Suzuki GN125F User manual

GN125F
99500H3030DE001

DACHANGJIANG GROUP CO.,LTD.
DECEMBER, 2014
(The 1st Edition)
©COPYRIGHT DA 2014CHANGJIANG GROUP CO.,LTD.
FOREWORD
8
This manual contains an introductory description on the
SUZUKI and procedures for its inspec-
tion/service and overhaul of its main components. Other
information considered as generally known is not
included.
Read the GENERAL INFORMATION section to familia-
rize yourself with the motorcycle and its maintenance.
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 better so
that you can assure your customers of fast and reliable
service.
GN125F
This manual has been prepared on the basis of the
latest specifications at the time of publication. If
modifications have been made since then, differ-
ences may exist between the content 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 motorcycles. If you do not
have the proper knowledge and tools, ask your
authorized motorcycle dealer to help you.SUZUKI
*
*
*
WARNING
Improper repair may result in injury to the
mechanic and may render the motorcycle unsafe
for the rider and passenger.
CAUTION
Inexperienced mechanics or mechanics without
proper tools, not to able to properly perform the
services described in this manual.
GROUP INDEX
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE
ELECTRICAL
CHASSIS
FUEL AND LUBRICATION
1
2
3
4
5
6
7
SERVICING INFORMATION

COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit, is its exploded view. Work instruction and tightening torque,
lubricating points and locking points, are provided.
Example: Front wheel
1
2
3
4
5
6
7
A
8
B
N•m Kgf•m
18-28
36-52
1.8-2.8
3.6-5.2
Front axle shaft
Spacer
Dustcover
Washer
Front brake disc
Oil seal
Roller bearing
Spacer
ITEM
9
10
Front tire
Front wheel rim
Speedometer gear driver
Oil seal
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1.The text of this manual is divided into 7 sections.
2.The section titles are listed in the GROUP INDEX.
3.Holding the manual as shown as 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.
A
B
Speedometer gear box
Brake disc bolt
Front axle nut
11
12
13

SYMBOL
The following symbols are instructions and necessary information for maintenance.
Torque control required.
Data beside it indicates specified
torque.
Apply oil. Use engine oil unless
otherwise specified.
Apply MOLY PASTE
99000-25140
Apply or use the absorber oil
Apply THREAD LOCK “1342"
99000-32050
Apply THREAD LOCK “1303"
99000-32030
Apply or use the brake fluid
Measure voltage
Apply sealant “1215”
99000-31110
Apply sealant “1207B”
99000-31140 Measure continuity test range
Use special tool
OIL
Apply SUPER GREASE “A”
99000-25010
Measure in resistance
Apply THREAD LOCK “1360"
99000-32130
SYMBOL DEFINITION SYMBOL DEFINITION
The data of maintenance

WIRE COLOR
O/Bl
O/W
O/Y
R/B
R/Y
W/B
W/R
Y/G
Y/R
Y/W
Orange with Blue tracer
Orange with White tracer
Orange with Yellow tracer
Red with Black tracer
Red with Yellow tracer
White with Black tracer
White with Red tracer
Yellow with Green tracer
Yellow with Red tracer
Yellow with White tracer
.............
.............
.............
.............
.............
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.............
.............
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B/Bl
B/Br
B/G
B/R
B/W
B/Y
Bl/W
Bl/Y
Br/Y
G/Y
O/B
Black with Blue tracer
Black with Brown tracer
Black with Green tracer
Black with Red tracer
Black with White tracer
Black with Yellow tracer
Blue with White tracer
Black with Yellow tracer
Brown with Yellow tracer
Green with Yellow tracer
Orange with Black tracer
.............
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.............
.............
.............
.............
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Black
Blue
Brown
Deep green
Green
.............
.............
.............
.............
.............
B
Bl
Br
Dg
G
Grown
Light blue
Light green
Orange
Pink
.............
.............
.............
.............
.............
Gr
Lbl
Lg
O
P
Red
Violet
White
Yellow
.............
.............
.............
.............
R
V
W
Y

GENERAL INFORMATION
1
CONTENTS
1
1-1
1-1
1-2
1-2
1-2
1-3
WARNING/CAUTION/NOTE
GENERAL PRECAUTIONS
SERIAL NUMBER LOCATION
FUEL AND OIL RECOMMENDATION
BREAK-IN PROCEDURE
SPECIFICATIONS

