SUZUKI

FOREWORD
This manual has been prepared to provide service operators with necessary information
for the maintenance and the repairs of the motorcycle. The contents are made plain зо
that less-experienced mechanics may carry out the proper jobs according to the items of
assembly and disassembly instructions.
For fully qualified mechanics, the necessary service data for the inspections and repairs is
provided in this manual. Since it is above all important on servicing a motorcycle to know
throughly its construction and the necessary data, it is highly recommended for those
who are engaged in servicing GP125 and GP125U to study beforehand this manual
notwithstanding their technical ability.
We trust the publication of this manual would be of assistance in the service activity as
well as in the study of models GP125 and GP125U.

Data, photo, etc. contained in this ervice r anual are valid as of the time of issue and sub:
ject to alteration without notice due to the improvement of quality and other reasons,

SUZUKI MOTOR CO.,LTD.

Service Department

Quoting, copying or otherwise using any part of this manual without explicit authoriza
tion from Suzuki Motor Co., Ltd. is not permitted.
There may be some differences among models depending on specifications. If the service
data differ, it is noted ther е by using the following symbols.
The series of symbols on е left stand for the countries and areas on the right.

£01 General E-18 Switzerland

E-02 UK E21 Belgium
E-04 France E22 W. Germany
E-06 S. Africa E-24 Australia
Е-10: Central & South America E31 Philippines
E-12 Indonesia E32 Nigeria
E-13 South East Asia E41 Greece
E-14 Thailand
E17 Sweden

ее

пе
 GROUP INDEX

re
GENERAL INFORMATION

PERIODIC MAINTENANCE AND

TUNE-UP PROCEDURES

SERVICING ENGINE

FUEL AND OIL SYSTEM

ELECTRICAL SYSTEM

CHASSIS

SERVICING INFORMATION
 GENERAL INFORMATION

E
CONTENTS
MODEL IDENTIFICATION T
SERIAL NUMBER LOCATION
SPECIFICATIONS
SPECIAL FEATURES ..
"е GENERAL INSTRUCTIONS . .
FUEL AND OIL RECOMMENDA TION .
PRECAUTIONS AND GENERAL INSTRUCTIONS
е
11
MODEL IDENTIFICATION
GP125

"е

6Р1250

зе

че
 12

SERIAL NUMBER LOCATION

The frame serial number is stamped on the right
side of the steering head pipe

The engine serial number is located on the left

side crankcase.

These numbers are required especially for registering the machine and ordering the spare parts.
13
SPECIFICATIONS
DIMENSIONS AND WEIGHT
Overall length 1 905 mm (75.0 іп)
Overall width 750 mm (29.5 in)
Overall height 1 075 mm (42.3 іп) е
Wheelbase 1 230 тт (48.4 іп)
Ground clearance 150 тт ( 5.9 іп)
Seat height 770 тт (30.3 іп)
Dry mass (weight) 92 kg
(203 Ibs) . GP125
89 kg (196 Ibs) . GP125U
ENGINE
Type Two-stroke cycle, air-cooled
Intake system Rotary disc valve
Number of cylinder 1
Bore 56 тт (2.205 in)
Stroke 50 mm (1.969 in)
Piston displacement 123 ст" (7.5 cu.in)
Corrected compression ratio 67:1
Carburetor MIKUNI VM24SS, single
Air cleaner Polyurethane foam element
Starter system Primary kick
Lubrication system SUZUKI “ССІ”
TRANSMISSION
Clutch Wet multi-plate type
Transmission 5-speed constant mesh
Gearshift pattern T-down 4-ир
Primary reduction 3.625 (58/16)
Final reduction 3.000 (45/15)
3.214 (45/14) Only for Philippines

Gear ratios, Low 3.090 (34/11)

2nd 1.812 (29/16)
3rd 1.250 (25/20) =
4th 0.956 (22/23) е
Top 0.800 (20/25)
Drive chain 0.1.0. 4280, 120 links or 122 links “|
 14
CHASSIS
Front suspension Telescopic, oil dampened
3 Rear suspension Swinging arm, oil dampened, spring
5-way adjustable
Steering angle 45° (right & left)
Caster 63
Trail 93 mm (3.7 in)
Turning radius 20m (6.6 ft)
Front brake Disc brake .....6Р125
Internal expanding .....GP125U
Rear brake Internal expanding
Front tire size 2.75-18-4PR
3.00-164PR .....Only for Philippines
Rear tire size 3,00-18-4PR
3.00-16-4PR .....Only for Philippines
ELECTRICAL
Ignition type SUZUKI “PEI” (Pointless Electronic
Ignition) or Magneto
Ignition timing 21° B.T.D.C. at 6 000 r/min .....“PEI” type
(NIPPON DENSO)
24° B.T.D.C. at 4 000 r/min ..... PEI type (KOKUSAN)
20° B.T.D.C. ..... Point type
Spark plug МСК ВВН5 or NIPPON DENSO W24FS
МСК B7HSorNIPPON DENSO W22FS ..... Only for
Philippines
Battery 6V 14.4 КС (4 Ah)/10 HR
Generator Flywheel magneto
Fuse 10A
CAPACITIES
Fuel tank including reserve 9.81. (2.6/2.2 US/Imp gal)
reserve 2.0L (2.1/1.8 US/Imp qt)
Engine oil tank 1.2L (1.3/1.1 US/Imp qt)
Transmission oil 800ml (0.85/0.70 US/Imp qt)
15

SPECIAL FEATURES
ROTARY DISC VALVE INTAKE SYSTEM
Rotary disc valve is located between the crank chamber and the carburetor. When the
fuel-air mixture flows from the carburetor into the crank chamber, the rotary disc valve
which rotates in accordance with the crankshaft closes and stops the fuel-air mixture flow
at appropriate timing. This valve operation makes it possible that necessary amount
fuel-air mixture is drawn into the engine of GP125 and the fuel-air mixture compressed ofin
the crank chamber is hindered from back flow. Thus enough compression ratio is secured
to obtain good engine power.
In case of the ordinary 2-cycle engine with a piston valve, an inlet port is necessary on the
cylinder wall, while in case of GP125, the rotary disc valve allows to eliminate this inlet
Port. Instead, GP125 is provided with the third scavenging port on that position. As
shown below, the fuel-air mixture compressed in the crank chamber moves from the back
Of the piston through the hole on its intake side and enters the cylinder groove. When it
finally flows into the combustion chamber, it pushes out the burned gas. By employing
this scavenging system, scavenging action is carried out more effectively in GP125 than in
the ordinary engine, fuel consumption is decreased and yet enough power is obtained.

Disc valve
L; Disc valve

Disc valve opening

Third scavenging port

 CARBURETOR
The carburetor of GP125 is of floating mount carburetor system, therefore is mounted
with an intake pipe and a carburetor top cap made of rubber as shown below.
In most cases, engine vibration is most likely propagated to the carburetor and gasoline in
the float chamber vibrates resulting in instability of its surface. Being free from this, the
carburetor of floating mount carburetor system constantly mixes fuel with air at the best
mixture ratio which ensures steady engine power either at high speed or low speed. At
the same time, it economizes fuel consumption.

Ci buretor top сар

Intake pipe
17 =
F
GENERAL INSTRUCTIONS
4 А №
Materials Required for Maintenance түтүү» ' E

The materials listed below are required for Г

maintenance works on the Models GP125 and
GP125U, and should be kept on hand for ready [] ;
use. In addition, such standard materials as
cleaning fluids, lubricants, etc., should also be
available. Methods of use are discussed in the
text of this manual on later pages. Suzuki lock super
“1озк”
Material Use 99000-32030
=
= Inner valve seat screws
il seals Front fork piston bol
Throttle grip iji е
Cables (speedometer and
tachometer) О

LE
Suzuki super grease Thread lock cement
99000-32040
"A" 99000-25010
Disc brake pads
S&S Use of Genuine Suzuki Parts
To replace any part of the machine, use a
j genuine SUZUKI replacement part. Imitation
parts or parts supplied from any other source
than SUZUKI, if used to replace parts of
Suzuki SUZUKI origin in the machine, е will lower the
те brake pad ыша: УРЫ |
inherent capacility of the machine and, even
99000-25100 worse, could induce costly mechanical trouble.
Brake caliper axle bolts E
aar 7
axle grease j
99000-25110 ©
Crankcase mating
surface
Rotary disc valve guide | ^|e

Suzuki bond No. 4

99000-31030
 1-8

FUEL AND OIL RECOMMENDATION

Be sure to use the specified fuel and oils. The following are the specifications

Fuel
Gasoline used should be graded 85 to 95 octane in Research Method, and should be unleaded or low-lead
where they are available.
Engine Oil
For the SUZUKI ССІ system, use of SUZUKI ССІ Oil or SUZUKI ССІ Super Oil is highly recommended,
but if they are not available, a good quality two-stroke oil (non diluent type) should be used.

Transmission Oil
Use a good quality SAE 20W/40 multi-grade motor oil.
Brake Oil
For the disc brake, replenish with one of the brake fluid graded below.

Specification and Classification

SAE J1703a/SAE J1703b/SAE J1703c

SAE 70R3 (obsolete spec.)

Front Fork Oil

For the front fork oil, be sure to use a motor oil whose viscosity rating meets the specifications of SAE
10М//20.
 1-9

PRECAUTIONS AND GENERAL INSTRUCTIONS 1

Observe the following items without fail when disassembling and reassembling motorcycles.
* Be sure to replace packings, gaskets, circlips, О rings and cotter pins with new ones.
* Tighten bolts and nuts from the ones of larger diameter to those of smaller diameter, and from inside
to out-side diagonally, with specified tightening torque.

* Use special tools where specified.

* Use specified genuine parts and oils recommended.
* When more than 2 persons perform works in cooperation, pay attention to the safety of each other.
* After the reassembly, check parts for tightening condition and operation.
* Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use è
gasoline as cleaning solvent.
Warning, caution and note are included in this manual occasionally, describing the following contents.

WARNING +». When personal safety of the rider is involved, disregard of the information could
result in this injury.
CAUTION . For the protection of the motorcycle, the instruction or rule must be strictly
adhered to.
МОТЕ....... ++ Advice calculated to facilitate the use of the motorcycle is given under this
heading.
 PERIODIC MAINTENANCE AND
@ ИМЕР PROCEDURES ў
a
CONTENTS
PERIODIC MAINTENANCESCHEDULE 21
MAINTENANCE PROCEDURE 23

>
2-1
PERIODIC MAINTENANCE SCHEDULE
Vehicles should be inspected after а certain period of running for wear of parts, carbon deposits, elongated
cables, etc. Inspections should be made periodically and defects should be repaired or adjusted beforehand
to prevent trouble and prolong the motorcycle’s service life.
Inspect and adjust the vehicle as indicated below.

NOTE
More frequent maintenance may be performed on motorcycles that are used in an extreme service
condition:

PERIODIC MAINTENANCE CHART

Engine
eral |Initio! 1 000 em Every 3 000km | Every 6000кт Every 12 000 km
= initia 600 miles Every 2 000miles Every 4000miles Every 8 000miles
Clean and adjust gap Replace
Contact breaker Check contest point æ (only for
prep em зар and ignition timing point type) |
Wash
peas pr Adjust throttle valve
mop screw, pilot i stop screw, pilot Ovérhau! and clean
adjust serow and adjust screw and
| Oi pump Check operation, adjust Check operation,
[revelan control lever aligning
Fuel hose | Replace every 2 years.
Fuel strainer | Clean Clean
Cylinder пев tighten eyinder T Retighten cylinder Remove carbon
and cylinder мет head тиз
Смет Глам Adjust
==] Change Change
Battery | Check & service |
Check & service.
electrolyte solution

Chassis
Г Interval | Initial 1 000 km. Every 3 000 km T Every 6 000 кт Every 12 000km
tom initial 600miles Every 2 000 miles Every 4 000 miles Every 8 000 miles
Bolts and nuts Retighten Retighten
Drivechain. Adjust Adjust Wash
Front brake (GP125) Check fluid level, | Check fuid level
Jeakage and pad leakage and pad
Front brake (GP125U)_ Adiust play Adjust play
Нем brake Adjust play Adjust play
Steering stem Adjust play

дд
LUBRICATION CHART
Rotating and rubbing parts must be lubricated periodically. Insufficient lubrication will cause rapid wear
and severe damage may result
Lubricate the following parts periodically.

Interval Initial Every Every

нет 1 000 km (600 mi) 3.000 km (2 000 mi) 6 000 km (4 000 mi)
Brake cam shaft E Grease
Brake cables ər oil
Clutch cable Motor oil
Drive chain Every 1 000 km (600 mi) Motor oil Wash and Motor oil
Speedometer cable = Grease
Tachometer cable Grease
Throttle and
oil pump cable Motorтогоой

WARNING
Be careful not to apply too much grease to the brake cam shafts. If grease gets on the linings, brake
slippage will result.

Lubricate exposed parts which are subject to rust, with either motor oil or SUZUKI super grease “А” (part
No. 99000-25010) whenever the motorcycle has been operated under wet or rainy conditions.

Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
23

MAINTENANCE PROCEDURE
SPARK PLUG

Check at initial 1 000 km (600 mi)

and every 4 000 km (2 000 mi)
Replace every 6 000 km (4 000 mi)
o
Neglecting the spark plug eventually leads to
difficult starting and poor performance. If the
spark plug is used for a long period, the elec-
trode gradually burns away and carbon builds up
along the inside part. In accordance with the
Periodic Inspection Chart, the plug should be
removed for inspection, cleaning and to reset the
gap. Spark plug дар
0.6 – 0.8 mm
* Carbon deposits on the spark plug will pre (0.024 — 0.031 in)
vent good sparking and cause misfiring. Clean * Check spark plug for burnt condition. If ab.
the deposits off periodically normal, replace the plug as indicated below.
(7 * General and Other

B7HS | w22FS г

B8HS | W24FS Standard

“ B9HS W27FS
на
м
indard plug is apt
eat, replace with

* Only for Philippines

© If the center electrode is fairly worn down,
the plug should be replaced and the plug gap
set to the specified gap using a thickness
= ae
И the standard plug is apt
gauge. Bens | W20FS
this plug.
Thickness gauge B7HS | w22rs Standard

Fi
09900-20804
I the standard plug
B8HS | wars то overheat, replace iswithapt
this plug,
* Tighten the spark plug in the cylinder head
with the specified torque.

