Suzuki EN125-2A User manual

SERVICE MANUAL

99500H06100-01E

EN125-2A

Prepared by

Customer Service Department

1st Ed. Aug, 2003

Part No.:99500H06100-01E

Printed in China

JIANG MEN DACHANGJIANG GROUP CO., LTD.

The SUZUKI EN125-2A was designed to offer superior performance through light weight

design and four stroke power. The new EN125-2A represents another major advance by

Suzuki in four stroke motorcycles.

This service manual has been produced primarily for experienced mechanics whose job is

to inspect, repair and service Suzuki Motorcycles. Apprentice mechanics and "do it

yourself " mechanics will also find this manual to be an extremely useful guide.

Model EN125-2A manufactured to standard specifications is the main 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 minor modifications (which are of no consequence in most cases as far as servicing

is concerned) had to be made to comply with the statutory requirements of your country.

This manual contains up-to-date information at the time of its issue. Latermade

modifications and changes will be explained to each SUZUKI distributor in respective

markets, to whom you are requested to make query about updated information, if any.

FOREWORD

SUZUKI MOTOR CORPORATION

JIANG MEN DACHANGJIANG GROUP CO., LTD.

Customer Service Department

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

GENERAL INFORMATION

CONTENTS

SERIAL NUMBER LOCATIONS

FUEL AND OIL RECOMMENDATIONS

BREAK-IN PROCEDURE

SPECIAL FEATURE

SPECIAL MATERIALS

SPECIFICATIONS

1-2

1-3

1-4

1-5

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1

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WARNING/CAUTION/NOTICE

1-1

1-1 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 messages highlighted

by these signal words.

WARNING:

Personal safety of the rider is involved, and disregard of the information could result in injury.

CAUTION:

For the protection of the motorcycle, the instruction or rule must be strictly adhered to.

NOTE:

Advice calculated to facilitate the repair of the motorcycle is given under this heading.

GENERAL PRECAUTION

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

and reliability of the motorcycle.

When more than 2 persons perform work in cooperation, pay attention to the safety of each other.

When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoors.

When working with toxic or flammable materials, make sure that area you work in is well-ventilated and that

you follow all of the material manufacturer s instrucations.

Never use gasoline as a cleaning solvent.

To avoid getting burned, do not touch the engine, engine oil, oil cooler and exhaust system until they have

cooled.

Afer servicing the fuel, oil, exhaust or brake systems, check all lines and fittings related to the system for

leaks.

WARNING:

If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent.

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 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 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 batery 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 diagonally from the inside working out and to the specified tightening

torque.

Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter pins,

circlips and certian 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 circilp, 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.

CAUTION:

To protect the environment, do not unlawfully dispose of used motor oil, engine coolant and other

fluids: batteries tires.

To protect Earth's natural resources, properly of uesd motorcycle and parts.

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 motorcycle. 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.

The frame serial number is stamped on the

steering head pipe. The engine serial number

is located on the crankcase.

These numbers are required especially for

registering the machine and ordering spare parts.

Ù

SERIAL NUMBER LOCATIONS

Use gasoline with an octane number of 90 97 or

higher (Research Method), preferably unleaded

-

FUEL AND OIL

RECOMMENDATIONS

FUEL

NOTE:

Unleaded and low-lead gasoline will extend

spark plug life.

ENGINE OIL

Be sure that the engine-oil you use comes under

API classification of SF or SG and that its

viscosity rating is SAE 10W-40. If SAE 10W-40

motor oil is not available, select the oil viscosity

according to the following chart:

FRONT FORK OIL

FORK OIL 10

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:

BREAK-IN PROCEDURE

Keep to these break-in gine speed limits:en

Upon reaching an odometer reading of 1,600 km

you can subject the motorcycle to full throttle

operation.

However, do not exceed 10,000 r/min at any

time.

Do not maintain constant engine speed for an

extended time period during any portion of the

break-in. Try to vary the throttle position.

Initial 800 km

Up to 1,600 km

Over 1,600 km

Below 4,500 r/min

Below 5,500 r/min

Below 10,000 r/min

SAE

40

30

20W/50

10W/50

10W/30

20W

10W

-20 -10 0 10 20 30 40

-4 14 32 50 68 86 104

C

F

Temp.

