Suzuki EN125-2A Service Manual
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Suzuki EN125-2A Service Manual

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EN125-2A
SERVICE MANUAL
99500H06100-01E

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Derek Anderson
January 16, 2025

Is this a two stroke and if so what should the oil/petrol mix be?

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Summary of Contents for Suzuki EN125-2A

  • Page 1 EN125-2A SERVICE MANUAL 99500H06100-01E...
  • Page 2 Prepared by JIANG MEN DACHANGJIANG GROUP CO., LTD. Customer Service Department 1st Ed. Aug, 2003 Part No.:99500H06100-01E Printed in China...
  • Page 3 FOREWORD The SUZUKI EN125-2A was designed to offer superior performance through light weight design and four stroke power. The new EN125-2A represents another major advance by Suzuki in four stroke motorcycles. This service manual has been produced primarily for experienced mechanics whose job is to inspect, repair and service Suzuki Motorcycles.

  • Page 4: Table Of Contents

    GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND BREAK-IN PROCEDURES ENGINE FUEL AND LUBRICATION SYSTEM CHASSIS ELECTRICAL SYSTEM SERVICING INFORMATION...
  • Page 6 GENERAL INFORMATION CONTENTS ......WARNING/CAUTION/NOTICE ......SERIAL NUMBER LOCATIONS .

  • Page 7: Warning/Caution/Notice

    CAUTION: 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.

  • Page 8: Serial Number Locations

    G E N E R A L I N F O R M AT I O N 1 - 2 SERIAL NUMBER LOCATIONS ENGINE OIL Be sure that the engine-oil you use comes under Ù The frame serial number is stamped on the API classification of SF or SG and that its steering head pipe.

  • Page 9: Special Feature

    TRANSISTORIZED IGNITION SYSTEM WITH ELECTRONIC ADVANCE DESCRIPTION On the Model EN125-2A, the timing advance characteristics of the ignition timing have been changed from the previously-employed mechanical timing advance system incorporating a centrifugal advance governor to an electronic timing advance system.

  • Page 10: Special Materials

    1 - 4 SPECIAL MATERIALS The materials listed below are needed for maintenance work on the EN125-2A and should be kept on hand for ready use. These items supplement such standard materials as cleaning fluids, lubricants, emery cloth and the like. How to use them and where to use them are described in the text of this manual.

  • Page 11: Specifications

    1 - 5 G E N E R A L I N F O R M AT I O N SPECIFICATIONS DIMENSIONS AND DRY MASS ........1945mm Overall length .
  • Page 12 G E N E R A L I N F O R M AT I O N 1 - 6 ELECTRICAL ........Ignition type Transistorized .
  • Page 13 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES CONTENTS ....PERIODIC MAINTENANCE SCHEDULE ......MAINTENANCE PROCEDURES .

  • Page 14: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 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. NOTE: More frequent servicing may be performed on motorcycles that are used under extreme severe conditions.

  • Page 15: Engine

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES PERIODIC LUBRICATION CHART The maintenance schedule, which follows, is based on this philosophy. It is timed by odometer indication, and is calculated to achieve the ultimate goal of motorcycle maintenance in the most economical manner. Initial and Every 6 000 km Every 12 000 km Interval...

  • Page 16: Maintenance Procedures

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES MAINTENANCE PROCEDURES This section describes the service procedures for each section of Periodic Maintenance. BATTERY Inspect initial 1 000 km and Every 4 000 km The battery must be removed to check the electrolyte level and specific gravity. Remove the right frame cover.

  • Page 17: Cylinder Head Nuts, Cylinder Nuts, Exhaust Pipe

    7 11 N m 6 mm (0.7 1.1 kg m) When installing cylinder head cover, apply SUZUKI BOND No.1215 to the mating surface of cylinder head (Refer to page 3-29). SUZUKI BOND No.1215 99000-31110 CYLINDER NUTS Tighten the two 6 mm nuts to the specified torque.

  • Page 18: Air Cleaner Element

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES AIR CLEANER ELEMENT Clean Every 3 000 km If the air cleaner is clogged with dust, intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption. Check and clean the element in the following manner.

  • Page 19: Valve Clearance

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES VALVE CLEARANCE Inspect initial 1 000 km and Every 4 000 km Excessive valve clearance results in valve noise and insufficient valve clearance results in valve damage and reduced power. At the distances indicated above, check and adjust the clearance to the following specification.

  • Page 20: Compression Pressure

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES COMPRESSION PRESSURE Inspect initial 1 000 km Every 4 000 km Refer to page 3-1. SPARK PLUG Inspect initial 1 000 km and Every 4 000 km Replace Every 8 000 km Remove the carbon deposits with a wire or pin and adjust the spark plug gap to 0.7-0.8 mm, measuring with a thickness gauge.

  • Page 21: Fuel Hose

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES FUEL HOSE Inspect initial 1 000 km and Every 4 000 km Replace every four years. Inspect the fuel hose and connections for damage and fuel leakage. If any defects are found, the fuel hose must be replaced.

  • Page 22: Engine Oil Filter

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES ENGINE OIL FILTER Replace initial 1 000 km and Every 4 000 km Replace the oil filter in the following manner: Drain engine oil by removing the drain plug. Remove the three screws securing the filter cap. Take off the cap, and pull out the filter.

  • Page 23: Carburetor

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-10 CARBURETOR Inspect initial 1 000 km and Every 4 000 km IDLING ADJUSTMENT NOTE: Make this adjustment when the engine is hot. Start up the engine and set its speed at anywhere between 1 300 and 1 500 r/min by turning throttle stop screw Engine idle speed 1400 100r/min...

  • Page 24: Drive Chain

    2-11 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES DRIVE CHAIN Inspect and Clean Every 1 000 km DRIVE CHAIN Visually inspect the drive chain for the below listed possible malconditions. (Lift the rear wheel by placing the center stand, and turn the rear wheel slowly by hand when the transmission in NEUTRAL.) Inspect for: 1.

  • Page 25: Brakes

    Specification DOT3, DOT4 and Classification SUZUKI BRAKE FLUID 99000-23021 CAUTION: The brake system of this motorcycle is filled with a glycol-based brake fluid. Do not use or mix different types of fluid such as...
  • Page 26 2-13 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES Air bleeding the brake fluid circuit Air trapped in the fluid circuit acts like a cushion to absorb a large proportion of the pressure developed by the master cylinder and thus interferes with the full braking performance of the caliper brake.
  • Page 27 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-14 REAR BRAKE Bring the brake pedal to a position about 10 mm (behind the frame). This is effected by turning the Ù brake pedal stopper after remove the two screws and take off the right cover. Be sure to tighten the lock nut securely after setting the bolt.

  • Page 28: Tires

    2-15 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES Brake lining wear limit This motorcycle is equipped with brake lining wear limit indicator on rear brake. As shown in the illustration at right, at the condition of normal lining wear, an extended line from the index mark on the brake camshaft should be within the range embossed on the brake panel with the brake on.

