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