2

1

Specification

and Classification

DOT3, DOT4

BRAKE FLUID

GENERAL INFORMATION 1-2

TRANSISTORIZED IGNITION SYSTEM WITH ELECTRONIC ADVANCE

DESCRIPTION

SPECIAL FEATURE

200

100

O

246810

Engine r/min (x 1000 r/min)

Fig.2

Closing angle (Degree)

1.0

0.5

246810

Engine r/min (x 1000 r/min)

Fig.3

Electric current (A)

On the Model EN125-2A, the timing advance characteristics of the ignition timing have been changed

from the previously-employed mechanical timing advance system incorporating a centrifugal advance

governor to an electronic timing advance system.

The ignitor has the following functions:

(1)Revolution advance angle control

Controls ignition timing in response to engine 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 performance during high-speed operations.

When engine speed is low, reduces the conducting period (closing angle) of the transistor (Tr) so

that power consumption is reduced; when engine speed is high, increases the conducting period

(closing angle) to prevent voltage drop of the ignition coil. (See Figure 2 and 3.)

01234567891011

Engine r/min (x 1000 r/min)

Fig.1

Advance angle (Degree)

BTDC

13 BASE

O

0

20

10

30

19.0 2.8 /4500rpm

OO

16.9 3 /7000rpm

OO

Signal generator

Signal rolor

Pick-up coil

(A)

(B)

Ignitor unit

(Tr)

(C)

Ig

1

Ig

2

Ignition coil

Spark plug

Battery

Ignition switch

1-3 GENERAL INFORMATION

The materials listed below are needed for maintenance work on the EN125-2A and should be kept on hand

for ready use. These items supplement such standard materials as cleaning fluids, lubricants, emery cloth

and the like. How to use them and where to use them are described in the text of this manual.

SPECIAL MATERIALS

THREAD LOCK SUPER

"1303B"

99000-32030

THREAD LOCK CEMENT

99000-32040

THREAD LOCK "1342"

99000-32050

THREAD LOCK SUPER

"1305"

99000-32100

Cam sprocket bolts

2nd drive gear

Starter clutch allen bolt

Gear position sw. bolts

Front fork damper rod

bolts

Magneto rotor 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"

99000-25010

SUZUKI MOLY PASTE

99000-25140

SUZUKI BOND No.4

99000-31030

SUZUKI BOND No.1215

99000-31110

Part

Page

Oil seals

Wheel bearing

Brake cam

Steering stem

Dust seal cover and

spacer

Speedometer gear box

Wheel mounting drum

Brake piston holder

Piston pin

Valve stem

Camshaft journal

Rocker arm shaft

Front fork damper rod

bolt

Cylinder head cover

Mating surfaces of left

and right crankcase

Material Part

Page

3-24

3-25

3-28

3-47

5-3

5-31

5-32

5-36

2-2

5-3

5-31

5-22

5-10

2-4

3-29

3-27

3-44

3-53

3-55

5-10

3-44

3-48

3-49

6-2

6-11

3-53

5-16

3-47

GENERAL INFORMATION 1-4

1-5 GENERAL INFORMATION

SPECIFICATIONS

DIMENSIONS AND DRY MASS

ENGINE

TRANSMISSION

Overall length

Overall width

Overall height

Wheelbase

Ground clearance

Seat height

Dry mass

Type

Number of cylinders

Bore

Stroke

Piston displacement

Compression ratio

Carburetor

Air cleaner

Starter system

Lubrication system

Clutch

Transmission

Gearshift pattern

Primary reduction

Final reduction

Gear ratios, Low

2nd

Drive chain

3rd

4th

Top

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Four-stroke, air-cooled, OHC

1

57.0mm

48.8mm

124cm

9.2:1

MIKUNI BS26SS, single

Polyurethane foam element

Wet sump

3

Electric

Wet multi-plate type

5-speed constant mesh

1-down, 4-up

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)

KMC 428H 118 Links

1945mm

735mm

1070mm

1265mm

160mm

750mm

122kg

GENERAL INFORMATION 1-6

ELECTRICAL

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Ignition type

lgnition timing

Spark plug

Battery

Fuse

Headlight

Tail/Brake light

Turn signal light

Turn signal indicator light

Neutral indicator light

Speedometer light

Tachometer light

Fuel capacity light

High beam indicator light

Position lamp

Gear position indicator

Transistorized

13 B.T.D.C. below 1 950 r/mim

NGK CR8E, NIPPON DENSO U24ESR-N

12V 28.8kc(7Ah) 10h

10A, 15A

12V 5W/21W

12V 21W

12V 2W 2

12V 2W

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

12V 35W/35W

CHASSIS

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Telescopic, coil spring, oil dampened

Swing arm, oil dampened

spring 5-way adjustable

42 (right and left)

64 30

90mm

2.1m

Disc

Internal expanding

80/100-18 4PR Tubeless

90/90-18

O

4PR Tubeless

Front suspension

Rear suspension

Steering angle

Caster

Trail

Turning radius

Front brake

Rear brake

Front tire size

Rear tire size

*The specifications subject to change without notice.

