2003-2009 Suzuki DR-Z125 DR-Z125L Service Repair Manual and Owner 's Manual Ultimate Set

1. GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
ENGINE 3
FUEL AND LUBRICATION
SYSTEM
4
CHASSIS 5
ELECTRICAL SYSTEM 6
SERVICING INFORMATION 7
FOREWORD
This manual contains an introductory description on
the SUZUKI DR-Z125/L and procedures for its
inspection/service and overhaul of its main compo-
nents.
Other information considered as generally known is
not included.
Read the GENERAL INFORMATION section to
familiarize yourself with the motorcycle and its main-
tenance. Use this section as well as other sections
to use as a guide for proper inspection and service.
This manual will help you know the motorcycle bet-
ter so that you can assure your customers of fast
and reliable service.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2002
* This manual has been prepared on the basis
of the latest specifications at the time of publi-
cation. If modifications have been made since
then, differences may exist between the con-
tent of this manual and the actual motorcycle.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures. They may not represent the
actual motorcycle exactly in detail.
* This manual is written for persons who have
enough knowledge, skills and tools, including
special tools, for servicing SUZUKI motorcy-
cles. If you do not have the proper knowledge
and tools, ask your authorized SUZUKI
motorcycle dealer to help you.
Inexperienced mechanics or mechanics
without the proper tools and equipment
may not be able to properly perform the
services described in this manual.
Improper repair may result in injury to the
mechanic and may render the motorcycle
unsafe for the rider.
GROUP INDEX
99500-41126-03E

2. 03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM

3. 03 ENGINE.book Page 105 Tuesday, February 28, 2006 3:03 PM
DR-Z125/LK4 (’04-MODEL)
DR-Z125/LK5 (’05-MODEL)
DR-Z125/LK6 (’06-MODEL)
8
9
SUPPLEMENTS
DR-Z125/LK7 (’07-MODEL)
DR-Z125/LK8 (’08-MODEL) 10
DR-Z125/LK9 (’09-MODEL) 11

4. HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed in the GROUP INDEX.
3. Holding the manual as shown at the right will allow you to find
the first page of the section easily.
4. The contents are listed on the first page of each section to
help you find the item and page you need.
COMPONENT PARTS AND WORK TO BE DONE
Under the name of each system or unit there is an exploded view which provides work instructions and other
service information (e.g., tightening torque, lubricating points, and locking agent points).
Example: Front wheel (DR-Z125L)
Bearing
Spacer
!Bearing
Brake disc
#Front axle
)Front axle nut
*Brake disc mounting nut
ITEM N·m kgf.m lb-ft
) 44 4.4 32.0
* 8.5 0.85 6.0
(

5. SYMBOL
Listed in the table below are the symbols indicating instructions and other information necessary for servic-
ing. The meaning of each symbol is also included in the table.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply THREAD LOCK “1342”.
99000-32050
Indicates service data. Apply or use brake fluid.
Apply oil. Use engine oil unless
otherwise specified.
Measure in voltage range.
Apply molybdenum oil solution.
(mixture of engine oil and SUZUKl
MOLY PASTE in a ratio of 1 : 1)
Measure in resistance range.
Apply SUZUKI SUPER GREASE “A”.
99000-25030 (For USA)
99000-25010 (For the other counties)
Measure in current range.
Apply SUZUKI SILICONE GREASE.
99000-25100
Measure in diode test range.
Apply SUZUKI MOLY PASTE.
99000-25140
Measure in continuity test range.
Apply SUZUKI BOND “1207B”.
99104-31140 (For USA)
99000-31140 (For the other countries)
Use special tool.
Apply SUZUKI BOND “1216B”.
99000-31230
Use fork oil.
99000-99001-SS8
Apply THREAD LOCK SUPER “1303”.
99000-32030
1216B

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

8. 1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes-
sages highlighted by these signal words.
!
Indicates a potential hazard that could result in death or injury.
Indicates a potential hazard that could result in vehicle damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the vehicle. In addition to the WARNINGS
and CAUTIONS stated, you must use good judgement and basic mechanical safety principles. If you are
unsure about how to perform a particular service operation, ask a more experienced mechanic for advice.
GENERAL PRECAUTIONS
!
* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the vehicle.
* When 2 or more persons work together, pay attention to the safety of each other.
* When it is necessary to run the engine indoors, make sure that exhaust gas is forced out-
doors.
* When working with toxic or flammable materials, make sure that the area you work in is well
ventilated and that you follow all of the manufacturer’s instructions.
* Never use gasoline as a cleaning solvent.
* To avoid getting burned, do not touch the engine, engine oil, radiator, and exhaust system
until they have cooled.
* After servicing the fuel, oil, exhaust or brake systems, check all of the lines, and fittings
related to the system for leaks.

