FOREWORD This motorcycle has been designed and produced utilizing Suzuki s most modern technology. The finest product, however, cannot perform properly unless it is correctly assembled and serviced. This set-up manual has been produced to aid you in properly assembling and servicing this motorcycle. Please review this set-up manual carefully before performing any work. Take special care to properly perform the required assembly and servicing marked by either a Warning or a Caution. Failure to follow the directions in either of these two (2) categories could lead to serious problems. and areas are denoted to emphasize certain areas and carry the following meanings: Indicates a potential hazard that could result in death or injury. Indicates a potential hazard that could result in motorcycle damage. This set-up manual is based on a motorcycle of standard specification. Some minor differences from this manual may be found in other specifications. K8 99505-01038-01E September 07 Printed in Japan (TK) 28
PREPARATION WORKSHOP The workshop where the machine is assembled should be clean, spacious, and have a level floor. A: Packed motorcycle B: Working space SELF PROTECTION The technician should wear protective clothing such as leather gloves, a long sleeve shirt, eye protection and safety shoes as shown in the illustration when handling metal crates. UNCRATING THE MOTORCYCLE Remove the carton. Metal crates may have sharp edges and may cause injury. A: Crate Remove the strap. Take out the front wheel assembly from the crate base. A: Strap B: Front wheel assembly 1
Remove the bolts of the bracket. Remove the bolts to take off the rear wheel holding bracket. A: Bolt Remove the bolts from the crate. A: Bolt Lift the steel frame to separate it from the base of the crate. Carefully remove the various component parts packaged around the motorcycle. Handling crates requires two operators. Be careful not to scratch the motorcycle. A: Steel frame B: Crate base 2
LOCATION OF PARTS Check all the components which have been removed from the base of the crate. Item Part Name Q ty Remarks Handlebars assembly 1 Clamp 2 Flange bolt 4 8 35 mm Strap 1 L:120 A1 Fuel tank vent hose 1 Engine stop switch holder 2 Upper and Lower Screw (with lock washer) 1 3 14 mm Lever cover 2 For front brake lever and clutch lever Handlebars assembly 1 Handlebar clamp 2 Flange bolt 4 8 35 mm A2 Strap 1 L:120 Fuel tank vent hose 1 Engine stop switch holder 2 Upper and Lower Screw (with lock washer) 1 3 14 mm Lever cover 1 For clutch lever For front brake Holder 1 B master cylinder Flange bolt 2 6 25 mm Fuel tank cover 2 Right and Left Flange bolt 4 6 16 mm C Stepped washer 2 OD:16.0 ID:6.5 T:3.5 Stepped washer (White) 2 OD:17.0 ID:6.5 T:6.5 Fastener 4 Rubber cushion 2 Item Part Name Q ty Remarks Front fender 1 D Flange bolt (with washer) 4 6 16 mm Collared spacer (Black) 4 OD:17.0 ID:6.5 T:6.5 E Front brake hub panel assembly 1 F1 Front wheel spacer 1 Washer 1 OD:20.0 ID:10.5 F2 Front wheel spacer 2 Washer 1 OD:24.0 ID:12.5 G Front brake cable clip 1 Flange bolt 1 6 10 mm H1 Front wheel assembly 1 H2 Front wheel assembly 1 I Fuel label 1 For limited market J Warning tag 1 K Owner s manual set 1 OD ID T L OD : Outside diameter (mm) ID : Inside diameter (mm) L : Length (mm) T : Thickness (mm) Item A1, E, F1, G, H1... For DR-Z125 Item A2, B, F2, H2... For DR-Z125L Please hand over the parts shown as Item K in the above table to your customer together with motorcycle. Parts listed above are installed respectively into the positions as follows. DR-Z125 H1 D G A1 F1 DR-Z125L H2 E D C A2 B C F2 C C F2 3
B A1 A2 C E D I F1 G J F2 H1 H2 K 4
