures. They may not represent the

actual motorcycle exactly in detail.

* This manual is written for persons who have

enough knowledge, skills and tools, including

special tools, for servicing SUZUKI motorcy-

cles. If you do not have the proper knowledge

and tools, ask your authorized SUZUKI

motorcycle dealer to help you.

Inexperienced mechanics or mechanics

without the proper tools and equipment

may not be able to properly perform the

services described in this manual.

Improper repair may result in injury to the

mechanic and may render the motorcycle

unsafe for the rider.

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX.

3. Holding the manual as shown at the right will allow you to find

the first page of the section easily.

4. The contents are listed 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 work instructions and other

service information (e.g., tightening torque, lubricating points, and locking agent points).

Example: Front wheel (DR-Z125L)

Bearing

Spacer

Bearing

Brake disc

Front axle

Front axle nut

Brake disc mounting nut

ITEM N·m kgf

.

m lb-ft

44 4.4 32.0

8.5 0.85 6.0

SYMBOL

Listed in the table below are the symbols indicating instructions and other information necessary for servic-

ing. The meaning of each symbol is also included in the table.

SYMBOL DEFINITION SYMBOL DEFINITION

Torque control required.

Data beside it indicates specified

torque.

Apply THREAD LOCK “1342”.

99000-32050

Indicates service data. Apply or use brake fluid.

Apply oil. Use engine oil unless

otherwise specified.

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)

99000-25010 (For the other counties)

Measure in current range.

Apply SUZUKI SILICONE GREASE.

99000-25100

Measure in diode test range.

Apply SUZUKI MOLY PASTE.

99000-25140

Measure in continuity test range.

Apply SUZUKI BOND “1207B”.

99104-31140 (For USA)

99000-31140 (For the other countries)

Use special tool.

Apply SUZUKI BOND “1216B”.

99000-31230

Use fork oil.

99000-99001-SS8

Apply THREAD LOCK SUPER “1303”.

99000-32030

1216B

1

GENERAL INFORMATION 1-1

CONTENTS

GENERAL INFORMATION

WARNING/CAUTION/NOTE ..............................................................1- 2

GENERAL PRECAUTIONS ................................................................1- 2

SUZUKI DR-Z125/LK3 (’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

DIMENSIONS AND DRY MASS ..................................................1- 7

ENGINE ........................................................................................ 1- 7

DRIVE TRAIN ...............................................................................1- 7

CHASSIS ......................................................................................1- 8

ELECTRICAL ...............................................................................1- 8

CAPACITIES ................................................................................1- 8

COUNTRY AND AREA CODES ..................................................1- 9

1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol

and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-

sages highlighted by these signal words.

!

Indicates a potential hazard that could result in death or injury.

"

Indicates a potential hazard that could result in vehicle damage.

NOTE:

Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all

potential hazards relating to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS

and CAUTIONS stated, you must 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

!

* Proper service and repair procedures are important for the safety of the service mechanic and

the safety and reliability of the vehicle.

* When 2 or more persons work together, pay attention to the safety of each other.

* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-

doors.

* When working with toxic or flammable materials, make sure that the area you work in is well

ventilated and that you follow all of the manufacturer’s instructions.

* Never use gasoline as a cleaning solvent.

* To avoid getting burned, do not touch the engine, engine oil, radiator, and exhaust system

until they have cooled.

* After servicing the fuel, oil, exhaust or brake systems, check all of the lines, and fittings

related to the system for leaks.

GENERAL INFORMATION 1-3

"

* If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equiv-

alent.

* When removing parts that are to be reused, keep them arranged in an orderly manner so that

they may be reinstalled in the proper order and orientation.

* Be sure to use special tools when instructed.

* Make sure that all parts used in reassembly are clean. Lubricate them when specified.

* Use the specified lubricants, bonds, 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 negative cable,

and replace the terminal cover on the positive terminal.

* When performing service to electrical parts, if the service procedures not require use of bat-

tery power, disconnect the negative cable the battery.

* When tightening the cylinder head 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, locking washers, self-locking nuts,

cotter pins, circlips, and certain other parts as specified, be sure to replace them with new

ones. Also, before installing these new parts, be sure to remove any left over material from the

mating surfaces.

* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger

than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is

completely seated in its groove and securely fitted.

* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a

thread is smeared with them.

* After reassembling, check parts for tightness and proper operation.

* To protect the environment, do not unlawfully dispose of used motor oil and all other fluids:

batteries and tires.

* To protect the Earth’s natural resources, properly dispose of used motorcycle and parts.

1-4 GENERAL INFORMATION

SUZUKI DR-Z125/LK3 (’03-MODEL)

SERIAL NUMBER LOCATION

The frame serial number or V.I.N. (Vehicle Identification Number)

1 is stamped on the right 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.

FUEL AND OIL RECOMMENDATION

FUEL

Gasoline used should be graded 95 octane (Research Method) or higher. An unleaded gasoline type is rec-

ommended.

LEFT SIDE

RIGHT SIDE

GENERAL INFORMATION 1-5

ENGINE OIL

Use a premium quality 4-stroke motor oil to ensure longer ser-

vice life of your motorcycle. Use only oils which are rated SF or

SG under the API service classification.

The recommended viscosity is SAE 10W-40. If an SAE 10W-40

motor oil is not available, select an alternative according to the

right chart.

BRAKE FLUID

# Specification and Classification: DOT 4

!

FRONT FORK OIL

SUZUKI fork oil SS-08 or an equivalent fork oil.

BREAK-lN PROCEDURES

During manufacture only the best possible materials are used and 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 reliability of the engine depends on the care and restraint

exercised during its early life. The general rules are as follows.

• Keep to this break-in throttle opening limits:

Initial 10 hours: Less than 1/2 throttle

Up to 15 hours: Less than

3/4

throttle

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manu-

facturer, do not use or mix different types of fluid such as silicone-based and petroleum-based

fluid for refilling the system, otherwise serious damage will result.

Do not use any brake fluid taken from old or used or unsealed containers.

Never re-use brake fluid left over from a previous servicing, which has been stored for a long

period.

1-6 GENERAL INFORMATION

INFORMATION LABELS

LABEL or PLATE NAME

NO

APPLIED SPECIFICATION

E-28 E-03

Noise label —

Information label —

Fuel caution label —

Manual notice label —

Warning safety label

Certification plate —

Compliance label —

DR-Z125/L

Frame (Left side)

Frame (Right side)

Fuel tank

Rear fender

E - 28

E - 03

GENERAL INFORMATION 1-7

SPECIFICATIONS

DIMENSIONS AND DRY MASS

Overall length ...................................................... 1 835 mm (72.2 in)

1 885 mm (74.2 in) ....... DR-Z125L

Overall width ....................................................... 770 mm (30.3 in)

Overall height ...................................................... 1 060 mm (41.7 in)

1 095 mm (43.1 in)....... DR-Z125L

Wheelbase .......................................................... 1 245 mm (49.0 in)

1 270 mm (50.0 in) ....... DR-Z125L

Ground clearance................................................ 260 mm (10.2 in)

290 mm (11.4 in) ....... DR-Z125L

Seat height .......................................................... 775 mm (30.5 in)

805 mm (32.0 in) ....... DR-Z125L

Dry mass ............................................................. 80 kg (176 lbs)

81 kg (178 lbs)......... DR-Z125L

ENGINE

Type .................................................................... Four-stroke, air-cooled, OHC

Number of cylinders ............................................ 1

Bore..................................................................... 57.0 mm (2.244 in)

Stroke .................................................................. 48.8 mm (1.921 in)

Displacement ...................................................... 124 cm³ (7.6 cu.in)

Compression ratio ............................................... 9.5 : 1

Carburetor ........................................................... MIKUNI VM20SS

Air cleaner ........................................................... Polyurethane foam element

Starter system ..................................................... Primary kick

Lubrication system .............................................. Wet sump

Idie speed............................................................ 1 700 ± 100 r/min

DRIVE TRAIN

Clutch .................................................................. Wet multi-plate type

Transmission....................................................... 5-speed constant mesh

Gearshift pattern ............................................... 1-down, 4-up

Primary reduction ratio ........................................ 3.470 (59/17)

Gear ratios, Low ................................................. 3.000 (33/11)

2nd .................................................. 1.857 (26/14)

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) .......................... DR-Z125L

Drive chain .......................................................... D.ID.428HG, 122 links

