Uz 125

UZ125
OWNER’S MANUAL
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IMPORTANT WARNING/CAUTION/NOTE
Please read this manual and follow its
BREAK-IN (RUNNING-IN) INFORMATION instructions carefully. To emphasize special
information, the words WARNING, CAU-
FOR YOUR MOTORCYCLE TION and NOTE carry special meanings
The first 1600 km are the most important in and should be carefully reviewed.
the life of your motorcycle. Proper break-in
operation during this time will help ensure
maximum life and performance from your WARNING
new motorcycle. Suzuki parts are manufac-
tured of high quality materials, and The personal safety of the rider may be
machined parts are finished to close toler- involved. Disregarding this information
ances. Proper break-in operation allows the could result in injury to the rider.
machined surfaces to polish each other and
mate smoothly.
CAUTION
Motorcycle reliability and performance These instructions point out special ser-
depend on special care and restraint exer- vice procedures or precautions that
cised during the break-in period. It is espe- must be followed to avoid damaging the
cially important that you avoid operating the machine.
engine in a manner which could expose the
engine parts to excessive heat.
NOTE: This provides special information to
Please refer to the BREAK-IN (RUNNING- make maintenance easier or important
IN) section for specific break-in recommen- instructions clearer.
dations.

FOREWORD All information, illustrations and specifica-
tions contained in this manual are based on
Motorcycling is one of the most exhilarating the latest product information available at
sports and to ensure your riding enjoyment, the time of publication. Due to improve-
you should become thoroughly familiar with ments or other changes, there may be some
the information presented in this Owner’s discrepancies in this manual. Suzuki
Manual before riding the motorcycle. reserves the right to make changes at any
time.
The proper care and maintenance that your
motorcycle requires is outlined in this man- Please note that this manual applies to all
ual. By following these instructions explicitly specifications or all respective destinations
you will ensure a long trouble-free operating and explains all equipment. Therefore, your
life for your motorcycle. Your Suzuki dealer model may have different standard features
has experienced technicians that are trained than shown in this manual.
to provide your machine with the best possi-
ble service with the right tools and equip-
ment.
SUZUKI MOTORCYCLE INDIA © COPYRIGHT SUZUKI MOTORCYCLE

PVT LTD INDIA PVT LTD 2007

TABLE OF CONTENTS
CONSUMER INFORMATION 1
CONTROLS 2
FUEL AND ENGINE OIL RECOMMENDATION 3
BREAK-IN (RUNNING-IN) AND INSPECTION BEFORE RIDING 4
RIDING TIPS 5
INSPECTION AND MAINTENANCE 6
TROUBLESHOOTING 7
MOTORCYCLE CLEANING AND STORAGE PROCEDURE 8
SPECIFICATIONS
INDEX

CONSUMER INFORMATION 1
ACCESSORY INSTALLATION AND PRECAUTION SAFETY TIPS ................. 1-2

MODIFICATION ................................................................................................... 1-4
SAFE RIDING RECOMMENDATION FOR MOTORCYCLE RIDERS ................ 1-4
SERIAL NUMBER LOCATION ........................................................................... 1-6
1-1

CONSUMER INFORMATION
WARNING
ACCESSORY INSTALLATION AND Improper accessories or modifications
PRECAUTION SAFETY TIPS can make your motorcycle unsafe and
There are a great variety of accessories can lead to an accident.
available to Suzuki owners. Suzuki can not
have direct control over the quality or suit- Never modify the motorcycle with
ability of accessories you may wish to pur- improper or poorly installed accesso-
chase. The addition of unsuitable ries. Follow all instructions in this
accessories can lead to unsafe operating owner’s manual regarding accessories
conditions. It is not possible for Suzuki to and modifications. Use genuine SUZUKI
test each accessory on the market or combi- accessories or equivalent designed and
nations of all the available accessories; how- tested for your motorcycle. Consult your
ever, your dealer can assist you in selecting SUZUKI dealer if you have any ques-
quality accessories and installing them cor- tions.
rectly.
Use extreme caution when selecting and

installing the accessories for your Suzuki.
We have developed some general guide-
lines which will aid you when deciding
whether, and how to equip your motorcycle.
1-2

• At any time that additional weight or • Accessories fitted to the handlebars or
aerodynamic affecting accessories are the front fork area can create serious
installed, they should be mounted as low stability problems. This extra weight will
as possible, as close to the motorcycle cause the motorcycle to be less respon-
and as near the centre of gravity as pos- sive to your steering control. The weight
sible. The mounting brackets and other may also cause oscillations in the front
attachment hardware should be carefully end and lead to instability problems.
checked to ensure that they provides for Accessories added to the handlebars or
a rigid, non-movable mount. Weak front fork should be as light as possible
mounts can allow the shifting of the and kept to a minimum.
weight and create a dangerous, unstable
condition. • The motorcycle may be affected by a lift-
ing condition or by an instability in cross
• Inspect for proper ground clearance and winds or when being passed or passing
bank angle. An improperly mounted load large vehicles. Improperly mounted or
could critically reduce these two safety poorly designed accessories can result
factors. Also confirm that the “load” does in an unsafe riding condition, therefore
not interfere with the operation of the caution should be used when selecting
suspension, steering or other control and installing all accessories.
operations.
• Certain accessories displace the rider
from his or her normal riding position.
This limits the freedom of movement of
the rider and may limit his or her control
ability.
1-3

• Additional electrical accessories may MODIFICATION
overload the existing electrical system. Modification of the motorcycle, or removal of
Severe overloads may damage the wir- original equipment may render the vehicle
ing harness or create a dangerous situa- unsafe or illegal.
tion due to the loss of electrical power
during the operation of the motorcycle.
SAFE RIDING RECOMMENDATION FOR
When carrying a load on the motorcycle,
mount it as low as possible and as close as
MOTORCYCLE RIDERS
possible to the machine. An improperly Motorcycle riding is great fun and an excit-
mounted load can create a high centre of ing sport. Motorcycle riding also requires
gravity which is very dangerous and makes that some extra precautions be taken to
the motorcycle difficult to handle. The size of ensure the safety of the rider and passen-
the “load” can also affect the aerodynamics ger. These precautions are:
and handling of the motorcycle. Balance the
load between the right and left sides of the WEAR A HELMET
motorcycle and fasten it securely. Motorcycle safety equipment starts with a
quality helmet. One of the most serious inju-
ries that can happen is a head injury.
ALWAYS wear a properly approved helmet.
You should also wear suitable eye protec-
tion.
1-4

RIDING APPAREL KNOW YOUR LIMITS
Loose, fancy clothing can be uncomfortable Ride within the boundaries of your own skill
and unsafe when riding your motorcycle. at all times. Knowing these limits and stay-
Choose good quality motorcycle riding ing within them will help you to avoid acci-
apparel when riding your motorcycle. dents.
INSPECTION BEFORE RIDING BE EXTRA SAFETY CONSCIOUS ON