9. GENERAL INFORMATION 1-3
* If parts replacement is necessary, replace the parts with SUZUKI Genuine Parts or their equiv-
alent.
* When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order and orientation.
* Be sure to use special tools when instructed.
* Make sure that all parts used in reassembly are clean. Lubricate them when specified.
* Use the specified lubricants, bonds, or sealant.
* When removing the battery, disconnect the negative cable first and then the positive cable.
When reconnecting the battery, connect the positive cable first and then the negative cable,
and replace the terminal cover on the positive terminal.
* When performing service to electrical parts, if the service procedures not require use of bat-
tery power, disconnect the negative cable the battery.
* When tightening the cylinder head and case bolts and nuts, tighten the larger sizes first.
Always tighten the bolts and nuts from the inside working out, in a crisscross manner.
* Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts,
cotter pins, circlips, and certain other parts as specified, be sure to replace them with new
ones. Also, before installing these new parts, be sure to remove any left over material from the
mating surfaces.
* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a
thread is smeared with them.
* After reassembling, check parts for tightness and proper operation.
* To protect the environment, do not unlawfully dispose of used motor oil and all other fluids:
batteries and tires.
* To protect the Earth’s natural resources, properly dispose of used motorcycle and parts.

10. 1-4 GENERAL INFORMATION
SUZUKI DR-Z125/LK3 (’03-MODEL)
SERIAL NUMBER LOCATION
The frame serial number or V.I.N. (Vehicle Identification Number) 1 is stamped on the right side of the
steering head pipe. The engine serial number 2 is located on the left side of the crankcase. These numbers
are required especially for registering the machine and ordering spare parts.
FUEL AND OIL RECOMMENDATION
FUEL
Gasoline used should be graded 95 octane (Research Method) or higher. An unleaded gasoline type is rec-
ommended.
LEFT SIDE RIGHT SIDE

11. GENERAL INFORMATION 1-5
ENGINE OIL
Use a premium quality 4-stroke motor oil to ensure longer ser-
vice life of your motorcycle. Use only oils which are rated SF or
SG under the API service classification.
The recommended viscosity is SAE 10W-40. If an SAE 10W-40
motor oil is not available, select an alternative according to the
right chart.
BRAKE FLUID
# Specification and Classification: DOT 4
!
FRONT FORK OIL
SUZUKI fork oil SS-08 or an equivalent fork oil.
BREAK-lN PROCEDURES
During manufacture only the best possible materials are used and all machined parts are finished to a very
high standard but it is still necessary to allow the moving parts to “BREAK-IN” before subjecting the engine
to maximum stresses. The future performance and reliability of the engine depends on the care and restraint
exercised during its early life. The general rules are as follows.
• Keep to this break-in throttle opening limits:
Initial 10 hours: Less than 1/2 throttle
Up to 15 hours: Less than 3/4 throttle
Since the brake system of this motorcycle is filled with a glycol-based brake fluid by the manu-
facturer, do not use or mix different types of fluid such as silicone-based and petroleum-based
fluid for refilling the system, otherwise serious damage will result.
Do not use any brake fluid taken from old or used or unsealed containers.
Never re-use brake fluid left over from a previous servicing, which has been stored for a long
period.