CAPACITIES

.......................

.....................................

...................................

Fuel tank including reserve

reserve

Engine oil

Front fork oil

14 L

2.0 L

1100 ml

139 ml

PERIODIC MAINTENANCE AND

TUNE-UP PROCEDURES

CONTENTS

PERIODIC MAINTENANCE SCHEDULE

MAINTENANCE PROCEDURES

BATTERY

CYLINDER HEAD NUTS, CYLINDER NUTS, EXHAUST PIPE

BOLTS 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

TIRES

STEERING

FRONT FORK OIL

CHASSIS AND ENGINE BOLTS AND NUTS

2-1

2-3

2-4

2-5

2-6

2-7

2-8

2-9

2-10

2-11

2-10

2-11

2-12

2-15

2-16

2-17

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2

2-1 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

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 used under extreme severe

conditions.

PERIODIC MAINTERNANCE CHART

ENGINE

Battery

Cylinder head nuts, cylinder nuts,

exhaust pipe bolts and nut

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

Interval

ltem

Inspect

Clean

Change

Replace

Inspect

-

Inspect

Initial 1 000 km

Clean every 3 000 km

Inspect

Change

Replace

Inspect

-

Every 4 000 km

Replace

Clean

-

Every 8 000 km

23

24

25

26

27

28

29

210

-

Page

Replace every 4 years

CHASSIS

Drive chain

Brakes

Brake hose

Brake fluid

Tires

Steering

Front fork oil

Chassis bolts and nuts

Inspect

Change

Inspect

Inspect and clean every 1 000 km

211

212

215

216

217

-

Replace every 4 years

Change every 2 years

Inspect

-

Change

-

52040

Km

Months

Interval

ltem

Initial 1 000 km

Every 4 000 km Every 8 000 km

Page

52040

Km

Months

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-2

PERIODIC LUBRICATION CHART

The maintenance schedule, which follows, is based on this philosophy. It is timed by odometer indication,

and is calculated to achieve the ultimate goal of motorcycle maintenance in the most economical manner.

Throttle cable

Throttle grip

Clutch cable

Speedometer cable

Speedometer gear box

Tachometer cable

Drive chain

Brake pedal

Brake cam shaft

Steering stem bearings

Swing arm bearings

Interval

ltem

Engine oil

Grease or engine oil

-

Initial and Every 6 000 km Every 12 000 km

Engine oil every 1 000 km

Greaseevery2yearsor20000km

Grease

-

Grease

Lubricate exposed parts which are subject to rust, with either motor oil or grease whenever the motorcycle

has been operated under wet or rainy conditions.

Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.

WARNING:

Be careful not to apply too much grease to the brake cam shafts. If grease gets on the linings,

brake slippage will result.

6

12

Km

Months

2-3 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

This section describes the service procedures for

each section of Periodic Maintenance.

MAINTENANCE PROCEDURES

For checking specific gravity, use a hydrometer to

determine the charged condition.

BATTERY

Inspect initial 1 000 km and Every 4 000 km

The battery must be removed to check the

electrolyte level and specific gravity.

Remove the right frame cover.

Remove battery lead at the battery terminal.

Remove battery lead.

Remove battery from the frame.

Check electrolyte for 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 specific

gravity

1.28 at 20

O

C

An S.G. reading of 1.22 (at 20 C ) or under means

that the battery needs recharging off the machine:

take it off and charge it from a recharger.

Charging the battery in place can lead to failure of

the regulator/rectifier.

O

To install the battery, reverse the procedure

described above.

Make sure that the breather pipe is tightly

secured and undamaged, and is routed as

shown in the figure.

WARNING:

When installing the battery lead wires, fix the

lead first and lead last.