Review thoroughly the instructions in the BAD WEATHER DAYS
“INSPECTION BEFORE RIDING” section of Riding on bad weather days, especially wet
this manual. Do not forget to perform an ones, requires extra caution. Braking dis-
entire safety inspection to ensure the safety tances double on a rainy day. Stay off the
of the rider and its passenger. painted surface marks, manhole covers and
greasy appearing areas as they can be
FAMILIARIZE YOURSELF WITH THE especially slippery. Use extreme caution at
MOTORCYCLE railway crossings and on metal gratings and
Your riding skill and your mechanical knowl- bridges. Whenever in doubt about road con-
edge form the foundation for safe riding dition, slow down!
practices. We suggest that you practice
riding your motorcycle in a non-traffic situa-
tion until you are thoroughly familiar with
your machine and its controls. Remember
practice makes perfect.
1-5

RIDE DEFENSIVELY SERIAL NUMBER LOCATION
The most common type of motorcycle acci-
dent occurs when a car traveling towards a
motorcycle turns round corner in front of the
motorcyclist. Ride defensively. Wise motor-
cyclist uses a strategy of assuming they are
invisible to other drivers, even in broad day-
light. Wear bright, reflecting clothing. Turn
on the headlight and taillight every time even
on a bright, sunny day to attract driver’s
attention. Do not ride in another driver’s
blind spot.
1-6

The frame and/or engine serial numbers are
used to register the motorcycle. They are
also used to assist your dealer when order-
ing parts or referring to special service infor-
mation. The frame number 1 is stamped on
the frame on left hand side. The engine
serial number 2 is stamped on the crank-
case assembly on left hand side.
Please write down the numbers in the box

provided below for your future reference.
Frame Number:
Engine Number:
1-7

CONTROLS
2
LOCATION OF PARTS ....................................................................................... 2-2
KEY ...................................................................................................................... 2-5
IGNITION SWITCH .............................................................................................. 2-5
INSTRUMENT PANEL ........................................................................................ 2-7
LEFT HANDLEBAR ............................................................................................ 2-8
RIGHT HANDLEBAR ........................................................................................ 2-11
FUEL TANK CAP .............................................................................................. 2-13
CHOKE KNOB ................................................................................................... 2-14
KICK STARTER LEVER ................................................................................... 2-15
TRUNK ............................................................................................................... 2-16
HELMET HOLDERS .......................................................................................... 2-17
HOOK ................................................................................................................ 2-18
CENTRE STAND ............................................................................................... 2-19
2-1

CONTROLS
LOCATION OF PARTS
1 Rear brake lever 5 Throttle grip

2 Left handlebar switches 6 Front brake lever
3 Instrument panel 7 Choke knob
4 Right handlebar switches 8 Ignition switch
2-2

9 Helmet holders D Battery and fuse
0 Spark plug E Passenger footrests
A Throttle stop screw F Engine oil filter
B Air cleaner G Centre stand
C Tools H Kick starter lever
2-3

I Fuel tank cap
J Engine oil filler cap
K Engine oil drain plug
2-4

KEY IGNITION SWITCH
To open the ignition key-hole shutter:
This motorcycle comes equipped with a

main ignition key and a spare one. Keep the 1. Match the ignition key head to the
spare key in a safe place. square hole on the ignition switch.
2. Turn the key clockwise.
The key number is stamped on the keys.
This number is used when making replace- NOTE:
ment keys. Please write your key number in • Apply anti-freeze chemicals when atmo-
the box provided for your future reference. spheric temperature becomes less than
freezing point to avoid ignition key-hole
Key No.
shutter freezing.
• Spray anti-corrosion chemicals to the
shutter release knob to avoid shutter cor-
rosion trouble.
2-5

“LOCK” Position
To lock the steering, turn the handlebar all
the way to the left. Push the key in and turn
OPEN
SE
AT
OPE
N
SHUT it to the “LOCK” position and remove the
F ON
OF
H
key. All electrical circuits are cut off.
S
PU
LOCK
 WARNING
IG
NIT
IO N Turning the ignition switch to the
“LOCK” position while the motorcycle is
moving can be hazardous. Moving the
“OFF” Position motorcycle while the steering is locked
All electrical circuits are cut off. The engine can be hazardous. You could lose your
will not start. The key can be removed. balance and fall, or you could drop the
motorcycle.
“ON” Position
The ignition circuit is completed and the Never attempt to move the motorcycle
engine can now be started. The key cannot when the steering is locked.
be removed from the ignition switch in this
position. Seat Lock Release
Turn the key counterclockwise to release the
seat lock.
2-6

INSTRUMENT PANEL SPEEDOMETER 2
The speedometer indicates the road speed
in kilometers per hour.
HIGH BEAM INDICATOR LIGHT 3

F
The blue indicator light will be lit when the
headlight high beam is turned on.
km
E ODOMETER 4
km/h
The odometer registers the total distance
that the motorcycle has been ridden.
FUEL METER 5
The “E” mark indicates the fuel tank is
TURN SIGNAL INDICATOR LIGHT 1 empty or nearly so. The “F” mark indicates
When the turn signals are being operated the fuel tank is full.
either to the right or to the left, the indicator
will flash at the same time.
NOTE: If a turn signal light is not operating

properly due to bulb filament or circuit fail-
ure, the indicator will flicker quickly to warn
the rider of existence of a trouble.
2-7

LEFT HANDLEBAR DIMMER SWITCH 2
“” position
The headlight low beam and taillight turn on.
“” position
The headlight high beam and taillight turn
on. The high beam indicator light also turns
on.
REAR BRAKE LEVER 1

The rear brake is applied by squeezing the
rear brake lever gently towards the grip. The
brake light will be lit when the lever is
squeezed inward.
2-8

TURN SIGNAL LIGHT SWITCH 3 HORN SWITCH “” 4
Moving the switch to the “” position will Press the switch to sound the horn.
flash the left turn signals. Moving the switch
to the “” position will flash the right turn
signals. The indicator light will also flash
intermittently. To cancel turn signal opera-
tion, push the switch in.
WARNING
Failure to use the turn signals, and fail-
ure to turn off the turn signals can be
hazardous. Other drivers may misjudge
your course and this may result in an
accident.
Always use the turn signals when you

intend to change lanes or make a turn.
Be sure to turn off the turn signals after
completing the turn or lane change.
2-9

Rear Brake Lock Use this lock to set and lock the rear brake.
To lock the rear brake lock, squeeze the rear
brake lever and engage this lock. To release
the rear brake lock, simply squeeze the lever
until the lock lever releases.
2-10

RIGHT HANDLEBAR LIGHT SWITCH 2
“” position
Headlight and taillight come on.
“•” position
All lights go off.
FRONT BRAKE LEVER 1

The brake is applied by squeezing the front
brake lever gently towards the grip. The
brake light will be lit when the lever is
squeezed inward.
2-11

CAUTION
To prevent electrical system damage, do
not operate the starter motor more than
five seconds at a time.
If the engine does not start after several

attempts, check the fuel supply and igni-
tion system. Refer to the TROUBLE-
SHOOTING section in this manual.
THROTTLE GRIP 4
ELECTRIC STARTER BUTTON “” 3 Engine speed is controlled by the position of
Push in the electric starter button to operate the throttle grip. Twist it toward you to
the starter motor. increase engine speed. Turn it away from
you to decrease the engine speed.
NOTE: If the brake lever is not squeezed,
the starter motor will not operate.
2-12

FUEL TANK CAP
1 Fuel level
2 Filler neck
The fuel tank cap is located under the seat.