е, е > ч Spark plug a 70Hp E

tightening
меп! torque 180-216 ipft

А
IGNITION TIMING
Adjust at initial 1 000 km (600 mi)
and every 3 000 km (2 000 mi)
Replace contact point every 6 000 km
(4 000 mi) (only for point type)
Check ignition timing(For РЕ! type)
* Connect the timing light cord to the high.
tension cord.
* Start the engine.
* Aim the light from the timing light at the Check contact points (For point type)
aligning mark (@ on the crankcase Raise the е Check the condition of contact point surfaces.
engine speed to 6 000 r/min or 4 000 r/min. If pitted or damaged, replace with а new set
At this time, the ignition timing is proper if of points. A point file, or flexstone may be
the aligning mark (D is aligned to the middle used to correct minor damage.
line @ of the three on the magneto rotor
when the timing light flashes.
Timing light 09900-27311

E 1 p |
WORN DIRTY
* Adjust the contact point gap @ wit athick
h
ness gauge.
* If the gap is too wide or too narrow, loosen
the contact breaker plate locking screw
and rotate the plate ($) with a plane head
screwdriver to achieve the correct gap.
[
| Thickness gauge 09900-20804
21*:2" B.T.D.C. at L
6 000 r/min
NIPPON DENSO
24°+2° B.T.D.C. at
4 000 r/min
KOKUSAN DENKI
If the ignition timing is not correct, readjust
following the procedure below.
* Remove the rotor using the special tools.
* Untighten the 3 screws fixing the stator.
* Align the index line (3) on the stator to the
center of the screw.
Rotor holder 09930-40113
Rotor remover shaft 09930-30102
Attachment С 09930-30161
Point gap 0.3 -0.4 mm
(0.012 - 0.016 in)
ООО

2-5

Check ignition ti ing with timing light

* Connect the timing light cord to the high:
tension соға.
© Start the engine.
* Aim the light from the timing light at the
aligning mark @ on the crankcase. The igni
tion timing is correct if the aligning mark (1
is aligned with the line @ on the magneto
rotor when the timing light flashes. If they are
not aligned, readjust thepointgap to 0.3 -0.4
mm (0.012 - 0.016 їп).
P * Find ТОС on the dial gauge by turning the
| ақа | ВОЗ crankshaft slowly. At TDC set the dial indi
cator to "ZERO" ,
% Turn the crankshaft slowly clockwise (the
reverse of normal engine rotation); stop when
the tester sound fades out. %
* Read the dial gauge indication. This shows the
ignition timing in piston travel from TDC.

Check ignition timing with timing gauge

and tester
* Remove the spark plug from the cylinder
head and install the timing gauge (i) in its
place.
* Connect one tester @ lead to the contact Т Timing | Timing
Point positive terminal or B/Y (B) lead wire, | Retard |STD =» |
the other to a ground | angle
Crankshaft
(бед) | 18° | 19° | 20° | 21° |22° | ”
Timing= gauge
|] 09931-
= 00112== Piston(mm)
distance |1 52 |1.69 |1.87 |2.06 |2.26
| ДЕР s 2 зра) |
Timing tester | 09900-27003
= * If timing is incorrect, loosen the screw @
and adjust by moving the ground side of the
contact braker.
 2-6

AIR CLEANER © Immerse the element in a pool of motor oil,

and squeeze the oil off the element to make it
Clean every З 000 km (2 000 mi) slightly wet with the oil
When the air cleaner element is clogged with
dust, air intake resistance is raised, reducing the
output and increasing the fuel consumption.
Clean the element periodically, following the
procedure below.
* Unscrew the screw (1) and remove the cleaner
case cover 2
non flammable
cleaning solvent

* Fix the element on the frame properly.

e Unfasten the hook (8) and remove element.

О X
CAUTION:
* Before and during the cleaning oper-
ation, examine the element to see if it
has a rupture or fissure. A ruptured or
fissured element must be replaced.
* Be sure to position the element snugly
and correctly, so that no incoming air
а washing pan of a proper size with non- will bypass it. Remember, rapid wear of
flammable cleaning solvent. piston rings and cylinder bore is often
Immerse the element in the solvent and wash caused by a defective or poorly fitted
it clean element.
* Squeeze the solvent off the washed element
by pressing it between the palms of both
hands: Do not twist and wring the element or
it will develop fissures.
2-7

CARBURETOR Adjusting throttle cable

* Loosen lock nut a.
Adjust at initial 1 000 km (600 mi) * Adjust the cable slack 4) to 1.0 — 1.5mm
and every 3 000 km (2 000 mi) (0.04 — 0.06 in) by turning adjuster 5

Adjusting idling speed 4 —

* Start the engine and allow it to warm up.
* After ће engine warms up, shut it off mo
mentarily.
* Screw the pilot air screw (1) all the way in,
and then loosen it 1- 1/2 turns.

© Start the engine again and adjust the throttle

valve stop screw (2 so that the engine runs at
its lowest idling speed.

* Screw the pilot air screw in or out within %

turn from the standard setting (1% turns) to
find the position where the engine runs most
smoothly.
: =
Idle speed 1 300 + 150 r/min
 2-8

OIL PUMP FUEL HOSE

Adjust at initial 1 000 km (600 mi) Replace every two years
and every 3 000 km (2 000 mi)
The engine oil is fed by the oil pump to the FUEL STRAINER
engine. The amount of oil fed to it is regulated
by engine speed and the oil pump control lever Clean at initial 1 000 km (600 mi)
which is controlled by the amount of throttle and every 6 000 km (4 000 mi)
opening.
Check the oil pump in the following manner to If the fuel strainer cup is dirty with sediment or
confirm correct operation for all throttle valve water, gasoline will not flow smoothly and a loss
opening positions. in engine power may result. Clean the strainer
© Turn the throttle grip until the dent mark 1 and the cup, leaving the fuel cock in OFF posi
on the throttle valve comes to the upper part tion.
of the hole.

дек.
* Check whether the mark on the oil pump
control lever is aligned with the index mark
when the throttle valve is positioned as above.

* If the marks are not aligned, adjust by means

of the cable adjuster 2 to align them
CAUTION
This adjustment could affect the throttle
cable play, so readjust the throttle cable
play if necessary
И

29

CYLINDER HEAD NUTS AND CLUTCH

EXHAUST PIPE CLAMP BOLTS
Adjust at initial 1 000 km (600 mi)
Retighten at initial 1 000 (600 mi) and every 3 000 km (2 000 mi)
and every 3 000 km (2 000 mi)
* Loosen lock nut 1 on the clutch lever side.
* Retighten cylinder head nuts and exhaust * Screw in adjuster (2) fully in the direction of
pipe clamp bolts as specified torque according the clutch lever,
to the following tightening order.
2-3mm
(0.08
—0.12 in)

2 e Loosen the lock nut 3: and screw in the

clutch cable adjuster 4. to give sufficient
E 2pmNm | kem | it play to the clutch cable,
[Cylinder head пис 23-27 2.3-2.7 16.5-19. 5 Temporarily loosen the lock nut ($ and
[Exhaust pipe tighten the release adjusting screw @ until
| clamp bolt |.9-12 |0.9-1.2| 0.5- 8.5
resistance is felt, then loosen it % -% turn.
Secthe ure lock nut 5
Adjust the clutch cable adjuster (2) again
until approximately 2-3 mm (0.08 -0.12 in.)
of play remains at the bottom of the clutch
lever.
3
 2-10
TRANSMISSION OIL BATTERY
Change at initial 1 000 km (600 mi) Check at initial 1 000 km (600 mi)
and every 3 000 km (2 000 ті) and every 3 000 km (2 000 mi)
After a long period of use, the transmission oil
will deteriorate and quicken the wear of sliding Battery specifications
and interlocking surfaces. Replace the transmis Type. ӨМАВ-2А 1 lead
sion oil periodically following the procedure storage battery |
below.
© Start the engine to warm up the oil, this will Voltage ву
facilitate draining of oil. Shut off the engine. Capacity 14.4 КС (4Ah) |
* Unscrew the oil filler cap 1 and drain plug Electrolyte for |
2. , and drain the oil completely. specific gravity 1.26 at 20°C (68°F)
* Tighten the drain plug
* Supply a good quality SAE 20W/40 multi- е Check to be sure that the vent pipe is secured
grade motor oil properly and routing correctly.
* Check the oil level with the oil level screw @ * Add distilled water, as necessary, to keep the
surface of the electrolyte above the LOWER
level line but not above the UPPER level line.

© If the electrolyte surface falls rapidly and

requires frequent addition of distilled water,
check the charging system for proper charging
rate.
* Periodically, check the electrolyte for specific
gravity by using a hydrometer to tell the state
of charge.

coy (0.85/0.70 US/Imp qt)

2-11

Hydrometer 09900-28403
STEERING STEM
Check at initial 1 000 km (600 mi) ‚
and every 3 000 km (2 000 mi)

a
47
Steering should be adjusted properly for smooth ,
manipulation of handlebars and safe running.
Too stiff steering prevents smooth manipulation
| of handlebars and too loose steering will cause
А poor stability.
Check to see that there is no play in the front
fork bearings.

= If any play can be found, adjust the steer g as

follows:
* A SG. reading of 1.20 (at 20°C) or under * Support the motorcycle body and jack up the ,
means that the battery needs recharging off front wheel.
the machine: take it off and charge it from a * Untighten the steering stem head bolt, the
recharger. Charging the battery in place from front fork cap bolts and lower clamp bolts. ^
the recharger can damage the rectifier. © Tighten the steering stem head nut using the
special tool so that the handlebars move
CAUTION: smoothly.
Do not use tap water for battery solution
Reconnect the battery vent hose after ге Steering stem nut
installing the battery. | wrench 09940-10122

NOTE
Tighten the steering so that the handlebar
pivots freely by its own weight
 2-12
* Tighten the bolts to the following torque
FRONT BRAKE(GP125)

Steering stem head bolt | 3.5 —5.5 kgm Check at initial 1 000 km (600 mi)
255—951 | and every 3 000 km (2 000 mi)
55 Мт
Front fork cap bolt 5.5 kgm Check brake fluid level
ssi] * Check the brake fluid level by observing the
20—30N m upper and lower limit lines on the brake fluid
Lower clamp bolt 20—30kgm | reservoir.
|! 148-215ьн * When the level is below the lower limit line
1, replenish with motor vehicle brake fluid
If any play is still found, inspect the following эз indicated below.
items and replace the affected parts, if necessa
ту. MN
* Wear of the inner and outer races

X
* Wear or damage of steel balls
* Number of steel balls
* Distortion of steering stem
Number of steel balls
Upper 22 pcs.
Lower 18 pcs.

Specification and Classification

SAE J1703a/SAE J1703b/SAE J1703c |
SAE 70R3 (obsolete spec.)

Check brake pads

Wear condition of brake pads can be checked by
observing the red limit line (2 marked around
the pad. When the wear exceeds the limit line,
replace the pad with a new one.
шко 000
2-13

Check brake fluid leaks REAR BRAKE

Brake fluid, if it leaks, will interfere with safe
running and discofor painted surfaces. Check the | Adjust at initial 1 000 km (600 mi)
brake hose for cracks and hose joint for leakage | and every 3 000km (2 000 mi)
periodically,
Adjusting
FRONT BRAKE(GP125U) * Adjust the free travel @)to 20 — 30 mm (0.8
— 1.2 in) by turning the adjusting nut @
Adjust at initial 1 000 km (600 mi),
| and every 3 000 km (2 000 mi)
Adjusting
* Measure the clearance between the brake lever
end and throttle grip when brake is fully ар.
plied. Adjust the clearance (1) to 20 — 30
mm (0.8 — 1.2 in) by turning the adjusting
nut @

BRAKE SHOE WEAR

r-
Check every 3 000 km (2 000 mi) |

This motorcycle is equipped with brake lining

wear limit indicator on front and rear. As shown
in Fig. At the condition of normal lining wear,
the extension line of the index mark on the
brake cam shaft should be within the range
embossed on the brake panel with brake on.
$
 2-14
DRIVE CHAIN

Check and adjust at initial 1 000 km

(600 mi) and every 3 000 km (2 000 mi)
Lubricate every 3 000 km (2 000 mi)
Wash every 6 000 km (4 000 mi)

Visually inspect the drive chain for the below.

listed possible malconditions.
* Loose pins
* Damaged rollers
Rusted links
Twisted or seized links
The extension line of the index mark is * Excessive wear
within the range If any defects are found, the drive chain must be
replaced
To check wear of the brake lining, perform the
following steps. Checking
* First check if the brake system is properly * Loosen axle nut 1 after pulling out cotter
adjusted. pin 2
* While operating the brake, check to see that * Tense the drive chain fully by tightening the
the extension line of the index mark is within adjusters 3
the range on the brake panel
* If the index mark is beyond the range as
shown in the Fig., the brake shoe assembly
should be replaced with a new one.

* Remove the chain case. Count out 21 pins (20

pitch) on the chain and measure the distance
between the two. If the distance exceeds
following limit, the chain must be replaced.

The extension line of the index mark is

beyond the range.
 Adjusting
* Loosen the adjuster (3) until the chain has 15 |
— 20 mm (0.6 — 0.8 in) of sag at the middle È
between engine and rear sprockets. The mark
4 on both chain adjusters must be at the
same position on the scale to ensure that the È
front and rear wheels are correctly aligned.

Service limit 259.5 mm (10.22 in) а 15 20 mm

04 06 0.8in)

Cleaning and lubricating

Wash the drive chain in cleaning solvent and
lubricate it with chain lube or motor oil. If the
motorcycle operates under dusty conditions,
frequent rapid acceleration or at sustained high
speeds, the drive chain should be cleaned and
lubricated more often.

* After adjusting the drive chain, tighten the

axle nut 1) securely and lock with cotter pin -
2) .Always use a new cotter pin.
1
|| Rear axle nut 36—52Nm
38—52kgm ||
tightening torque 260 sibi
 2-16
TIRE If the tire pressure is too high or too low,
steering will be adversely affected and tire wear
Check every day increased.
Therefore, maintain the correct tire pressure for
Tire tread condition good roadability or shorter tire life will result
Operating the motorcycle with the excessively Cold inflation tire pressure is as follows.
worn tires will decrease riding stability and
consequently invite a dangerous situation. It is CAUTION
highly recommended to replace the tire when The standard tire fitted on this motorcycle
the remaining depth of tire tread reaches the is 2.75-184PR (3.00-16-4PR) for front and
following specifications, 3.00-184PR (3.00-16-4PR) for rear.
The use of a tire other than the standard
may cause instability. It is highly recom:
mended to use a SUZUKI Genuine Tire.