D.ID.428HG, 130 links............ DR-Z125L

1-8 GENERAL INFORMATION

CHASSIS

Front suspension .................................................Telescopic, coil spring, oil damped,

Rear suspension ..................................................Link type, coil spring, oil damped,

Front suspension stroke.......................................180 mm (7.1in)

Rear wheel travel .................................................160 mm (6.3in)

170 mm (6.7in) ..............DR-Z125L

Caster ..................................................................28°

27° 30’ ...........................DR-Z125L

Trail......................................................................88 mm (3.46 in)

99 mm (3.90 in) .............DR-Z125L

Steering angle......................................................45° (right & left)

Turning radius ......................................................1.9 m (6.2 ft)

2.0 m (6.6 ft)..................DR-Z125L

Front brake...........................................................Drum brake

Disc brake .....................DR-Z125L

Rear brake ...........................................................Drum brake

Front 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 timing .......................................................13° B.T.D.C. at 1 700 r/min

Spark plug............................................................NGK: DR8EA or DENSO: X24ESR-U

Generator.............................................................Single-phase A.C. generator

CAPACITIES

Fuel tank, including reserve ................................. 6.6 L (1.7/1.5 US/Imp gal)

Reserve ............................................... 1.7 L (0.4/0.4 US/Imp gal)

Engine oil, oil change ........................................... 850 ml (0.9/0.7 US/Imp qt)

with filter change ................................ 950 ml (1.0/0.8 US/Imp qt)

overhaul..............................................1 100 ml (1.2/1.0 US/Imp qt)

Front fork (each leg)............................................. 172 ml (5.8/6.1 US/Imp oz)

These specifications are subject to change without notice.

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

2

6

PERIODIC MAINTENANCE 2-1

CONTENTS

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE ............................................2- 2

PERIODIC MAINTENANCE CHART ...........................................2- 2

LUBRICATION POINTS ...............................................................2- 3

MAINTENANCE AND TUNE-UP PROCEDURES ...............................2- 4

AIR CLEANER .............................................................................2- 4

VALVE CLEARANCE ..................................................................2- 5

CAM CHAIN TENSION ADJUSTER ............................................2- 6

SPARK PLUG ..............................................................................2- 7

THROTTLE CABLE PLAY ...........................................................2- 8

ENGINE IDLE 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

BRAKE HOSES (DR-Z125L) .......................................................2-17

STEERING ...................................................................................2-17

TIRES ...........................................................................................2-17

SPOKE NIPPLES .........................................................................2-18

EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLT ....2-19

FRONT FORK ..............................................................................2-19

REAR SUSPENSION ...................................................................2-19

CHASSIS BOLTS AND NUTS .....................................................2-20

COMPRESSION PRESSURE CHECK .................................................2-22

COMPRESSION TEST PROCEDURE .........................................2-22

OIL PRESSURE CHECK ......................................................................2-23

OIL PRESSURE TEST PROCEDURE .........................................2-23

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

The chart below lists the recommended intervals for all the required periodic service work necessary to keep

the motorcycle operating at peak performance and economy.

NOTE:

More frequent servicing may be performed on motorcycles that are use under severe conditions.

PERIODIC MAINTENANCE CHART

NOTE:

Inspect: I=Inspect and clean, adjust, replace or lubricate as necessary; C=Clean; R=Replace; T=Tighten

Interval

months

Initially Every Every

Item 1 month 6 months 12 months

Air cleaner element — I I

Exhaust pipe bolts and muffler mounting

bolts

TTT

Valve clearance I I I

Spark plug — I R

Spark arrester — — C

Fuel line

III

Replace every 4 years.

Cam chain tension adjuster I I I

Engine oil filter R — R

Engine oil R R R

Throttle cable I I I

Idle speed I I I

Clutch I I I

Drive chain Clean, oil and inspect each time motorcycle is ridden.

Brakes I I I

Brake hose

—I I

Replace every 4 years.

Brake fluid

—I I

Replace every 2 years.

Tires — I I

Spoke nipple Inspect each time the motorcycle is ridden.

Steering I — I

Front forks — — I

Rear suspension — — I

Chassis nuts and bolts T T T

PERIODIC MAINTENANCE 2-3

LUBRICATION POINTS

Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.

Major lubrication points are indicated below.

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 whenever the

motorcycle has been operated under wet or rainy condition.

