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.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2002
* 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)
1 Bearing
2 Spacer
3 Bearing
4 Brake disc
5 Front axle
A Front axle nut
B Brake disc mounting nut
ITEM N·m kgf.m lb-ft
A 44 4.4 32.0
B 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)
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
1 Noise label — ¡
2 Information label — ¡
3 Fuel caution label ¡ —
4 Manual notice label — ¡
5 Warning safety label ¡ ¡
6 Certification plate — ¡
7 Compliance label ¡ —
DR-Z125/L
Frame (Left side)
Frame (Right side)
Fuel tank
Rear fender
E - 28
E - 28
E - 03