WARNING
To open the fuel tank cap, turn it counter- Overfilling the fuel tank can cause the
clockwise. fuel to overflow when it expands due to
heat from the engine or the sun. Spilled
fuel can catch on fire.
Never fill the fuel above the bottom of

the filler neck.
2-13

CHOKE KNOB
WARNING
Fuel and fuel vapor are highly flammable
and toxic. You can be burned or poi-
soned when refueling.
• Stop the engine and keep flames,

sparks and heat sources away.
• Refuel only outdoors or in a well venti-
lated area.
• Do not smoke.
• Wipe up spills immediately.
• Avoid breathing fuel vapor. The carburetor is equipped with a choke
• Keep children and pets away. system to provide easy starting when the
engine is cold. When starting the cold
engine, pull the choke knob all the way
toward you. The choke works best when the
throttle is in the closed position. When the
engine is warm, you do not need to use the
choke system for starting.
NOTE: Refer to the RIDING TIPS section of

this manual for the engine starting proce-
dure.
2-14

KICK STARTER LEVER This motorcycle is equipped with a kick
starter lever located on the left side of the
engine. To start the engine, place the motor-
cycle on the centre stand and depress the
kick starter lever forcefully.
WARNING
An improperly retracted kick starter lever
can interfere with rider control.
Be sure the kick starter lever is returned

to its home position after starting the
engine.
2-15

TRUNK
The trunk load capacity is 10 kg. Do not
allow water to get inside the trunk.
NOTE:
• Do not keep heat-sensitive items in the
trunk since the trunk may get hot.
• Do not keep valuable items in the trunk
when leaving the motorcycle unat-
tended.
• Push down the rear end of the seat if the
seat does not unlock with key operation.
Place helmets as shown, or seat may not be

completely locked.
2-16

HELMET HOLDERS
WARNING
Riding with a helmet fastened to the hel-
met holder can interfere with rider con-
trol.
Never carry a helmet fastened to a hel-

met holder. Fix the helmet securely atop
the seat if you must carry it.
Hook the helmet ring to the helmet holders

and close the seat.
2-17

HOOK
This motorcycle is equipped with the hook.
The hook load capacity is 1.5 kg.
To use the hook, turn the hook and open the

hook by turning the upper lever.
2-18

CENTRE STAND
This motorcycle is equipped a centre stand.
To place the motorcycle on the centre stand,

place your foot on the stand extension and
then rock the motorcycle to the rear and
upward with the passenger hand rail with
your right hand, while steadying the handle-
bars with your left hand.
2-19

FUEL AND ENGINE OIL
RECOMMENDATION
FUEL .................................................................................................................... 3-2
ENGINE OIL AND GEAR OIL ............................................................................. 3-2 3
3-1

FUEL AND ENGINE OIL ENGINE OIL AND GEAR OIL
RECOMMENDATION Oil quality is a major contributor to your
engine’s performance and life. Always select
good quality SAE 10W-30 engine oil.
FUEL
Use unleaded gasoline with an octane rating SAE Engine Oil Viscosity
or 91 or higher (Research method). Suzuki recommends the use of SAE 10W-
Unleaded gasoline can extend spark plug 30 engine oil. If SAE 10W-30 engine oil is
life and exhaust components life. not available, select an alternative according
to the following chart.
CAUTION
Spilling gasoline containing alcohol can
harm your motorcycle. Alcohol can dam-
age painted surfaces.
Be careful not to spill any fuel when fill-

ing the fuel tank. Wipe spilled gasoline
up immediately.
3-2

BREAK-IN (RUNNING-IN) AND
INSPECTION BEFORE RIDING
MAXIMUM THROTTLE OPENING RECOMMENDATION .................................. 4-2
VARY THE ENGINE SPEED ............................................................................... 4-2
BREAKING IN THE NEW TYRES ....................................................................... 4-3 4
AVOID CONSTANT LOW SPEED ...................................................................... 4-3
ALLOW THE ENGINE OIL TO CIRCULATE BEFORE RIDING ......................... 4-3
OBSERVE YOUR FIRST AND MOST CRITICAL SERVICE .............................. 4-4
INSPECTION BEFORE RIDING .......................................................................... 4-4
4-1

BREAK-IN (RUNNING-IN) AND VARY THE ENGINE SPEED
INSPECTION BEFORE RIDING The engine speed should be varied and not
held at a constant speed. This allows the
parts to be “loaded” with pressure, and then
The opening explains how important proper
unloaded, allowing the parts to cool. This
break-in is to achieve maximum life and per-
aids the mating process of the parts. It is
formance from your new Suzuki. The follow-
essential that some stress be placed on the
ing guidelines explain proper break-in
engine components during break-in to
procedures.
ensure this mating process. Do not, though,
apply excessive load on the engine.
MAXIMUM THROTTLE OPENING
RECOMMENDATION
The table below shows the maximum throt-
tle opening recommendation during the
break-in period.
Initial 800 km Less than 1/2 throttle

Up to 1600 km Less than 3/4 throttle
4-2

BREAKING IN THE NEW TYRES AVOID CONSTANT LOW SPEED
New tyres need proper break-in to assure Operating the engine at constant low speed
maximum performance, just as the engine (light load) can cause parts to glaze and not
does. Wear in the tread surface by gradually seat in. Allow the engine to accelerate freely
increasing your cornering lean angles over through the gears, without exceeding the
the first 160 km before attempting maximum recommended maximum limits. Do not,
performance. Avoid hard acceleration, hard however, use full throttle for the first 1600
cornering, and hard braking for the first 160 km.
km.
WARNING ALLOW THE ENGINE OIL TO

CIRCULATE BEFORE RIDING
Failure to perform break-in of the tyres Allow sufficient idling time after warm or cold
could cause tyre slip and loss of control. engine start-up before applying load or rev-
ving the engine. This allows time for the
Use extra care when riding on new tyres. lubricating oil to reach all critical engine
Perform proper break-in of the tyres as components.
described in this section and avoid hard
acceleration, hard cornering, and hard
braking for the first 160 km.
4-3