(FOR DR-Z125) The photograph shown indicates the parts dismounted from the motorcycle in addition to the items shown in the preceding page. A: Throttle assembly Engine stop switch B: Clutch cable (FOR DR-Z125L) The photograph shown indicates the parts dismounted from the motorcycle in addition to the items shown in the preceding page. A: Front brake master cylinder B: Throttle assembly Engine stop switch C: Clutch cable Before assembling the motorcycle, thoroughly understand the Safety Check Out described on page 32. After completion of assembly, carefully check the motorcycle referring to the Safety Check Out, then deliver the motorcycle to the customer. 5
ASSEMBLY REMOVING THE BRACKET (FOR DR-Z125L) Remove the bolt to take off the front brake master cylinder from the bracket. Keep the position of front brake master cylinder with its cap facing upwards until it is installed. The bolt is no longer needed and this may be discarded. A: Front brake master cylinder B: Bolt C: Bracket Remove the bracket from the handlebar holder. Be careful not to scratch the fuel tank. The bracket and bolts are no longer needed and these may be discarded. A: Bracket B: Bolt HANDLEBARS Loosen the throttle housing retaining screws. Insert the throttle assembly onto the handlebars. A: Throttle assembly B: Handlebars 6
Install the handlebars assembly using the two clamps and four bolts. The punch mark on the clamps shows front side. Align the dot mark on the handlebars with the mating surface of the front side of left clamp. A: Clamp B: 8 35 mm flange bolt C: Dot mark D: Punch mark Tighten the handlebar clamp bolts to the specified torque. Handlebar clamp bolt: 23 N m (2.3 kgf-m) FORWARD To install the handlebars correctly, first tighten the bolt A of the front side with specified torque and then tighten the bolt B of the rear side. Make sure that the clamp has no clearance at the front side as shown in the illustration. A: 8 35 mm flange bolt B: 8 35 mm flange bolt C: Dot mark THROTTLE Align the dot mark on the handlebars with mating surface of the throttle housing. Tighten the throttle assembly with two screws after the assembly is positioned so that there is approximately 0.5 1.0 mm of clearance between the grip end and the end of the handlebars. Check to ensure that the throttle operates freely and closes automatically. A: Throttle assembly B: Dot mark C: Screw 7
FRONT BRAKE MASTER CYLINDER (FOR DR-Z125L) Install the front brake master cylinder onto the handlebars. Align the dot mark on the handlebars with the master cylinder-to-holder fitting surface. Tighten the front brake master cylinder mounting bolts to the specified torque. Front brake master cylinder mounting bolt: 10 N m (1.0 kgf-m) To install the holder correctly, first tighten the bolt B of the upper side with specified torque and then tighten the bolt C of the lower side. A: Front brake master cylinder B: 6 25 mm flange bolt C: 6 25 mm flange bolt D: Holder E: Dot mark Install the holder in position according to the mark UP. Make sure that the holder has no clearance at the upper side as shown. Check for brake fluid leakage. A: 6 25 mm flange bolt B: Holder C: Front brake master cylinder D: Handlebars Remove the crate axle bracket from the crate base. The bracket and bolt are no longer needed and may be discarded. A: Crate axle bracket B: Bolt 8
1. Lift the front of motorcycle by using a hoist. 2. Raise the rear of motorcycle. 3. Pull the crate base forward, then balance the motorcycle. FRONT FENDER Install the front fender with four sets of mounting parts as shown. A: Front fender B: Collared spacer OD:17.0 mm ID:6.5 mm T:6.5 mm C: 6 16 mm flange bolt (with washer) FRONT Install the front fender to the front fork lower bracket. A: Front fender B: Collared spacer OD:17.0 mm ID:6.5 mm T:6.5 mm C: 6 16 mm flange bolt (with washer) D: Front fork lower bracket FRONT WHEEL (FOR DR-Z125) Remove the front axle nut. Remove the front axle from the fork legs. The vinyl tube is no longer needed and this may be discarded. A: Front axle nut B: Front axle C: Vinyl tube 9