12. 1-6 GENERAL INFORMATION
INFORMATION LABELS
LABEL or PLATE NAMENO
APPLIED SPECIFICATION
E-28 E-03
Noise label — ¡
Information label — ¡
! Fuel caution label ¡ —
Manual notice label — ¡
# Warning safety label ¡ ¡
$ Certification plate — ¡
% Compliance label ¡ —
DR-Z125/L
Frame (Left side)Frame (Right side)
Fuel tank
Rear fender
E - 28
E - 28
E - 03

13. GENERAL INFORMATION 1-7
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ...................................................... 1 835 mm (72.2 in)
1 885 mm (74.2 in) ....... DR-Z125L
Overall width ....................................................... 770 mm (30.3 in)
Overall height ...................................................... 1 060 mm (41.7 in)
1 095 mm (43.1 in)....... DR-Z125L
Wheelbase .......................................................... 1 245 mm (49.0 in)
1 270 mm (50.0 in) ....... DR-Z125L
Ground clearance................................................ 260 mm (10.2 in)
290 mm (11.4 in) ....... DR-Z125L
Seat height .......................................................... 775 mm (30.5 in)
805 mm (32.0 in) ....... DR-Z125L
Dry mass ............................................................. 80 kg (176 lbs)
81 kg (178 lbs)......... DR-Z125L
ENGINE
Type .................................................................... Four-stroke, air-cooled, OHC
Number of cylinders ............................................ 1
Bore..................................................................... 57.0 mm (2.244 in)
Stroke.................................................................. 48.8 mm (1.921 in)
Displacement ...................................................... 124 cm³ (7.6 cu.in)
Compression ratio ............................................... 9.5 : 1
Carburetor ........................................................... MIKUNI VM20SS
Air cleaner ........................................................... Polyurethane foam element
Starter system ..................................................... Primary kick
Lubrication system .............................................. Wet sump
Idie speed............................................................ 1 700 ± 100 r/min
DRIVE TRAIN
Clutch .................................................................. Wet multi-plate type
Transmission....................................................... 5-speed constant mesh
Gearshift pattern ............................................... 1-down, 4-up
Primary reduction ratio ........................................ 3.470 (59/17)
Gear ratios, Low ................................................. 3.000 (33/11)
2nd .................................................. 1.857 (26/14)
3rd................................................... 1.368 (26/19)
4th ................................................... 1.095 (23/21)
Top.................................................. 0.923 (24/26)
Final reduction ratio............................................. 3.642 (51/14)
4.071 (57/14) .......................... DR-Z125L
Drive chain .......................................................... D.ID.428HG, 122 links
D.ID.428HG, 130 links............ DR-Z125L

14. 1-8 GENERAL INFORMATION
CHASSIS
Front suspension .................................................Telescopic, coil spring, oil damped,
Rear suspension..................................................Link type, coil spring, oil damped,
Front suspension stroke.......................................180 mm (7.1in)
Rear wheel travel.................................................160 mm (6.3in)
170 mm (6.7in) ..............DR-Z125L
Caster ..................................................................28°
27° 30’...........................DR-Z125L
Trail......................................................................88 mm (3.46 in)
99 mm (3.90 in) .............DR-Z125L
Steering angle......................................................45° (right left)
Turning radius......................................................1.9 m (6.2 ft)
2.0 m (6.6 ft)..................DR-Z125L
Front brake...........................................................Drum brake
Disc brake .....................DR-Z125L
Rear brake ...........................................................Drum brake
Front tire size .......................................................70/100-17 40M, tube type
70/100-19 42M, tube type ..... DR-Z125L
Rear tire size........................................................90/100-14 49M, tube type
90/100-16 52M, tube type ..... DR-Z125L
ELECTRICAL
lgnition type..........................................................Electronic ignition (CDl)
lgnition timing.......................................................13° B.T.D.C. at 1 700 r/min
Spark plug............................................................NGK: DR8EA or DENSO: X24ESR-U
Generator.............................................................Single-phase A.C. generator
CAPACITIES
Fuel tank, including reserve ................................. 6.6 L (1.7/1.5 US/Imp gal)
Reserve ............................................... 1.7 L (0.4/0.4 US/Imp gal)
Engine oil, oil change ........................................... 850 ml (0.9/0.7 US/Imp qt)
with filter change ................................ 950 ml (1.0/0.8 US/Imp qt)
overhaul..............................................1 100 ml (1.2/1.0 US/Imp qt)
Front fork (each leg)............................................. 172 ml (5.8/6.1 US/Imp oz)
These specifications are subject to change without notice.