OBSERVE YOUR FIRST AND MOST INSPECTION BEFORE RIDING
CRITICAL SERVICE
The 1000 km service is the most important WARNING
service your motorcycle will receive. During
break-in, all of the engine components will Failure to inspect and maintain your
have worn in and all of the other parts will motorcycle properly increases the
have seated in. All adjustments will be chance of an accident or equipment
restored, all fasteners will be tightened, and damage.
the dirty engine oil and engine oil filter will
Always perform a pre-ride inspection
be replaced. Timely performance of the
before each ride. Refer to the table on
1000 km service will ensure optimum ser-
the right for check items. For further
vice life and performance from the engine.
details, refer to the INSPECTION AND
MAINTENANCE section.
NOTE: The 1000 km service should be per-
formed as outlined in the INSPECTION
AND MAINTENANCE section of this
Owner’s Manual. Pay particular attention to
WARNING
the CAUTION and WARNING in that sec- Using worn, improperly inflated, or
tion. incorrect tyres will reduce stability and
can cause an accident.
Follow all instructions in the TYRES sec-
tion in this owner’s manual.
4-4

Before riding the motorcycle, be sure to
WHAT TO
check the following items. Never underesti- CHECK
CHECK FOR:
mate the importance of these checks. Per-
form all of them before riding the Steering • Smoothness
• No restriction of movement
motorcycle. • No rattle or looseness
Throttle • Correct play in the throttle cable
WARNING • Smooth operation and positive
return of the throttle grip to the
Checking maintenance items when the closed position
engine is running can be hazardous. You Brakes • Brake shoes not to be worn down
could be severely injured if your hands to the limit line
• Correct lever play
or clothing get caught in moving parts. • No “sponginess”
Shut the engine off when performing Suspensions • Smooth movement

• No oil leakage
maintenance checks, except when
checking the engine stop switch and Fuel Enough fuel for the planned distance
of operation
throttle.
Tyres • Correct pressure
• Adequate tread depth
• No cracks or cuts
Engine oil Correct level
Lighting Operation of all lights and indicators
Horn Correct function
4-5

RIDING TIPS
STARTING THE ENGINE .................................................................................... 5-2
STARTING OFF ................................................................................................... 5-4
STOPPING AND PARKING ................................................................................ 5-5
5-1

RIDING TIPS When the Engine is Cold:
1. Pull the choke knob all the way up. (full
choke position)
STARTING THE ENGINE 2. Squeeze the front or rear brake lever.
Place the motorcycle on the centre stand. 3. Close the throttle grip and push the elec-
Insert the ignition key into the ignition switch tric starter button or depress the kick
and turn it to the “ON” position. starter lever.
4. Immediately after the engine starts,
WARNING return the choke knob halfway and warm
up the engine.
Starting the engine improperly can be 5. Return the choke knob all the way to its
hazardous. Starting the engine with the disengaged position.
centre stand released can move motor-
cycle forward as soon as engine starts. NOTE: Opening the throttle grip before start-
ing the engine will make the engine hard to
Place the motorcycle on the centre stand start. Do not open the throttle grip before
before starting the engine and do not starting.
release the centre stand until engine
revs at idling speed.
5-2

When the Engine is Warm:
1. Squeeze the front or rear brake lever.
2. Close the throttle grip and push the elec-
CAUTION
tric starter button or depress the kick Running the engine too long without
starter lever. riding may cause the engine to overheat.
Overheating can result in damage to
NOTE: Operation of the carburetor choke internal engine components and discol-
system is not necessary when the engine is oration of exhaust pipes.
warm.
Shut the engine off if you cannot begin
your ride promptly.
WARNING
Running the engine indoors or in a
garage can be hazardous. Exhaust gas
contains carbon monoxide, a gas that is
colorless and odorless and can cause
death or severe injury.
Only run the engine outdoors where

there is fresh air.
5-3

STARTING OFF
WARNING
WARNING Removing your hands from the handle-
Riding this motorcycle at excessive bars or feet from the footrests during
speed increases your chances of losing operation can be hazardous. If you
control of the motorcycle. This may remove even one hand or foot from the
result in an accident. motorcycle, you can reduce your ability
to control the motorcycle.
Always ride within the limits of your
skills, your motorcycle, and the riding Always keep both hands on the handle-
conditions. bars and both feet on the footrests of
your motorcycle during operation.
5-4

Close the throttle and apply the brake when STOPPING AND PARKING
taking the motorcycle off the centre stand. 1. Twist the throttle grip away from yourself
Open the throttle grip toward you and the to close the throttle completely.
motorcycle will start moving forward. 2. Apply the front and rear brakes evenly
and at the same time.
WARNING
Sudden side winds, which can occur WARNING
when being passed by larger vehicles, at Inexperienced riders tend to underuti-
tunnel exits or in hilly areas, can upset lize the front brake. This can cause
your control. excessive stopping distance and lead to
a collision. Using only the front or rear
Reduce your speed and be alert to side brake can cause skidding and loss of
winds. control.
Apply both brake levers evenly and at

the same time.
WARNING
Hard braking while turning may cause
wheel skid and loss of control.
Brake before you begin to turn.
5-5

3. Select a level ground and place the
WARNING motorcycle on its centre stand.
4. Turn the ignition switch to the “OFF”
Hard braking on wet, loose, rough, or position to stop the engine.
other slippery surfaces can cause wheel 5. Turn the ignition switch to the “LOCK”
skid and loss of control. position to lock the steering.
6. Remove the ignition key from the switch.
Brake lightly and with care on slippery or
irregular surfaces.
WARNING
WARNING A hot muffler can burn you. The muffler
will be hot enough to burn you for some
Following another vehicle too closely time after stopping the engine.
can lead to a collision. As vehicle
speeds increase, stopping distance Park the motorcycle where pedestrians
increases progressively. or children are not likely to touch the
muffler.
Be sure you have a safe stopping dis-
tance between you and the vehicle in
front of you.
5-6

INSPECTION AND MAINTENANCE
MAINTENANCE SCHEDULE .............................................................................. 6-2
TOOLS ................................................................................................................. 6-6
LUBRICATION POINTS ...................................................................................... 6-8
BATTERY .......................................................................................................... 6-10
AIR CLEANER ................................................................................................... 6-14
SPARK PLUG .................................................................................................... 6-18
FUEL HOSE ....................................................................................................... 6-22 6
ENGINE OIL ...................................................................................................... 6-22
GEAR OIL .......................................................................................................... 6-29
CARBURETOR .................................................................................................. 6-30
COOLING FAN FILTER .................................................................................... 6-32
BRAKES ............................................................................................................ 6-33
TYRES ............................................................................................................... 6-38
LIGHT BULB REPLACEMENT ......................................................................... 6-41
FUSE .................................................................................................................. 6-50
6-1