FRONT | ВЕАВ
1.6 тт (0.06 їп) 1.6 тт (0.06 їп)

Tire air pressure

SOLO RIDING DUAL RIDING
General and other Only for E-31 General and other | Only for E-31
175 kPa 150kPa 175 kPa
FRONT 1.75 kg/cm? | 150 kPa
1.50 kg/cm | 1.75 kg/cm? [ 1.50 kg/em?
| 25 psi 21 psi | жі | | 21 psi
225 кРа 200 кРа 250 kPa 225 kPa
REAR 2.25 kg/cm? | |2.00 kg/cm? 2.50 kg/cm? 2.25 kg/cm
32 psi 38 psi
| 28 psi | | | 32 psi |
 SERVICING ENGINE

- = — —— CONTENTS — —
ENGINE COMPONENTS REMOVAL WITH THE ENGINE IN PLACE
ENGINE REMOVAL +
ENGINE DISASSEMBLY
ENGINE COMPONENTS INSPECTION AND SERVICING
ENGINE REASSEMBLY :
34 2
ENGINE COMPONENTS REMOVAL WITH THE ENGINE ІМ PLACE 3

Rotary disc valve, Piston, cylinder

ы. |
" We.
scr Satna рн
Gish атик кашы млн. |——À t sig >
быша Жаан Кии
7 T S

Gear shifting shaft, етс. Magneto rotor and stator

Kick starter drive gear etc.

ENGINE REMOVAL
Before taking the engine out of the frame, wash
the engine with a steam cleaner and drain trans:
mission oil etc. The procedure of engine removal
is sequentially explained in the following steps,
and engine installation is effected by reversing
the removal procedure.

1. Disconnect battery © lead wire 1 2. Turn fuel cock to “OFF” position and dis:
connect fuel hose from the fuel cock.
 3-2
3. Remove the two bolts 1, right and left, 6. Disconnectoilhose (3
and take off seat

7. Remove gearshift lever and sprocket cover.

4. Loosen fuel tank retaining bolt (2) and take
off fuel tank.

8. Disconnect drive chain by removing clip (4

5. Disconnect lead wires of the magneto and < со
spark plug cord.
33

9. Remove oil pump cover and disconnect oil 12. Loosen the four screws and slide up
pump contrcl cable (1 carburetor top cap 2

ENTEU
13. Remove carburetor inspection cap and dis-
connect each hose.

11. Take off muffler by removing exhaust pipe

clamp bolts and swinging arm pivot shaft 14. Loosen carburetor clamp screw and take
nut. off carburetor.
 34
15. Disconnect tachometer cable 3. .(Only for 18. Remove cylinder head.
GP125)

19. Loosen engine mounting bolts and remove

engine.

17. Remove bolts (5) and take off air cleaner Tightening torque
13—23Nm
Eit |1.3— 2.3 kgm
9.5 — 16.5 Ib-ft
25—40N m
Dia. 2.5 — 40 kgm |
| 90m 18.0 — 29.0 Ib-ft
CAUTION: m
Self-lock nut are used for engine mounting.

NOTE
After engine installation, following adjust-
ments are required
* Throttle cable play.
* Oil pump control cable.
* Clutch cable play.
* Drive chain sag. |
 35
ENGINE DISASSEMBLY
The procedure for engine disassembly is 4. Loosen the rotor nut by using special tool. \
sequencially explained in the following steps.
Rotor holder 09930-40113
1. Remove cylinder. |

2. Remove the piston pin circlip. Use а rug, as 5. Remove the rotor by using special tool.
shown, in order to avoid dropping the circlip -
into the crankcase. Rotor remover shaft | 09930-30102
Attachment С | 09930-30161

3. Draw out piston pin by using special tool ^

and take off piston.
$ I ams 6. Remove the stator by loosening stator secur.
| Pitonpinpulle | (06801034510 | ina screws and neutral lead wire.
 36

7. Flatten the lock washer and loosen the 10. Remove kick starter lever and clutch cover.
engine sprocket nut by using special tool.
Rotor holder 09930-40113

да

| 11. Using special tool, pull out clutch spring

pins and take off clutch pressure plate.
Take off push piece and clutch plates.
| 8. Remove
theoilpump. Spring hook 09920-20310

12. Flatten the clutch sleeve hub washer, and

remove hub nut by using special tool
Take off clutch sleeve hub and primary
driven gear.
Clutch sleeve hub
holde 09920-53710
37
13. Draw outgearshift shaft. 16. Flatten primary drive gear washer and 1
loosen primary drive gear nut by using
special tool. )
Take off gear.
Con-rod stopper 09910-20115 | |
з

14. Remove circlip by using special tool and

draw out kick starter idle gear.
Snap ring plier 09900-06107

17. Remove outer valve seat.

15. Draw out oil pump drive gear and kick

starter drive gear.
 3-8
19. Remove inner valve seat. 22. Loosen crankcase securing screws.

23. Separate the crank case by using special

tool.
Crankcase separating
| too! 09910-80113

21. Pull out gearshifting cam driven gear.

24. Take out spring guide and remove kick

starter return spring.
Draw out starter shaft.
3-9

25. Draw out gearshift fork shaft and shift fork. 28. Remove the crankshaft by using special
tool.

25
[ Crankshaft remover 09920-13111 1

26. Take off gearshift cam.

29. Remove oil seal by using special tool.

Oil seal remover 09913-70122 |

J

27. Draw out the counter and drive shafts at

the same time.

30. Remove bearing by using special tool.

| Bearing remover 09913-50120

|
| 09913. 80111
ENGINE COMPONENTS INSPECTION AND SERVICING
BEARINGS CRANKSHAFT
Wash the bearing with cleaning solvent and Crankshaft deflection
lubricate with motor oil before inspecting Support crankshaft by “V” blocks, with the dial
* Hold the bearing by the inner race. gauge rigged to read the runout. Deflection is
* Turn the outer race and check to see that the total dial reading, and is specified to be within
outer race turns smoothly. If it does not turn the following limit
lightly, quietly and smoothly, or if noise is
heard, the bearing is defective and must be
replaced with a new опе.

Service Limit 0.05 mm (0.002 in)

Excessive crankshaft deflection is often res.
ponsible for abnormal engine vibration. Such vi
OIL SEALS bration shortens engine life.
Damage to the lip © of the oil seal may result
in leakage of the mixture or oil. Inspect for Condition of big end bearing
damage and be sure to replace damaged parts if Wear on the big end of the connecting rod can
there are any. 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
connecting rod’s big end. If wear exceeds the
limit, connecting rod, crank pin and crank pin
bearing should all be replaced.

Service Limit 3.0 mm (0.12

in)
 3-11

GEARS AND SHIFTING FORKS CLUTCH

Upon disassembling the engine, immediately Drive plates and driven plates
inspect the transmission internals, visually ex. Clutch plates in service remain in oily condition
amining the gears for damage and checking the as if they were lubricated with oil. Because of
meshed condition of gear teeth. Using a thick- this condition, both drive and driven plates are
ness gauge, check the shifting fork clearance in subject to little wearing action and therefore last
the groove of its gear. much longer. Their life depends largely on the
quality of oil used in the clutch and also on the
|b Thickness gauge | 09900-20804 way the clutch is operated.
These plates are expendable. they are meant to
be replaced when found worn down or distorted
to the respective limit: use a caliper to check
thickness and a thickness gauge and surface plate
to check distortion.
| Vernier caliper 09900 20101
| Thickness gauge 09900-20803

Drive plate thickness:

This clearance for each of the three shifting

forks plays an important role in the smoothness
and positiveness of shifting action. Each fork has
its prongs fitted into the annular groove provid-
ed in its gear. In operation, there is sliding
contact between fork and gear and, when a shift
ing action is injtiated, the fork pushes the gear
axially. Too much a clearance is, therefore,
liable to cause the meshed gears to slip apart. If
the clearance checked is noted to exceed the | Service limit 2.6 mm (0.10 in) ]
limit specified, replace the fork or its gear, or
both.
Drive plate claw width:
Shift fork-groove clearance
2 =
| Service limit |
| For 3rd drive gear
|==Рогат driven
—] gear | 0.45 mm
оар,
| For Sth driven gear

Г Service limit 11.3 mm (0.44 in) ]

 Drive plate distortion: Clutch springs
Clutch springs which have lost their tension also
cause clutch slipping, resulting in loss of power
қ and rapid wear of the clutch plates.
Remove the clutch springs and measure their
free length with calipers.
NOTE:
If one of them is longer than service limit,
renew all of them at a time.

Service limit 0.4 mm (0.016 in)

Driven plate distortion: K

NYI Service lini 33.6 mm (1.32 in)

Clutch release bearing
Inspect this thrust-type bearing for any abnor.
mality, particularly cracks, upon removal from
Service limit 0.1 mm (0.004 in) the clutch, 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,
3-13
CYLINDER HEAD Cylinder head wapag
Remove the carbon and clean the cylinder head. A
Check the scratch on the mating surface.

A Y

Service limit 0.05 mm (0.002 in)

Using a surface plate and red lead paste, check

the gasketed surface of the cylinder head for CYLINDER
flatness. If high and low spots are noted, remove Decarbon the exhaust port and the upper part of
them by rubbing the surface against emery paper the cylinder, taking care not to damage the
(of about #400) laid flat on the surface plate in cylinder wall surface.
a lapping manner. The gasketed surface must be
smooth and perfectly flat in order to secure a
tight joint. a leaky joint can be the cause of
reduced power output and increased fuel
consumption.

The wear of the cylinder wall is determined

from diameter reading taken at 15 mm (0.59 in)
from the top of the cylinder with a cylinder
gauge. If the wear thus determined exceeds the
limit indicated below, rework the bore to the
next oversize by using a boring machine or ге.
place the cylinder with a new one. Oversize
pistons are available in two sizes: 0.5 mm
(0.0196 in) and 1.0 mm (0.0394 in) oversizes. E
9
 Cylinder gauge set 09900-20508
PISTON
Cylinder to piston clearance
Cylinder-to-piston clearance is the difference
between piston diameter and bore diameter. Be
sure to take the miked diameter at right angles
to the piston pin. The value of elevation (A) is
prescribed to be 20 mm (0.79 in)

Micrometer 09900-20202

Service limit 56.095 mm (2.2085 in)

After reworking the bore to an oversize, be sure

to chamfer the edges of ports and smoothen the
chamfered edges with sandpaper. To chamfer,
use a scraper, taking care not to nick the wall
surface.
Piston diameter for cylinder-to-piston clearance
determination.
The measurement for the bore diameter will be
1.0 -1.5mm made at (8 20 mm (0.79 in) from the cylinder
(0.040 -0.059 in)
1 top surface.
03-05 mm
(0.012 -0.019 in) это Service limit
т
1.0-1.5 тт Cylinder 56.000 — 56.015 mm | 56.095mm
(0.040 -0.059 in) (2.2047 - 2.2053 іп) | (2.2085 in)
Piston 55.960 -55.975тт | 55.880 тт
(2.2031 —2.2037 in) (2.2000 in)
Cylinder | 0.035 —0.045 mm 0.120 mm
NOTE to piston | (0.0014 —0.0018 in) | (0.0047 in)
Minor surface flaws on the cylinder wall
due to seizure or similar abnormalities can
be corrected by grinding the flaws off with
fine-grain sandpaper. If the flaws are deep
grooves or otherwise persist, the cylinder
must be reworked with a boring machine to
the next oversize.
CI
zm
al
3-15
Decarbon the piston and piston ring grooves, as PISTON RINGS
shown in Fig. After cleaning the grooves, fit the Check each ring for end gap, reading the gap
rings and rotate them in their respective grooves
with a thickness gauge, as shown in Fig. If the
to be sure that they move smoothly end gap is found to exceed the limit, indicated
Carbon in the groove is liable to cause the piston below, replace it with a new one.
ring to get stuck in the groove, and this condi

,
The end gap of each ring is to be measured with
tion will lead to reduced engine power output. the ring fitted squarely into the cylinder bore
and held at the least worn part near the cylinder
bottom, as shown in Fig
^

Service limit 0.80 mm (0.031 in)

As the piston ring wears, its end gap increases

>’ reducing engine power output because of the
resultant blowby through the enlarged gap. Here
lies the importance of using piston rings with
end gaps within the limit.
Measure the piston ring free end gap to check
A piston whose sliding surface is badly grooved the spring tension.
or scuffed due to overheating must be replaced.
Shallow grooves or minor scuff can be removed
by grinding with emery paper of about #400.

| Service limit 6.0 mm (0.24 in)

 3-16
Fix the piston ring in the piston ring groove, CONNECTING ROD
measure the ring side clearance with the thick
ness gauge while matching the sliding surfaces of Measure the con-rod small end bore with the
piston and ring.
caliper gauge.

d
Service limit 14.040 mm (0.5528 in)
STD clearance |0.03-0.07 mm(0.001-0.003in)

PISTON PIN
Measure the piston pin outside diameter with
the micrometer.

Ey]

Service limit 13.980 mm (0.5504 in.)

3-17
ENGINE REASSEMBLY
Reassembly is generally performed іп the reverse order to disassembly but there are a number of reassem:
bling steps that demand or deserve detailed explanation or emphasis. These steps will be taken up for re-
spective parts and components.

BEARINGS
Insert the bearing into the crankcase using the ® Ве sure to apply “Thread Lock Cement” to
special tool. After the bearing is installed, be outer surfaces of right and left crankshaft oil
sure to lubricate to prevent initial wear. seals, to prevent them moving.
B ы 09913-70122
t | 4 Thread Lock Cement | 99000-32040 |
байы lal 09913-80111

ко
* When fitting the oil seal in the crankcase,
insert it slowly using the special tool.
OIL SEALS
Fit the oil seals to the crankcase following the | 09913-70122 |
Oil seal installer
procedure below. 09913-80111 |
Replace removed oil seals with new ones.
* Apply SUZUKI Super Grease “A” to the lip
of the ой seal.
SUZUKI Super
Grease “А” | 99000-25010

т”

NOTE
Apply engine oil to each running and slid:
ing part before installing it in reassembling.
CRANKSHAFT

т Key
2 RH crankshaft
3 Thrust
D
$
6
7
8 LH crankshaft

Crankshaft rebuilding CAUTION

Decide the length between the webs referring to When mounting the crankshaft in the
the figure below when rebuilding the crankshaft. crankcase, it is necessary to drive its right
end into the crankcase.