Mount the front wheel assembly properly. A: Right fork leg B: Left fork leg C: Axle nut D: Washer OD:20.0 mm ID:10.5 mm E: Front wheel spacer F: Front brake hub panel assembly G: Front axle Clean the brake drum with alcohol or other non-petroleum based solvent. Examine the brake shoes, springs, and operating mechanisms. Install the brake panel into the front wheel hub. A: Front brake hub panel assembly Attach the front wheel spacer to the front wheel hub. When attaching the front wheel spacer, be careful not to damage the oil seal lip. The flange side of the spacer faces the right fork leg. Place the front wheel assembly into the fork legs, aligning the brake hub panel anchor slot onto the stub on the left fork leg. A: Front wheel spacer B: Stub C: Anchor slot D: Oil seal (Lip) 10
Insert the front axle from the left side of fork leg and fix the front wheel assembly to the front fork. Never use force to install the front axle. If it cannot be installed by hand, it is not correctly aligned. Place the washer on the right end of the front axle. A: Front axle B: Washer OD:20.0 mm ID:10.5 mm Tighten the front axle nut to the specified torque. Front axle nut: 42 N m (4.2 kgf-m) A: Axle nut FRONT WHEEL (FOR DR-Z125L) To prevent brake squeaking and pad contamination, carefully clean the front brake disc plate with alcohol or other non-petroleum based solvent. This will remove the rust-preventive coating and dirt. Remove the front axle nut. Remove the front axle from the fork legs. The vinyl tube is no longer needed and this may be discarded. A: Front axle nut B: Front axle C: Vinyl tube 11
Mount the front wheel assembly properly. A: Right fork leg B: Left fork leg C: Axle nut D: Washer OD:24.0 mm ID:12.5 mm E: Front wheel spacer F: Front axle Remove the supporter from the brake pad of the front brake caliper. Carefully insert the front brake disc plate between the caliper brake pads. A: Supporter B: Disc plate C: Pads RIGHT LEFT Attach the front wheel spacers between the front wheel hub and fork leg. The large flange of the spacer faces the hub. A: Spacer Insert the front axle from the left side of fork leg and fix the front wheel assembly to the front fork. Never use force to install the front axle. If it cannot be installed by hand, it is not correctly aligned. Place the washer on the right end of the front axle. A: Front axle B: Washer OD:24.0 mm ID:12.5 mm 12
Tighten the front axle nut to the specified torque. Front axle nut: 49 N m (4.9 kgf-m) A: Axle nut Place the motorcycle on the side-stand, then remove the hoist hook. (FOR DR-Z125) The line drawings on page 29 and 31 show the proper routing of the control cables and wirings. Refer to them in addition to following the instructions carefully. A: Clutch cable B: Throttle cable C: Front brake cable D: Engine stop switch wiring harness (FOR DR-Z125L) The line drawings on page 29, 30 and 31 show the proper routing of the control cables, hose and wirings. Refer to them in addition to following the instructions carefully. A: Clutch cable B: Throttle cable C: Front brake hose D: Engine stop switch wiring harness 13
FRONT BRAKE CABLE (FOR DR-Z125) Pass the front brake cable to the guide. Pass the front brake cable to the lever cover. A: Front brake cable B: Guide C: Lever cover Check the brake cable end. Align the brake cable end with the recess of brake cam lever as shown. A: Brake cable end B: Brake cam lever Turn the brake cable adjuster and lock nut in as far as possible and align the slots. Insert the inner cable end into the recess in the brake lever, then pull on the outer cable housing and insert it into the adjuster. Do not adjust at this time. Adjustment will be covered in the SERVICING section. Before installing the cable, grease the cable end. Install the lever cover. A: Front brake cable B: Adjuster C: Lock nut D: Cable end E: Lever cover 14