INSPECTION AND
MAINTENANCE WARNING
Improper maintenance or failure to per-
MAINTENANCE SCHEDULE form recommended maintenance
The chart indicates the intervals between increases the chance of an accident or
periodic services in kilometers and months. motorcycle damage.
At the end of each interval, be sure to
inspect, check, lubricate and service as Always follow the inspection and mainte-
instructed. If your motorcycle is used under nance recommendations and schedules
high stress conditions such as continuous in this owner’s manual. Ask your SUZUKI
full throttle operation, or is operated in a dealer to do the maintenance items
dusty climate, certain services should be marked with an asterisk (*). You may per-
performed more often to ensure reliability of form the unmarked maintenance items
the machine as explained in the mainte- by referring to the instructions in this
nance section. Your Suzuki dealer can pro- section, if you have mechanical experi-
vide you with further guidelines. Steering ence. If you are not sure how to do any
components, suspensions and wheel com- of the jobs, have your SUZUKI dealer do
ponents are key items and require very spe- them.
cial and careful servicing. For maximum
safety we suggest that you have these items
inspected and serviced by your authorized
Suzuki dealer.
6-2

WARNING CAUTION
Running the engine indoors or in a Using poor quality replacement parts
garage can be hazardous. Exhaust gas can cause your motorcycle to wear more
contains carbon monoxide, a gas that is quickly and may shorten its useful life.
colorless and odorless and can cause
death or severe injury. Use only genuine Suzuki replacement
parts or their equivalent.
Only run the engine outdoors where
there is fresh air.
NOTE: The MAINTENANCE CHART speci-

fies the minimum requirements for mainte-
nance. If you use your motorcycle under
severe conditions, perform maintenance
more often than shown in the chart. If you
have any questions regarding maintenance
intervals, consult your SUZUKI dealer.
6-3

MAINTENANCE CHART
Interval: This interval should be judged by odometer reading or months, whichever comes
first.
Interval km 1000 4000 8000

Item months 5 20 40
Battery (specific gravity of electrolyte) – I I
– I I
Air cleaner element
Replace every 12000 km
* Exhaust pipe bolts and muffler mounting nut T – T
* Valve clearance I I I
Spark plug – I R
Fuel line – I I
Engine oil R R R
Engine oil filter R – R
* Final gear box oil – – I
Throttle cable play I I I
Idle speed I I I
* PAIR (air supply) system – I I
* Drive belt – I I
Brakes I I I
6-4

Interval km 1000 4000 8000
Item months 5 20 40
Tyres – I I
* Steering I – I
* Front forks – – I
* Rear suspension – – I
* Chassis bolts and nuts T T T
NOTE: I= Inspect and clean, adjust, replace or lubricate as necessary;

R= Replace; T= Tighten
6-5

TOOLS
A tool kit is supplied and is located under the

seat.
6-6

1 ... Tool bag
2 ... Plier
3 ... Open end wrench (10 mm × 12 mm)
4 ... Open end wrench (14 mm × 17 mm)
5 ... Screwdriver (+, –)
6 ... Screwdriver grip
7 ... Hexagon wrench (4 mm)
8 ... Socket wrench (16 mm)
9 ... Socket wrench (10 mm × 12 mm)
0 ... Box wrench handle
A ... Box wrench (12 mm)
B ... Box wrench (17 mm)
C ... Box wrench (22 mm)
6-7

LUBRICATION POINTS
Proper lubrication is important for smooth CAUTION
and long life of each working part of your
motorcycle and also for safe riding. It is a Lubricating switches can damage the
good practice to lubricate the motorcycle switches.
after a long rough ride or after it gets wet in
the rain or after washing it. Major lubrication Do not apply grease and oil to the
points are indicated as follows. switches.
6-8

1....Rear brake lever holder 3 ... Throttle cable
2....Centre stand pivot and spring hook 4 ... Front brake lever holder
 .... Motor oil

 .... Grease
6-9

BATTERY
The battery is located under the mainte-
nance lid. The electrolyte level must be kept
between the MAX and MIN level lines at all
times. If the solution level is below the MIN
limit line, add ONLY distilled water up to the
MAX limit line. NEVER use tap water.
To remove the battery, follow procedure

below:
2. Remove the screw and bolts. Remove

the maintenance lid 2.
1. Remove the foot board cover 1.
6-10

3. Remove the screw. Remove the cooling 4. Disconnect the negative (–) terminal
belt duct 3 from the maintenance lid 2. first, then disconnect the positive (+) ter-
minal.
5. Pull out the battery 4.
6-11

If the battery is discharged, recharge the
WARNING battery at the standard charging rate of 0.5A
× 10 hours. Never exceed the standard
Battery acid is harmful to eyes, skin and charging rate.
clothing.
If battery acid gets in eyes or comes in CAUTION

contact with skin, flush eyes or skin with Exceeding the standard charging rate for
water and call your physician immedi- the motorcycle battery can shorten its
ately. Never add battery acid to your bat- life.
tery.
Never exceed the standard charging
WARNING rate.
Hydrogen gas produced by batteries can NOTE: Check the specific gravity of the bat-
explode if exposed to flames or sparks. tery’s cells with a battery hydrometer. This
will determine the exact condition of each of
Keep flames and sparks away from the the six cells. If you do not have a hydrome-
battery. Never smoke when working near ter, have your dealer perform this service.
the battery.
6-12

CAUTION
Reversing the battery lead wires can
damage the charging system and the
battery.
The red lead must go to the positive (+)

terminal and the black (or black with
white tracer) lead must go to the nega-
tive (–) terminal.
CAUTION
Battery acid can damage your motorcy-
cle’s finish.
Route the battery breather pipe as

shown.
6-13

AIR CLEANER
If the air cleaner element has become CAUTION
clogged with dust, intake resistance will
increase with a resultant decrease in power Clean or replace the air cleaner element
output and an increase in fuel consumption. frequently if the motorcycle is used in
If riding under dusty conditions, the air dusty, wet or muddy conditions. The air
cleaner element must be cleaned or cleaner element will clog under these
replaced more frequently than maintenance conditions, and this may cause engine
schedule. Check and clean the air cleaner damage, poor performance, and poor
element periodically according to the follow- fuel economy.
ing procedure.
Clean the air cleaner case and element
immediately if water gets in the air
WARNING cleaner box.
Operating the engine without the air
cleaner element in place could allow a
flame to spit back from the engine to the
air cleaner, or could allow dirt to enter
the engine. This could cause a fire or
severe engine damage.
Never run the engine without the air

cleaner element properly installed.
6-14

Follow the procedure below to remove the
air cleaner element.
2. Remove the screws. Remove the air

cleaner cover 2.
1. Open the seat. Remove the trunk with
the seat 1 by removing the bolts and
screws.
6-15

3. Remove the air cleaner element 3. 4. Carefully use an air hose to blow the
dust from the air cleaner element.
NOTE: Always apply air pressure to the

inside of the air cleaner element only. If you
apply air pressure to the outside, dirt will be
forced into the pores of the element, restrict-
ing the air flow through the element.
6-16

Air Cleaner Drain Plug
CAUTION
A torn air cleaner element will allow dirt
to enter the engine and can damage the
engine.
Carefully examine the air cleaner ele-

ment for tears during cleaning. Replace
it with a new one if it is torn.
5. Reinstall the air cleaner element in the

reverse order of the removal. Be abso-
lutely sure that the element is securely in
position and is sealing properly. Remove the plug and drain water and oil at
the periodic maintenance interval.
CAUTION
Failure to position the air cleaner ele-
ment properly can allow dirt to bypass
the air cleaner element. This will cause
engine damage.
Be sure to properly install the air cleaner

element.
6-17

SPARK PLUG
To remove the spark plug, follow the proce-
dure below:
3. Disconnect the spark plug cap.