  • Page 29: Steering

    PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-16 STEERING Inspect initial 1 000 km and Every 4 000 km Steering stem bearings be adjusted properly for smooth turning of the handlebars and safe running. Steering which is too stiff prevents smooth movement of handlebars. Steering which is too loose will cause vibration and damage to the steering bearings.
  • Page 30 2-17 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES CHASSIS AND ENGINE MOUNTING BOLTS AND NUTS Inspect initial 1 000 km and Every 4 000 km The nuts and bolts listed are important parts, and they must be in good condition for safety. They must be retightened, as necessary, to the specified torque with a torque wrench.
  • Page 31 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-18...
  • Page 32 ENGINE CONTENTS ... COMPRESSION PRESSURE AND OIL PRESSURE ..... ENGINE REMOVAL AND REMOUNTING .
  • Page 33 ENGINE COMPRESSION PRESSURE AND OIL PRESSURE COMPRESSION PRESSURE NOTE: Before testing the engine for compression pressure, make sure that the cylinder head nuts and bolts are tightened to specified torque values and valves are properly adjusted. Have the engine warmed up by idling before testing it.
  • Page 34 ENGINE ENGING REMOVAL AND REMOUNTING ENGING REMOVAL Before taking the engine out of the frame, thoroughly clean the engine with a suitable cleaner. The procedure of engine removal is sequentially explained in the following steps. Take off the right and left frame covers. Disconnect the lead wires of battery.
  • Page 35 ENGINE Take off the clutch cable by removing the clutch lever bolt and adjuster lock nut. Take off the breather pipe. Disconnect the couplers of generator and gear position indicator. Loosen the throttle cable adj ster lock nuts, and take off the throttle cable. Remove the carburetor by unscrewing the clamp screws.
  • Page 36 ENGINE Remove gear shift lever. Take off the engine sprocket cover. Take off the drive chain by removing the clip. Direction of travel Disconnect the ground wire from the crankcase. Disconnect the lead wire of starter motor. Take off the spark plug cap.
  • Page 37 ENGINE Remove the tachometer cable. Take off the left and right caps of the cylinder head cover. Remove the exhaust pipe nuts and muffler mounting bolt, then take off the muffler. Remove engine mounting bolts, swing arm pivot nut, footrest bar bolts and brackets. Use both hands, and lift the engine from the frame.

  • Page 38: Engine Remounting

    ENGINE ENGINE REMOUNTING After remounting the engine, following adjust- ments are necessary. The engine can be mounted in the reverse order of removal. Throttle cable play (Page: 2 Temporarily fasten the engine mounting bracket Clutch cable (Page: 2 10) before inserting the engine mounting bolts. Drive chain (Page: 2 11) Idling speed...
  • Page 39 ENGINE UPPER END COMPONENTS DISASSEMBLY CYLINDER HEAD COVER AND CYLINDER HEAD NOTE: If top end repair only is being performed, it is not necessary to remove the engine from the frame. As already noted, seat, fuel tank, frame covers etc. must be removed. Drain engine oil.
  • Page 40 ENGINE Bring the piston to top dead center. NOTE: When removing cylinder head cover, piston must be at top dead center on compression stroke. First, remove the tachometer sleeve securing screw, and then pull out the tachometer driven Do not gear shaft with sleeve.
  • Page 41 ENGINE Remove cylinder base nuts and cylinder. CAUTION: If tapping with plastic hammer is necessary. do not break the fins. Remove rocker arm shaft set bolts. Pull out the rocker arm shafts with pliers.
  • Page 42 ENGINE 3-10 Compress the valve spring by using the special tool. Valve lifter 09916-14510 Take off the valve cotters from valve stem. Tweezers 09916-84510 Take out the valve spring retainer, inner spring and outer spring. Pull out the valve from the other side. Remove oil seal, using long-nose pliers.
  • Page 43 3-11 ENGINE Remove valve guide by using the special tool. Valve guide remover 09916-44910 CAUTION: Only oversize valve guide is available as a spare part. Place a clean rag over the cylinder base to prevent piston pin circlip from dropping into crankcase and then, remove the piston pin circlip with long-nose pliers.
  • Page 44 UPPER END COMPONENTS INSPECTION AND SERVICING CYLINDER HEAD COVER DISTORTION After removing sealant (SUZUKI BOND No.1215) from the fitting surface of the cylinder head cover, place the cylinder head cover on a surface plate and check for distortion with a thickness gauge.

  • Page 45: Camshaft Runout

    3-13 ENGINE CAMSHAFT CAM WEAR Worn-down cams are often the cause of mistimed valve operation resulting in reduced output power. The limit of cam wear is specified for both intake and exhaust cams in terms of cam height which is to be measured with a micrometer. Replace camshafts if found it worn down to the limit.
  • Page 46 ENGINE 3-14 CYLINDER HEAD DISTORTION Decarbon combustion chamber. Check the gasketed surface of the cylinder head for distortion with a straightedge and thickness gauge, taking a clearance reading at several places as indicated. If the largest reading at any position of the straightedge exceeds the limit, replace the cylinder head.

  • Page 47: Valve Guide Installation

    3-15 ENGINE VALVE STEM WEAR If the valve stem is worn down to the limit, when measured with a micrometer, replace the valve. Micrometer 09900-20205 (0 25 mm ) Valve stem O.D. Standard 4.975-4.990 mm 4.955-4.970 mm Inspect valve stem end face for pitting and wear. CAUTION: This remedy is permissible where the length...
  • Page 48 ENGINE 3-16 Oil the stem hole, in each valve guide and drive the guide into the guide hole using the valve guide installer. Valve guide installer 09916-44310 After fitting all valve guides, re-finish their guiding bores with a 5.0 mm reamer. Be sure to clean and oil the guides after reaming.
  • Page 49 3-17 ENGINE VALVE SEAT WIDTH Coat the valve seat with prussian blue uniformly. Fit the valve and tap the coated seat with the valve face in a rotating manner, in order to obtain a clear impression of the seating contact. In this operation, use the valve lapper to hold the valve head.
  • Page 50 ENGINE 3-18 Insert with a slight rotation, the solid pilot that gives a snug fit. The shoulder on the pilot should be about 10 mm from the valve guide. Using the 45 cutter, descale and cleanup the seat with one or two turns. Inspect the seat by the previous seat width measurement procedure.

  • Page 51: Valve Springs

    3-19 ENGINE VALVE SPRINGS Check the springs for strength by measuring their free lengths and also the force required to compress them. If the limit indicated below is exceeded by the free length reading or if the measured force does not fall within the range specified, replace with a new spring as a set .

  • Page 52: Piston Diameter

    ENGINE 3-20 PISTON DIAMETER Using a micrometer, measure the piston outside diameter at the place 10 mm from the skirt end as shown in Fig. If the measurement is less than the limit, replace the piston. Micrometer 09900-20203 (50 75 mm) Service limit 56.880 mm NOTE:...

