2003-2006 Kawasaki Klx125 Workshop Service Repair Manual

GROUP INDEX

FOREWORD This manual contains an introductory description on the SUZUKI DR-Z125/L and procedures for its inspection/service and overhaul of its main components.

Other information considered as generally known is not included.

Read the GENERAL INFORMATION section to familiarize 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. * This manual has been prepared on the basis 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, including special tools, for servicing SUZUKI motorcycles. If you do not have the proper knowledge and tools, ask your authorized SUZUKI motorcycle dealer to help you.

Inexperienced mechanics or mechanics without the proper tools and equipment may not be able to properly perform the services described in this manual.

Improper repair may result in injury to the mechanic and may render the motorcycle unsafe for the rider.

GENERAL INFORMATION

1

PERIODIC MAINTENANCE

2

ENGINE

3

FUEL AND LUBRICATION SYSTEM

4

CHASSIS

5

ELECTRICAL SYSTEM

6

SERVICING INFORMATION

7

03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM

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03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM

SUPPLEMENTS DR-Z125/LK4 (’04-MODEL) DR-Z125/LK5 (’05-MODEL)

8

DR-Z125/LK6 (’06-MODEL) DR-Z125/LK7 (’07-MODEL)

9

DR-Z125/LK8 (’08-MODEL)

10

DR-Z125/LK9 (’09-MODEL)

11

HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections.

2. The section titles are listed in the GROUP INDEX. 3. Holding the manual as shown at the right will allow you to find the first page of the section easily.

4. The contents are listed on the first page of each section to help you find the item and page you need.

COMPONENT PARTS AND WORK TO BE DONE Under the name of each system or unit there is an exploded view which provides work instructions and other service information (e.g., tightening torque, lubricating points, and locking agent points).

Example: Front wheel (DR-Z125L)

1 Bearing 2 Spacer 3 Bearing 4 Brake disc 5 Front axle A Front axle nut B Brake disc mounting nut

@

ITEM

A B

N·m

kgf.m

lb-ft

44

4.4

32.0

8.5

0.85

6.0

SYMBOL Listed in the table below are the symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is also included in the table.

SYMBOL

DEFINITION

SYMBOL

DEFINITION

Torque control required.

Data beside it indicates specified torque.

Apply THREAD LOCK “1342”.

99000-32050

Indicates service data.

Apply or use brake fluid.

Apply oil. Use engine oil unless otherwise specified.

Measure in voltage range.

Apply molybdenum oil solution. (mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1)

Measure in resistance range.

Apply SUZUKI SUPER GREASE “A”.

99000-25030 (For USA) 99000-25010 (For the other counties)

Measure in current range.

Apply SUZUKI SILICONE GREASE. 99000-25100

Measure in diode test range.

Apply SUZUKI MOLY PASTE. 99000-25140

Measure in continuity test range.

Apply SUZUKI BOND “1207B”.

99104-31140 (For USA)

Use special tool.

99000-31140 (For the other countries) 1216B

Apply SUZUKI BOND “1216B”.

99000-31230 Apply THREAD LOCK SUPER “1303”.

99000-32030

Use fork oil.

99000-99001-SS8

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GENERAL INFORMATION

1-1

GENERAL INFORMATION 1 CONTENTS WARNING/CAUTION/NOTE .............................................................. 1- 2 GENERAL PRECAUTIONS ................................................................ 1- 2 SUZUKI DR-Z125/LK3 (’03-MODEL) .................................................1- 4 SERIAL NUMBER LOCATION ...........................................................1- 4 FUEL AND OIL RECOMMENDATION ............................................... 1- 4 FUEL ............................................................................................ 1- 4 ENGINE OIL ................................................................................. 1- 5 BRAKE FLUID .............................................................................1- 5 FRONT FORK OIL ....................................................................... 1- 5 BREAK-lN PROCEDURES ................................................................ 1- 5 INFORMATION LABELS ....................................................................1- 6 SPECIFICATIONS ..............................................................................1- 7 DIMENSIONS AND DRY MASS ..................................................1- 7 ENGINE ........................................................................................ 1- 7 DRIVE TRAIN ............................................................................... 1- 7 CHASSIS ...................................................................................... 1- 8 ELECTRICAL ............................................................................... 1- 8 CAPACITIES ................................................................................ 1- 8 COUNTRY AND AREA CODES ..................................................1- 9

1-2

GENERAL INFORMATION

WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. !