4. Remove the spark plug with a spark plug
wrench.
1. Remove the spark plug maintenance lid
1.
2. Remove the maintenance lid 2 by refer-
ring to the BATTERY section.
6-18

CAUTION
An improper spark plug may have an
incorrect fit or heat range for your
engine. This may cause severe engine
damage which will not be covered under
warranty.
0.6 – 0.7 mm Use one of the spark plugs listed or

equivalent. Consult your Suzuki dealer if
you are not sure which spark plug is cor-
rect for type of usage.
Remove the carbon deposits periodically
from the spark plug. Readjust the spark plug
gap to 0.6 – 0.7 mm by using a spark plug
gap thickness gauge.
Whenever removing the carbon deposits, be

sure to observe the operational color of the
spark plug’s porcelain tip. This color tells
you whether or not the standard spark plug
is suitable for your type of usage. A normal
operating spark plug should be very light
brown in color.
6-19

Plug Replacement Guide NOTE: This motorcycle uses resistor-type
spark plug to avoid jamming electronic
NGK REMARKS parts. Improper spark plug selection may
CR6HSA Standard cause electronic interference with your
motorcycle ignition system, resulting in
If the standard plug is
very white or glazed in
motorcycle performance problems. Use rec-
CR7HSA ommended spark plugs.
appearance replace with
this plug.
CHAMPION REMARKS
P-RZ9HC Standard
If the standard plug is
very white or glazed in
P-RZ8HC
appearance replace with
this plug.
6-20

CAUTION CAUTION
A crossthreaded or overtightened spark Dirt can damage your engine if it enters
plug will damage the aluminum threads an open spark plug hole.
of the cylinder head.
Cover the spark plug hole whenever the
Follow the procedure below to tighten spark plug is removed.
the spark plug properly.
Carefully turn the spark plug by hand into

the threads until it is finger tight. If the spark
plug is new, tighten it with a wrench about 1/
2 turn past finger tight. If you are reusing the
old spark plug, tighten it with a wrench about
1/8 turn past finger tight.
6-21

FUEL HOSE ENGINE OIL
Long engine life depends much on the
selection of a quality oil and the periodic
changing of the oil. Daily oil level checks and
periodic changes are two of the most impor-
tant maintenance items to be performed.
ENGINE OIL LEVEL CHECK
L F
1. Remove the trunk with the seat by refer- Check the engine oil level with the engine oil
ring to the AIR CLEANER section. dipstick. The dipstick comes out together
2. Inspect the fuel hose for damage and with the oil filler cap as shown. The level on
fuel leakage. If any defects are found, the dipstick should be between the “L” (Low)
the fuel hose must be replaced. and “F” (Full) lines.
6-22

WARNING CAUTION
Exhaust pipe and muffler are hot enough The engine oil level must be between the
to burn you. “L” (Low) line and “F” (Full) line, or
engine damage may occur.
Wait until the exhaust pipe and muffler
are cool enough to touch with bare Check the oil level with the dipstick, with
hands before removing the oil filler cap. the motorcycle held vertically on level
ground before each use of the motorcy-
The oil level inspection should be performed cle.
under the following conditions:
1. Place the motorcycle on the centre
stand. Hold the motorcycle vertically.
2. The oil filler cap threads are not run in
but touching the filler hole upper edge.
6-23

ENGINE OIL AND FILTER CHANGE
Change the engine oil and engine oil filter at
the initial 1000 km and at each maintenance
interval. The engine oil should be changed
when the engine is hot so that the engine oil
will drain thoroughly from the engine. The
procedure is as follows:
1. Place the motorcycle on the centre

stand.
3. Place a drain pan under the drain plug

2.
4. Remove the drain plug 2 and drain out
the engine oil.
2. Remove the engine oil filler cap 1.
6-24

WARNING  WARNING
Engine oil and exhaust pipes can be hot New and used oil can be hazardous.
enough to burn you. Children and pets may be harmed by
swallowing new or used oil. Repeated,
Wait until the oil drain plug and exhaust prolonged contact with used engine oil
pipes are cool enough to touch with bare may cause skin cancer. Brief contact
hands before draining oil. with used oil may irritate skin.
• Keep new and used oil away from chil-

dren and pets.
• Wear a long-sleeve shirt and water-
proof gloves.
• Wash with soap if oil contacts your
skin.
NOTE: Recycle or properly dispose of used

oil.
6-25

5. Remove the three bolts 3 holding the fil- 6. Replace the engine oil filter 5 with a
ter cap 4 in place. new one.
6-26

CAUTION
Using an oil filter with the wrong design
can cause engine damage.
Use a genuine SUZUKI oil filter for your

motorcycle.
CAUTION
Failure to insert the new element cor-
rectly can damage the engine. No oil 7. Before replacing the engine oil filter
flow will result if the element is inserted cover, be sure to check that the engine
backwards. oil filter spring 6 and the “O” rings 7
are installed correctly.
Insert the open end of the new oil filter
element into the engine. NOTE: Use new “O” rings each time the
engine oil filter element is replaced.
6-27

8. Replace the oil filter cover and tighten 10. Tighten the oil filler cap.
the bolts securely but do not overtighten 11. Start the engine and allow it to idle for a
them. few minutes.
9. Replace the drain plug and tighten it 12. Check the oil level according to Oil Level
securely. Pour fresh oil through the filler Check procedure.
hole. Approximately 1000 ml of oil will be
required. NOTE: Check to see that no oil is leaking
from the oil filter cover.
NOTE: Approximately 900 ml of oil will be
required when changing oil only without
replacing the oil filter.
CAUTION
Engine damage may occur if you use oil
that does not meet Suzuki’s specifica-
tions.
Use the oil specified in the FUEL AND