50.020.1mm
(1.97+0.004in)
STD width between webs
50.0+0.1
mm (1.97 +0.004 іп)
3-19

KICK STARTER

1 2 Plate
Spring
Kick starter
Circlip
Washer
Kick starter shaft

| CO
|

Hitch one end of return spring to crankcase Two punch marks are provided on the starter
stopper: rotate the spring about 90 degree and shaft, as shown in Fig. When mounting the
clockwise; and hitch the other end to the hole kick starter on the shaft, be sure that these two
provided in kick starter shaft. punch marks meet each other.
TRANSMISSION
Drive shaft

1) Thrust washer 4) Circlip 7) Circlip 10 2nd driven gear

2) Ist driven gear 5) 3rd driven gear 8) Sth driven
gear Т) Drive shaft
3) 4th driven gear 8) Thrust washer 9 Circlip

CAUTION
Seat the circlip in the groove and its ends
A) should be located as shown in the
photo.
 3-21

In reassembling the transmission, attention must be given to the locations and positions of washers and
circlips. The cross sectional view given here will serve as a reference for correctly mounting the gears,
washers and circlips.

The 2nd drive gear (1) has been press-fitted into

the counter shaft. Remove it using a hydraulic
press.
Before reassembling, coat the internal face of
the 2nd drive gear with SUZUKI lock super
“10307” and install so 4
SUZUKI lock super
Й || 99000-32030
я
|

| Counter shaft 80.3 -80.4 mm

Standard length (3.16 -3.17 in)
GEARSHIFT MECHANISM
The exploded view of the mechanism give in Fig. serves as a reference for reassembly work.

Рам lifter
Cam driven gear
Рам No. 2
Pin
Spring
Cam guide
Gear shifting fork No. 1
Fork shaft No. 1
Gear shifting cam
Oring
Рам No, 1
12 Cam stopper
18 Spring
14 Stopper housing
15 Spring
16 Contact
17 Gear shifting switch body
18 Gear shifting fork No. 2
19 Fork shaft No. 2

Turn
ч the gearshifting
gearshift cam, and and meet
mi the neutral I NOTE
ith th
PONTON ко WIE пе лоша Stopper ] Set the cam guide before installing the fork
shaft.
3-23

CRANKCASE INNER VALVE SEAT

Wipe the crankcase mating surfaces (both sur- Apply "Thread Lock Cement" to the 5 screws
faces) with cleaning solvent and coat one of a when installing the inner valve seat.
pair with SUZUKI Bond No. 4 in the usual
manner, just before assembling the crankcase. Thread Lock Cement | 99000-32040

SUZUKI Bond No. 4 | 99000-31030

VALVE GUIDE
© Before installing the valve guide in the crank-
PAWL LIFTER AND CAM GUIDE shaft, be sure to apply "SUZUKI Bond No. 4”
Apply “Thread Lock Cement" to the 4 screws to the side in contact with the crankshaft
when installing the pawl lifter and cam guide. bearing, the outer surface of which has not
been treated, as shown in Fig.
| Thread Lock Cement 99000-32040 Put the valve guide on the crankshaft facing
the fine grinded portion upward not to
damage the oil seal lip.
SUZUKI Bond No. 4 | 99000-31030 |
VALVE PLATE PRIMARY DRIVE GEAR NUT
* Insert the valve plate into the valve guide so Using special tool, tighten the primary drive gear
that the side with the mark 1 faces outward nut with specified torque.
and aligning mark (2) (notch) and key way on
the crankshaft are aligned. If installed in the Con-rod stopper 09910-20115
wrong way, it will prevent the engine from
starting
Apply motor oil to the valve plate surfaces.

ил
IT
Tightening torque 3.6 — 5.0 кат |
26.0 — 36.0 Ib-ft

GEARSHIFT RETURN SPRING

Attach the spring to the gearshift shaft correctly
as indicated in Fig.

Take care so that the O-ring (3) does not fall

out when installing the outer valve seat.
Applying grease between the O-ring and the
ring groove will facilitate insertion.
Apply motor oil to outer valve seat.
© "X
3-25

* Installing the gearshift shaft in the crankcase.

Referring to Fig. gearsifting cam gear 1 has
two groups of teeth. This gear takes its posi
tion with the large group coming into mesh
with the shifting gear (2 mounted on the
shifting shaft. Be sure to mesh gears 1) and 2
with their center lines coinciding with each
other or the mechanism will shift poorly or
will not shift at all

CLUTCH
Housing and sleeve hub

Light side =

)
С
)(
|
To short 4

* Be sure that the ends of the clutch spring

bottom are kept at the same height as the
bottom surface of the clutch sleeve hub.
NOTE
Attach so that the spring does not pop out
of hub bottom surface, as shown by ® in
the Fig.
Clutch sleeve hub nut STATOR AND ROTOR
Using special tool, tighten the clutch sleeve hub When fitting the stator, align the index line
nut with specified torque. 3 with the center of screw 4

= T
Clutch sleeve hub
holder | 09920-53710

Clean throughly both mating surfaces of the

rotor and crankshaft with cleaning solvent. Then
fix the rotor with the key, apply thread lock
20 — 30 Мт cement to the rotor nut and tighten the nut by
Tightening torque 2.0 —3.0 кот using special tool.
14.5 — 21.5 Ib-ft Rotor holder 09930-40113
Thread Lock Cement 99000-32040
Pressure plate
Install the clutch pressure plate so that boss (Т. in
the clutch sleeve hub is aligned with mark (2 оп
the pressure plate.

30 — 40 Мт
Tightening torque 3.0 4.0kg m
21.5 —29.0 Ib-ft
 3-27

ENGINE SPROCKET
The "О” ring 41 located on the drive shaft is for
sealing the clearance between the drive shaft and
the spacer. Tighten the engine sprocket with
specified torque by using special tool.
Rotor holder 09930-40113

PISTON
Before connecting the piston to the connecting
rod, be sure to apply SUZUKI CCI Ой or two:
stroke oil to the connecting rod big end and
small end bearings.

Р 40 — 60 N.m |
Tightening torque 4.0 — 6.0 kgm
| | (29.0 — 43.5 Ib-ft

PISTON RINGS
The two piston rings, 1st and 2nd, are identical
in shape and key-stone type with the stamped
mark, “М” or оп their upper sides. Each
ring in place should be so positioned as to hug
the locating pin. The arrow mark on the piston crown points to
the exhaust port side.
The circlip should be mounted in such a position
| that the mating ends of the circlip do not CYLINDER HEAD
coincide with the groove portion of the piston. Tighten the cylinder head nut with the following
order and specified torque.

Before inserting the piston in the cylinder, be

sure to apply SUZUKI CCI Oil or two-stroke oil 23 —27 N.m
Tightening torque 2.3 — 2.7 кат
to the outer surfaces of the piston and piston
ring grooves. 16.5 — 19.5 Ib-ft
 FUEL AND ОШ SYSTEM

CONTENTS
FUEL TANK AND FUEL COCK...
CARBURETOR .
OIL PUMP
ми...
F

41
FUEL TANK AND FUEL COCK
The fuel tank is provided with a tank cap and fuel cock. An air vent is provided in the tank cap to supply ”
gasoline smoothly to the carburetor. The fuel cock has the structure as shown in Fig. А valve is provided at
the top of the fuel cock lever and can switch over to “OFF”, “ОМ” and "RES". With the valve ON
(normal), the main passage opens. With the valve OFF, both holes close. ^
Generally, water or other impurities are contained in gasoline. A filter is provided to remove them and filter
cup to deposit them.

Filter |)

CLEAN
The fuel cock filter will collect impurities, and therefore must be periodically checked cleaned.
The fuel tank should be cleaned at the same time the fuel cock filter is being cleaned.
INSPECTION
If the fuel leaks from the cap or from around the fuel cock, the cup gasket or cock gasket may be damaged
Visually inspect these parts, and replace them if necessary. Examine the air vent in the cap to see if it is
obstructed. Use compressed air to clean an obstructed vent.
CARBURETOR
CONSTRUCTION

Needle jet
Throttle valve adjusting screw
Air screw
Pilot jet
Main jet
Needle valve Ass'y
Float
Drain plug
Jet needle
Throttle valve

А 1.0. number location

CARBURETOR SETTING TABLE

ITEM SPECIFICATION
| Carburetor type MIKUNI VM24SS
Idle r/min 1300* 150 r/min
Bore size 24.0 (0.94)
1. D. No. 30111 39122
Float height 235:10mm (0,93%0.04 in) | —
Air screw (AS) 1%
Cutaway (С.А) 25
| Jet needle (IN. 4EJ14.3
Pilotjet (Р)
Pilot outlet (P.O.)
Needle jet. (N.J.)
By-pass (В.Р)
Mainjet (МЈ)
 43
FLOAT HEIGHT ADJUSTMENT DIAGNOSIS OF CARBURETOR
To check the float height, invert the carburetor Whether the carburetor is producing a proper
body, holding the float arm pin so that the pin mixture of fuel and air can be told by making a в
will not slip off. With the float arm kept free, road test (simulating the way the user operates
measure the height (4) while float arm is just in the machine) with a standard spark plug (NGK
contact with needle valve by using the caliper. ВВН5 or NIPPON DENSO W24FS) fitted to the — WM
Bend the tongue 1) as necessary to bring the engine. After the road test, remove the spark
height ® to this value. plug, and observe the appearance of the plug as
well as the surfaces of the piston crown. The
Float height 23.5 + 1.0 mm color observed tells whether the mixture is too
(0.93 +0.04 in) | rich or too lean.

MIXTURE ADJUSTMENT p
* This adjustment is effected mainly by main
jet and jet needle.
Before doing so, check to be sure that the >
float level is correctly set and that the over-
flow hose, air vent hose, inlet hose and air
cleaner are in sound condition.
* Find out at which throttle position the engine
lacks power or otherwise performs poorly.
Drive the machine at that throttle position for
NEEDLE VALVE INSPECTION a distance of about 10 km, after which the
If foreign matter is caught between the valve spark plug and piston crown should be
seat and the needle, the gasoline will continue inspected for color and appearance.
flowing and cause it to overflow. If the seat and * The mixture can be made “richer” or “leaner”
needle are worn out beyond the permissible in three ways: namely, by alterring main jet,
limits, similar trouble will occur. Conversely, if jet needle and air adjusting screw. Effective
the needle sticks, the gasoline will not flow into ness of these ways depends on the throttle
the float chamber. position, as shown in this chart.
Remove the carburetor, float chamber and т
floats, and clean the float chamber and float Throttle
parts with gasoline. If the needle is worn as
Main jet =| ^
UC ој
shown below, replace it together with a valve
seat. Clean the fuel passage of the mixing
chamber with compressed air.
Pilot air screw —
NOTE
If the machine is tested at 1/2 throttle re
sulting in a color and appearance indicating ө
a mixture that is too rich or too lean, рег.
form adjustment by means of jet needle
and air adjusting screw. | ‘9

eee
CARBURETION
Adequate carburetion is determined according to the results of various tests, mainly concerning engine
power, fuel consumption and cooling effect of fuel on engine, and jet settings are made so as to satisfy and
balance all of these conditions. Therefore, the jet should not be replaced with a size other than the original,
and the positions of adjustable parts should not be changed except when compensating for the mixture
ratio due to altitude differences or other climatic conditions. When adjustment is necessary, refer to the
following.

Fuel-air mixture ratio can be changed as follows:

Throttle Opening Method of Changing Ratio Standard setting

Air adjusting screw

richer 1-1/2 turns back

1.3/4 turns back
(Only for 1.0. Мо. 39122)

Slight

Jet needle
Leaner
AEJI4 —3rd Groove
(1.0. №. 39111 and 39130)
richer 4125 - 3rd Groove
(I.D. No. 39122)
4Р6 —3rd Groove
(I.D. No. 39150)

Medium

Main jet

90 (1.0. №. 39111)
05 (1.0.№. 39122)
292.5 (1.0.No. 39130)
7.5(1.0.No. 39150)
Larger number
icher mixture
Smaller number
leaner mixture
45

OIL PUMP

AIR BLEEDING CC! oil gauge 09900-21602

Whenever evidence is noted of some air having
leaked into the oil pipe from the oil tank in a
machine brought in for servicing, or if the oil
pump has to be removed for servicing, be sure to
carry out an air bleeding operation with the oil
pump in place before returning the machine to
the user.
To bleed the air, hold the machine in standstill
condition. Loosen the screw (Т. to let out the air
and after making sure that the trapped air has all
been bled, tighten the screw good and hard.

CHECKING OIL PUMP Гоп discharge 11.30 — 1.60 mi (0.044/0.046 — |

Use the special tool, to check the pump for ca | amount 0.054/0.056 US/Imp oz)
pacity by measuring the amount of oil the pump
draws during the specified interval | NOTE XE E
Adjust both throttle and oil pump control
The checking procedure follows: | cable play after checking oil pump. *
* Have the tool filled with SUZUKI CCI or CCI
SUPER OIL and connect it to the suction side
of the pump.
* Run the engine at 2 000 r/min.
е Holding engine speed at the same 2 000
r/min., move the lever up to the fully open
position (2) and let the pump draw for 2 min
uties. For this operation, the reading taken on
the device should be from 1.30 — 1.60 ml
(0.044/0.046 — 0.054/0.056 US/Imp oz)

анарны
Il ан лиот -5
 ELECTRICAL SYSTEM

| СОМТЕМТ$
DISCRIPTION л
INSPECTION AND MAINTENANCE
5-1
IGNITION SYSTEM(For РЕ! type)
The magneto has three coils to meet all electric power needs -charging, lighting loads and ignition. Unlike
conventional magneto units, it is of a contactless type, i.e., no contact breaker is used.
Ignition energy is produced by a SUZUKI “PEI” system, to which the energy for initiating each ignition is
”
supplied from the low-speed and high-speed coils mounted in the magneto. The РЕ! system is highlighted
by these three advantages:
* For the entire speed range from low-speed to high-speed, the sparking voltage induced in the secondary
”
side of the ignition coil is stable.
* № need for frequent checking and servicing of the ignition system since there are no mechanical contact
points as in ordinary contact breakers.
* Ignition timing is corrected electronically to suit each level of engine speed.