  • Page 53: Piston Ring Groove Width

    3-21 ENGINE Piston ring groove width Piston ring thickness Piston ring Piston ring Service limit Service limit 1.01 1.03 mm 0.97-0.99 mm 1.01 1.03 mm 0.97-0.99 mm 2.01 2.03 mm PISTON RING FREE END GAP AND PISTON RING END GAP Before installing piston rings, measure the free end gap of each ring using vernier calipers.
  • Page 54 ENGINE 3-22 PISTON PIN AND PIN BORE Using a caliper gauge, measure the piston pin bore inside diameter, and using a micrometer measure the piston pin outside diameter. If the difference between these two measurements is more than the limits, replace both piston and piston pin.
  • Page 55 3-23 ENGINE UPPER END COMPONENTS REASSEMBLY OIL RING Install spacer into the bottom ring groove first. Then install both side rails , one on each side of the spacer. The spacer and side rails do not have a specific top or bottom when they are new. When reassembling used parts.
  • Page 56 ENGINE 3-24 PISTON The following are reminders for piston installation: Rub a small quantity of SUZUKI MOLY PASTE onto the piston pin. Place a clean rag over the cylinder base to prevent piston pin circlip from dropping into crankcase, and then fit the piston pin circlip with long-nose pliers.
  • Page 57 3-25 ENGINE VALVE AND SPRING Insert the valves, with their stems coated with SUZUKI MOLY PASTE all around and along the full stem length without any break. Similarly oil the lip of the stem seal. SUZUKI MOLY PASTE 99000-25140 CAUTION: When inserting each valve, take care not to damage the lip of the stem seal.
  • Page 58 ENGINE 3-26 CYLINDER HEAD Fit dowel pins to cylinder head and then, attach new gasket to cylinder head. CAUTION: Use a new cylinder head gasket to prevent oil leakage. Do not use the old gasket. Copper washers and cap nuts are used to secure the cylinder head.
  • Page 59 3-27 ENGINE CAMSHAFT Align the mark on magneto rotor with the index mark on the crankcase keeping the camshaft drive chain pulled upward. CAUTION: If crankshaft is turned without drawing the camshaft drive chain upward. the chain will be caught between crankcase and cam chain drive sprocket.
  • Page 60 SUZUKI MOLY PASTE 99000-25140 VALVE ROCKER ARM AND SHAFT Apply SUZUKI MOLY PASTE to the rocker arms and shafts. Place the spring and the wave washer and arm in the exhaust side. Place the wave washer and arm in the inlet side.
  • Page 61 Dowel Pin Dowel Pin SUZUKI BOND 99000-31110 No.1215 NOTE: Do not apply SUZUKI BOND No.1215 to the camshaft end cap. Fit a gasket to head cover bolt correctly as shown in Fig. CAUTION: Use only new gasket. To prevent oil leakage.
  • Page 62 ENGINE 3-30 LOWER END COMPONENTS DISASSEMBLY MAGNETO ROTOR Remove magneto cover bolts and detach magneto cover. Loosen and remove the starter motor mounting bolts. Take off the starter motor. Remove the starter idle gear. Remove magneto rotor nut. Rotor holder 09930-44511 NOTE: Do not allow camshaft drive chain to be...
  • Page 63 3-31 ENGINE Remove magneto rotor and key. Rotor remover 09930-30180 attachment Slide shaft 09930-30102 Remove starter clutch gear. Remove cam drive chain. Remove roller , spring and push piece from starter clutch. Clamp the rotor with a vise taking care not to damage it and remove the three allen bolts using th 5 mm "T"...
  • Page 64 ENGINE 3-32 CLUTCH Remove clutch cover bolts and oil filter cap bolts, and detach clutch cover by tapping with a plastic hammer. R e m o v e c l u t c h s p r i n g m o u n t i n g b o l t s diagonally while holding the primary driven gear, and remove clutch pressure plate.
  • Page 65 3-33 ENGINE OIL PUMP DRIVE GEAR, DRIVEN GEAR AND PRIMARY DRIVE GEAR Flatten the lock washer, then remove the nut, lock washer and oil pump drive gear. Conrod holder 09910-20116 CAUTION: This is a left-hand thread nut. Remove oil pump driven gear, then remove primary drive gear and key.
  • Page 66 ENGINE 3-34 DRIVE SHAFT RETAINER Remove the drive shaft retainer circlip by using snap ring pliers. Snap ring pliers 09900-06107 GEAR POSITION SWITCH Remove gear position switch. NOTE: When removing gear position switch, do not lose contact and spring. ENGINE SPROCKET Flatten the lock washer, then remove the sprocket nut by using the special tool.
  • Page 67 3-35 ENGINE Remove sump filter. Remove crankcase securing bolts. Separate the crankcase into 2 parts, right and left with crankcase separating tool. Crankcase 09920-13120 separating tool Fit the crankcase separating tool, so that the tool plate is parallel with the end face of the crankcase.
  • Page 68 ENGINE 3-36 TRANSMISSION Remove gear shifting cam stopper spring. Draw out gear shifting fork shafts and take off forks. Remove clusters of gears and gear shifting cam. CRANKSHAFT Remove crankshaft by using crankshaft rem ver. Crankshaft remover 09920-13120...
  • Page 69 3-37 ENGINE OIL SEAL AND BEARING Remove retainers, oil seals and bearings. Oil seal remover 09913-50121 Bearing puller 09923-73210 09940-53311 09924-84510 Bearing installer 09913-75820 09913-80112...

  • Page 70: Crankshaft Runout

    ENGINE 3-38 LOWER END COMPONENTS INSPECTION AND SERVICING CONROD DEFLECTION AND CONROD BIG END SIDE CLEARANCE Wear on the big end of the conrod can be estimated by checking the movement of the small end of the rod. This method can also check the extent of wear on the parts of the conrod's big end.
  • Page 71 3-39 ENGINE CLUTCH DRIVE PLATE Measure the thickness and claw width of each drive plate with vernier calipers. Replace drive plates found to have worn down to the limit. Vernier calipers 09900-20101 Item Limit Standard Thickness 2.9 3.1 mm 2.6 mm Claw width 11.8 12.0 mm 11.0 mm...
  • Page 72 ENGINE 3-40 CLUTCH RELEASE BEARING Inspect the release bearing for any abnormality, particularly cracks, to decide whether it can be reused or should be replaced. Smooth engagement and disengagement of the clutch depends much on the condition of this bearing. SHIFTING FORK AND GEAR Using a thickness gauge, check the shifting fork clearance in the groove of its gear.
  • Page 73 3-41 ENGINE PRIMARY DRIVEN GEAR Primary dr ven gear is composed as shown. Ù Primary driven gear Rivet Damper Clutch housing Plate If the internal damper wears, play is generated between gear and housing, causing abnormal noise. If the play is extreme, replace the primary driven gear assembly with a new one.
  • Page 74 ENGINE 3-42 LOWER END COMPONENTS REASSEMBLY CRANKSHAFT Decide the width between the webs referring to When mounting the crankshaft in the crankcase, the figure below when rebuilding the crankshaft. it is necessary to pull its left end into the crankcase. 53.0 0.1 mm Crankshaft installer 09910-32812...
  • Page 75 3-43 ENGINE CAUTION: Never fit the crankshaft into the crankcase by striking it with a plastic hammer. Always use the special tool, otherwise crankshaft alignment accuracy will be affected. TRANSMISSION CAUTION: Never reuse a circlip. After a circlip has been removed from a shaft, it should be discarded and a new circlip must be installed.
  • Page 76 ENGINE 3-44 Washers and circlips thickness 1.2 mm (0.05 in) 0.5 mm(0.02 in) 1.0 mm (0.04 in) 1.0 mm(0.04 in) NOTE: When reassembling the bearing retainer, apply a small quantity of THREAD LOCK "1342" to the threaded parts of the bearing retainer screws. In reassembling the transmission, attention must be given to the locations and positions of washers and circlips.
  • Page 77 3-45 ENGINE GEAR SHIFTING CAM AND FORK Fit the gear shifting cam on the crankcase. Position the cam as shown in Fig. so that the gear shifting fork can be installed easily.
  • Page 78 ENGINE 3-46 NOTE: Two kinds of gear shifting forks, Ù used. They resemble each other very closely in external appearance and configuration. Carefully examine the illustration for correct installing positions and directions. After cam stopper and gear shifting forks have been fitted, hook cam stopper spring onto the crankcase.
  • Page 79 ENGINE CRANKCASE When reassembling the crankcase pay attention to the following. Coat SUZUKI SUPER GREASE "A" to the lip of oil seals. Remove sealant material on the fitting surfaces of right and left halves of crankcase and thor- oughly remove oil stains.
  • Page 80 ENGINE 3-48 GEAR SHIFTING CAM DRIVEN GEAR When installing the gear shifting pawls into the cam driven gear. The large shoulder must face to the outside as shown. Next, install cam guide and pawl lifter, Apply a small quantity of THREAD LOCK "1342" to the threaded parts of the securing screws.
  • Page 81 3-49 ENGINE Before mounting the oil pump, apply engine oil to the sliding surfaces of the case, outer rotor, inner rotor and shaft. Apply a small quantity of THREAD LOCK "1342" to the threaded parts of oil pump mounting screws. THREAD LOCK 99000-32050 "1342"...
  • Page 82 ENGINE 3-50 CLUTCH 1.5 mm 2.0 mm Install the clutch camshaft by positi ning the face to right side. Install the oil seal by using the 17 mm socket. Tighten the oil seal retainer screw.
  • Page 83 3-51 ENGINE Assemble the clutch, in the reverse order of disassembly. Pay attention to the following points. When inserting spacer on countershaft, apply a small quantity of engine oil to both inside and outside of the spacer. Tighten clutch sleeve hub nut using the special tool to the specified torque;...
  • Page 84 ENGINE 3-52 Clutch release screw adjustment Loosen the lock nut, and turn in the release screw to feel high resistance. From that position, turn out the release screw 1/4 1/2 turn, and tighten the lock nut. 1 1 / / 4 4 When reassembling the clutch cover, fit a gasket to correctly position as shown in Fig.