FRONT BRAKE CABLE CLIP (FOR DR-Z125) Install the front brake cable clip as shown, leaving the proper amount of slack in the cable between the clip and the brake hub panel. A: Cable clip B: 6 10 mm flange bolt C: Front brake cable INSIDE CLUTCH CABLE Pass the clutch cable to the lever cover. A: Clutch cable B: Lever cover Turn the clutch cable adjuster and lock nut in as far as possible and align the slots. Insert the inner cable end into the recess in the clutch lever, then pull on the outer cable housing and insert it into the adjuster. Do not adjust at this time. Adjustment will be covered in the SERVICING section. Before installing the cable, grease the cable end. Install the lever cover. A: Clutch cable B: Adjuster C: Lock nut D: Cable end E: Lever cover 15
ENGINE STOP SWITCH Hook the holders on the grooves of the engine stop switch assembly. Use the holder with an internal thread cutting at the lower side. A: Engine stop switch assembly B: Holder (Upper) C: Holder (Lower) D: Thread cutting Install the engine stop switch to the left of handlebars. A: Engine stop switch assembly B: 3 14 mm screw (with lock washer) CLAMP Clamp the engine stop switch wiring harness with strap. A: Strap L:120 mm B: Engine stop switch wiring harness C: Handlebars FRONT NUMBER PLATE Pass the strap of the number plate around the handlebar bridge pipe. Fit the strap of the number plate into the guide. A: Strap B: Handlebar bridge pipe C: Guide 16
FUEL TANK COVER Remove the bolts to take off the seat. A: Seat assembly B: Flange bolt, Stepped washer Stick the rubber cushion to the fuel tank cover (Right and Left) at the mark-off line. Remove the stain from the sticking part and degrease the fuel tank cover. A: Rubber cushion B: Fuel tank cover C: Mark-off line Install the fuel tank cover with flange bolt, stepped washer and fastener. To install the fastener, pull the center pin and fix the fastener by pushing the center pin. A: Fuel tank cover B: 6 16 mm flange bolt C: Stepped washer OD:17.0 mm ID:6.5 mm T:6.5 mm D: Stepped washer OD:16.0 mm ID:6.5 mm T:3.5 mm E: Fastener F: Stay To install the seat, insert the seat hook into the seat hook retainer. Tighten the bolts. A: Seat assembly B: Seat hook C: Seat hook retainer 17
FUEL TANK VENT HOSE Install the fuel tank vent hose to the fuel tank cap. Insert the free end of fuel tank vent hose to the hole of front number plate. Be sure not to bend or twist the hose when installing. A: Fuel tank vent hose B: Fuel tank cap C: Front number plate D: Hole FOOTREST Remove the shipping pin from the footrest. Confirm that the right and left footrests move smoothly. A: Footrest B: Shipping pin FUEL LABEL (FOR LIMITED MARKET) Stick the label on the fuel tank cover. A: Fuel tank cover B: Fuel label WARNING TAG Place the warning tag to the handlebar. This hangtag is not to be removed before sale. A: Warning tag 18
SERVICING LOWER BRAKE FLUID (FOR DR-Z125L) Keep the motorcycle upright and place the handlebars straight. Check the brake fluid level in the front master cylinder reservoirs. If the fluid level is below the LOWER level indicated in the figure, add the correct type of brake fluid. Refer to the chart below for the proper selection. Specification and Classification DOT 4 Be careful not to spill any brake fluid on the paint or plastic components as they will be damaged. BRAKE AIR BLEEDING (FOR DR-Z125L) Any air which may have been trapped in the brake fluid circuit must be bled completely. If the brake lever feels spongy or weak, then most likely there is air in the hydraulic circuit. To bleed the air from the front brake, use the following procedure: 1. Connect a clear hose to the air bleeder valve and run the hose into a suitable clear container. 