Engine kill >. Engine kill switeh

witch 0 2 "a
Am.
“гг
бк
—
НІ
в Г] g »
coir (t2г.рF — а 2% Timing
High speed
ШІ
и
EXE {В |e [oot |}
СЕН 4 | | ka n |
| Mametoz| 45 ] |= E
Ее |] al} Ге Bw =
Lx сесі m
NIPPON DENSO KOKUSAN

РЕ! Operating principles

When the engine is running in low-speed range,
primary coil voltage for charging the condenser #5
is supplied mainly from low-speed coil (L, ); in HE To timing circuit
high-speed range, however, high-speed сой (L) к к ——
supplies most of the voltage. The sum of these
two output voltages is relatively constant over H To capacitor
the normal engine speed range as will be noted $:
in Fig. 5

Output voltage It is the positive shot that charges the condenser

С, the negative shot applies to the timing circuit
Ы / and triggers the SCR into conductive state.
p
LA High-speed сой or Pulser As the SCR becomes conductive, the condenser е
Ме” coil (L2) discharges instantly through the SCR and the
^7 75 d Low speed coil or Exciter primary winding of the ignition coil to induce
Ss, coil (L1)
Engine speed the high-voltage surge in the secondary winding, ө
The high voltage current causes the plug to spark
During half a revolution of the magneto rotor, two times by each rotation of crankshaft
two shots of energy are supplied from the
primary coils to the CDI unit. One shot is posi
tive and the other negative as shown in Fig.

“ыан
IGNITION SYSTEM(For point type)

The flywheel magneto type ignition system is

wired as shown in the diagram. As the flywheel
magneto rotates, current is generated in the Ignition
primary coil mounted on the stator. When the
breaker points close, this current flows to
ground through them, because the primary coil
is grounded and thus has no influence on the
primary ignition coil. When the contact points
open, the current induced in the flywheel
magneto primary coil flows into the primary
ignition coil to provide high voltage induction in Flywheel
the secondary coil, thereby creating a sufficient: magneto
ly strong spark to jump the spark plug electrode
gap.

INSPECTION AND MAINTENANCE

Electro tester (5511) 09900-28106
Checking CDI unit(For PEI type)
The purpose of inspecting the CDI unit is to
determine whether or not the unit is electrically
in good condition. There are two ways to іп
spect. one is simpler and based on the use of a
special tool, which is the Туре 55-11 SUZUKI
electro tester; the other involves the use of
SUZUKI Pocket Tester.
Checking with electro tester:
White/Blue hi
Connect the CDI unit to the electro tester, as Black/white mie te Red
shown in Fig. Twist the selector knob to “PEI” € 1 7
range, and tum on the power switch. The “РЕ!”
indicator lamp will light up to tell that the CDI
unit is in good, sound condition; if the lamp will
not light up, it means, that the CDI is defective
and needs to be replaced.

KOKUSAN

White/Blue Black/White

NIPPON DENSO
53

CHECKING WITH POCKET TESTER

Use a SUZUKI pocket tester in reference to the following chart by adhering to these rules.
* Before starting to check the “CDI” unit, be sure to have all lead-wire couplers unmade.
* Just before putting your pocket tester to two “CDI” terminals, briefly shortcircuit them with a jumper.
© Set the tester knob to "RX1K" range.

| Pocket tester 09900-25001

Checking chart(for NIPPON DENSO CDI unit):

в ва | ва | BW | wal
B/Y ON | OFF | OFF | OFF | OFF
B ON | J OFF OFF OFF OFF
Put negative (—) pin of tester to. | - | : | |
B/R | OFF | ОРЕ | OFF | OFF | OFF
в/в |35kn |зако |ЕРІ ON | OFF
B/W | 3-5ка 35kn | 35ks ON OFF
МВ! | OFF | OFF | OFF | OFF | OFF

Checking chart(for KOKUSAN CDI unit):

© Set the tester knob to “RX100” range.
Put positive (+) pin of tester to:
RW | вм | вв | BY | we
RW | orr | ОРЕ | ОРЕ | ОРЕ
Put negative (-) pin of tester to BW _ [70075021] | OFF 14004500] OFF
B/R | OFF OFF 400-4500) OFF
[ву | ОРЕ |ОРЕ [ОРЕ | | OFF
[wei | ОРЕ | ОРЕ |ОРЕ | OFF |
B/Y . Black with Yellow tracer R/B Red with Black tracer
B Black B/W . Black with White tracer
B/R : Black with Red tracer W/Bl. White with Blue tracer
R/W: Red with White tracer
This chart presupposes that the “CDI” unit is in sound condition; “оп”, “off and each resistance in the
boxes of the chart refer to what your pocket tester will indicate when its positive and negative pins are put
to the indicated terminals of a good “CDI” unit.
 5-4

CHECKING IGNITION COIL CHECKING WITH POCKET TESTER:

The ignition coil is essentially a transformer A SUZUKI pocket tester or an ohm meter may
which changes low voltage into high. For this be used, instead of the electro tester. In either
reason there are two windings; the first (low case, the ignition coil is to be checked for conti
voltage — input side) is the primary coil and the nuity in both primary and secondary windings.
second (high voltage — output) the secondary Exact ohmic readings are not necessary, but, if
coil. the windings are in sound condition, their conti
Use a electro tester type 55-11 to verify ignition nuity will be noted with these approximate
coil performance. ohmic values.

* Set the power switch to “OFF” Pocket tester 09900-25002

* Connect the coil test leads with the yellow tip
attached to the coils B/Y (ог B, ВИА) wire
and the black tip to the coils mounting
bracket (ground). Connect the high tension
leads with the red @) lead attached to the
spark plug cable and the black © lead to the
coils mounting bracket (ground).
Set the test selector knob to “IG. COIL”.
Switch the power ON
Note the spark in the spark gap window. It
should be strong and continuous, not inter
mittent, across a preset 8 mm (0.3 in) дар
Allow the spark to jump the test gap for at
least five minutes continuously, to insure
proper operation under the temperature con: * CDI type (NIPPON DENSO)
ditions
ofactual riding. [Primary (B/W — W/BI) Approx. 0.52
* [Secondary (Plug cap — Ground) |Approx ЕТ!
Electro tester | 09900-28106

* CDI type (KOKUSAN)

park Primary (B/Y —Ground) Approx 0.053]
Main switch А
Secondary
(Plug cap —Ground) [Approx 12k2

* Point type
|Primary (B/Y—Ground) Approx. 1 E
Secondary(Plug
cap —-Ground) [Approx 15kn|
 55

CHECKING MAGNETO COILS

Use a SUZUKI pocket tester or an ohm meter
and check each coils for continuity.

Pocket tester 09900-25002 |

* CDI type (NIPPON DENSO)

[ Coil Resistance
| Highspeed
(B- B/R) | Approx. 270
Low speed (B/R — R/B)| Approx. 2002 |
Charging (G/W -Ground) | Approx. 0.29 |
Lighting (Y — Ground) Approx. 0.32 CONDENSER(For point type)
A condenser is connected parallel with the
* CDI type (KOKUSAN) contact points to minimize point arking. The
—] amount of charge the condenser can store is
Coil | Resistance
determined by its capacity.
Exciter (B/R — B/W) Approx. 2102 The capacity should be checked using an electro
[ Pulser (B/R — RW) Approx. 242 tester.
Charging (G/W — Y) ~ Approx. 0.22 * Insert insulation between the points and the
Lighting (Y — Ground) Approx. 0.32
condenser body should be isolated from
ground.
© Set the tester selector knob to "MF".
* Point type (E-24 and E-35) © Set the power switch to “ON” and calibrate
[coil | Resistance the multimeter “D” scale to the “CAL” posi
tion using the "MF" calibration screw.
| Primary (B/Y — Ground) | Approx. 0.19 * Connect the red (positive) lead to the con.
Charging (М/А — Ground)| Approx. 0.22| denser lead and the black (negative) lead to
Lighting (УЛУ — Ground) | Approx. 0.30 the condenser case mounting tab.
© Press the test button and note the "D" scale
* Point type (for other)
reading.
If the reading does not fall within the stan.
Coil Resistance dard range, replace the condenser.
| Primary (В/У — Ground) | Approx. 0.050
Electro tester 09900-28106
| Charging (М/Н — Ground)| Approx. 0.20
| Lighting (Y/W — Ground) | Approx. 0.29.
STD condensor capacity range 1
NIPPON DENSO таке [0.18 +0.02uF `
KOKUSAN DENKI make | 0.25 + 0.03yF
 5-6

Calibration CHARGING AND LIGHTING COIL

PERFORMANCE
Below are the steps for checking lighting/charg.
ing coil performance.

NOTE
Be sure to use a 6V 4A-h (14.4 KC) battery
which is completely charged. When con
necting the pocket tester terminals, be sure
to differentiate the two terminals, plus (+)
and minus (-)

SILICON RECTIFIER Pocket tester 09900-25002

The silicon rectifier converts AC to DC by allow-
ing current to pass іп one direction only Charging performance check
Check the silicon rectifier for continuity.
Set the pocket tester to the “N x 1" scale * Set the pocket tester knob to DC Ampere
Contact the pocket tester plus terminal (+) to range 20A.
the rectifier AC terminal (~) and minus * Start the engine.
terminal (—) to plus terminal (+). * Check that the proper charging occurs at the
Reverse the test connections. various engine speeds shown in the following
If first step shows any continuity and 2nd chart. (Values in the list below indicate mini
step shows no continuity, the rectifier is mum limit. Therefore, they should be more
sound condition. than indicated under normal condition.)
CDI type (NIPPON DENSO)
Pocket tester 09900-25002
Above 0.5A at 4 000 r/min.
Day | Below 4.0A at 8 000 r/min
Above ОЛА at 4 000 r/min.
9
Nighi
| Below
0.8A at8000 r/min.
* CDI type (KOKUSAN)
Above 0.8A at 4 000 r/min.
Day Below 4.0A at 8 000 r/min.
Above 0.2A at 4 000 r/min.
Night | Below 0.5A at 8 000 r/min.
5-7
* Point type (Е-24 and E-35) Point type (for other)
Above ОВА at 4 000 r/min. Above 0.8A at 4 000 r/min.
Day | Below 4.0A at 8 000 r/min Day | Below 2.5A at 8 000 r/min
Above 0.1A at 4 000 r/min. Above 0.7A at 4 000 r/min.
Night | Below 1.0A at 8 000 r/min iaht | Below 1.5A at 8 000 r/min
Nigh

=
Silicon ectifier
ж-

Charging/
Lighting сой Lighting switch
Pr "ШИ
в

Lighting performance check

* Set the pocket tester knob to AC Volt range
10.
* Connect the terminal as shown in Figure.
• Start engine.
© Check that the voltmeter reads as follows.
| Above 6.0V at 2 500 r/min.
Below 8.5V at 8 000 r/min
э
 5-8
Be sure to turn the tester knob to OHM (22) as FRONT AND REAR BRAKE LIGHT
shown in Fig. before measuring resistance of the SWITCH
following sections. Check the conductivity between the switch ter:
minals while the brake pedal or lever is de-
Pocket tester | 09900-25002
pressed. If conductivity is present, the brake
switch is normal.
\

IGNITION SWITCH
Check the conductivity of each lead wire by us
ing the connections shown in the following
table. If there is conductivity where no connec
tion is shown in the table or no conductivity
where a connection is indicated, replace the
switch.
5-9

LEFT HANDLEBAR SWITCH ENGINE KILL SWITCH

Check the conductivity between the respective
(Only for GP125)
lead terminals on the left handle switch box Check the conductivity between the B/Y lead
(headlight housing). Refer to the following chart terminal on the right handle switch box inside
for this check. the headlight housing and the handlebar ground,
Dimmer switch while the engine kill switch is turn to RUN. If
по conductivity is present, the engine kill switch
w Y is normal.
HI

Fod
Тит signal switch
| B | ы La
zd ГО

HORN BUTTON
Check the conductivity between the green lead
terminal on the left handle switch box inside the
headlight housing and the handlebar ground,
while the horn button is pressed. If conductivity
is present, the horn button is normal.
EN
BATTERY

Initial charge
This battery is a dry-charge type, unlike larger
capacity batteries. It must be initially charged at
the specified rate before it is used, because the
plates may have been slightly oxidized during
storage.
Initial charge rate 0.44, 10- 12 hours
Electrolyte specific 10 12 14
gravity 1.26 at 20°C (68°F)
Charging time (hour)

Recharge
To check the battery capacity, and hence its NOTE
condition, measure the specific gravity of the If starting engine without battery, it may
electrolyte using a hydrometer. Refer to the cause damage of the rectifier
following chart
NOTE
Hydrometer 09900-28403 When recharging, be sure to remove the
battery from the motorcycle to protect the
rectifier against excessive voltage.
е WARNING
When checking, servicing, or charging a
battery, always be certain that the battery
| vent is open and that the vent hose is
properly routed. An obstructed vent or
vent hose could result in the battery case
f
exploding with resultant acid damage.

Specific gravity at Condition Measure

20°С (68°F)
1.260 -1.270 Normat
1.220 -1.250 Under: Recharge
charged
Run down Recharge
Below 1.220 ог replace
 CHASSIS

—CONTENTS —
WHEELS а desino ти d
FRONT FORK
STEERING ......
REAR SUSPENSION
BRAKE
6-1
WHEELS
FRONT WHEEL EXPLODED VIEW(For GP125)

FRONT WHEEL EXPLODED VIEW(For GP125U)

FRONT WHEEL REMOVAL FRONT WHEEL REMOVAL
(For GP125) (For GP125U)
1, Support the machine by center stand. 1. Support the machine by center stand.
Disconnect speedometer cable (1) and loosen Disconnect front brake adjuster (1) and
axle nut (2 after removing cotter ріп 8 speedometer cable 2

77
2. Loosen axle nut (3) after removing cotter pin
—É
6-3
|
4. Draw out wheel bearings. |

ww

REAR WHEEL EXPLODED VIEW э

= ” ”

ЖІ Ж

М, т

B2
с^ Ор,
Фм,

57° = So ”
f
REAR WHEEL REMOVAL 4. Draw out wheel bearings.
1, Remove muffler
Disconnect brake adjuster 1 and remove
torque link nut (2) after removing pin (3

INSPECTION
WHEEL BEARINGS
Visually inspect the wheel hub bore, from
which the bearings have been extracted, for
evidence of abnormal wear caused possibly by
spinning, if any, of bearing outer races.
Check the wheel bearings in the usual manner
after washing them, Make sure that the
bearings spin smoothly without any noise or
resistance: spin them with your fingers. Never
use an air gun for this purpose.
6-5

AXLE SHAFT SPOKE NIPPLE

* Using a dial gauge, check the axle shaft for Check to be sure that all nipples are tight, and
deflection and replace it if the deflection retighten them as necessary using special tool.
exceeds the limit. Loose spoke nipples are likely to result in spoke
damage or in rim distortion.
Dial gauge (1/100) 09900-20603
Spoke nipple wrench | 09940-60112 к
ә
Magnetic stand 09900-20701

2.5 — 3.0 N.m

Axle runout 0.25 mm
(Front& Rear) (0.01 in) Tightening torque 0.25 — 0.3 kgm
1.8 — 2.1 Ib-ft

RIM
Make sure that the rim runout checked as
shown, does not exceed the service limit. Adjust
the tension of the spokes and, if this proves to
be of no effect, replace the rim.