GENERAL INFORMATION
WARNING/CAUTION/NOTE
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in motorcycle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
GENERAL PRECAUTION
WARNING
WARNING
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.
Please note, however, that the warnings and the 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
WARNING and CAUTION stated, you must use good judgment and basic mechanical safety principles. If
you are unsure about how to perform a particular service operation, ask a more experienced technician for
advice.
Proper service and repair procedures are important for the safety of the service technician and the
safety and reliability of the motorcycle.
When 2 or more persons work together, pay attention to safety of each other.
When it is necessary to run the engine indoors, make sure that exhaust gas is forced outdoor.
When working with the toxic or flammable materials, make sure that the area you work in is well-
ventilated and that you follow all of the material manufacturer's instructions.
Never use gasoline as a cleaning solvent.
To avoid getting burned, do not touch the engine, engine oil or exhaust system during or for a while
after engine operation.
After servicing fuel, oil, exhaust or brake system, check all lines and fittings related to the system
for leakage.
1-1

1-2
GENERAL INFORMATION
NOTE:
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, and also lubricated when specified.
When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified
type.
When performing service to electrical parts, if the service procedures not require used of battery
power, disconnect the positive terminal.
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.
Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with
smaller diameter, from inside to outside diagonally, to the specified tightening torque.
Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, cotter pins, cir-clips,
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 odd material from the mating surfaces.
Never reuse a circlip. When installing a new circlip, take care not to expend 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.
Do not use self-locking nuts a few times over.
Use a torque wrench to tighten fasteners to the torque values when specified. Wipe off grease or oil
if a thread is smeared with them.
After reassembly, check parts for tightness and operation.
To protect environment, do not unlawfully dispose of used motor oil and other fluids,
batteries and tires.
To protect earth's natural resources, properly dispose of used motorcycles and parts.
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SERIAL NUMBER LOCATIONS
The frame serial number or V.I.N. (Vehicle
Identification Number) 1 is stamped on the right
side of the steering head pipe. The engine serial
number 2 is located on the left side of the
crankcase. These numbers are required
especially for registering the machine and
ordering spare parts.
FUEL AND OIL
RECOMMENDATIONS
FUEL
Use fuel with an octane number of 90-97
(Research method), preferably unleaded.
NOTE:
Unleaded fuel will extend spark plug life.
ENGINE OIL
Be sure that the motorcycle engine oil you use
comes under API classification of SF or SG and its
viscosity rating is SAE 10W-40. If SAE 10W-40
engine oil is not available, select the oil viscosity
according to the following chart:
SAE
20W/50
10W/50
10W/30
20W
10W
40
30
C
F
-20
-4
-10
14
0
32
10
50
20
68
30
86
40
104
Temp.
BREAK-IN PROCEDURE
During the manufacture only the best ossible
are used and all machined parts are
finished to a very high standard
allow the moving part to “BREAK-IN”
subjecting the engine to maximum stresses
s the care and restraint exercised during
its early life The general rules are as follows:
p
materials
, it is still necessary
to before
.The
future performance and reliability of the engine
depend on
.
GENERAL INFORMATION
The throttle must not be opened to the full during
the new motorcycle's break-in period. Throttle
opening should be limited to less than 3/4 of its
maximum, while violent acceleration should be
avoided.
Do not maintain constant engine gear and
speed for an extended time period during any
portion of the break-in. Try to vary the throttle
position. During the period of break-in, increase
the throttle opening properly to enable break-in
fully.
When engine is running at constant low speed
(low load), parts will wear rapidly leads to bad
brake-in.
1-2
ABSORBER OIL
SUZUKI ABSORBER OIL #32 OR EQUIVALENT
BRAKE FLUID
DOT4

GENERAL INFORMATION
1-3
SPECIFICATIONS
DIMENSIONS AND CURB WEIGHT
2 000 mm
815 mm
1 100 mm
1 300 mm
175 mm
113 kg
Overall length
Overall width
Overall height
Wheelbase
Ground clearance
Curb weight
ENGINE
Single cylinder, vertical, air-cooled, four stroke
1
57 mm
48.8 mm
124 ml
9.2:1
BS type
P
Wet sump
olyurethane foam element
Electric
Type
Number of cylinders
Bore
Stroke
Piston displacement
Compression ratio
Carburetor
Air cleaner
Starter system
Lubrication system
TRANSMISSION
Clutch
Transmission
Primary reduction ratio
Final reduction ratio
Gear ratios, Low
2nd
3rd
4th
Top
Drive chain
Wet multi-plate type
5-speed constant mesh
3.470
2.867
3.000
1.857
1.368
1.143
0.957
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