DR125SM.K9 (ID=2303).pdf

FOREWORD

GROUP INDEX

This manual contains an introductory description on

the SUZUKI DR125SM and procedures for its

inspection/service and overhaul of its main compo-

nents.

Other information considered as generally known is

not included.

Read the GENERAL INFORMATION section to

familiarize 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.

GENERAL INFORMATION

PERIODIC MAINTENANCE

ENGINE

FI SYSTEM DIAGNOSIS

* This manual has been prepared on the basis

of the latest specifications at the time of publi-

cation. If modifications have been made since

then, differences may exist between the con-

tent 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 motorcy-

cles. If you do not have the proper knowledge

and tools, ask your authorized SUZUKI

motorcycle dealer to help you.

FUEL SYSTEM AND THROTTLE

BODY

EXHAUST SYSTEM

CHASSIS

ELECTRICAL SYSTEM

SERVICING INFORMATION

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 and passenger.

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

1 Speedometer gear box

2 Bearing

3 Spacer

4 Front wheel rim

5 Front axle

6 Brake disc

7 Dust seal

8 Front axle spacer

9 Front axle shaft

A Front axle nut

B Brake disc bolt

ITEM

N·m

kgf-m

6.5

1.0

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

SYMBOL

DEFINITION

Torque control required.

Data beside it indicates specified

torque.

Apply THREAD LOCK SUPER “1342”.

99000-32050

Indicates service data.

Apply THREAD LOCK SUPER “1360”.

99000-32130

Apply oil. Use engine oil unless other-

wise specified.

Apply or use brake fluid.

Apply molybdenum oil solution.

(mixture of engine oil and SUZUKI

MOLY PASTE in a ratio of 1 : 1)

Measure in voltage range.

Apply SUZUKI SUPER GREASE “A” or

equivalent.

99000-25011

Measure in resistance range.

Apply SUZUKI SILICONE GREASE.

99000-25100

Measure in current range.

Apply SUZUKI MOLY PASTE or equiva-

lent.

99000-25140

Measure in diode test range.

Apply SUZUKI BOND “1215”.

99000-31110

Measure in continuity test range.

1216

Apply SUZUKI BOND “1216B”.

99000-31230

Use special tool.

Apply THREAD LOCK SUPER “1322”.

99000-32110

Use fork oil or equivalent.

99000-99044-10G

Apply THREAD LOCK SUPER “1303”.

99000-32030

ABBREVIATIONS USED IN THIS

MANUAL

A AC

: Alternating Current

H HO2 Sensor : Heated Oxygen Sensor (HO2S)

ACL

: Air Cleaner, Air Cleaner Box

I IAP Sensor : Intake Air Pressure Sensor (IAPS)

IAT Sensor : Intake Air Temperature Sensor

(IATS)

API

: American Petroleum Institute

A/F

: Air Fuel Mixture

B BTDC

: Before Top Dead Center

: Ignition

ISC Valve

: Idle Speed control valve (ISCV)

B+

: Battery Positive Voltage

C CKP Sensor : Crankshaft Position Sensor

(CKPS)

L LCD

: Liquid Crystal Display

: Left Hand

CKT

: Circuit

MAL-Code

CPU

: Central Processing Unit

: Malfunction Code

(Diagnostic Code)

D DC

: Direct Current

Max

: Maximum

MIL

: Malfunction Indicator Lamp

(LED)

DMC

: Dealer Mode Coupler

DTC

: Diagnostic Trouble Code

Min

: Minimum

E ECM

: Engine Control Module

Engine Control Unit (ECU)

(FI Control Unit)

N NOx

: Nitrogen Oxides

O OHC

ET sensor

: Engine Temperature sensor

: Over Head Camshaft

F FI

: Fuel Injection, Fuel Injector (Dis-

charge pump; DCP)

R RH

: Right Hand

ROM

: Read Only Memory

FPR

: Fuel Pressure Regulator

G GEN

SAE

: Society of Automotive Engineers

: Generator

SDS

: Suzuki Diagnosis System

GND

: Ground

T TO Sensor : Tip Over Sensor (TOS)

TP Sensor

: Throttle Position Sensor (TPS)

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