  • Page 85: Starter Clutch

    3-53 ENGINE STARTER CLUTCH Apply THREAD LOCK SUPER "1303B" to allen bolts and tighten with specified torque. THREAD LOCK 99000-32030 SUPER "1303B" "T" type hexagon 09911-73730 wrench (5 mm) 15 20 N m Tightening torque (1.5 2.0 kg m) MAGNETO ROTOR Fit key in the key slot on the crankshaft.
  • Page 86 ENGINE 3-54 STARTER IDLE GEAR AND MOTOR Install the starter idle gear. Install the starter motor. DRIVESHAFT OIL SEAL AND Oil seal ENGINE SPROCKET CAUTION: O-ring Always replace the driveshaft oil seal with a new one every disassembly to prevent oil leakage.
  • Page 87 3-55 ENGINE Tighten the engine sprocket nut to the specified torque and bend up the washer. Rotor and 09930-40113 Sprocket holder 80 100 N m Tightening torque (8.0 10.0 kg m) GEAR POSITION SWITCH Apply THREAD LOCK SUPER "1303B" to gear position switch bolts.

  • Page 88: Fuel And Lubrication System

    FUEL AND LUBRICATION SYSTEM CONTENTS ..........FUEL COCK .

  • Page 89: Fuel Cock

    FUEL AND LUBRICATION SYSTEM FUEL COCK CLEANING Rust from the fuel tank tends to build up in the filter, which, when the filter has been neglected for a long period, inhibits the flow of fuel. Remove the rust from the filter using compressed air.
  • Page 90 FUEL AND LUBRICATION SYSTEM CARBURETOR CARBURETOR CONSTRUCTION Unit: mm ITEM SPECIFICATION ITEM SPECIFICATION Carburetor type MIKUNI BS26SS Jet needle (J,N,) 4DH41-2nd P-0 (390) Bore size Needle jet (N.J.) £ I.D.No. 26-183 Pilot jet (P.J.) 12.5 £ Idle r/min. Starter jet (G.S) 1450 50 r/min 37.5...
  • Page 91 FUEL AND LUBRICATION SYSTEM REMOVAL AND DISASSEMBLY Take off the carburetor (Refer to page 3-2and 3) Remove the carburetor top cover by unscrewing the cover screws. Remove the throttle valve and spring. Remove the float chamber body by unscrewing the two screws. Loosen the fitting screw and remove the float.
  • Page 92 FUEL AND LUBRICATION SYSTEM Remove the needle valve retainer and needle valve. Remove the main jet. Remove the needle jet. Remove the pilot jet. Remove the main air jet. NEEDLE VALVE INSPECTION If foreign matter is caught between the valve seat and the needle, the gasoline will continue flowing and cause it to overflow.

  • Page 93: Idling Adjustment

    FUEL AND LUBRICATION SYSTEM REMOUNTING R e m o u n t t h e c a r b u r e t o r b y r e v e r s i n g t h e s e q u e n c e o f r e m o v a l s t e p s , a n d f o l l o w i n g adjustments and inspection are necessary after remounting the carburetor.

  • Page 94: Lubrication System

    FUEL AND LUBRICATION SYSTEM LUBRICATION SYSTEM CAMSHAFT JOURNAL CONROD SMALL END AND CAM FACE ROCKER ARM CYLINDER WALL CAM CHAIM SHAFT CONROD BIG END BEARING CLUTCH RELEASE CAM CONTERSHAFT DRIVESHAFT BEARING OIL FILTER BEARING COUNTERSHAFT AND GEARS DRIVESHAFT OIL PUMP AND GEARS PRIMARY DRIVEN GEAR SPACER...
  • Page 95 FUEL AND LUBRICATION SYSTEM...

  • Page 96: Chassis

    CHASSIS CONTENTS ..........FRONT WHEEL .

  • Page 97: Front Wheel

    CHASSIS FRONT WHEEL Tightening torque Item kg m 36 52 3.6 5.2 15 25 1.5 2.5 REMOVAL AND DISASSEMBLY Support the machine by center stand and jack or block. Pull out the cotter pin and remove the axle Draw out the axle shaft and take off the wheel. NOTE: Do not operate the front brake lever while dismounting the front wheel.
  • Page 98 CHASSIS Using the appropriate drift, drive out the wheel bearings. Unlock the washers and remove the four bolts. Separate the disc plate from the wheel. CAUTION: Do not reuse the lock washers. INSPECTION WHEEL BEARING Play Inspect the play of wheel bearings inner race by Play hand while fixing it in the wheel hub.

  • Page 99: Speedometer Gear Box

    (1.5 2.5 kg m) NOTE: Always use new lock washers. Bend the washer to the bolts. WHEEL BEARING Apply grease to the bearings before installing. SUZUKI SUPER 99000-25010 GREASE "A" Install the wheel bearings by using the special tool. Bearing installer...