Indicates a potential hazard that could result in death or injury. " Indicates a potential hazard that could result in vehicle damage.

NOTE: Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.

GENERAL PRECAUTIONS ! * Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the vehicle. * When 2 or more persons work together, pay attention to the safety of each other. * When it is necessary to run the engine indoors, make sure that exhaust gas is forced 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, radiator, and exhaust system until they have cooled. * After servicing the fuel, oil, exhaust or brake systems, check all of the lines, and fittings related to the system for leaks.

GENERAL INFORMATION

" * 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. Lubricate them when specified. * Use the specified lubricants, bonds, or sealant. * When removing the battery, disconnect the negative cable first and then the positive cable.

When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal. * When performing service to electrical parts, if the service procedures not require use of battery power, disconnect the negative cable the battery. * When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first.

Always tighten the bolts and nuts from the inside working out, in a crisscross manner. * Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter pins, circlips, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. * Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. * Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them. * After reassembling, check parts for tightness and proper operation. * To protect the environment, do not unlawfully dispose of used motor oil and all other fluids: batteries and tires. * To protect the Earth’s natural resources, properly dispose of used motorcycle and parts.

1-3

1-4

GENERAL INFORMATION

SUZUKI DR-Z125/LK3 (’03-MODEL)

LEFT SIDE

RIGHT SIDE

SERIAL NUMBER LOCATION 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 RECOMMENDATION FUEL

Gasoline used should be graded 95 octane (Research Method) or higher. An unleaded gasoline type is recommended.

GENERAL INFORMATION

1-5

ENGINE OIL Use a premium quality 4-stroke motor oil to ensure longer service life of your motorcycle. Use only oils which are rated SF or SG under the API service classification.

The recommended viscosity is SAE 10W-40. If an SAE 10W-40 motor oil is not available, select an alternative according to the right chart.

BRAKE FLUID # Specification and Classification: DOT 4 !

Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manufacturer, do not use or mix different types of fluid such as silicone-based and petroleum-based fluid for refilling the system, otherwise serious damage will result.

Do not use any brake fluid taken from old or used or unsealed containers.

Never re-use brake fluid left over from a previous servicing, which has been stored for a long period.

FRONT FORK OIL SUZUKI fork oil SS-08 or an equivalent fork oil.

BREAK-lN PROCEDURES During manufacture only the best possible materials are used and all machined parts are finished to a very high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows.

• Keep to this break-in throttle opening limits: Initial 10 hours: Less than 1/2 throttle Up to 15 hours: Less than 3/4 throttle

1-6

GENERAL INFORMATION

INFORMATION LABELS DR-Z125/L NO

1 2 3 4 5 6 7

LABEL or PLATE NAME Noise label Information label Fuel caution label Manual notice label Warning safety label Certification plate Compliance label

APPLIED SPECIFICATION E-28 E-03 — ¡ — ¡ ¡ — — ¡ ¡ ¡ — ¡ ¡ —

E - 28

E - 28 E - 03 Fuel tank Rear fender

Frame (Right side)

Frame (Left side)

GENERAL INFORMATION

SPECIFICATIONS

DIMENSIONS AND DRY MASS Overall length ...................................................... 1 835 mm (72.2 in) 1 885 mm (74.2 in) ....... DR-Z125L Overall width ....................................................... 770 mm (30.3 in) Overall height ...................................................... 1 060 mm (41.7 in) 1 095 mm (43.1 in)....... DR-Z125L Wheelbase .......................................................... 1 245 mm (49.0 in) 1 270 mm (50.0 in) ....... DR-Z125L Ground clearance................................................ 260 mm (10.2 in) 290 mm (11.4 in) ....... DR-Z125L Seat height .......................................................... 775 mm (30.5 in) 805 mm (32.0 in) ....... DR-Z125L Dry mass .............................................................