Rim runout
2.0 mm (0.08 in)
| (Radial & Axial)
SPEEDOMETER GEAR BOX TIRE
(GP125U) For proper braking and riding stability, the tire
Apply grease to the pinion and gear. should have sufficient groove depth from the
tread surface, If the groove depth, measured as
shown in the figure, reaches the wear limit, re-
place the tire.

OIL SEAL
Apply grease to the sprocket drum oil seal Wear limit of tire 1.6 mm (0.06 in.)

TIRE PRESSURE
Inflation pressure affects the durability, riding
comfort and safety of a tire to a great extent, so
it is necessary to maintain a proper inflation
pressure.
| КОТЕ
Tire pressure should be measured when tire
is cold.

Tire air pressure

SOLO RIDING DUAL RIDING

General andother | Only for E 31 General and other Only for E-31

175 kPa 150kPa 175 kPa 150 kPa

1.50 kg/cm? | | 1.75 kg/cm? | |1.50 kg/cm?
ШЕМЕНІ
1.75 kg/cm?
21 psi 25 psi 21 psi |
225 kPa 200 kPa 250 kPa 225 кРа
2.25 kg/cm? |2.50 kg/cm? 2.25 kg/cm?
(m | ||
2.00 kg/cm? |
28 psi 36 psi 32 psi
6-7

REASSEMBLY

SPEEDOMETER GEAR BOX REAR WHEEL

Before installing the speedometer gear box 1), CAUTION:
grease it and align groove (2) (for fitting the two When reinstalling the rear wheel, be sure to
drive pawls to the hub) with the hub to insert adjustment for drive chain slack.
the gear box in the wheel

BOLTS AND NUTS

Tighten the following bolts and nuts with
specified torque. |
| [Nm Пет pm т
Front адеп | 27 27-43 [195-310
Rear axle nut 36 38-52 (260-375
“Torque link nut. |10-15 | 10-15 70-110)
Sprocket nut 15-20
|+
|1.5- 2.0 ІШ
i
14.5
©
Fasten the speedometer gear box at the position
shown in the drawing below and take care not to
bend the speedometer cable excessively.

э
^*
FRONT FORK

1) Cap bolt
Oring
Bolt
Spring
Inner tube
8) Ring
Spring
Cylinder
Dust seal
Snap ring
Oil seal
Outer tube
Gasket
Bolt

Cap bolt
Oring
Gasket
Outer cover
Spring guide
Spring
Outer tube cover
Inner tube
Ring
Spring
Cylinder
Snap ring
Oil seal
Outer tube
Gasket
Bolt
6-9 |
SPPING CHARACTERISTICS
* General and other
160

vw
$ Еј
(kg)
Load

0 10 20 30 40 50 60 70 80 90 100 110 E
Travel (mm)
Only for Philippines э
20 г -
| Ju
200

160)

120

80

40

0 20 40 60 80 100 110
n
* Only for Nigeria т
140 [—
120
100
kg) 80
Lo 60
40
20

Travel (mm)

НЕ
 6-10

DISASSEMBLY 4. Remove front fork cap bolt and loosen lower

clamp bolt.
1, Remove front wheel (See page 6-2 )
Disconnect brake caliper by loosening bolts.
(Only for GP125)

5, Remove front fork

Remove the fork inner bolt using special tool.
l
2. Remove fender by loosening securing bolts. Hexagon wrench 09941-03610
(8 x 10 mm)

A аа

3. Remove handlebar clamp bolts and discon-

nect handlebar. . Draw out fork spring.

Invert the fork and stroke it several times to
let out the ой inside. Under the condition
(inverted condition), hold the fork for a few
minutes.
6-11
7. Remove cylinder securing bolt by using 10. Remove the oil seal by using special tool.
special tool
Oil seal remover 09913-50120
"L' type wrench ( 8 mm)| 09911-71510
T handle 09940-34520
Attachment D 09940-34561

8. Draw out cylinder and rebound spring.

p nt

9. Remove the snap ring.

INSPECTION REASSEMBLY

Measure the fork spring free length if it is Reassemble the front fork by reversing the
shorter than service limit, replace it.
sequence of disassembling steps and by referring
to the exploded view.

CYLINDER BOLT
Apply thread lock cement to the cylinder bolt
and tighten with specified torque.
ғақ! "L' type wrench (8 mm) | 09911-71510
99000-32040
Thread Lock Cement

* General and other

Service limit 481.0 mm (18.94 in)

* E-06 (GP125U)
Service limit 200.0 mm (7.87 in)

* E-12, 13 and E-30

Service limit 447.0

mm (17.60 in)
6—9N.m |
Tightening torque 0.6—0.9 kgm | |
* E31 4.5 — 6.5 lb-ft |
SR L:266.0 mm (10.47 in) |
ervice limit | 5: 423.0 mm (4.84 іп)
OIL SEAL
Е-32 Mounting oil seal on the outer tube using special
Service limit | 185.0 mm (7.28 in) tool.

|
Oil seal installer 09940-50110
Inspect and check the removed parts for the
following abnormalities.
Oil seal damage
Cylinder ring damage
Inner tube scuffing
Outer tube scuffing

<x 4
6-13
FORK OIL General and other
For the fork oil, be sure to use a motor oil Oil level 188 mm (7.4 in)
whose viscosity rating meets the spe fications
of SAE 10 W/20. * E-12, 13 and E-30
Oil level 165 mm (6.5 in)

* E-06 (GP125U)

Oil level 36 mm (1.4 in)

* E31

Oil level 176 mm (6.93 in)

* E32
т
Oil level 49 mm (1.9 in)
General and other т
90 mi (3.04/3.17 US/Imp oz)
When install the front fork spring, closed pitch
end should position upside.

* E-06 (GP125U)
Closed pitch
132 ml (4.46/4.65 US/Imp oz)

* E-12, 13 and E-30

146 ml (4.93/5.14 US/Imp oz)
* E31
168 mi (5.68/5.92 US/Imp oz)

* E32
200 ml (6.76/7.04 US/Imp ог)

Adjust the front fork он ievel with a special

tool

Fork oil gauge 09943-74111 Tighten the following bolts and nut with speci
fied torque.
NOTE
Remove the fork spring and compress the Nm кот шн
inner tube fully to measure the oil level. Cylinder bolt 6- 9|06-09| 45- 65
Cap bolt 35-55 |3.5-5.5 254-400
Lowe clamp bolt |25-35 |3.5-3.5 |18.0- 25.5
Front axle nut 27.43 | 27.43 195-310
STEERING

DISASSEMBLY INSPECTION
1. Remove the handlebar and the steering stem Inspect and check the removed parts for the
head by loosening the fork cap bolts and the following abnormalities.
steering stem head bolt. Handlebar distortion
Handlebar clamp wear
Race wear and brinelling
Worn or damaged steel balls
Distortion of steering stem
Upper
Number of balls
Lower

REASSEMBLY
© Install the front fork assémbly, upper bracket
and handlebars, in that order. Set the handle
bars to match its punched mark 1 to the
2. Remove the steering stem nut with special mating face of the holder.
tool.
| Steering stem nut wrench 09940-10122

* As in case of axle clamps, secure each handle-

bars clamp in such a way that the clearances
A ahead of and behind the handlebars are
equalized.
3. Slide off the stem and be careful not to loose
any of the steel balls.
6-15

REAR SUSPENSION

REAR SHOCK ABSORBER э

The rear suspension incorporates a hydraulically damped swinging arm. Shocks received by the rear wheel
are damped by rear shock absorbers mounted between the frame and this swinging arm. These shock
absorbers are telescopic oil damper types. 19

{
EEL т

1) Upper metal 4) Rear damper comp.

2) Lock nut 5) Spring
3) Stopper rubber (©) Spring set

SPPING CHARACTERISTIC
* General and Other * Only for Philippines
ю T—1 T —1 : 2007 —
во - ^-
160|— “ 4

120 —
то)
во В
60
40 ^ т
20 -
тө |
0 10 3 30 40 9% 70 7 е т
SWINGING ARM INSPECTION
1. Remove rear wheel (See page 6-4 ). Inspect and check the removed parts for the
Remove chain case by loosening two bolts 1 following abnormalities.
Damaged chain buffer
Damaged busing
Distortion of swinging arm
wy
6-17

BRAKE
FRONT BRAKE(GP125) * Remove the bleeder valve dust cap and attach
BRAKE FLUID a bleeder tube (2) to the valve. If a transparent
tube is used, it will be easier to see air bubbles
Check the brake fluid level. The level of the as they escape.
fluid is visible without removing the reservoir * The tube end must be submerged in brake
cap. If the level is found to be lower than the fluid, in a clean container.
level mark (Т. embossed on the reservoir, re © Fill the reservoir with brake fluid selected
plenish the reservoir with a brake fluid specified from the table.
below. © Screw on the reservoir сар to prevent spurting
and to block dust.
ж”
© Build up pressure in the hydraulic system by
rapidly depressing the lever several times and
then holding it tightly depressed.
© Open the bleeder valve by unscrewing onehalf
turn, then depress the lever all the way.
* Hold it in this position and close the bleeder
valve; do not release the lever until the valve is
9
9
completely closed.
* Repeat the above steps until no more air
bubbles escape into the Меедег tube or con
tainer, then close the bleeder valve securely.
* Remove the tube and install the valve dust
Specification and Classification cap.
* Check the fluid level in the reservoir and refill
SAE J1703a/SAE J1703b/SAE J1703c
if necessary.
Reinstall the diaphragm and the diaphragm
CAUTION plate, then retighten the reservoir cap.
* Since the brake system of this motor
cycle is filled with a glycol base brake " Њ
fluid by the manufacturer, do not use or
mix different types of fluid such as
silicone-based or petroleum-based fluid
for refilling the system, otherwise serious ^з
damage will result.
* Do not use any brake fluid taken from
old or used or unsealed containers.
* Brake fluid will damage the paint finish
and instrument gauge lenses.

BLEEDING AIR CHANGING BRAKE FLUID ^4

If brake lever travel becomes excessive, or if the The boiling point of brake fluid falls consider
lever action becomes soft and spongy, there is ably with the absorption of moisture. No matter ^| <
probably air in the system which must be how carefully maintenance is carried out, some
purged. This can be done more easily by two absorption is inevitable with long use. Therefore,
persons. Follow these steps: periodic draining and refilling are required.
| Fluid change interval: Every one year
When changing the brake fluid, take care to pre
vent entry of any foreign materials. They will
block the master cylinder return port and cause
brake drag or squeaking.
* Attach a bleeder tube to the bleeder valve.
Drain out the old fluid by depressing the
brake lever until no more comes out.
Now the system can be refilled by following
the same procedure used for purgingairfrom
the system (above)

BRAKE PADS © After pad No. 2 is removed, slide the caliper

Inspection body to the left side of the motorcycle and
Check the friction pads for wear. If any are remove pad No. 1 3
worn to the red limit line 1 on their circum
ferences, replace them.

* Lightly coat the back and sliding peripheral

edge of pad No. 1 with "SUZUKI BRAKE
PAD GREASE".
Replacement Brake pad grease 99000-25100
NOTE
Wash the front wheel and caliper to remove
mud and dust before beginning the
replacement procedure.
Loosen the caliper mounting bolts and take
off caliper.
Remove the pad No. 2 (stationary side) by
loosening securing screw (2

NOTE
* Do not apply SUZUKI pad grease or any
other grease to No. 2 pad.
* Be careful not to smear the friction faces
of brake pads with grease.
6-19
CALIPER

D Caliper axle.
2) Axle O-ring
3) Axle washer
4) Bleeder cap
5) Bleeder
8) Housing cover
7) Caliper holder
8) Axle dustcover
5
9) Pad set
10 Piston boot
1p Piston seal
12 Piston
18. Bolt

DISASSEMBLY
* Unscrew the brake hose union bolt and Unscrew the caliper axle bolts with the special
caliper fitting bolts. tool and separate the caliper holder from the
* Pull the caliper body out from the disc plate. caliper body.
* type wrench 09911-71510
* Remove pads and the piston boot INSPECTION
è Blow out the piston with compressed air
(hold it with your finger to keep it from Inspect and check the removed parts for the
following abnormalities.
flying off)
* Damaged piston seal
е Damaged O-ring for caliper axle
© Damaged dust seal
е Scuffing piston and cylinder surface.

* Remove the piston seal

Ж

• Wash the piston, boot, seal and axle O-rings іп

fresh brake fluid.

NOTE
Do not use gasoline or other petroleum
products, as parts may be damaged.
Do not wash the pads, and be sure no brake
fluid is spilled or splashed onto them.
6-21
REASSEMBLY
Piston seal
CAUTION
Be careful that the piston seal (1) is not tilted or Bleeding air after reassembly (See page
twisted during installation 6-17).
After a test run, check that the pads do not
press against the disc when the brake is not
applied. Do this by raising the motorcycle
and turning the wheel by hand.

Piston
Apply a generous amount of brake fluid to the
inner surface of the cylinder and the piston
surface
Caliper axle
Apply SUZUKI! Caliper Axle Grease to the
caliper axles. This grease has ideal heat resist
ance.
| Caliper axle grease | 99000-25110

"э

o —
т

“4
MASTER CYLINDER

Master cylinder ass'y

Piston and cup set
Reservoir
Cap
Diaphragm
Diaphragm plate.
O-ring
Washer
Bolt
Brake hose
Washer
Bolt
6-23

DISASSEMBLY * Unscrew the fwo master cylinder fitting bolts

and remove the master cylinder body from
* Remove brake lever. the handlebars.

* Remove the right hand rear view mirror and * Remove the circlip and washer.
the cap lock plate.

