Suzuki DR 125 Manuel utilisateur

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

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)

1is stamped on the right side of the

steering head pipe. The engine serial number

2is 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

Ce manuel convient aux modèles suivants

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