80 kg (176 lbs) 81 kg (178 lbs)......... DR-Z125L

ENGINE Type .................................................................... Four-stroke, air-cooled, OHC Number of cylinders ............................................ 1 Bore..................................................................... 57.0 mm (2.244 in) Stroke .................................................................. 48.8 mm (1.921 in) Displacement ...................................................... 124 cm³ (7.6 cu.in) Compression ratio ............................................... 9.5 : 1 Carburetor ........................................................... MIKUNI VM20SS Air cleaner ........................................................... Polyurethane foam element Starter system ..................................................... Primary kick Lubrication system .............................................. Wet sump Idie speed............................................................ 1 700 ± 100 r/min

DRIVE TRAIN Clutch .................................................................. Wet multi-plate type Transmission....................................................... 5-speed constant mesh Gearshift pattern ............................................... 1-down, 4-up Primary reduction ratio ........................................ 3.470 (59/17) Gear ratios, Low ................................................. 3.000 (33/11) 2nd .................................................. 1.857 (26/14) 3rd ................................................... 1.368 (26/19) 4th ................................................... 1.095 (23/21) Top .................................................. 0.923 (24/26) Final reduction ratio............................................. 3.642 (51/14) 4.071 (57/14) .......................... DR-Z125L Drive chain .......................................................... D.ID.428HG, 122 links D.ID.428HG, 130 links............ DR-Z125L

1-7

1-8

GENERAL INFORMATION

CHASSIS Front suspension .................................................Telescopic, coil spring, oil damped, Rear suspension ..................................................Link type, coil spring, oil damped, Front suspension stroke.......................................180 mm (7.1in) Rear wheel travel .................................................160 mm (6.3in) 170 mm (6.7in) ..............DR-Z125L Caster ..................................................................28° 27° 30’ ...........................DR-Z125L Trail ......................................................................88 mm (3.46 in) 99 mm (3.90 in) .............DR-Z125L Steering angle......................................................45° (right & left) Turning radius ......................................................1.9 m (6.2 ft) 2.0 m (6.6 ft) ..................DR-Z125L Front brake...........................................................Drum brake Disc brake .....................DR-Z125L Rear brake ...........................................................Drum brake Front tire size .......................................................70/100-17 40M, tube type 70/100-19 42M, tube type ..... DR-Z125L Rear tire size........................................................90/100-14 49M, tube type 90/100-16 52M, tube type ..... DR-Z125L

ELECTRICAL lgnition type..........................................................Electronic ignition (CDl) lgnition timing .......................................................13° B.T.D.C. at 1 700 r/min Spark plug............................................................NGK: DR8EA or DENSO: X24ESR-U Generator.............................................................Single-phase A.C. generator

CAPACITIES Fuel tank, including reserve ................................. 6.6 L (1.7/1.5 US/Imp gal) Reserve ............................................... 1.7 L (0.4/0.4 US/Imp gal) Engine oil, oil change ........................................... 850 ml (0.9/0.7 US/Imp qt) with filter change ................................ 950 ml (1.0/0.8 US/Imp qt) overhaul..............................................1 100 ml (1.2/1.0 US/Imp qt) Front fork (each leg)............................................. 172 ml (5.8/6.1 US/Imp oz) These specifications are subject to change without notice.

GENERAL INFORMATION

COUNTRY AND AREA CODES The following codes stand for the applicable countries and areas.

CODE E-03 E-28

COUNTRY OR AREA USA Canada

1-9

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PERIODIC MAINTENANCE

2-1

PERIODIC MAINTENANCE

CONTENTS PERIODIC MAINTENANCE SCHEDULE ............................................2- 2 PERIODIC MAINTENANCE CHART ...........................................2- 2

