Suzuki UG110 2021 User manual

UG110
99500-11180-01E

FOREWORD
This manual contains an introductory description on
the SUZUKI UG110 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 fa-
miliarize yourself with the motorcycle and its main-
tenance. Use this section as well as other sections
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 ba-
sis of the latest specifications at the time of
publication. If modifications have been made
since then, differences 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, includ-
ing special tools, for servicing SUZUKI mo-
torcycles. If you do not have the proper
knowledge and tools, ask your authorized
SUZUKI motorcycle dealer to help you.
!
Inexperienced mechanics or mechanics with-
out the proper tools and equipment may not
be able to properly perform the services de-
scribed in this manual. Improper repair may
result in injury to the mechanic and may ren-
der the motorcycle unsafe for the rider and
passenger.
Motorcycle Service Department
© COPYRIGHT SUZUKI MOTOR CORPORATION 1999
GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE 3
FUEL AND LUBRICATION 4
SYSTEM
CHASSIS 5
ELECTRICAL SYSTEM 6
SERVICING INFORMATION 7

HOWTO USETHIS MANUAL
TO LOCATEWHATYOU 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 al-
low 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 WORKTO BE DONE
Under the name of each system or unit, is its exploded view.Work instructions and other service information
such as the tightening torque, lubricating points and locking agent points, are provided.
Example: Front wheel
1Front axle
2Spacer
3Dust seal
4Bearing
5Spacer
6Front wheel
7Speedometer gearbox
8Brake disc
AFront axle nut
BBrake disc bolt
ITEM N.m kgf.m
A42 4.2
B23 2.3
"

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
"Torque control required.
Data beside it indicates specified
torque.
#Apply oil. Use engine oil unless
otherwise specified.
$Apply SUZUKI SUPER GREASE
“A”.
99000-25010
%Apply SUZUKI SILICONE
GREASE.
99000-25100
&Apply SUZUKI MOLY PASTE.
99000-25140
'Apply THERMO GREASE.
99000-25300
(Apply SUZUKI BOND “1215”.
99000-31110
)Apply THREAD LOCK “1322”.
99000-32110
*Apply THREAD LOCK “1342”.
99000-32050
+Apply THREAD LOCK SUPER
“1360”.
99000-32130
SYMBOL DEFINITION
,Apply or use brake fluid.
-Measure in voltage range.
.Measure in resistance range.
/Measure in current range.
0Measure in diode test range.
1Measure in continuity test range.
2Use special tool.
3Use fork oil.
99000-99044-10G
4Indication of service data.

1
GENERAL INFORMATION
CONTENTS
WARNING/CAUTION/NOTE...................................................................1- 2
GENERAL PRECAUTIONS ...................................................................1- 2
SUZUKI UG110Y (2000-MODEL) ..........................................................1- 4
SERIAL NUMBER LOCATION...............................................................1- 4
FUEL AND OIL RECOMMENDATIONS .................................................1- 4
FUEL................................................................................................1- 4
ENGINE OIL ....................................................................................1- 5
FINAL GEAR OIL ............................................................................1- 5
BRAKE FLUID.................................................................................1- 5
FRONT FORK OIL...........................................................................1- 5
BREAK-IN PROCEDURES ....................................................................1- 5
INFORMATION LABELS........................................................................1- 6
SPECIFICATIONS ..................................................................................1- 7
COUNTRY AND AREA CODES.............................................................1- 9
GENERAL INFORMATION 1-1

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.
5
Indicates a potential hazard that could result in motorcycle 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 motorcycle. In addition to the WARN-
INGS 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 motorcycle.
* When two 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 outdoors.
* 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 and exhaust system until they
have cooled.
* After servicing fuel, oil, exhaust or brake systems, check all of the lines and fittings related to
the system for leaks.

GENERAL INFORMATION 1-3
5
* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva-
lent.
* 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.
* 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 lubricant, bond, or sealant.
* When removing the battery, disconnect the --
--
-battery lead wire first, and then the ++
++
+battery
lead wire.
* When reconnecting the battery, connect the ++
++
+battery lead wire first, then the --
--
-battery lead
wire. Finally, cover the ++
++
+battery terminal with the terminal cover.
* When performing service to electrical parts, disconnect the --
--
-battery lead wire, unless the
service procedure requires the battery power.
* When tightening cylinder head and crankcase bolts and nuts, tighten the larger sizes first.
Always tighten the bolts and nuts from the inside working out, diagonally and to the specified
tightening torque.
* Whenever you remove oil seals, gaskets, packing, O-rings, self-locking nuts, locking washers,
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, batteries, and tires.
* To protect the earth’s natural resouces, properly dispose of used motorcycles and parts.