Breather pipe

Battery

1

2

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-4

Remove the seat and fuel tank

(Refer to page 3-2)

Remove the right and left caps of the cylinder

head cover after remove the tachometer cable

().

Remove the cylinder head cover

(Refer to page 3-8)

Tighten the four 10mm nuts and two 6-mm

nuts to the specified torque with a torque

wrench, when engine is cold.

.

Refer to page 3-5

.

CYLINDER HEAD NUTS, CYLINDER

NUTS, EXHAUST PIPE BOLTS 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 BOND No.1215

99000-31110

Tighten the two 6 mm nuts to the specified

torque.

CYLINDER NUTS

Tightening torque

711Nm-

-(0.7 1.1 kg m)

Tightening

torque

10 mm

25 N m

(2.5 .5 kg m)

-35

-3

6mm

711Nm

(0.7 1.1 kg m)

-

Tighten the exhaust pipe bolts and muffler

clamp bolt to the specified torque.

EXHAUST PIPE BOLTS AND MUFFLER

CLAMP BOLT

Tightening torque

Exhaust pipe

bolts and muffler

clamp bolt

912Nm

(0.9 1.2 kg m)

-

2

4

3

1

5

2-5 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

Fill a washing pan of a proper size with

nonflammable cleaning solvent. Immerse the

element in the cleaning solvent and wash it clean.

Squeeze the cleaning solvent out of the washed

element by pressing it between the palms of

both hands.

Immerse the element in motor oil, and squeeze

the oil out of the element leaving it slightly wet

with oil.

AIR CLEANER ELEMENT

Clean Every 3 000 km

If the air cleaner is clogged with dust, 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 the screws and take out the air cleaner

element assembly.

Separate the polyurethane foam element from

the element frame.

NOTE:

When installing the air cleaner case cover,

place the "UP" mark upward.

NOTE:

Do not twist or wring the element because it

will tear or the individual cells of the element

will be damaged.

CAUTION:

Inspect the element carefully for rips, torn

seams, etc. If any damage is noted, replace

the element.

Element

Non-flammable

Cleaning

Solvent

4

3

1

2

Motor oil

PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-6

Excessive valve clearance results in valve noise

and insufficient valve clearance results in valve

damage and reduced power. At the distances

indicated above, check and adjust the clearance

to the following specification.

The procedure for adjusting the valve clearance

is as follows:

Remove the seat and fuel tank.

Remove the tachometer cable.

Remove the left cap of the cylinder head cover.

Remove spark plug, valve inspection caps ,

and valve timing inspection plug .

Remove the magneto cover cap and rotate

the magneto rotor with the 14 mm box wrench to

set the piston at (TDC) of the compression

stroke.

(Rotate 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 cap of the cylinder head cover.

"

NOTE:

Valve clearance is be checked when the

engine is cold.

Both the intake and exhaust valves must be

checked and adjusted when the piston is at

Top-Dead-Center (TDC) of the compression

stroke.

VALVE CLEARANCE

Inspect initial 1 000 km and Every 4 000 km

Thickness gauge

09900-20803

Valve clearance specifications

IN.

EX.

0.04 0.07 mm

0.13 0.18 mm

-

If clearance is off the specification, bring it into

the specified range by using the special tool.

Tappet adjust driver

09917-13210

Reinstall spark plug, valve inspection caps,

cylinder hand cover caps, tachometer cable, valve

timing inspection plug and magneto cover cap.

1

2

3

2-7 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES

Remove the carbon deposits with a wire or pin and

adjust the spark plug gap to 0.7-0.8 mm,

measuring with a thickness gauge.

When removing carbon deposits, be sure to

observe the appearance of the plug, noting the

color of the carbon deposits. The color observed

indicates whether the standard plug is suitable or

not. If the standard plug is 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

specifications and it means that the resistor

is located at the center electrode to prevent

radio noise.

COMPRESSION PRESSURE

Inspect initial 1 000 km Every 4 000 km

Refer to page 3-1.

SPARK PLUG

Inspect initial 1 000 km and Every 4 000 km

Replace Every 8 000 km

NGK CR7E

NIPPON DENSO U22ESR-N

Hot type

NGK CR8E

NIPPON DENSO U24ESR-N

Standard

NGK CR9E

NIPPON DENSO U27ESR-N

Cold type

0.7 mm-0.8 mm

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Suzuki EN125-2A User manual

Suzuki EN125-2A User manual

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