11

* Remove the boot and circlip by using special

© Place a rag underneath the union bolt on«the tool. A
master cylinder to catch spilled drops of
brake fluid. Unscrew the union bolt and ШЕШІ plier 09900-06106 |
connect the brake hose.
49
| Remove the piston, primary cup and spring. INSPECTION

Inspect and check the removed parts for the

following abnormalities.
е Damaged O-ring and boot
© Scuffing piston and cylinder surface
e Damaged primary and secondary cup.

* Remove the reservoir cap and reservoir by

loosening bolts

* Remove the reservoir O-ring

e Put all removed parts in a clean container and

wash them in fresh brake fluid.

NOTE
Do not wash the parts in gasoline or other
petroleum products. This will damage the
rubber parts
6-25
REASSEMBLY

АЈ

її 120 (”

Tighten the following bolts and nut with speci

fied torque. aJ
| Nm | kom | њк |
Union bolt 25-40 | 25-40 [180-290
Caliper axle bolt |15-20 | 15-20 |110-145 "ө
Caliper bolt 15-25 | 15-25 [110-180
Master cylinder
clamp bolt 9 06-09 | 45- 65

CAUTION
Bleeding air after reassembly (See page
6—17).
BRAKE DISC(Only for GP125) BRAKE SHOE AND DRUM

INSPECTION Disassembly
* Measure disc thickness. е Remove the wheel Front and Rear (See page
6-1)

Inspection
е Measure the brake drum 1.0.

Service limit 3.0 mm (0.12 in)

© Measure disc runout.

Service limit 130.7

mm (5.15 in)

* Measure the brake lining thickness.

Service limit 0.3 mm (0.01 in)

Service limit 1.5 mm (0.06 in)

6-27
REASSEMBLY

Brake cam
* Apply grease to brake cam.

* Reassembly the wheel Front and Rear (See (”

page 6-1)
 SERVICING INFORMATION

CONTENTS
TROUBLE SHOOTING . 8
TIGHTENING TORQUE
SPECIAL TOOLS
SERVICE DATA я
WIRE AND CABLE ROUTING
WIRING DIAGRAM
UNIT CONVERSION TABLE
71
TROUBLE SHOOTING

ENGINE DIFFICULT TO START

First check that there is fuel in the tank. If there is a sufficient amount of fuel, check the following.

Test(1)

| ко Е |

fs spark NO (Dry) Check carburetor |

: |
M eni — Ero
Y

Test(2)

Detective?

Ге
ШШ noui

boo Detective? >- Check ignition coi ]

]
 7-2

Test(3)

$ Faulty spark г plug gas Г

Check for proper engine е Stuck piston
compression

NO — [Checkforcompression leak NO
ylinder head gasket ue

ves
ves КЕРІ ше
pm

ENGINE OVERHEATS
If the engine tends to overheat during low-speed running, check the condition of the lubrication system, the
brakes (for dragging) and cylinder fin cleanliness. If no abnormality is found, make the follo wing checks

Test(1)

operly adjusted oil pump control lever

© Air inoil lines
Tank breather pipe clogged
ө Incorrect oil used
Check for сагы
Test(2) Combustion chambe
мыны не =]
ө Exhaust pipe
plugheat range 1
Spark Г
ког carbur
mixture
С»
on timing Hp Abnormal e | Correct? NO>=}[Clean
Sian and
Y ves L жей іуvesfor
— Check
Adjust x slip
Replace with colder plug

P:
EAS
Ге
Probable cause
ө Worn clutch springs
€ Worn clutch plates d
 7-3

GEAR SHIFT PROBLEMS

Case1 Gears do not епдаде тест)

85% heck gearshift system andgea

cam, forks,cam stopper, gear:
[ ves
i

5.
Case2 Gear shift lever does not return to normal position

Test(2)

Case3 Gears disengage while running

AA
( Test(3)
"т

Check gear dog teeth

Worn? _

е! 4
POOR STABILITY AND STEERING
Handlebar feels stiff to turn
( Test(1)

ves |[Checkst |
Normal?

№
| adjust
Adi

Handlebar operation unstable

Test2)
Check tire tread

[neck tront
ana|
E
ЕЕЕ ЕТІ A
ce Е YES нота?
NO <Normal?
ves
Check front fork, swinging bolts and nuts
arm, frame and whee!
 7-5

TIGHTENING TORQUE
Tighten all bolts and nuts described below to the proper torque using an accura
ciently tightened, a bolt or nut may become damaged or fall off, possible te torque wrench. If insuffi
cycle and injury to the rider. A bolt
resulting in damage to the motor
or nut which is over tightening may become damaged, strip and
internal thread, or break and then fall out. The following tables list the tightening torque
for the major
bolts and nuts of engine and chassis.
When checking the tightening torque of the bolts
and nuts, first loosen the bolt or nut by half a turn and
then tighten to specified torque.

ENGINE
r— - - т
| ITEM Мт 1
кот lb-ft
NT | 3-2 23-27 | 15-195
| Magneto rotor nut — 30—40 | 30-40 215-290
| Primary drive gear nut | 35 | 36-50
[ Clutch sieeve tub cut 200-360 |
| 20-30 20-30 145-215
Engine sprocket nut 40 —60 40-60
| Ensine mounting 290-435 |
nutdiamm 3-23 | 13—23 | 95-165
L |
dia. 10 mm | 25-40 25-40 | 180-280 ]

CHASSIS

ITEM мт kgm Ib-ft

Front axle nut | аз-аз 27-43
Caliper boit 195-310 |
| 5 | 15-25 110 18.0
| Brake hoseunion boit
"Front fork lower clamp bolt
‘| 25-40
25-35
| 25-40 180-290 | ^t
25-35 180-255 |
Le 35—55 35-55 | 255—400
[ Steering stem heed bolt 35—55 | 35-55 255-400 |
Handlebar clamp bolt 12-20 | 12-20
Rear swinging arm pivot nut —
85-145
| 45-70 | 45-70 | 325—505
| Rear shock absorber nut | 20-30 20-30 14.5 — 21.5 |
ШЕСІ | 10-15 | 10-15 70-0 |
Rear axle nut 36—52 36-52 | soas —
Brakecamlever nut
(Front
andRea) | 5-8 | бо | 35- 60
TORQUE SPECIFICATIONS
The table below, relating tightening torque to thread diameter, lists the basic torque for the generality bolts
and nuts used on Suzuki Motorcycles. However, the actual torque that is necessary may vary among bolts
and nuts with the same thread diameter. Refer to this table for only the bolts and nuts and included in the
above tables “Engine” and "Chassis" All of the values are for use with dry, solvent-cleaned threads.

(КС |
Conventional bolt marked bolt

4" marked bolt 7"marked bolt

Thread Conventional ог "4" marked bolt “ж” or "7" marked bolt

Jia. (mm) | = ё |
(А) Nm кат Ib-ft N.m kem | Ib-ft
4 1 15 | 01- 0.15 08- 10 15- 25 | 015- 025 11- 18 |
5 2 0.2 0.3 1.5 2.0 3 5 0.3 0.5 20- 35 |
в 4-6 04- 06 30- 45| 6 9 06 - 09 45- 65 |
8 9- 12 09- 12 65- 85| 15 - 20 15 — 20 | 110- 145
10 20- 25 20- 25 14.5- 180| 30 - 37 30 — 37 | 215- 270
12 35 40 3.5 4.0 25.0 28.5 50 65 5.0 - 6.5 36.5- 47.0
14 60- 70 60- 70 435- 505 | 90 —110 90 -110 | 655- 795 |
16 90-110 90-110 655- 795 |MO -170 140 -170 | 101.5- 122.5
140-160 101.5 —1155 210 -250 |1520- 180.5
SPECIAL TOOLS
[ м PartNami І PartNo
[л a | Snap rng ples [opens type! | 0890006104 LJ
| | Snap ring pliers (closing type) | 09900-06108
з 5һоск driver set | 0990009002 |
4 | Verniea caliper 09900-20101
5 | Micrometer 09900-20202
в Cylinder gauge set 09000-20508
7 | Dial gauge (1/100) 09900-20602 ШЕН!
в | Magnetic stand 09900-20701
9 телен ие 09900-20804

n" | Pocket tester 09900-25002

12 | Timing 09900-27003

EN" | Timing light 0990027311 4”

м | Hydromet 09900-28403
15 | Electro tester [ 09900-28106
16 | | Sud bolt installer 09910-10710
17 | nrod stopper 09910-20115 1
| Piston pin puller 09910-34510
Crank case separating toc (09910-8011
20 L type hexagon wrench 09911-70120
21 Oil seal remover | 09913-50120
22 | Bearing and ой seal installing tool 09913-70122 1
23 | Bearing and oil seal installing tool 09913-80111
24 | Crankshaft remove | 09920-13111
25 tch spring hook | 09920-20310 | | L:
(за | Clutch sleeve hub holde 0992053710 |
27 [ Spark plug wrench 09930-10111 n
28 Rotor remover shaft | ›9930-30102
29 Rotor remover attachment “С 0993030161
30 Rotor holder | 09930-40113 ]
| m | теа 09310012 |
T Steering stem nut ich 39940-10122
эз T^ handle 0094034520
34 | achment "D | 9403456 еј:
35 | Front fork oilseal installe = 99405010 —|
36
| Spoke nipple wrench 39940-60112 Е
^
3 Hexagon combination wrench
(8x10 09981-03610 |
38 install 9941-34511 |
 7-10
—
No, 32 №. 33
4 <
b. ES

ы iia

| No. 35 No. 36

No. 38 No. 39
7-11
SERVICE DATA
Piston + Ring + Cylinder

ITEM | STANDARD
Piston — Cylinder clearance 0.035 —0.045 (0.0014 — 0.0018) 0.120 (0.0047)
Cylinder bore | 56.000 — 56.015 (2.2047 — 2.2053) 56.095 (2.2085)
Piston dia. /Measurement point 55.960 —55.976 (2.2013 —2.2037)/20.0(0.79) |55.880 (2.2000)
Cylinder warpage | = 0.06 (0.002)
Cylinder head warpagea
am = — = 0.05 (0.002) pa
Piston ring free end gap тя
|-М | Approx. 7.5(0.30) | 6.0(0.24) |
2nd
Piston ring end gap n 0.15 — 0.35(0.006 —0.014) 0.80(0.031)
2nd
Piston ring — Groove clearance Е
0.03 – 0.07 (0.001 —0.003) --
2nd
Piston pin — Pin bore clearance 0.002 (tight) —0.011 (0.0001 —0.0004) 0.080 (0.0031)
13.998 — 14.006 (0.5511 — 0.5514) -
Piston рїп О. D. 13.995 — 14.000 (0.5510 — 0.5512) |

Crankshaft Unitimmilin)
ITEM STANDARD LIMIT
Con-rod smallendbore "18.003—18,011 (0.7088
—0.7091) 18.040 (0.7102)
|. Piston pin0.D. a] 13.995—14.000 (0.5510
—0.5512) | 13.980 (0.5504)
| Con-rod deflection &malend) | р — Е [зо (0.12) |
Con-rod big end wear | | 0.08 (0.003) |
Crankshaft runout | — [05 (0.002)

SPECIFICATION
| Oi! pump reduction ratio 3.625 (58/16 x 29/17 x 17/29)
| сс pump discharge rate (Full open) |1.30-1.60 mi (0.044/0.046—0.054/0.056 US/Imp oz) 2 minutes at 2000r/min
 7-12
Unit:mm(in)
ITEM STANDARD LIMIT
Drive plate thickness 3.0 (0.11 —0.12 2.6 10.10)
Drive plate distortion 0.4 (0.016)
Driven plate thickness 1.6 (0.063)
Driven plate distortion ол (0.004)
Drive plate claw width 11.8 —12.0 (0.46 — 0.47) 11.3 (045)
Cluch spring free length 32.0 (1.26) 335 (1.32)
Pri. drive —Driven gear backlash 0.02 0.07 (0.001 —0.003) 0,10 (0.004

Transmission Unit: mm(in)

ITEM STANDARD LIMIT |
Primary reduction 3.625 (58/16)
Final reductio: 3.000 (45/15) 3.214 (45/14) Only for Philippines
Gear rations, Low 3.090 (34/11)
2nd 1.812 (29/16)
3rd 20)
4th 0.956 (22/23)
Top 0.800 (20/25)
2nd,3rd, 4th andTop
Cear backlash st, 2nd, 0.10 (0.004) 0.15 (0.006)
Shift fork —Groove clearance мол 0.45 (0.018)
0.05 0.25 (0.002 —0.010)
No. 2
Shift fork groove width № 1|4.45 —4.55 (0.175 —0.179)
№ 2| 5.45 —5.55 (0.215 —0.219)
Shift fork thickness No. 1|4.30 —4.40 (0.169 - 0.173)
Nc 2| 5.30 —5.40 (0.209 —0.213)
Drive chain size 0.1.0 #4280, 120 links or 122 links
20 pitch length 254.0 (10.00)
 7-13
Carburetor
ITEM SPECIFICATION
Carburetor type MIKUNI VM24SS
idle r/min 1300 +150 r/min
ЕНЕСІНЕ | 24.0 (0.94)
1.0. No. | 39111 39122 39130 39150
Float height | 23,5:1.0 mm (0.93*0.04 іп) - - [roa
Air screw (AS) 1% 1% D -
Е Cutaway (СА) | 25 - - —
Jet needle (J.N) 4ЕЛаЗ 4253 4EJI43 4P63
Pilotjet 27) #25 #175 #5 |
Pilot outlet (P.0.) 08 10 08
| Needlejet.(М) 0-2 P-2
| By-pass (ВР) 12 08 12 10
| Mainjet (MJ) #90 #105 #925 #975
Electrical
| ITEM | SPECIFICATION
| Ignition timing |Point type 20° + 2° B.T.D.C.
CDI type (KOKUSAN) 24° + 2° B.T.D.C. at 4 000 r/min
CDI type (NIPPON DENSO) 21° + 2° B.T.D.C. at 6 000 r/min
Piston stroke (point type) |1.52 — 1.87 —2.26 (0.060 - 0.074 — 0.089)
Spark plug МСК BBHS or NIPPON DENSO W24FS
NGK B7HS or NIPPON DENSO W22FS Only for Philippines
Spark plug gap | 0.6 —0.8(0.024 —0.031)
Contact point gap | о.35+0.05 (0.014+0.002)
Dwell angle 170
Spark performance Over 8 (0.3) at 1 atm
Condensor capacity | 0.28:0.034F . KOKUSAN 0.18t0.024F .....NIPPON DENSO
Ignition сой resistance | CDI type (KOKUSAN)|СО!type (NIPPON DENSO) Point type
Primary Approx. 0.052 | Approx. 0.502 Approx. 1.52
Secondary | Approx. 1280 Approx. 13k Approx. 1559
Magneto coil resistance | CDI type (KOKUSAN) CDI type (NIPPON DENSO)
Exciter coil | B/R-B/W:Approx. 2102 | High speed coil |B-B/R:Approx. 272
Pulser coil | B/R-R/W:Approx. 240 Low speed coil |8/R—R/B:Approx. 20002
Chargingcoil| G/W-Y:Approx. 0.2% |Charging coil | G/W-Ground:Approx. 0.2
Lighting coil Y—Ground:Approx. 0.30 |Lighting coil Y Ground: Approx. 0.301
Point type (E-24 and E-35) Point type (for other)
Primary coil B/Y—Ground: Approx. 0.05% Primary coil B/Y Ground: Approx. 0.052
Charging coil|G/W Ground:Approx. 0.182 |Charging coil W/R-Ground:Approx. 0.29
Lighting coil Y Ground: Approx. 0.29 Lighting coil YMW-Ground:Approx. 0.212
 7-14
Jnit:mm(n)
ITEM SPE FICATION
Battery capacity ву 14.4kC (4 Ah) 10 HR
Specific gravity 1.26at20°C
Charging rate CDI type Day Above ОБА at 4 000 r/min, Below 4.0A at 8 000r
(NIPPON DENSO)|Night Above ОЛА at 4 000 r/min, Below 0.8A at 8 000 r
CDI type Day Above ОВА at 4 000 r/min, Below 4.04 at 8 000 г
(KOKUSAN) (Night Above 0.2A at 4 000 r/min, Below 0.5A at 8 000 r
Point type Day Above ОВАat 4 000 r/min, Below 4.0А at 8 000 r.
(Е:24 and E35) (Night Above ОЛА at 4 000 r/min, Below 1.0А at 8 000r
Point type Day Above ОВА at 4 000 r/min, Below 2.5A at 8 000 г
(Other) Night Above 0.7A at 4 000r/min, Below 1.5A at 8 000 r
Lighting coil performance Above 6V at 2 500 r/min, Below 8.5V at 8 000 r/min
Resistor resistance | Approx. 40 (Only for Е-02, 04 17, 18, 21 and E-22)
Fata 10А