15. GENERAL INFORMATION 1-9
COUNTRY AND AREA CODES
The following codes stand for the applicable countries and areas.
CODE COUNTRY OR AREA
E-03
E-28
USA
Canada

17. 2
6
PERIODIC MAINTENANCE 2-1
CONTENTS
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE ............................................2- 2
PERIODIC MAINTENANCE CHART ...........................................2- 2
LUBRICATION POINTS ...............................................................2- 3
MAINTENANCE AND TUNE-UP PROCEDURES ...............................2- 4
AIR CLEANER .............................................................................2- 4
VALVE CLEARANCE ..................................................................2- 5
CAM CHAIN TENSION ADJUSTER ............................................2- 6
SPARK PLUG ..............................................................................2- 7
THROTTLE CABLE PLAY ...........................................................2- 8
ENGINE IDLE SPEED ..................................................................2- 8
FUEL HOSE .................................................................................2- 9
CLUTCH .......................................................................................2- 9
ENGINE OIL AND OIL FILTER ....................................................2-10
SPARK ARRESTER ....................................................................2-11
DRIVE CHAIN ..............................................................................2-12
FRONT BRAKE LEVER PLAY (DR-Z125) ..................................2-14
FRONT DISC BRAKE (DR-Z125L) ..............................................2-14
REAR BRAKE PEDAL HEIGHT ..................................................2-16
BRAKE HOSES (DR-Z125L) .......................................................2-17
STEERING ...................................................................................2-17
TIRES ...........................................................................................2-17
SPOKE NIPPLES .........................................................................2-18
EXHAUST PIPE BOLTS AND MUFFLER MOUNTING BOLT ....2-19
FRONT FORK ..............................................................................2-19
REAR SUSPENSION ...................................................................2-19
CHASSIS BOLTS AND NUTS .....................................................2-20
COMPRESSION PRESSURE CHECK .................................................2-22
COMPRESSION TEST PROCEDURE .........................................2-22
OIL PRESSURE CHECK ......................................................................2-23
OIL PRESSURE TEST PROCEDURE .........................................2-23

18. 2-2 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the motorcycle operating at peak performance and economy.
NOTE:
More frequent servicing may be performed on motorcycles that are use under severe conditions.
PERIODIC MAINTENANCE CHART
NOTE:
Inspect: I=Inspect and clean, adjust, replace or lubricate as necessary; C=Clean; R=Replace; T=Tighten
Interval
months
Initially Every Every
Item 1 month 6 months 12 months
Air cleaner element — I I
Exhaust pipe bolts and muffler mounting
bolts
T T T
Valve clearance I I I
Spark plug — I R
Spark arrester — — C
Fuel line
I I I
Replace every 4 years.
Cam chain tension adjuster I I I
Engine oil filter R — R
Engine oil R R R
Throttle cable I I I
Idle speed I I I
Clutch I I I
Drive chain Clean, oil and inspect each time motorcycle is ridden.
Brakes I I I
Brake hose
— I I
Replace every 4 years.
Brake fluid
— I I
Replace every 2 years.
Tires — I I
Spoke nipple Inspect each time the motorcycle is ridden.
Steering I — I
Front forks — — I
Rear suspension — — I
Chassis nuts and bolts T T T

19. PERIODIC MAINTENANCE 2-3
LUBRICATION POINTS
Proper lubrication is important for smooth operation and long life of each working part of the motorcycle.
Major lubrication points are indicated below.
NOTE:
* Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.
* Lubricate exposed parts which are subject to rust, with a rust preventative spray especially whenever the
motorcycle has been operated under wet or rainy condition.
Clutch lever holder
Side-stand pivot
and spring hook
Drive chain
Throttle cable
Front brake
lever holder
Brake pedal pivot

20. 2-4 PERIODIC MAINTENANCE
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each item in the Periodic Maintenance chart.
AIR CLEANER
If the air cleaner is clogged with dust, intake resistance will be
increase, resulting in a decrease in engine output and an
increase in fuel consumption. Clean the air cleaner element in
the following manner.
• Remove the left frame cover. (!5-2)
• Remove the air cleaner cover 1.
• Remove the air cleaner element 2.
• Separate the polyurethane foam element 3 and element
frame 4.
• Fill a container with a non-flammable cleaning solvent.
• Immerse the air cleaner element in the cleaning solvent and
wash it.
• Squeeze the cleaning solvent out of the washed element by
pressing it between the palms of both hands: do not twist or
wring the element or it will develop tears.
• Immerse the element in motor oil and squeeze the oil out of
the element leaving it slightly wet with oil.
A Non-flammable cleaning solvent
B Motor oil SAE #30 or SAE 10W-40
Clean every 6 months.
Inspect the air cleaner element for tears. A torn ele-
ment must be replaced.