  • Page 100: Front Fork

    CHASSIS FRONT FORK Tightening torque Item kg m 15 30 1.5 3.0 20 26 2.0 2.6 REMOVAL AND DISASSEMBLY Remove the front wheel (See page 5-1). Remove the two bolts and dismount the front caliper.
  • Page 101 CHASSIS Remove the four bolts and take off the front fender. Remove the two screws and take off the head- light. Disconnect the couplers and lead wires. Remove the lead wires from the headlight housing. Remove the two bolts and take off the head- light housing.
  • Page 102 CHASSIS Disconnect the couples of handle switch gear position switch (Refer to page 3-4) R e m o v e t h e t a c h o m e t e r c a b l e a n d t h e speedometer cable.
  • Page 103 CHASSIS Loosen the front fork upper clamp bolts. Remove the stem head bolt. Remove the head of steering stem. NOTE: Slightly loosen the front fork cap bolts to facilitate later disassembly. Remove the brackets of headlamp right and left. Remove the cover of steering stem after remove the flashers right and left.
  • Page 104 CHASSIS Remove the cap bolt and draw out the fork spring. Invert the fork and stroke it several times to remove the oil. Hold the fork inverted for a few minutes. Remove damper rod bolt by using the special tools and 8mm hexagon wrench. "T"...
  • Page 105 CHASSIS Remove the stopper ring. Remove the oil seal by using the special tool. Oil seal remover 09913-50121 CAUTION The oil seal removed should be replaced with a new one. INSPECTION DAMPER ROD RING Inspect the damper rod ring for wear and damage. INNER TUBE AND OUTER TUBE Inspect the inner tube and outer tube sliding surfaces for any scuffing or flaws.
  • Page 106 DAMPER ROD BOLT Apply SUZUKI BOND No.4 and THREAD LOCK CEMENT to the damper rod bolt and tighten the bolt by using the 8 mm hexagon wrench and special tools.

  • Page 107: Fork Oil

    FORK OIL For the fork oil, be sure to use a front fork oil whose viscosity rating meets specifications below. Fork oil type FORK OIL #10 Capacity ( each leg ) Hold the front fork vertical and adjust thefork oil level with the special tool.
  • Page 108 REMOUNTING When installing the front fork assembly, align the top of inner tube to the upper surface of the steering stem head. Tighten the upper and lower clamp bolt the specified torque. Tightening torque Tighten the stem head bolt to the specified torque.
  • Page 109 Tightening torque Item REMOVAL AND DISASSEMBLY Remove the front wheel ( See page 5-1). Remove the front fork (See page 5-4 ). Remove the steering stem nut and draw out steering stem. NOTE: Hold the steering stem by hand to prevent from falling.
  • Page 110 Remove the upper and lower steel balls. Upper 22pcs Number of balls Lower 18pcs Remove the outer race fitted on the steering stem. This be done with a chisel. Draw out the two inner races fitted to the top and bottom ends of the head pipe.
  • Page 111 INSPECTION Inspect and check the remove parts for the following abnormalities. Handlebars distortion. Handlebars clamp wear. Race wear and brinelling. Worn or damaged steel balls. Distortion of steering stem. REASSEMBLY Reassemble and remount the steering stem in the reverse order of disa sse mbly and removal, and also carry out the following steps: INNER RACES Press in the upper and lower inner races using the...

  • Page 112: Steering Stem

    STEEL BALL Apply grease to the upper and lower inner races when installing the steel balls. SUZUKI SUPER 99000-25010 GREASE Upper 22pcs Number of balls Lower 18pcs STEERING STEM NUT Tighten the steering stem nut to 40-50N m by using the special tool...
  • Page 113 Tighten the steering stem head bolt, the upper and lower clamp bolts to the special torque (Refer to page 6-12). Tightening turque Tightening turque CAUTION: After performing the adjustment and instal- ling the steering stem upper head, rock the front wheel assembly forward and back- ward to ensure that there is no play and that the procedure was accomplished correctly.

  • Page 114: Front Brake

    CHASSIS 5-18 FRONT BRAKE Tightening turque Item kg m 0.5 0.8 0.7 0.9...

  • Page 115: Brake Pad Replacement

    BRAKE PAD REPLACEMENT Lossen the tow pins of caliper Remove the caliper mounting bolts and take off the caliper. CAUTION: Do not operate the brake level while dismo- unting the caliper. Push the piston and piston holder all the way to the caliper when removing the brake pads.
  • Page 116 CHASSIS 5-20 CALIPER REMOVAL AND DISASSEMBLY Disconnect the brake hose from the caliper by remove the bolt and catch the brake fluid in a suitable receptacle (Refer to page 2-13). Loosen the two pins of caliper. Remove the caliper mounting bolts and take off the caliper.

  • Page 117: Brake Disc

    5-21 CHASSIS INSPECTION CALIPER CYLINDER Inspect the cylinder bore wall for nick, scratch or other damage. PISTON Inspect the piston surface for any scratches or damage. RUBBER PARTS Inspect the each rubber part for damage and wear. BRAKE DISC Measure the disc thickness by using the micrometer.
  • Page 118 Never use cleaning solvent or gasoline to wash them. Apply brake fluid to the caliper bore and all internal parts before inserting into the bore. Apply SUZUKI SUPER GREASE to the piston holder. SUZUKI SUPER 99000-25100 GREASE...

  • Page 119: Master Cylinder Removal And Disassembly

    5-23 CHASSIS MASTER CYLINDER REMOVAL AND DISASSEMBLY Place a cloth underneath the union bolt on the master cylinder to catch spilled drops of brake fluid. Unscrew the union bolt and disconnect the brake hose from the master cylinder joint. CAUTION: Immediately and completely wipe off any brake fluid contacting any part of the motorcycle.
  • Page 120 CHASSIS 5-24 INSPECTION Inspect the master cylinder bore for any scraches or other damage. Inspect the piston surface for scratches or other damage. Inspect the primary cup, secondary cup and dust seal boot for wear or damage. REASSEMBLY Reassemble and remount the master cylinder in the reverse orders of disassembly and removal, and also carry out the following steps.

  • Page 121: Rear Wheel And Rear Brake

    5-25 CHASSIS REAR WHEEL AND REAR BRAKE Tightening torque Item kg m 50 80 5.0 8.0 0.5 0.8 18 28 1.8 2.8 REMOVAL Support the machine by the center stand. Remove the rear brake adjuster nut and disconnect the brake rod. Pull off the cotter pin and remove the torque link nut and bolt.

  • Page 122: Rear Wheel

    CHASSIS 5-26 Pull off the cotter pin and remove the rear axle nut. Loosen the chain adjuster lock nut and adjuster bolt, right and left. Draw out the axle shaft and take off the chain from rear sprocket. Take off the rear wheel and separate the brake panel from the wheel.
  • Page 123 5-27 CHASSIS Remove the bearing and retainer from the mounting drum. Remove the cushion from the wheel. Remove the right and left side wheel bearings. NOTE: Removing the left side bearing first makes the job easier.
  • Page 124 CHASSIS 5-28 REAR BRAKE Take off the brake shoes. Remove the cam lever nut and bolt. Pull off the brake cam, washer, O-ring and cam lever.
  • Page 125 5-29 CHASSIS INSPECTION WHEEL BEARING Play Inspection the wheel bearings for play by hand. Play Rotate the inner race by hand to inspect whether abnormal noise occurs and it rotates smoothly. Replace the bearing if there are any defects. AXLE SHAFT Using the special tools, check the axle shaft for runout and replace it if the runout exceeds the limit.
  • Page 126 CHASSIS 5-30 SPROCKET Inspect the sprocket teeth for wear. If they are worn as illustrated, replace the sprocket and drive chain. REAR BRAKE DRUM Measure the brake drum I.D. to determine the extent of wear and, if the limit is exceeded by the wear noted, replace the drum.

  • Page 127: Mounting Drum

    Reassemble and remount the rear wheel and rear brake in the reverse order of disassembly and removal, and also carry out the following steps: WHEEL BEARING Apply grease to the bearings before installing. SUZUKI SUPER 99000-25010 GREASE "A" Install the wheel bearings by using the special tool.

