Suzuki DR 125 Manuals

Suzuki DR 125 Manuals

Manuals and User Guides for Suzuki DR 125. We have 1 Suzuki DR 125 manual available for free PDF download: Service Manual

Suzuki DR 125 Service Manual

Suzuki DR 125 Service Manual (222 pages)

Brand: Suzuki | Category: Motorcycle | Size: 11.07 MB

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

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