2

LUBRICATION POINTS ...............................................................2- 3 MAINTENANCE AND TUNE-UP PROCEDURES ...............................2- 4 AIR CLEANER .............................................................................2- 4 VALVE CLEARANCE ..................................................................2- 5 CAM CHAIN TENSION ADJUSTER ............................................2- 6 SPARK PLUG ..............................................................................2- 7 THROTTLE CABLE PLAY ...........................................................2- 8 ENGINE IDLE SPEED ..................................................................2- 8 FUEL HOSE .................................................................................2- 9 CLUTCH .......................................................................................2- 9 ENGINE OIL AND OIL FILTER ....................................................2-10 SPARK ARRESTER ....................................................................2-11 DRIVE CHAIN ..............................................................................2-12 FRONT BRAKE LEVER PLAY (DR-Z125) ..................................2-14 FRONT DISC BRAKE (DR-Z125L) ..............................................2-14 REAR BRAKE PEDAL HEIGHT ..................................................2-16 BRAKE HOSES (DR-Z125L) .......................................................2-17 STEERING ...................................................................................2-17 TIRES ...........................................................................................2-17 SPOKE NIPPLES .........................................................................2-18 EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLT ....2-19 FRONT FORK ..............................................................................2-19 REAR SUSPENSION ...................................................................2-19 CHASSIS BOLTS AND NUTS .....................................................2-20 COMPRESSION PRESSURE CHECK .................................................2-22 COMPRESSION TEST PROCEDURE .........................................2-22 OIL PRESSURE CHECK ......................................................................2-23 OIL PRESSURE TEST PROCEDURE .........................................2-23

6

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.

NOTE: More frequent servicing may be performed on motorcycles that are use under severe conditions.

PERIODIC MAINTENANCE CHART Interval

months

Item Air cleaner element Exhaust pipe bolts and muffler mounting bolts Valve clearance Spark plug Spark arrester Fuel line Cam chain tension adjuster Engine oil filter Engine oil Throttle cable Idle speed Clutch Drive chain Brakes Brake hose Brake fluid Tires Spoke nipple Steering Front forks Rear suspension Chassis nuts and bolts

Initially 1 month —

Every 6 months I

Every 12 months I

T

T

T

I — — I

I I I R — C I I Replace every 4 years.

I I I R — R R R R I I I I I I I I I Clean, oil and inspect each time motorcycle is ridden.

I I I — I I Replace every 4 years.

— I I Replace every 2 years.

— I I Inspect each time the motorcycle is ridden.

I — I — — I — — I T T T

NOTE: Inspect: I=Inspect and clean, adjust, replace or lubricate 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.

Clutch lever holder

Side-stand pivot and spring hook Drive chain

Throttle cable

Front brake lever holder

Brake pedal pivot

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 condition.

2-4

PERIODIC MAINTENANCE

MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each item in the Periodic Maintenance chart.

AIR CLEANER Clean every 6 months.

If the air cleaner is clogged with dust, intake resistance will be increase, resulting in a decrease in engine output and an increase in fuel consumption. Clean the air cleaner element in the following manner.

• Remove the left frame cover. (!5-2) • Remove the air cleaner cover 1.

• Remove the air cleaner element 2.

• Separate the polyurethane foam element 3 and element frame 4.

• Fill a container with a non-flammable cleaning solvent.

• Immerse the air cleaner element in the cleaning solvent and wash it.

• Squeeze the cleaning solvent out of the washed element by pressing it between the palms of both hands: do not twist or wring the element or it will develop tears.

• Immerse the element in motor oil and squeeze the oil out of the element leaving it slightly wet with oil. " Inspect the air cleaner element for tears. A torn element must be replaced.

A Non-flammable cleaning solvent B Motor oil SAE #30 or SAE 10W-40

PERIODIC MAINTENANCE

• Remove the drain plug 1 to allow any water to drain out.

• Reinstall the cleaned air cleaner element in the reverse order of removal. !

Be sure to position the element snugly and correctly, so that no incoming air will by-pass it. Remember, the rapid wear of piston rings and the cylinder bore is often caused by a defective or poorly fitted element. !

If driving under dusty conditions, clean the air cleaner element more frequently. The surest way to accelerate engine wear is to operate the engine without the element or to use a torn element. Make sure that the air cleaner is in good condition at all times. The life of the engine depends largely on this component!

VALVE CLEARANCE Inspect initially at 1 month and every 6 months thereafter.

REMOVAL • Remove the frame covers, seat and fuel tank. ("5-2) • Remove the spark plug. ("2-7) • Remove the valve inspection caps 1.

• Remove the valve timing inspection plug 2 and generator cover plug 3.

INSPECTION The valve clearance specification is different for intake and exhaust valves. Valve clearance adjustment must be checked and adjusted, 1) at the time of periodic inspection, 2) when the valve mechanism is serviced, and 3) when the camshaft is disturbed by removing it for servicing.

2-5

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• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

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