1-4 GENERAL INFORMATION
SUZUKI UG110Y (2000-MODEL)
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) 1is stamped on the right side of the
frame. The engine serial number 2 is located on the end of the crankcase. These numbers are required
especially for registering the machine and ordering spare parts.
FUEL AND OIL RECOMMENDATIONS
Be sure to use the specified fuel and oils. Fuel and oil specifica-
tions are listed below.
FUEL
Use unleaded gasoline that is graded 91 octane or higher rated
by the Reserch Method.
RIGHT SIDE LEFT SIDE
* Difference between photographs and the actual motorcycles depends on the markets.
1Fuel tank cap

GENERAL INFORMATION 1-5
FINAL GEAR OIL
Use a good quality SAE 10W/40 multi-grade motor oil.
BRAKE FLUID
,,
,,
,Specification and classification: DOT 4
!
* This motorcycle uses a glycol-based brake fluid. Do not use or mix different types of brake
fluid such as silicone-based and petroleum-based fluids for refilling the system, otherwise
serious damage will result to the brake system.
* Never use any brake fluid taken from old, used, or unsealed containers.
* Never reuse brake fluid left over from a last servicing or which has been stored for a long
period of time.
FRONT FORK OIL
Use SUZUKI FORK OIL G10 (#10) or an equivalent fork oil.
BREAK-IN PROCEDURES
During manufacturing only the best possible materials are used and all machined parts are finished to a
very high standard. 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. Refer to the following throttle position recommendations.
•Keep to these break-in throttle positions.
Initial 800 km (500 miles) : Less than 1/2 throttle
Up to 1 600 km (1 000 miles): Less than 3/4 throttle
•Upon reaching an odometer reading of 1 600 km you can subject the motorcycle to full throttle operation
for short periods of time.
ENGINE OIL
Use only SUZUKI CCI SUPER OIL or an equivalent premium
quality 2-stroke synthetic engine oil. Use only oils which are rated
FC under the JASO classification.
1Engine oil tank cap

1-6 GENERAL INFORMATION
INFORMATION LABELS
1Warning safety label
2Engine starting label
3Warning screen label
4Tire pressure label
5Fuel caution plate (For E-02)
6Loading capacity label
7Anti-tampering label
8ID plate
10 mm
10 mm 1mm

GENERAL INFORMATION 1-7
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ........................................................... 1 855 mm
Overall width ............................................................ 630 mm
Overall height ........................................................... 1 280 mm
Wheelbase ............................................................... 1 265 mm
Ground clearance .................................................... 125 mm
Seat height............................................................... 740 mm
Dry mass.................................................................. 96 kg
ENGINE
Type ......................................................................... Two-stroke, forced air-cooled
Intake system........................................................... Crankcase reed valve
Number of cylinders ................................................ 1
Bore ......................................................................... 52.5 mm
Stroke....................................................................... 52.2 mm
Displacement ........................................................... 113 cm3
Corrected compression ratio ................................... 6.8 : 1
Carburetor ................................................................ MIKUNI VM18SH, single
Air cleaner................................................................ Polyurethane foam element
Starter system ......................................................... Electric and kick
Lubrication system .................................................. SUZUKI “CCI”
TRANSMISSION
Clutch ....................................................................... Dry shoe, automatic, centrifugal type
Gearshifting ............................................................. Automatic, variable ratio
Gear ratios ............................................................... Variable reduction ratio (2.719 –0.778)
Final reduction ratio ................................................. 7.921 (43/19 ×63/18)
Drive system ............................................................ V-belt drive

1-8 GENERAL INFORMATION
CHASSIS
Front suspension ..................................................... Telescopic, coil spring, oil damped
Rear suspension ..................................................... Swingarm type, coil spring, oil damped
Front fork stroke ....................................................... 80 mm
Rear wheel travel ..................................................... 80 mm
Steering angle ......................................................... 45°(right and left)
Caster ...................................................................... 25°
Trail .......................................................................... 75 mm
Turning radius .......................................................... 1.6 m
Front brake ............................................................... Disc brake
Rear brake ............................................................... Internal expanding
Front tire size ........................................................... 90/90-12 44J, tubeless
Rear tire size............................................................ 100/80-12 56J, tubeless
ELECTRICAL
Ignition type ............................................................. Electronic ignition (CDI)
Ignition timing .......................................................... 12°BTDC at 1 800 r/min
Spark plug ............................................................... NGK BPR7HS or DENSO W22FPR
Battery ..................................................................... 12 V 14.4 kC (4 Ah)/10 HR
Generator ................................................................. A.C. generator
Fuse ......................................................................... 10 A
Headlight.................................................................. 12 V 35/35 W
Position/Parking light ............................................... 12 V 5 W
Brake light/Taillight ................................................... 12 V 21/5 W
License plate light .................................................... 12 V 5 W
Turn signal light ....................................................... 12 V 21 W
Speedometer light ................................................... 12 V 1.7 W
Fuel level gauge light .............................................. 12 V 1.2 W
Turn signal indicator light......................................... 12 V 1.7 W
High beam indicator light......................................... 12 V 1.7 W
Oil level indicator light ............................................. 12 V 1.7 W
Trunk light ................................................................ 12 V 2 W
CAPACITIES
Fuel tank .................................................................. 6.0 L
Engine oil tank ......................................................... 1.2 L
Final gear oil, oil change ......................................... 120 ml
overhaul ............................................ 130 ml
Front fork oil (each leg)............................................ 81 ml
Specifications are subject to change without notice.