  • Page 128: Brake Cam

    18 28 N m Tightening torque (1.8 2.8 kg m) BRAKE CAM Apply grease to the brake cam. SUZUKI SUPER 99000-25010 GREASE "A" WARNING: Be careful not to apply too much grease to the brake cam. If grease gets on the lining, brake slippage will result.

  • Page 129: Rear Swing Arm

    5 - 3 3 C H A S S I S REAR SWING ARM Tightening torque kg m Item 50 80 .0 .0 10 15 1.0 1.5 REMOVAL AND DISASSEMBLY Remove the rear wheel (See page 5-25). Remove the rear shock absorber units and take off the shock absorber units.
  • Page 130 C H A S S I S 5 - 3 4 Remove the two screws and take off the chain case. Remove the swing arm pivot nut and draw out the shaft. Remove the swing arm. Pull off the cotter pin and remove the nut and bolt.
  • Page 131 5 - 3 5 C H A S S I S Draw out the bushings by using the special tools. Bearing puller 09923-73210 Rotor remover 09930-30102 slide shaft INSPECTION BUSHING Inspect the bushing for wear and damage. SWING ARM PIVOT SHAFT Using a dial gauge, check the pivot shaft for runout and replace it if the runout exceeds the limit.
  • Page 132 SWING ARM BUSHINGS Force-fit the bushings into the swing arm by using the special tool. Bearing installer set 09924-84510 SPACER AND DUST SEAL COVER Apply grease to the spacer and dust seal cover when installing. SUZUKI SUPER 99000-25010 GREASE "A"...

  • Page 133: Electrical System

    ELECTRICAL SYSTEM CONTENTS ......... IGNITION SYSTEM .

  • Page 134: Ignition System

    ELECTRICAL SYSTEM IGNITION SYSTEM DESCRIPTION In the full-transistorized ignition system, the electrical energy on the pick-up coil generated by the magneto rotor tip flows to the transistor/ignition timing control circuit. This energy is released in a single surge at the specified ignition timing point, and current flows through the primary side of the ignition coil. A high voltage current is induced in secondary windings of the ignition coil resulting in strong spark between the spark plug gap.
  • Page 135 ELECTRICAL SYSTEM INSPECTION PICK-UP Using the pocket tester(RX1 range), measure the resistance between the lead wires in the following table . Pocket tester 09900-25002 Pick-up coil Approx.120 resistance WIRE COLOR Y _ Y Charging coil Approx.0.5 _ 2.0 L : Blue resistance G : Green Y : Yellow...

  • Page 136: Ignition Coil

    ELECTRICAL SYSTEM IGNITION COIL Check the ignition coil with electro tester. Test the ignition coil for sparking performance. Test connection is as indicated. Make sure that the three-needle sparking distance is at least 8 Electro tester 09900-28106 8 mm Spark performance Check the ignition coil with pocket tester.
  • Page 137 Turn the ignition switch ON. The ignitor unit is in good condition if the follow- ing is observed. Connect probe of SUZUKI Pocket Tester (x1 range) with Green lead wire on the ignitor side and probe with Blue lead wire. Next connect...

  • Page 138: Charging System

    ELECTRICAL SYSTEM CHARGING SYSTEM DESCRIPTION The circuit of the charging system is indicated in figure ,which is composed of an AC generator, regulator/rectifier unit and battery. The AC current generated from AC generator is converted by rectifier and is turned into DC current, then it charges the battery.
  • Page 139 ELECTRICAL SYSTEM 6-6 When the engine r/min becomes higher, the generated voltage of AC generator also becomes higher and the voltage between points of regulator becomes high according, and when it reaches the adjusted voltage of control unit, control unit becomes "ON" condition consequently. On the "ON" condition of control unit, signal will be sent to the SCR (Thyristor) gate probe and SCR will become"ON"...
  • Page 140 ELECTRICAL SYSTEM INSPECTION CHARGING OUTPUT CHECK Start the engine and keep it running at 5 000r/min. Using the pocket tester, measure the DC voltage between the battery terminal If the tester reads under 13.5V or over 16.0V, check the AC generator no-load performance and regulator/rectifier.
  • Page 141 ELECTRICAL SYSTEM REGULATOR/RECTIFIER Using the pocket tester (X1 tange), measure the resistance between the lead wires in the following table. If the resistance checked is incorrect, replace the regulator/rectifier. Pocket tester 09900-25002 Unit: Probe of tester 7 8 - 7 8 - 7 8 - 35-55...

  • Page 142: Starter System

    ELECTRICAL SYSTEM STARTER SYSTEM DESCRIPTION The starter system is shown in the diagram below: namely, the starter motor, relay, engine kill switch, IG switch, starter button and battery. Depressing the starter button (on the right handlebar switch box) energizes the relay, causing the contact points to close which connects the starter motor to the battery. The motor draws about 80 amperes to start the engine.

  • Page 143: Starter Motor Inspection

    ELECTRICAL SYSTEM 6-10 STARTER MOTOR INSPECTION CARBON BRUSHES When the brushes are worn, the motor will be unable to produce sufficient torque, and the engine will be difficult to turn over. To prevent this, periodically, inspect the length of the brushes, replacing them when they are too short or chipping.

  • Page 144: Starter Motor Reassembly

    6 - 1 1 E L E C T R I C A L S Y S T E M STARTER MOTOR REASSEMBLY BRUSH HOLDER AND HOUSING END When fixing brush holder to starter motor case, Ù align the protrusion of the starter motor case with the notch of the brush holder.

  • Page 145: Combination Meter

    E L E C T R I C A L S Y S T E M 6 - 1 2 COMBINATION METER Remove the combination meter (See page 5-5) Disassemble the combination meter. INSPECTION Using the pocket tester, check the continuity be- tween lead wires in following diagram.

  • Page 146: Lights

    6 - 1 3 E L E C T R I C A L S Y S T E M LIGHTS HEADLIGHT TURN SIGNAL LIGHT TAIL/BRAKE LIGHT SWITCHES Inspect each switch for continuity with the pocket tester referring to the chart. If it is found any abnormality, replace the respective switch as- sembly with new one.
  • Page 147 E L E C T R I C A L S Y S T E M 6 - 1 4 LIGHTING SWITCH Ù ENGINE KILL SWITCH STARTER SWITCH FRONT BRAKE LIGHT SWITCH DIMMER SWITCH Ù TURN SIGNAL LIGHT SWITCH HORN SWITCH...

  • Page 148: Rear Brake Light Switch

    6 - 1 5 E L E C T R I C A L S Y S T E M REAR BRAKE LIGHT SWITCH GEAR POSITION INDICATOR LIGHT SWITCH Ground Br/R Neutral WIRE COLOR ..... Black Black with White tracer ..

  • Page 149: Battery

    E L E C T R I C A L S Y S T E M 6 - 1 6 BATTERY SPECIFICATIONS Batter y Type designation GM7Z-A Breather pipe Capacity 28.8kc(7Ah)/10HR 1.28 at 20 C Standard electrolyte S.G. (68 F) In fitting the battery to the motorcycle, connect the breather tube to the battery vent.

