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DR 125
Suzuki DR 125 User Manual
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ENG
IN
E 3-45
•
Ins
tall
the
bearing
re
taine
r
1
.
NOT
E:
Ap
ply a
s
mall
q
uan
tity of
T
HR
EAD
L
OCK
“
134
2”
to
the
bear
ing
ret
ainer
scre
ws.
!
9
900
0-3
205
0: T
HRE
AD
LO
CK “
13
42”
CLUTCH REL
EASE CAMSHAFT
REM
OVAL
•
Rem
ov
e t
he o
il sea
l re
tainer
1
.
•
Rem
ov
e t
he clutc
h
rele
ase ca
ms
ha
ft
2
.
REA
SSEM
BLY
•
Ins
tall
the c
lutc
h
releas
e
cams
h
aft
2
, wa
sher
3
a
nd
new
o
il
seal
4
.
•
Install t
he oil seal reta
iner
1
.
80
82
Table of Contents
Foreword Group Index
2
Table of Contents
2
How to Use this Manual
3
General Information
6
Suzuki Dr-Z125/Lk3 ('03-Model)
8
Serial Number Location
8
Fuel and Oil Recommendation
8
Fuel
8
Engine Oil
9
Brake Fluid
9
Front Fork Oil
9
BREAK-Ln PROCEDURES
9
Information Labels
10
Specifications
11
Dimensions and Dry Mass
11
Engine
11
Drive Train
11
Chassis
12
Electrical
12
Capacities
12
Country and Area Codes
13
General Precautions
6
Warning/Caution/Note
6
Periodic Maintenance
14
Periodic Maintenance Schedule
15
Periodic Maintenance Chart
15
Lubrication Points
16
Maintenance and Tune-Up Procedures
17
Air Cleaner
17
Engine
17
Valve Clearance
18
Cam Chain Tension Adjuster
19
Spark Plug
20
Throttle Cable Play
21
Engine Idle Speed
21
Fuel Hose
22
Clutch
22
Engine Oil and Oil Filter
23
Spark Arrester
24
Drive Chain
25
Front Brake Lever Play (Dr-Z125)
27
Front Disc Brake (Dr-Z125L)
27
Rear Brake Pedal Height
29
Brake Hoses (Dr-Z125L)
30
Steering
30
Tires
30
Spoke Nipples
31
Exhaust Pipe Bolts and Muffler Mounting Bolt
32
Front Fork
32
Rear Suspension
32
Chassis Bolts and Nuts
33
Compression Pressure Check
35
Compression Test Procedure
35
Oil Pressure Check
36
Oil Pressure Test Procedure
36
Engine
37
Engine Components Removable with Engine in Place
38
Engine Left Side
38
Engine Right Side
38
Engine Center
38
Engine Removal and Reinstallation
39
Engine Removal
39
Engine Reinstallation
42
Engine Disassembly
45
Engine Components Inspection and Service
54
Cylinder Head Cover
54
Cylinder Head
56
Camshaft
65
Cylinder
66
Camshaft Runout
66
Piston and Piston Pin
67
Piston Ring Groove Width
68
Piston Ring Thickness
68
Piston Ring End Gap
68
Crankshaft and Conrod
70
Crankshaft Runout
71
Transmission
72
Primary Driven Gear
74
Clutch
75
Oil Filter
76
Oil Sump Filter
76
Kick Starter
77
Crankcase Bearings
79
Clutch Release Camshaft
81
Engine Reassembly
82
Clutch
88
Fuel and Lubrication System
97
Fuel and Lubrication
97
Fuel Tank
98
Fuel Tank Removal
98
Fuel Valve
99
Fuel Valve/Fuel Filter Removal
99
Fuel Filter Inspection and Cleaning
99
Fuel Hose Inspection
99
Carburetor
100
Construction
100
Specifications
101
I.D. No. Location
101
Removal
101
Disassembly
102
Cleaning
104
Inspection
105
Reassembly and Remounting
105
Engine Lubrication System
106
Engine Lubrication System Chart
106
Oil Pressure
107
Oil Filter
107
Oil Sump Filter
107
Chassis
108
Exterior Parts
109
Removal
109
Remounting
109
Front Wheel and Front Brake (Dr-Z125)
110
Removal
110
Inspection and Disassembly
112
Reassembly
113
Remounting
114
Front Wheel (Dr-Z125L)
115
Removal
115
Inspection and Disassembly
116
Reassembly and Remounting
116
Front Brake (Dr-Z125L)
117
Brake Pad Replacement
118
Brake Fluid Replacement
119
Brake Caliper Removal and Disassembly
119
Brake Caliper Inspection
120
Brake Caliper Reassembly and Remounting
121
Brake Disc Inspection
122
Master Cylinder Removal and Disassembly
123
Master Cylinder Inspection
124
Master Cylinder Reassembly and Remounting
124
Front Fork
126
Removal and Disassembly
126
Inspection
129
Reassembly and Remounting
129
Steering
132
Removal and Disassembly
132
Inspection
134
Reassembly and Remounting
134
Rear Wheel and Rear Brake
138
Removal
138
Inspection and Disassembly
140
Reassembly and Remouning
140
Rear Swingarm and Suspension
142
Removal
143
Inspection and Disassembly
144
Reassembly and Remounting
147
Suspension Setting
149
Rear Shock Absorber Disposal
150
Electrical System
151
Cautions in Servicing
152
Connectors
152
Couplers
152
Clamps
152
Semi-Conductor Equipped Parts
152
Wiring Procedure
152
Using the Multi Circuit Tester
153
Ignition System
154
Description
154
Troubleshooting
154
Inspection
155
Servicing Information
159
Troubleshooting
160
Engine
160
Carburetor
163
Chassis
164
Brakes
165
Electrical
166
Wiring Diagram
167
Wire, Cable and Hose Routing
168
Wire Routing
168
Cable Routing
170
Front Brake Hose Routing
171
Fuel Hose and Fuel Tank Mounting
172
Side Stand Set-Up
173
Carburetor Installation/Hose Routing
174
Special Tools
175
Tightening Torque
178
Engine
178
Chassis
179
Tightening Torque Chart
180
Dr-Z125/Lk4 ('04-Model)
189
Service Data
191
Dr-Z125/Lk6 ('06-Model)
200
Dr-Z125/Lk8 ('08-Model)
209
5
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Suzuki DR 125 Specifications
General
Brand
Suzuki
Model
DR 125
Category
Motorcycle
Language
English
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