Brake + Wheel Unit:mmlin)

ITEM | STANDARD LIMIT
Axle runout (Front
& Rear) | 0.25 (0.010)
Brake drum 1. О. 130.0 (5.12) 130.7 (5.15)
Вгаке ining thickness (Front & Rear) 1.5(0.06)
Brake disc thickness 3.8 -4.2 (0.150 —0.165) 3.0(0.12)
Brake disc runout 0.3 (0.01)
Master cylinder cylinder dia. 12.700 — 12.743 (0.5000 — 0.5017]
Master cylinder piston dia. 12.650 —12.670 (0.4980 —0.4988
Brake caliper cylinder bore 33.960 —34.000 (1.3370 — 1.3386)
Brake caliper piston Dia. 33.890 — 33.910 (1.3342 — 1.3350)
Wheel rim гш out (Radial & Axial 2.0(0.08)

ITEM STANDARD LIMIT

Tiresize. Front 275 18—4PR 3.00 16 – АРА Only for Philippines
Rear 3.00 — 18 –АРА 3.00 — 16 АРВ Onlyfoor Philippines
re Tread depth Front 1.6 (0.06)
Rear 1.6 (0.06)
7-15
Tire air pressure
SOLO RIDING DUAL RIDING
General and other Only for Е-31 General and other ] Only for ЕЗІ
175 kPa 150 kPa
1.50 kg/cm?
| | (“ам |
200 kPa 225 kPa
REAR | 2.00 kg/cm? 2.25 kg/cm?
| (“ам | | 32 psi |

Unit:mm(in)
STANDARD LIMIT
Front fork stroke 110.0 (4.32)
Rear wheel travel 85.0 (3.35)
Fork spring free length General and other 496.0 (19.53) 481.0 (18.94)
E-06 (GP125U) 220.0 (8.66) 200.0 (7.87)
E-T2, 13 and E-30 462.0 (18.19) 447.0 (17.60)
L: 277.5 (10.93) 266.0 (10.47) |
E31
5: 156.5 (6.16) 123.0 (4.84)
E32 200.0 (7.87) 185.0 (7.28)
Fork oil level General and other | 188 (7.4)

E-06 (GP125U) | з6(14)

E-12, 13 and ЕЗ0 С] 165(6.5)
ЕЗ1 [176 (6.9)
E32 [49 (1.9)
Swinging arm pivot shaft runout 0.6(0.02)
 7-16

Capacity
Unit:mmln)
ITEM SPECIFICATION
Fuel tank including reserve 9.8 L(2.6/2.2 US/Imp gal)
2.0 L (2.1/1.8 US/Imp at)
Engine oil tank 12 L(1.3/1.1 US/Imp at)
Transmission oi Change: 800 ті (0.85/0.70 US/Imp at)
Overhaul: 850 mi (0.90/0.75 US/Imp at)
Front fork oil (each leg) General and other [90 mi (3.04/3.17 US/Imp ог)
ЕЛ2, 13 апі ЕЗ0 | 146 ml (4.93/5.14 US/Imp oz]
Е-06 (GP125U) 132 mi (4.46/4.65 US/Imp oz)
E31 T 168 ті(5.68/5.92 US/Imp oz)
E32 [200 mi (6.76/7.04 US/Imp oz)
Fuel type. Octane number of 90 or higher (Research Method), preferably unleaded
or/ow-lead.
Engine oil type. SUZUKI СС! or CCI SUPER
Transmission oil type SAE 20 W/40
Front fork oil type SAE 10 W/20
7-17
WIRE AND CABLE ROUTING
со

punoi ai peaj с-2Азацев

ы“ jal
жән | dwe asm peaj oraubew
Aimeg
А
ШІ a
дшеүә ззәшец Bui
жәшец б

өшер
ssausey
Maneg
дшеүә
билм
WIRING DIAGRAM (General and other)

40709
о
зым
©
WIRING DIAGRAM (E-02, 04, 17 and E-21)

COLOR
WIRE
7-21
WIRING DIAGRAM(E-18)

>
3
88
E=
7-23

WIRING DIAGRAM(E-24)

Оз В
di i
шү

ното?
зым
>:
ТЕНИ

тумон
«ог
E
1
&
№
:
HТ
pRO
амбпаузн
 UNIT CONVERSION TABLE
Volumes
cc, ст), mt 061023
03380 US oz
03621 Imp. oz
002113 US pt.
001760 Imp. pt
1 000 се, ст?, тё
26420 US gal
21997 Imp. gal.
1.0567 US at
8799 Imp. ак
33.80 US oz
35.21 Imp. oz
US gal 3.78533 e
Imp. gal 4.54596 e
} US gal 8326 Imp. gal.
Imp. gal. 1.2010 US gal
US at 9463 [|
25 US gal.
Imp. at 1.1365 e
25 Imp. gal.
US pt 473,26 сс, сто, тё
125 US gal
Imp. pt 568.18 се, em”, тё
125 Imp. gal.
US oz 29.57 сс, ст?, тё
0625 US р.
Imp. oz 28.41 cc, ст?, тё
05 Imp. pt
16.39
Weights
grams 001
0022
03527
ка 1000 grams
35.274 oz.
2.2046 Ibs.
Ibs. 453.6 grams
16
45359 kg
J oz 28.3495 grams
0625 Ibs.
kgf 10 Newton IN)
Distance
03937 in
ст 3937
т 3.281 ft
 кт
miles

ft

Torque
кост
кет

Weft

kgf. m Newton meter (М.т) Joule (J)

Pressure
kg/cm 14,22
0001
100 kPa
kPa о kg/cm
Би? or p 07031
Velocity
36
3.281
2.237
miles/h 1.6093
1.467
4470
km/h 2778
9113
6214

Square

10.764
155
001
09290 3
6.4516
Temperature
F 9/5x C +32
c 5/9 x (F —32) C : Семи
Capacity
Ah 36
 LIST OF ABBREVIATIONS
A ampere, amperes kg-m/sec kilogram тете 5 рег second
АС alternating current kilo-ohm

АСУ alternating current voltage kilo Pascal

AH amperes-hour kilowatts

ammeter, amperemeter pounds-foot

AM
Amp. ampere Ibs pounds

B.T.D.C before top dead center Ibs/in pounds per square inch
cc cubic centimeters liter, litre
cm centimeters meter, meters
cm square centimeters square meters
ст cubic centimeters m cubic meters
сиіп cubic inches mi. mile, miles
oc direct current miles/h miles per hour

DCA direct current ampere mt milliliters

осу direct current voltage mm millimeters

) ft foot, feet MPa Mega Pascal
ft squaré feet m/sec meters per second
ft/sec. feet per second uF microfarad
hp horsepower N Newton
Imp. gal Imperial gallons N.m Newton meters

Imp. pt Imperial pints ohm

Imp. qt Imperial quarts oz ounce, ounces
ог. Imperial ounces
percent, per cent
Imp.
in. inch, inches
psi pounds per square inch
in’ square inches
r/min revolutions per minute
in cubic inches rpm revolutions per minute
J Joule SAE Society of Automotive

kc kilo coulomb
Engineers
kg kilogram, kilograms US gal. US gallons
Д ко! kilogram-force US oz US ounces

kgf.m kilogram-force meter US pt US pints

kg-cm kilogram centimeters US qt US quarts
] kg/cm kilograms per square centimeter У volt, volts

kg-m kilogram meters ум voltmeter

km kilometers м watt, watts
kilometers per hour
7-27

DECIMAL EQUIVALENTS
INCH мм INCH мм
015625 515625
03125 17 53125 |
132
046875 546875 | 14mm:
= 55118 inch
0625 | li 5625 |
078125 2mm- 57125 | 15mm=
өзе | 07874 inch 19
B | 59375 59055 inch
109375 3mm- 609375
125 11811 inch 625 16тт-
| | 62992 inch
140625 640625 |
5 15625 4тт- 21 65625 17тт-
| 32 |32
15748 inch 66929 inch
171875 671875
-і
1875 бтт- n 6875
| 16 | 19685 inch 16
203125 703125 18тт-
iz |
21875 23 | 71875 70866 inch
32 |32
234375 бтт- 734375 19mm
23622 inch 74803 inch
75
7mm- 765625
ЕЈ 27559 inch 20mm-
25| | 78125 78740 inch
32 32
I—4 796875
Bmm- 13 8125 21mm
16 шн: ч!
31496 inch 82677 inch
| 328125 828125|
тт Г 34375 9mm: T27
32 132 84375
35433 inch
359375 859375 22тт-
86614 inch
875
10тт- 23m
БІЗ T 39370 inch 28 90551 inch
32 3! |
421875 | 11тт- 921875
43307 inch Tis
4375 NET 9375 24mm-
453125 94488 inch
953125
46875 12тт= Тат 96875
32 24тт-
47244 inch 98425 inch
484375 984375
13mm=
51181 inch
 7-28

MILLIMETERS-INCHES CONVERSION TABLE

MILLIMTERS TO INCHES
T
T ml P 1 2 | а и “|4 7 8 9
inches (in.)
o | - [oos | 0.0079 [oona |0.0187 |00197 |0.0236 |00276 |0.0315 |0.0364
1 0.0394 |00433 | 0.0472 |0.0512 |0.0551 | 0.0591 |0.0630 |0.0669 |0.0709 | 0.0748
2 0.0787 |0.0827 | 0.0866 |00906 |0.0945 |0.0984 |0.1024 |0.1063 | 0.1102 |0.1142
3 0.1181 |0.1220 |0.1260 |0.1290 |0.1320 |0.1378 | 0.1417 |0.1457 | 0.1496 |0.1535
4 0.1575 |0.1614 | 0.1654 |0.1693 |0.1732 | 0.1772 |0.1881 |0.1850 |0.1890 | 0.1929
5 0.1969 |0.2008 | 0.2047 |0.2087 |0.2126 |0.2165 |0.2205 0.2244 0.2283 |0.2323
в |олзвг 02402 | 0.2441 | 0.2480 |0.2520 |0.2559 |02598 02638 |0.2677 02717
7 0.2756 |0.2795 |0.2835 |02874 |0.2913 | 0.2963 |0.2992 | 0.3031 |0.9071 |0.3110
8 0.3150 |0.3189 | 0.3228 |0.3268 |0.3307 | 0.3346 | 0.3386 | 0.3425 |0.3465 | 0.3504
ә [0353 |0.3883 | 03822 |0.3661 |03701 03740 |03780 |03819 |03858 |озвов
10 | 0.3037 [93976 |0.4016 |0.4055 |олова | вата |04173 | 04213 | 0.4252 |0.4201|

INCHES TO MILLIMETERS
- т
пон o 01 02 03 04 05 06 07 | ов 09
millimeters (mm)
0 - [озы | osos | 0262 | 1016 | 1.270 | 1524 | 1178 | 2032 | 2286
1 2540 | 2794 | зов | 3302 | 3556 | asio | aosa |4318 | 4672 | 4826
2 5080 | 5334 | 5588 | 5842 | 6096 | 6350 | 6604 | 6858 | 7.112 | 7.366
3 7620 | 7874 | 8.128 | 8382 | 8.636 | 8890 | 9.144 | 9.398 | 9.652 | 9.906
4 10.160 |10414 | 10.668 | 10.922 |11.176 | 11.430 |11.684 |11.938 | 12.192 | 12.446
5 12700 |12.954 | 13208 |13462 |13716 | 13970 |14224 | 14.478 | 14732 |14.988
6 15.240 |15494 | 15748 | 16002 | 16.256 | 16.510 | 16.764 |17.018 | 17.272 | 17526
7 17780 |18.034 |18288 |18542 |18796 | 19050 19304 19558 |19812 | 20066
8 20.320 |20574 |20828 |21.082 | 21.996 |21.590 |21844 22098 |22.952 | 22.606
9 22860 | 23.114 | 23.368 |23822 |23876 | 24.120 |24.384 24638 |24.892 | 25.146
10 25.400 |25654 |25908 |26.162 |26416 |26670 |26.924 |27.178 |27432 |27.686
 Prepared by
SUZUKI MOTOR CO.,LTD.
Service Department
Overseas Operations Division
May, 1979
Manual No. SR-1270 (E-01)
Printed in Japan
SUZUKI MOTOR CO.,LTD.