GENERAL INFORMATION 1-9
COUNTRY AND AREA CODES
The following codes stand for the applicable country(-ies) and area(-s).
CODE COUNTRY OR AREA
E-02 UK
E-04 France
E-19 EU

2
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE SCHEDULE .............................................2- 2
PERIODIC MAINTENANCE CHART..............................................2- 2
LUBRICATION POINTS .................................................................2- 3
MAINTENANCE ANDTUNE-UP PROCEDURES.................................2- 4
CYLINDER HEAD NUTS AND EXHAUST PIPE NUTS .................2- 4
CYLINDER HEAD AND CYLINDER...............................................2- 4
SPARK PLUG .................................................................................2- 5
FUEL HOSE....................................................................................2- 6
AIR CLEANER................................................................................2- 6
CARBURETOR...............................................................................2- 7
OIL PUMP.......................................................................................2- 8
FINAL GEAR OIL ...........................................................................2- 8
BRAKES.........................................................................................2- 9
TIRES .............................................................................................2-11
STEERING......................................................................................2-12
FRONT FORKS ..............................................................................2-12
REAR SUSPENSION .....................................................................2-12
CHASSIS BOLTS AND NUTS........................................................2-13
AUTOMATIC CLUTCH INSPECTION....................................................2-15
INITIAL ENGAGEMENT .................................................................2-15
CLUTCH LOCK-UP ........................................................................2-16
PERIODIC MAINTENANCE 2-1

2-2 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to
keep the motorcycle operating at peak performance and economy. Maintenance intervals are expressed in
terms of kilometers and months, and are dependant on whichever comes first.
NOTE:
More frequent servicing may be performed on motorcycles that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Interval km 1 000 6 000 12 000 18 000 24 000
miles 600 4 000 7 500 11 000 15 000
Item months 1 6 12 18 24
Cylinder head nuts and exhaust pipe nuts –TTTT
Cylinder head and cylinder –CCCC
Spark plug –RRRR
Fuel hose –IIII
Replace every four years.
Air cleaner C CCCC
Carburetor IIIII
(throttle cable play and engine idle speed)
Oil pump I I I I I
Final gear oil I –I–I
Brakes I I I I I
Brake hose –IIII
Replace every four years.
Brake fluid –IIII
Replace every two years.
Tires I I I I I
Steering –– I–I
Front forks –– I–I
Rear suspension –– I–I
Chassis bolts and nuts T T T T T
NOTE:
I: Inspect and clean, adjust, lubricate or replace as necessary
C: Clean R: Replace T: Tighten

PERIODIC MAINTENANCE 2-3
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
* Lubricate exposed parts which are subject to rust, with a rust preventative spray especially whenever the
motorcycle has been operated under wet or rainy conditions.
$6Rear brake lever holder
$6Center stand pivot
and spring hook
$6Front brake lever holder
#6Speedometer cable

2-4 PERIODIC MAINTENANCE
MAINTENANCE ANDTUNE-UP PROCEDURES
This section describes the servicing procedures for each item mentioned in the Periodic Maintenance chart.
CYLINDER HEAD AND CYLINDER
Remove carbon every 6 000 km (6 months).
(73-15) Carbon
CYLINDER HEAD NUTS AND EXHAUST PIPE
NUTS
Tighten initially at 1 000 km (1 month) and every 6 000
km (6 months) thereafter.
Cylinder head nuts, when they are not tightened to the specified
torque, may result in leakage of the compressed mixture and
reduce output. Tighten the cylinder head nuts as follows.
•Remove the lower leg shield. (75-5)
•Remove the frame covers. (75-7)
•Remove the clutch cover. (73-9)
•Disconnect the spark plug cap.
•Remove the cylinder cover.
•Tighten the exhaust pipe nuts to the specified torque.
"Exhaust pipe nut: 10 N.m (1.0 kgf.m)
•Tighten the cylinder head nuts to the specified torque.
""
""
"Cylinder head nut: 23 N.m (2.3 kgf.m)