2. Pour approximately 1/2 in of brake fluid into the container so that the end of the clear hose is submerged and cannot draw any additional air back into the circuit during the air bleeding servicing. 3. Close the valve, pump and squeeze the lever, and open the valve while squeezing brake lever. 4. Repeat this process until the fluid flowing into the receptacle no longer contains air bubbles. Do not drop brake fluid level below lower level line while bleeding air. 5. After bleeding the brake circuit, tighten the bleeder valve to the specified torque. Reinstall the rubber protective cap. 6. Be sure to check the brake fluid level in the reservoir tank. Brake caliper air bleeder valve: 7.5 N m (0.75 kgf-m) A: Bleeder valve 19
FRONT BRAKE (FOR DR-Z125) Check the front brake lever play at the brake lever end when squeezing the lever until pressure is felt. Front brake lever play: 15 25 mm If adjustment is necessary, carry out the procedure below. 1. Remove the bolt A and front brake cable clip B. 2. Loosen the lock nut F of the brake lever adjuster and turn in the adjuster E as far as possible. 3. Loosen the two lock nuts C of the front brake hub panel. 4. Relocate the adjuster D to obtain the correct play. 5. Firmly tighten the two lock nuts C of the brake panel. Minor adjustments can now be made with the brake lever adjuster E. 6. Tighten the lock nut F and place the lever cover G. 7. Reinstall the front brake cable clip B. This motorcycle is delivered from the factory not tightened the lock nuts C. FRONT BRAKE (FOR DR-Z125L) Remove the lever cover. Check the brake lever play. Front brake lever play: 0.1 1.5 mm If adjustment is necessary, carry out the procedure below: 1. Loosen the lock nut A. 2. Turn the adjuster B in or out until the correct play. 3. Tighten the lock nut A. 4. Fit the lever cover. 20
THROTTLE CABLE Check the throttle cable play at the throttle grip. Throttle cable play: 2.0 4.0 mm If adjustment is necessary, carry out the procedure below: 1. Loosen the throttle cable adjuster lock nut A. 2. Turn the adjuster B in or out until the correct play is obtained. 3. Tighten the lock nut A while holding the adjuster B. 4. Place the rubber boot C. After the adjustment is completed, check that handlebar movement does not raise the engine idle speed and that the throttle grip returns smoothly and automatically. CLUTCH CABLE Check the clutch lever play at the clutch lever end when squeezing the lever until pressure is felt. Clutch lever play: 10 15 mm If adjustment is necessary, carry out the procedure below. 1. Loosen the lock nut A of the clutch lever adjuster and turn in the adjuster B as far as possible. 2. Loosen the cable adjuster lock nut C. 3. Turn the cable adjuster D to obtain the correct play. 4. Tighten the lock nuts C. Minor adjustments can now be made with the clutch lever adjuster B. 5. Place the rubber boot E. 6. Tighten the lock nut A and place the lever cover F. 21
DRIVE CHAIN Check the drive chain slack. Drive chain slack: 35 45 mm If it is too tight or too loose, follow these procedures: 1. Loosen the axle nut. 2. Adjust the slack in the drive chain by turning the right and left chain adjuster nuts. 3. Proper chain slack is obtained when drive chain slack is up and down, at a point midway between the two sprockets. A: Axle nut B: Adjuster nut C: Reference marks 4. After adjusting, tighten the axle nut to the specified torque. 5. Tighten the adjuster nuts securely. Rear axle nut: 54 N m (5.4 kgf-m) 35 45 mm Make sure that the rear sprocket is properly aligned with the engine sprocket. Verify the reference marks on the swing-arm by sighting down along the chain from the rear end of the motorcycle. Verify that the chain joint clip is installed properly. The opening of the chain joint clip faces away from the direction of travel. A: Direction of travel B: Chain joint clip 22