21. PERIODIC MAINTENANCE 2-5
• Remove the drain plug 1 to allow any water to drain out.
• Reinstall the cleaned air cleaner element in the reverse order
of removal.
!
!
VALVE CLEARANCE
REMOVAL
• Remove the frame covers, seat and fuel tank. (5-2)
• Remove the spark plug. (2-7)
• Remove the valve inspection caps 1.
• Remove the valve timing inspection plug 2 and generator
cover plug 3.
INSPECTION
The valve clearance specification is different for intake and
exhaust valves. Valve clearance adjustment must be checked
and adjusted, 1) at the time of periodic inspection, 2) when the
valve mechanism is serviced, and 3) when the camshaft is dis-
turbed by removing it for servicing.
Be sure to position the element snugly and correctly,
so that no incoming air will by-pass it. Remember, the
rapid wear of piston rings and the cylinder bore is
often caused by a defective or poorly fitted element.
If driving under dusty conditions, clean the air cleaner
element more frequently. The surest way to accelerate
engine wear is to operate the engine without the ele-
ment or to use a torn element. Make sure that the air
cleaner is in good condition at all times. The life of the
engine depends largely on this component!
Inspect initially at 1 month and every 6 months there-
after.

22. 2-6 PERIODIC MAINTENANCE
NOTE:
* The piston must be at (TDC) on the compression stroke in
order to check the valve clearance or to adjust valve clear-
ance.
* The clearance specification is for COLD state.
* To turn the crankshaft for clearance checking, rotate in the nor-
mal running direction. The spark plug should be removed.
• Turn crankshaft to bring the “TDC” line on the rotor to the
index mark A on the generator cover.
• Insert a thickness gauge between the valve stem end and the
adjusting screw on the rocker arm.
If the clearance is out of specification, bring it into the speci-
fied range.
# 09900-20803: Thickness gauge
09917-13210: Valve clearance adjusting driver
$ Valve clearance (when cold):
IN.: 0.08 – 0.13 mm (0.003 – 0.005 in)
EX.: 0.13 – 0.18 mm (0.005 – 0.007 in)
CAM CHAIN TENSION ADJUSTER
The cam chain is maintained at the proper tension by a manually
adjusted cam chain tension adjuster. To prevent chain noise, the
cam chain tension adjuster must be adjusted at the intervals
listed abobe. The procedure for adjusting the cam chain tension
adjuster is as follows:
• Loosen the lock nut 1 on the cam chain tension adjuster and
back out the set screw 2 one turn. This will allow a spring to
push the push rod firmly on to the cam chain tensioner, and
provide proper operating chain tension.
• Tighten the set screw 2 to lock the push rod in position and
tighten the lock nut 1 to secure the set screw 2.
Inspect initially at 1 month and every 6 months there-
after.

23. PERIODIC MAINTENANCE 2-7
NOTE:
If the cam chain is noisy after having been adjusted, the push
rod is probably sticking. Remove the cam chain tension adjuster,
clean and lubricate the push rod to obtain smooth movement
and proper tensioning action.
SPARK PLUG
• Disconnect the spark plug cap 1 and remove the spark plug
2.
! 09930-10121: Spark plug wrench set
• Carbon deposits on the spark plug will prevent good sparking
and may cause the engine to misfire. Be sure to clean the car-
bon deposits off periodically.
• If the center electrode is fairly worn down, the spark plug
should be replaced and the spark plug gap set to the specifi-
cation using a thickness gauge.
! 09900-20804: Thickness gauge
# Spark plug gap: 0.6 – 0.8 mm (0.024 – 0.031 in)
• Check the spark plug for burns. If any abnormalities are
found, replace the spark plug as indicated below.
Inspect every 6 months.
Replace every 12 months.
NGK DENSO
STD DR8EA X24ESR-U
Confirm the thread size and reach when replacing the
spark plug. If the reach is too short, carbon will be
deposited on the screw portion of the plug hole and
engine damage may result.