PERIODIC MAINTENANCE 2-5
SPARK PLUG
Replace every 6 000 km (6 months).
•Remove the left and right side leg shields. (75-4)
•Remove the lower leg shield. (75-5)
•Disconnect the spark plug cap and remove the spark plug.
NGK DENSO Remarks
BPR6HS W20FPR If the standard spark plug is apt
to get wet, replace with this plug.
BPR7HS W22FPR Standard
BPR8HS W24FPR If the standard spark plug is apt to
overheat, replace with this plug.
CARBON DEPOSIT
Check for carbon deposits on the spark plug. If any carbon is
deposited on the spark plug, remove it using a spark plug cleaner
machine or carefully use a tool with a pointed end.
SPARK PLUG GAP
Use a thickness gauge to measure the spark plug gap. If out of
specification, adjust the gap.
4Spark plug gap
Standard: 0.6 –0.7 mm
209900-20804:Thickness gauge
ELECTRODES
Check the condition of the electrodes.
If the electrode is extremely worn or burnt, replace the spark
plug with a new one.
Also, replace the spark plug if it has a broken insulator, damaged
threads, etc.
5
Check the tread size and reach when replacing the spark
plug. If the reach is too short, carbon will be deposited
on the screw portion of the spark plug hole and engine
damage may result.
SPARK PLUG INSTALLATION
5
To avoid damaging the cylinder head threads; first, fin-
ger tighten the spark plug,and then tighten it to the speci-
fied torque using the spark plug wrench.
•Insert the spark plug and finger tighten it to the cylinder head
and then tighten it to the specified torque.
"Spark plug: 28 N.m (2.8 kgf.m)

2-6 PERIODIC MAINTENANCE
FUEL HOSE
Inspect every 6 000 km (6 months).
Replace every four years.
•Remove the left and right side leg shields. (75-4)
•Remove the lower leg shield. (75-5)
Inspect the fuel hose for damage. If any damages are found, re-
place the fuel hose with a new one.
AIR CLEANER
Clean initially at 1 000 km (1 month) and every 6 000 km
(6 months) thereafter.
If the air cleaner is clogged with dust, intake resistance will be
increased, with a resultant decrease in engine output and an in-
crease in fuel consumption. Check and clean the air cleaner ele-
ment in the following manner.
•Remove the air cleaner case cover 1.
•Remove the air cleaner element 2.
•Fill a washing pan of a proper size with a non-flammable clean-
ing solvent. Immerse the air cleaner element in the cleaning
solvent and wash it.
•Press the air cleaner element between the palms of both hands
to remove the excess solvent: do not twist or wring the element
or it will develop tears.
•Immerse the element in motor oil, and squeeze out the excess
oil. The element should be wet but not dripping.
5
Inspect the air cleaner element for tears. A torn element
must be replaced.
ANon-flammable cleaning solvent
BMotor oil SAE #30 or SAE 10W/40

PERIODIC MAINTENANCE 2-7
•Properly install the air cleaner element into the air cleaner case.
5
* When installing the air cleaner element, have the large
mesh side of the element face out.
* Be sure to position the air cleaner element snugly and
correctly, so that no incoming air will by-pass it. Re-
member, rapid wear of the piston rings and cylinder
bore is often caused by a defective or poorly fitted air
cleaner element.
CARBURETOR
THROTTLE CABLE PLAY
Inspect initially at 1 000 km (1 month) and every 6 000 km
(6 months) thereafter.
Throttle cable play Ashould be 2 –4 mm as measured at the
throttle grip when turning the throttle grip lightly. If the throttle
cable play Ais incorrect, adjust it as follows:
•Loosen the locknut 1and turn the adjuster 2in or out until
the specified play is obtained.
•Tighten the locknut 1while holding the adjuster 2.
4Throttle cable play A: 2 –4 mm
!
After the adjustment is completed, check that handlebar
movement does not raise the engine idle speed and that
the throttle grip returns smoothly and automatically.
ENGINE IDLE SPEED
•Adjust the throttle cable play. (See above.)
•Warm up the engine.
NOTE:
Make this adjustment when the engine is hot.
•Remove the maintenance lid 1.
•Connect the multi circuit tester to the high-tension cord.
209900-25008: Multi circuit tester set