REAR BRAKE PEDAL Check the rear brake pedal height. Rear brake pedal height: 0 10 mm If the rear brake pedal height is not correct, adjust in the following manner: 1. Loosen the lock nut A. 2. Adjust the brake pedal height by turning the brake pedal stopper bolt B to locate the pedal to the correct height below the top face of the footrest C. 3. Tighten the lock nut A. After the brake pedal height has been adjusted, check the brake pedal free travel. Rear brake pedal free travel: 20 30 mm If adjustment is necessary, adjust the free travel by turning the brake rod adjuster nut D. TIRE PRESSURE Using an accurate air gauge, check the air pressure of the front and rear tires. The pressure should be as shown. COLD INFLATION TIRE PRESSURE FRONT 100 kpa 1.00 kgf/cm 2 14 psi REAR 100 kpa 1.00 kgf/cm 2 14 psi 23
ENGINE OIL This motorcycle is shipped from factory with the engine filled with engine oil. Be sure to check oil level. Check the engine oil level through the engine oil inspection window with the motorcycle held vertically on level ground. 1. Start the engine and allow it to run for a few minutes at idling speed. 2. Turn off the engine and wait about three minutes, then check the oil level through the inspection window. 3. If the level is below the L mark, add oil to F level. If the level is above the F mark, drain oil to F level. 4. Reinstall the drain plug and engine oil filler plug. Tighten them securely. Oil drain plug: 28 N m (2.8 kgf-m) A: Engine oil filler plug B: Engine oil level inspection window SAE API JASO 10W-40 SF or SG 10W-40 SH or SJ MA Engine oil Oil quality is a major contributor to your engine s performance and life. Always select good quality engine oil. Use oil with an API (American Petroleum Institute) classification of SF/SG or SH/SJ, or with a JASO classification of MA. API: American Petroleum Institute JASO: Japanese Automobile Standards Organization 24
ENGINE OIL VISCOSITY RATING SELECTION CHART 20W - 50 15W - 40 15W - 50 ENGINE OIL 10W - 40 10W - 50 SAE Engine Oil Viscosity Suzuki recommends the use of SAE 10W-40 engine oil. If SAE 10W-40 engine oil is not available, select an alternative according to the left chart. 10W - 30 TEMP. C F -30-20 -10 0 10 20 30 40-22 -4 14 32 50 68 86 104 JASO T903 The JASO T903 standard is an index to select engine oils for 4-stroke motorcycle and ATV engines. Motorcycle and ATV engines lubricate clutch and transmission gears with engine oil. JASO T903 specifies performance requirements for motorcycle and ATV clutches and transmission. There are two classes, MA and MB. The oil container shows the classification as shown. A: Code number of oil sales company B: Oil classification ENERGY API SERVICE SJ SAE 10W-40 CONSERVING API SERVICE SJ SAE 10W-40 Energy Conserving Suzuki does not recommend the use of ENERGY CONSERVING oils. Some engine oils which have an API classification of SH or higher have an ENERGY CONSERVING indication in the API classification doughnut mark. These oils can affect engine life and clutch performance. Not recommended Recommended 25
IDLE SPEED ADJUSTMENT After completing all of the servicing procedures, adjust the engine idle speed by turning the throttle stop screw. The engine idle should be adjusted with engine warmed up. Engine idle speed: 1 600 1 800 r/min A: Throttle stop screw Test ride the motorcycle checking all mechanical functions. Tighten all nuts, bolts, and miscellaneous mounting parts to the proper torque specs. Confirm that all cables and wiring harnesses are connected and routed correctly. 26