Clutch lever holder

Side-stand pivot

and spring hook

Drive chain

Throttle cable

Front brake

lever holder

Brake pedal pivot

2-4 PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the servicing procedures for each item in the Periodic Maintenance chart.

AIR CLEANER

If the air cleaner is clogged with dust, intake resistance will be

increase, resulting in a decrease in engine output and an

increase in fuel consumption. Clean the air cleaner element in

the following manner.

• Remove the left frame cover. (!5-2)

• Remove the air cleaner cover

1.

• Remove 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 and

wash it.

• Squeeze the cleaning solvent out of the washed element by

pressing it between the palms of both hands: do not twist or

wring the element or it will develop tears.

• Immerse the element in motor oil and squeeze the oil out of

the element leaving it slightly wet with oil.

"

A Non-flammable cleaning solvent

B Motor oil SAE #30 or SAE 10W-40

Clean every 6 months.

Inspect the air cleaner element for tears. A torn ele-

ment must be replaced.

PERIODIC MAINTENANCE 2-5

• Remove the drain plug

1 to allow any water to drain out.

• Reinstall the cleaned air cleaner element in the reverse order

of removal.

!

VALVE CLEARANCE

REMOVAL

• Remove the frame covers, seat and fuel tank. ("5-2)

• Remove the spark plug. ("2-7)

• Remove the valve inspection caps

1.

• Remove the valve timing inspection plug

2 and generator

cover plug

3.

INSPECTION

The valve clearance specification is different for intake and

exhaust valves. Valve clearance adjustment must be checked

and adjusted, 1) at the time 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 incoming air will by-pass it. Remember, the

rapid wear of piston rings and the cylinder bore is

often caused by a defective or poorly fitted element.

If driving under dusty conditions, clean the air cleaner

element more frequently. The surest way to accelerate

engine wear is to operate the engine without the ele-

ment or to use a torn element. Make sure that the air

cleaner is in good condition at all times. The life of the

engine depends largely on this component!

Inspect initially at 1 month and every 6 months there-

after.

2-6 PERIODIC MAINTENANCE

NOTE:

* The piston must be at (TDC) on the compression stroke in

order to check the valve clearance or to adjust valve clear-

ance.

* The clearance specification is for COLD state.

* To turn the crankshaft for clearance checking, rotate in the nor-

mal running direction. The spark plug should be removed.

• Turn crankshaft to bring the “TDC” line on the rotor to the

index mark

A on the generator cover.

• Insert a thickness gauge between the valve stem end and the

adjusting screw on the rocker arm.

If the clearance is out of specification, bring it into the speci-

fied range.

# 09900-20803: Thickness gauge

09917-13210: 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 tension by a manually

adjusted cam chain tension adjuster. To prevent chain noise, the

cam chain tension adjuster must be adjusted at the intervals

listed abobe. The procedure for adjusting the cam chain tension

adjuster is as follows:

• Loosen the lock nut

1 on the cam chain tension adjuster and

back out the set screw

2 one turn. This will allow a spring to

push the push rod firmly on to the cam chain tensioner, and

provide proper operating chain tension.

• Tighten the set screw

2 to lock the push rod in position and

tighten the lock nut

1 to secure the set screw

2.

Inspect initially at 1 month and every 6 months there-

after.

PERIODIC MAINTENANCE 2-7

NOTE:

If the cam chain is noisy after having been adjusted, the push

rod is probably sticking. Remove the cam chain tension adjuster,

clean and lubricate the push rod to obtain smooth movement

and proper tensioning action.

SPARK PLUG

• Disconnect the spark plug cap

1 and remove the spark plug

2.

! 09930-10121: Spark plug wrench set

"

• Carbon deposits on the spark plug will prevent good sparking

and may cause the engine to misfire. 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 thickness gauge.

! 09900-20804: Thickness gauge

# Spark plug gap: 0.6 – 0.8 mm (0.024 – 0.031 in)

• Check the spark plug for burns. If any abnormalities are

found, replace the spark plug as indicated below.

Inspect every 6 months.

Replace every 12 months.

NGK DENSO

STD DR8EA X24ESR-U

Confirm the thread size and reach when replacing the

spark plug. If the reach is too short, carbon will be

deposited on the screw portion of the plug hole and

engine damage may result.

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