  • Page 150: Recharging Operation

    6 - 1 7 E L E C T R I C A L S Y S T E M Check the electrolyte level and add distilled water, as necessary, to raise the electrolyte to each cell's UPPER LEVEL. Check the battery for proper charge by taking an electrolyte S.G.
  • Page 151 E L E C T R I C A L S Y S T E M 6 - 1 8 1.28 1.24 1.20 1.16 1.12 1.08 12 14 16 18 Charging time(hour) SERVICE LIFE Lead oxide is applied to the pole plates of the battery which will come off gradually during the Service.

  • Page 152: Servicing Information

    SERVICING INFORMATION CONTENTS ........TROUBLESHOOTING .

  • Page 153: Troubleshooting

    7 - 1 S E R V I C I N G I N F O R M AT I O N TROUBLESHOOTING ENGINE Complaint Symptom and possible causes Remedy Engine will not start Compression too low or is hard to start. 1.
  • Page 154 S E R V I C I N G I N F O R M AT I O N 7 - 2 Complaint Symptom and possible causes Remedy Noisy engine. Noise seems to come from transmission 1. Gears worn of rubbing. Replace.
  • Page 155 7 - 3 S E R V I C I N G I N F O R M AT I O N Complaint Symptom and possible causes Remedy Engine lacks power. 1. Loss of valve clearance. Adjust. 2. Weakened valve springs. Replace.
  • Page 156 S E R V I C I N G I N F O R M AT I O N 7 - 4 Complaint Symptom and possible causes Remedy Spark plug become Replace. 1.Worn piston rings. fouled too soon. Replace. 2.Pistons or cylinder worn. Replace.
  • Page 157 7 - 5 S E R V I C I N G I N F O R M AT I O N Complaint Symptom and possible causes Remedy Battery runs down 1. The charging method is not correct. Check the generator, regulator/rectifier and circuit quickly connections, and make necessary adjustments to obtain specified charging operation.
  • Page 158 S E R V I C I N G I N F O R M AT I O N 7 - 6 Complaint Symptom and possible causes Remedy Wobbly rear wheel. Remedy 1. Distorted wheel rim. Replace. 2. Worn-down rear wheel bearings. Replace.

  • Page 159: Special Tools

    7 - 7 S E R V I C I N G I N F O R M AT I O N SPECIAL TOOLS PART NO. PART NAME ITEM 09900-06107 Snap ring pliers (opening type) 09900-06108 Snap ring pliers (closing type) 09900-09003 Impact driver set Vernier calipers (150 mm)
  • Page 160 S E R V I C I N G I N F O R M AT I O N 7 - 8 PART NO. PART NAME ITEM 09930-44511 Rotor holder 09940-14911 Steering stem nut socket wrench 09940-34520 "T"handle Attachment "D" 09940-34561 Fork oil seal installer 09940-50112...
  • Page 161 7 - 9 S E R V I C I N G I N F O R M AT I O N...
  • Page 162 S E R V I C I N G I N F O R M AT I O N 7 - 1 0...
  • Page 163 7 - 1 1 S E R V I C I N G I N F O R M AT I O N...
  • Page 164 S E R V I C I N G I N F O R M AT I O N 7 - 1 2 TIGHTENING TORQUE ENGINE kg m ¤ ITEM ¤ Cylinder head cover bolt 0.9 1.0 9 10 Camshaft sprocket bolt 1.0 1.3 10 13 Cylinder head nut 8 mm Diam...
  • Page 165 7 - 1 3 S E R V I C I N G I N F O R M AT I O N CHASSIS kg m ¤ ITEM ¤ Front axle nut 3.6 5.2 36 52 Front fork damper rod bolt 2.0 2.6 20 26 Front fork lower clamp bolt...

  • Page 166: Service Data

    S E R V I C I N G I N F O R M AT I O N 7 - 1 4 SERVICE DATA VALVE + GUIDE Unit: mm ITEM STANDARD LIMIT 25.5 Valve diam 22.5 0.04 0.07 Valve clearance (when cold) 0.13 0.18 Valve guide I.D.
  • Page 167 7 - 1 5 S E R V I C I N G I N F O R M AT I O N CYLINDER + PISTON Unit: mm ITEM STANDARD LIMIT 1 000 1 400 kPa 800 kPa Compression pressure (8.0 kg/cm ) (10.0 14.0 kg/cm ) 0.120...
  • Page 168 S E R V I C I N G I N F O R M AT I O N 7 - 1 6 CONROD + CRANKSHAFT Unit: mm ITEM STANDARD LIMIT Conrod small end I.D. 14.004 14.012 14.040 Conrod deflection 1.00 Conrod big end side clearance 0.10 0.45...
  • Page 169 7 - 1 7 S E R V I C I N G I N F O R M AT I O N TRANSMISSION + DRIVE CHAIN Unit: mm ITEM STANDARD LIMIT Primary reduction ratio 3.470(59/17) Final reduction ratio 3.214(45/14) Gear ratios 3.000(33/11) 1.857(26/14)
  • Page 170 S E R V I C I N G I N F O R M AT I O N 7 - 1 8 CARBURETOR Unit: mm ITEM SPECIFICATION Carburetor type MIKUNI BS26SS Bore size I.D.No. 26-183 Idle r/min. 1450 50 r/min Flat height 29 0.5 Main jet...
  • Page 171 7 - 1 9 S E R V I C I N G I N F O R M AT I O N ELECTRICAL Unit: mm ITEM SPECIFICATION NOTE 13 B.T.D.C. below 1 950 r/mim 32 B.T.D.C. between 4 000-5 000 r/min Ignition timing 29.9 B.T.D.C.
  • Page 172 S E R V I C I N G I N F O R M AT I O N 7 - 2 0 BRAKE + WHEEL Unit: mm ITEM STANDARD LIMIT Rear brake pedal free travel 20 30 Rear brake pedal height Brake disc thickness Front 4.0 0.2...

  • Page 173: Tire Pressure

    7-21 SERVICING INFORMATION SUSPENSION Unit: mm ITEM STANDARD LIMIT Front fork stroke Front fork spring free length Front fork oil level Rear wheel travel Swing arm pivot shaft runout FUEL+OIL ITEM SPECIFICATION NOTE Gasoline used should be graded 90 97 oc- Fuel type tane or higher.
  • Page 174 SERVICING INFORMATION 7-22 WIRE AND CABLE ROUNTING Clamp Magneto Starter relay Wiring harness Gear position indicator Starter motor lead wire Tail/Brake light Fuse 10A Magneto Tail/Brake light Wiring harness Rear turn signal light (R), (L) Gear position indicator Clamp Clamp Clamp Throttle cable Handle switch wire...

  • Page 175: Wiring Diagram

    7-23 SERVICING INFORMATION WIRING DIAGRAM...
  • Page 176 EN125HU SUPPLEMENTARY SERVICE MANUAL...
  • Page 177 Prepared by JIANGMEN DACHANGJIANG GROUP CO., LTD. October 2004 Part No.:99501-38140-01E Printed in China...
  • Page 178 ) has to be made to comply with the statutory requirements of your country. ( Modifications in the 4th paragraph are as follows: ) This manual is for EN125HU motorcycle, which is a variation of EN125-2A for Mexico. This EN125HU manual, relating only the modifications made on the basis of EN125-2A, should be used together with "EN125-2A SERVICE MANUAL"...
  • Page 180 GROUP INDEX FRONT WHEEL AND FRONT BRAKE REAR WHEEL AND REAR BRAKE CARBURETOR KICK STARTER WIRING DIAGRAM...
  • Page 182 FRONT WHEEL AND FRONT BRAKE CONTENTS ....FRONT WHEEL AND FRONT BRAKE ... . FRONT WHEEL ASSEMBLY DETAIL DRAWING .