ENGINE OIL RECOMMENDATION sec-
tion.
6-28

GEAR OIL
3. Remove the oil level plug 2 and inspect

the oil level. If the level is below the level
1. Remove the clutch cover cap 1 by hole, add oil until it flows out from the
removing the bolts. level hole.
2. Place an oil pan under the final gear 4. Tighten the oil level plug 2.
case.
NOTE: If oil is dirty with sludge or used for a
long period, drain the oil by removing the
drain plug 3 and pour fresh oil through the
oil level hole.
6-29

CARBURETOR 2. After engine warms up, turn the throttle
The carburetor is factoryset for the best car- stop screw 1 located on the carburetor
buretion. Do not attempt to alter its setting. in or out so that engine may run at 1400
There are two items of adjustment, however, – 1600 r/min. Use a commercially avail-
under your care: idle speed and throttle able screwdriver to turn the throttle stop
cable play. Adjust the carburetor idle speed screw.
and throttle cable play periodically.
THROTTLE CABLE ADJUSTMENT
IDLE SPEED ADJUSTMENT
2.0 – 4.0 mm
Measure the throttle cable play by turning

the throttle grip. The throttle grip should
have 2.0 – 4.0 mm play.
1. Start up the engine and let the engine

run until it warms up fully.
6-30

WARNING
Inadequate throttle cable play can cause
engine speed to rise suddenly when you
turn the handlebars. This can lead to
loss of rider control.
Adjust the throttle cable play so that

engine idle speed does not rise due to
handlebar movement.
1. Loosen the lock nut 1.

2. Adjust the cable play by turning adjuster
2 in or out to obtain the correct play.
3. After adjusting the play, tighten the lock
nut 1.
6-31

COOLING FAN FILTER
The cooling fan filter is located on the left
side of crankcase assembly. Clean the cool-
ing fan filter every 3000 km.
Follow the procedure below to remove the

cooling fan filter.
2. Remove the cooling fan filter 3.
1. Remove the screws 1 and cover 2.
6-32

BRAKES
Initial 1000 km and every 4000 km, check
the brakes as follows:
WARNING
Brakes are items of personal safety and
should always be maintained in proper
adjustment.
FRONT BRAKE ADJUSTMENT
2. If adjustment is necessary, turning the

front brake adjusting nut 1 clockwise
will increase the distance.
1. Measure the front brake lever play at the

brake lever end. The play should be 15 –
25 mm.
6-33

FRONT BRAKE LINING WEAR LIMIT 2. While fully applying the brake check to
The motorcycle is equipped with the brake see that the extension line of the index
lining wear limit indicator on the front brake. mark is within the range on the brake
To check wear of the brake lining, perform panel as shown in the Fig. A.
the following:
Index mark Range
1. Check if the brake system is properly
adjusted.
Index mark Range
Fig.B The extension line of the index mark

is out of the range.
Fig.A The extension line of the index mark

is within the range.
6-34

3. If the extension line is beyond the range REAR BRAKE ADJUSTMENT
as shown in the Fig. B have the brake
shoe assembly replaced by your Suzuki
dealer to ensure safe operation.
WARNING
Too much play in the rear brake lever can
cause poor braking performance and
WARNING may lead to an accident. Too little play
Riding with worn brake shoes will may force brake shoes to rub against the
reduce braking performance and will drum at all times, causing damage to the
increase your chance of having an acci- shoes and the drum.
dent.
Follow the steps in this section to adjust
Inspect brake shoe wear before each the rear brake lever properly.
use. Ask your SUZUKI dealer to replace
brake shoes if the shoes are worn to the
limit.
6-35

Measure the amount of brake lever distance
between the brake lever end and grip when
the brake is operated. The distance should
be 15 – 25 mm. Check the play every time
before riding and adjust it if necessary, as
follows:
1. Turn the rear brake adjusting nut 1

clockwise or counterclockwise to obtain
the specified play. Turning the adjusting
nut clockwise will decrease the play.
2. After adjusting the play, check that there
is no dragging when turning rear wheel
with the wheel off the ground and that
there is enough clearance between the
rear brake lever and grip when the lever
is tightly squeezed.
6-36

REAR BRAKE LINING WEAR LIMIT 1. Check if the brake system is properly
The motorcycle is equipped with the brake adjusted.
lining wear limit indicator on the rear brake. 2. While operating the brake, check if the
To check wear of the brake lining, perform Indicator is as shown in Fig.A.
the following:
Fig.A
Indicator Limit mark
Rear brake
Fig.A Indicator is within the limit mark.
6-37

TYRES
WARNING
WARNING Failure to perform break-in of the tyres
Failure to follow these warnings may could cause tyre slip and loss of control.
result in an accident due to tyre failure.
The tyres on your motorcycle form the Use extra care when riding on new tyres.
crucial link between your motorcycle Perform proper break-in of the tyres
and the road. referring to the BREAK-IN section and
avoid hard acceleration, hard cornering,
Follow these instructions: and hard braking for the first 160 km.
• Check tyre condition and pressure,
and adjust pressure before each ride.
• Avoid overloading your motorcycle.
• Replace a tyre when worn to the speci-
fied limit, or if you find damage such
as cuts or cracks.
• Always use the size and type of tyres
specified in this owner’s manual.
• Read this section of owner’s manual
carefully.
6-38

TYRE PRESSURE AND LOADING Cold Tyre Inflation Pressure
Proper tyre pressure and proper tyre loading
are important factors. Overloading your SOLO RIDING DUAL RIDING
tyres can lead to tyre failure and loss of 125 kPa 125 kPa
motorcycle control. FRONT 1.25 kgf/cm2 1.25 kgf/cm2
18 psi 18 psi
Check tyre pressure each day before you 175 kPa 250 kPa
ride, and be sure the pressure is correct for REAR 1.75 kgf/cm2 2.50 kgf/cm2
the motorcycle load according to the table 25 psi 36 psi
as follows. Tyre pressure should only be
checked and adjusted before riding, since Under-inflated tyres make smooth cornering
riding will heat up the tyres and lead to difficult, and can result in rapid tyre wear.
higher inflation pressure readings. Over-inflated tyres have a smaller amount of
tyre in contact with the road, which can con-
tribute to skidding and loss of control.
6-39

TYRE CONDITION AND TYPE Check tyre conditions each day before you
ride. Replace tyres if tyres show visual evi-
dence of damage, such as cracks or cuts, or
if tread depth is less than 1.6 mm front, 1.6
mm rear.
Whenever you replace a tyre, use a tyre of

the size and type listed below. If you use a
different size or type of tyre, vehicle handling
may be adversely affected, possibly result-
ing in loss of vehicle control.
FRONT REAR
SIZE 90/100-10 53J 90/100-10 53J
Proper tyre condition and proper tyre type MRF MRF
affect motorcycle performance. Cuts or TYPE
NYLOGRIP FE NYLOGRIP FE
cracks in the tyres can lead to tyre failure
and loss of motorcycle control. Worn tyres
are susceptible to puncture failures and sub-
sequent loss of motorcycle control. Tyre
wear also affects the tyre profile, changing
motorcycle handling characteristics.
6-40