TIGHTENING TORQUE (FOR DR-Z125) Item Part Name N m kgf-m FRONT FORK A Handlebar clamp bolt 23 2.3 B Steering stem head nut 65 6.5 C Front fork upper bracket bolt 23 2.3 D Front fork lower bracket bolt 33 3.3 BRAKE E Front brake cam lever nut 7.7 0.77 F Rear brake cam lever nut 7.7 0.77 Item Part Name N m kgf-m AXLE G Front axle nut 42 4.2 H Rear axle nut 54 5.4 ABSORBER I Rear shock absorber bolt (Upper) 50 5.0 J Rear shock absorber nut (Lower) 50 5.0 OTHERS K Rear swingarm pivot nut 65 6.5 L Front footrest bolt 55 5.5 For other bolts and nuts not listed, refer to this chart. Bolt Diameter (mm) Conventional or 4 marked bolt 7 marked bolt N m kgf-m N m kgf-m 4 1.5 0.15 2.3 0.23 5 3 0.3 4.5 0.45 6 5.5 0.55 10 1.0 8 13 1.3 23 2.3 10 29 2.9 50 5.0 12 45 4.5 85 8.5 14 65 6.5 135 13.5 16 105 10.5 210 21.0 18 160 16.0 240 24.0 Conventional bolt 4 marked bolt 7 marked bolt A C B D F I E J H L K G 27
TIGHTENING TORQUE (FOR DR-Z125L) Item Part Name N m kgf-m FRONT FORK A Handlebar clamp bolt 23 2.3 B Steering stem head nut 65 6.5 C Front fork upper bracket bolt 23 2.3 D Front fork lower bracket bolt 33 3.3 BRAKE E Front brake caliper mounting bolt 26 2.6 F Front brake master cylinder mounting bolt 10 1.0 G Rear brake cam lever nut 7.7 0.77 H Brake caliper air bleeder 7.5 0.75 Item Part Name N m kgf-m AXLE I Front axle nut 49 4.9 J Rear axle nut 54 5.4 ABSORBER K Rear shock absorber bolt (Upper) 50 5.0 L Rear shock absorber nut (Lower) 50 5.0 OTHERS M Rear swingarm pivot nut 65 6.5 N Front footrest bolt 55 5.5 For other bolts and nuts not listed, refer to this chart. Bolt Diameter (mm) Conventional or 4 marked bolt 7 marked bolt N m kgf-m N m kgf-m 4 1.5 0.15 2.3 0.23 5 3 0.3 4.5 0.45 6 5.5 0.55 10 1.0 8 13 1.3 23 2.3 10 29 2.9 50 5.0 12 45 4.5 85 8.5 14 65 6.5 135 13.5 16 105 10.5 210 21.0 18 160 16.0 240 24.0 Conventional bolt 4 marked bolt 7 marked bolt F A C B D E G K H L J N M I 28
CABLE ROUTING Front brake cable (FOR DR-Z125) Front brake cable (FOR DR-Z125) Wiring harness Clip Clamp Clutch cable Clutch cable Throttle cable 29
FRONT BRAKE HOSE ROUTING (FOR DR-Z125L) Brake hose Guide Brake hose 1 mm Clamp Clamp 30
HARNESS ROUTING Throttle cable Clutch cable Front brake cable (FOR DR-Z125) Front brake hose (FOR DR-Z125L) Clamp Engine stop switch lead wire CDI unit UP Engine stop switch lead wire Throttle cable Clamp Clamp Face the clamp end down Clamp Clamp Clutch cable Clamp Generator lead wire 31
SAFETY CHECK OUT After completion of the setting-up the motorcycle all the following items should be doublechecked to confirm that the operation and function of the motorcycle are satisfactory. Now, setting-up the motorcycle and pre-delivery inspection have been completed and the motorcycle can be passed to the customer. ENGINE AND TRANSMISSION ITEM MEASURE SPECIFICATIONS Engine oil Check/Refill 850 ml Fuel tank Drain/Fill 4.8 L Throttle cable Check/Adjust 2.0 4.0 mm Idle r/min Check/Adjust 1 60 1 800 r/min Exhaust system Leakage Fuel system connection Leakage/Circlip CHASSIS ITEM MEASURE SPECIFICATIONS Disc brake (FOR DR-Z125L) Clean/Fluid level Front brake lever (FOR DR-Z125L) Check/Adjust 0.1 1.5 mm Front brake lever (FOR DR-Z125) Check/Adjust 15 25 mm Rear brake pedal Check/Adjust Height: 0 10 mm Play: 20 30 mm Clutch cable Check/Adjust 10 15 mm Drive chain Check/Adjust/ Lubricate 35 45 mm Front fork Check Rear shock absorber Check Oiling points All necessary points Wiring and cable Routing/Operation Wiring connectors Clean/Tight Tighten all nuts and bolts Cotter pins, circlip and fasteners Torque those listed in this manual Check COLD TIRE INFLATION PRESSURE FRONT 100 kpa 1.0 kgf/cm 2 14 psi ITEM Switch Operations Engine stop switch Engine Transmission Drive chain Clutch Brake Steering Suspension Control cables Leakage ELECTRICALS REAR 100 kpa 1.0 kgf/cm 2 14 psi CHECK FOR Operation ROAD TEST INSPECTION ITEM CHECK FOR Starting/Acceleration/ Smoothness/Noise Operation/Noise Operation/Noise Operation/Noise Operation/Noise Stability Operation Operation/Proper return Fuel/Oil/Exhaust 32