  • Page 183: Front Wheel Assembly Detail Drawing

    FRONT WHEEL AND FRONT BRAKE FRONT WHEEL AND FRONT BRAKE FRONT WHEEL ASSEMBLY DETAIL DRAWING Front tire specification: 2.75-18 4PR DISMANTLING OF PARTS FRONT WHEEL Support motorcycle with center stand or a jack. Remove speedometer cable and front brake cable. Loosen and dismantle front wheel axle nut.

  • Page 184: Front Brake

    FRONT WHEEL AND FRONT BRAKE Remove dust boot and oil seal. Pull out right and left bearings of front wheel. FRONT BRAKE Remove the brake shoes. Dismantle brake cam lever bolt. 5 8N.m Tightening torque 0.5 0.8kg.m...
  • Page 185 FRONT WHEEL AND FRONT BRAKE Remove the brake cam lever. Remove the oil seal with special tool. Oil seal dismantling tool 09913-50121 Remove the spring collar with special tool. Spring collar clipper 09900-06107 Remove the speedometer drive gear unit.

  • Page 186: Inspection

    FRONT WHEEL AND FRONT BRAKE Remove the screw and speedometer drive gear. INSPECTION Play WHEEL BEARING Play Fix wheel hub and inspect with hand the play of bearing inner collar. Rotate the inner collar with hand to see if there is any abnormal noise and if rotation is easy.

  • Page 187: Front Wheel Axle

    FRONT WHEEL AND FRONT BRAKE FRONT WHEEL AXLE Check with a dial indicator to see if there is any run-out in front axle. In case of excessive run-out, front axle should be replaced. Dial gauge ( 1/100 ) 09900-20606 Magnetic dial gauge rack 09900-20701 V-block ( 100mm ) 09900-21304...
  • Page 188 FRONT WHEEL AND FRONT BRAKE BRAKE SHOE Brake panel incorporate a brake lining wear limit indicator. If the lining condition is normal, the brake camshaft index mark line , when extended, will fall within the range embossed on the brake panel (when brake is on).
  • Page 189 WHEEL BEARING Install the wheel bearings by using the special tool. Bearing fitting tools 09924-84510 Apply lubricating grease to bearing. SUZUKI super lubricating 99000-25010 grease "A" Install the brake cam lever as shown in illustration.
  • Page 190 REAR WHEEL AND REAR BRAKE CONTENTS ..... REAR WHEEL AND REAR BRAKE ......REAR WHEEL DETAIL DRAWING .

  • Page 191: Rear Wheel And Rear Brake

    REAR WHEEL AND REAR BRAKE REAR WHEEL AND REAR WHEEL BRAKE REAR WHEEL ASSEMBLY DETAIL DRAWING Rear tire specification: 3.00-18 4PR DISMANTLING OF PARTS REAR WHEEL Support motorcycle with center stand; Screw out rear brake adjusting nut and dismantle rear brake lever; Pull out split pin and dismantle torsion bar tightening nut;...

  • Page 192: Rear Sprocket

    REAR WHEEL AND REAR BRAKE Remove the rear wheel axle nut and remove rear wheel axle; Remove the chain from the large sprocket; Remove the rear wheel; Separate the rear wheel and drive sprocket; REAR SPROCKET Flatten the lock washer and screw out the sprocket nuts;...

  • Page 193: Rear Brake

    REAR WHEEL AND REAR BRAKE REAR BRAKE Remove the brake shoes. Remove the brake cam lever. Remove the brake camshaft, gasket, O-ring and camshaft swing arm; INSPECTIONS ( see pages 1-4 ) Wheel bearing ( see pages 1-5 ) Rear wheel axle ( see pages 1-5 ) Wheel rim ( see pages 1-5 )

  • Page 194: Rear Sprocket

    Confirm that brake shoes are free from grease or else slippage occurs when braking. WHEEL BEARING Use special tools in fitting wheel bearings and wheel hub bearings. Bearing-fitting tools 09924-84510 Apply SUZUKI super lubricating grease to bearings. SUZUKI super 99000-25010 lubricating grease "A"...
  • Page 195 REAR WHEEL AND REAR BRAKE Tighten the following bolts and nuts at specified torques. Kg m Item Torsion bar tightening nut 10-15 1.0-1.5 Sprocket tightening 18-28 1.8-2.8 Brake cam lever nut 0.5-0.8 Rear wheel axle nut 50-80...
  • Page 196 CARBURETOR CONTENTS ......... . . CARBURETOR .

  • Page 197: Carburetor

    CARBURETOR CARBURETOR CARBURETOR STRUCTURE Jet needle Piston valve Pilot air screw Throttle valve stop screw Needle valve Float Pilot jet Needle jet Main jet Specification Specification Item Item Carburetor Needle jet MIKUNI Throttle valve Idle speed jet 20.4 Transient jet Reticule mark VM22-405 Idle speed ( r/min )

  • Page 198: Dismantling Carburetor

    CARBURETOR DISMANTLING AND SEPARATION OF PARTS DISMANTLING CARBURETOR Turn fuel switch to "OFF" position; Remove the fuel hose; Unscrew bolt and drain gasoline in carburetor; Warning: Handle gasoline with care as it is inflammable and explosive. Note: There is no fuel filter on carburetor oil inlet tube in this model.
  • Page 199 CARBURETOR Pull out float pin and remove the float chamber; Remove the needle valve; Dismantle bolt , remove float needle valve seat pressure plate and take out float needle valve Dismantle main jet , needle jet and remove holder Dismantle pilot jet Dismantle pilot screw , remove spring gasket...
  • Page 200 CARBURETOR Remove the throttle cable clamp from throttle valve; Remove the needle jet; Dismantle top cap unit; Remove the starter unit;...

  • Page 201: Inspection And Fitting

    CARBURETOR INSPECTION AND FITTING FLOAT VALVE In case there is foreign matter between valve seat and needle, there is overflow of oil when oil supply continues. In case wear of valve seat and needle exceeds the limit, the same trouble occurs. On the contrary, when the needle is jammed, gasoline shall not enter float bowl.
  • Page 202 CARBURETOR Fit needle valve in throttle valve as shown in the figure; REFITTING Fit other parts of carburetor in the reverse order of removal.

  • Page 204: Kick Starter

    KICK STARTER CONTENTS ......... . KICK STARTER .

  • Page 205: Dismantling Kick Starter

    KICK STARTER KICK STARTER DISMANTLING KICK STARTER Remove the bolt and remove the kick starter Remove the clutch cover Remove the kick starting gear washer kick starting gear Dismantle bolts , remove kick starting guide plate and limiting plate Remove kick starting ratchet wheel , spring and washer...
  • Page 206 KICK STARTER Remove the clutch unit ( Refer to "EN125-2A SERVICE MANUAL" 99500H06100-01E ) ; Remove the kick starting idle wheel clip washer and remove kick starting idle wheel and washer Take out kick starting idle wheel shaft after separating right and left crankcases;...

  • Page 207: Inspection

    When fitting clutch cover, bind the knurled part of kick starting shaft end with transparent adhesive tape to prevent it from damaging oil seal lip Evenly apply SUZUKI super grease to the inner side oil seal lip. SUZUKI super grease "A" 99000-25010...
  • Page 208 WIRING DIAGRAM...

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