Be sure to balance the wheel after repairing LIGHT BULB REPLACEMENT
a puncture or replacing the tyre. Proper The wattage rating of each bulb is shown on
wheel balance is important to avoid variable the chart below. When replacing a burned
wheel-to-road contact, and to avoid uneven out bulb, always use the exact same wattage
tyre wear. rating. Using other than the specified rating
can result in overloading the electrical sys-
WARNING tem or premature failure of a bulb.
An improperly repaired, installed, or bal-

anced tyre can cause loss of control or CAUTION
shorten tyre life. Using a light bulb with the wrong watt-
age rating can cause electrical system
• Ask your SUZUKI dealer or a qualified damage or shorten bulb life.
mechanic to perform tyre repair,
replacement, and balancing because Always use the specified light bulb.
proper tools and experience are
required.
Headlight 12V 35/35W (HS1)
• Install tyres according to the rotation
direction shown by arrows on the side- Front turn signal light 12V 10W × 2
wall of each tyre. Rear turn signal light 12V 10W × 2
Brake light/Taillight 12V 21/5W
License plate light 12V 5W
6-41

HEADLIGHT
To replace the headlight bulb, follow the pro-
cedure below:
1. Remove the mirrors.

2. Remove the screws.
3. Remove the front cover with the head
lamp assembly 1.
6-42

4. Disconnect the socket 2 and remove 5. Unhook the bulb holder spring 4, and
the rubber cap 3. pull out the bulb 5.
CAUTION
Oil from your skin may damage the head-
light bulb or shorten its life.
Grasp the new bulb with a clean cloth.
6-43

HEADLIGHT BEAM ADJUSTMENT BRAKE LIGHT/TAILLIGHT
To replace the brake light/taillight bulb, follow
the procedure below:
The headlight beam can be adjusted verti-

cally if necessary. To adjust the beam, move
the adjuster bolt 1 forward or backward. 1. Remove the lens by removing the
screws 1.
6-44

CAUTION
Overtightening the screws when rein-
stalling the lens may cause the lens to
crack.
Tighten the screws only until they are

snug.
2. Push in on the burned-out bulb, turn it to

the left, and pull it out.
3. To fit the replacement bulb, push it in and
turn it to the right while pushing.
6-45

FRONT TURN SIGNAL LIGHT
To replace the front turn signal light bulb, fol-
low the procedure below.
2. Turn the socket counterclockwise and

remove it.
1. Remove the screws and the lens.
6-46

REAR TURN SIGNAL LIGHT
To replace the rear turn signal light bulb, fol-
low the procedure below.

1. Remove the screw 1.
CAUTION 2. Insert the screwdriver between the cover
and lens to unhook the lens hook.
Overtightening the screws when rein- 3. Take off the lens.
crack.

snug.
6-47

CAUTION
Overtightening the screws when rein-
crack.

snug.

6-48

LICENSE PLATE LIGHT
To replace the license plate light bulb, follow
the procedure below:
2. Pull off the bulb from the socket.
1. Turn the license plate lens assembly

counterclockwise and remove it.
6-49

FUSE
CAUTION
Installing a fuse of incorrect rating or
using aluminum foil or wire instead of a
fuse may seriously damage the electrical
system.
Always replace a blown fuse with a fuse

of the same type and rating. If the new
fuse blows in a short time, consult your
Suzuki dealer immediately.
The fuse is located under the maintenance

lid. Remove the maintenance lid by referring
to the BATTERY section.
The 10A fuse is equipped. It is designed to

open when a circuit overload exists in indi-
vidual electrical system circuits. If any elec-
trical system fails to operate, then the fuse
must be checked. To check the fuse, remove
the right frame cover. A 10A spare fuse is
provided in the vinyl case.
6-50

TROUBLESHOOTING
FUEL SUPPLY CHECK ....................................................................................... 7-2
IGNITION SYSTEM CHECK ................................................................................ 7-4
ENGINE STALLING ............................................................................................ 7-4
7-1

TROUBLESHOOTING FUEL SUPPLY CHECK
1. Make sure there is enough fuel in the
This troubleshooting guide is provided to fuel tank.
help you find the cause of some common 2. Make sure there is enough fuel reaching
complaints. the carburetor.
a. Loosen the drain screw located under
the carburetor. Drain fuel from the car-
CAUTION buretor into a container.
Failure to troubleshoot a problem cor-
rectly can damage your motorcycle.
Improper repairs or adjustments may
damage the motorcycle instead of fixing
it. Such damage may not be covered
under warranty.
If you are not sure about the proper

action, consult your Suzuki dealer or a
qualified mechanic about the problem.
7-2

b. Tighten the drain screw.
WARNING c. Turn the ignition switch to the “ON”
position.
Fuel and fuel vapor are highly flammable d. Turn the ignition switch to the “OFF”
and toxic. You can be burned or poi- position several seconds later.
soned when handling fuel. e. Loosen the drain screw and check that
the carburetor is filled back up with
When draining the carburetor: fuel.
• Stop the engine and keep flames, f. Tighten the drain screw.
sparks, and heat sources away. 3. If fuel is reaching the carburetor, ignition
• Drain fuel only outdoors or in a well- system should be checked next.
ventilated area.
• Do not smoke.
• Avoid breathing fuel vapor.
• Keep children and pets away.
• Dispose of drained fuel properly.
7-3

IGNITION SYSTEM CHECK
1. Remove the spark plug and reattach it to WARNING
the spark plug lead.
Performing the spark test improperly can
cause a high voltage electrical shock or
an explosion.
Avoid performing this check if you are

not familiar with this procedure, or if you
have a heart condition or wear a pace-
maker. Keep the spark plug away from
the spark plug hole during this test.
ENGINE STALLING
1. Check the fuel supply in the fuel tank.
2. While holding the spark plug firmly 2. Check the ignition system for intermittent
against the engine, crank the engine spark.
with the ignition switch in the “ON” posi- 3. Check the idle speed.
tion. If the ignition system is operating
properly, a blue spark should jump
across the spark plug gap. If there is no
spark, consult your Suzuki dealer for
repairs.
7-4

MOTORCYCLE CLEANING AND
STORAGE PROCEDURE
MOTORCYCLE CLEANING ................................................................................ 8-2
STORAGE PROCEDURE ................................................................................... 8-4
PROCEDURE DURING STORAGE .................................................................... 8-6
PROCEDURE FOR RETURNING TO SERVICE ................................................ 8-6
8-1

MOTORCYCLE CLEANING AND 3. Once the dirt has been completely
removed, rinse off the detergent with
STORAGE PROCEDURE running water.
4. After rinsing, wipe off the motorcycle
MOTORCYCLE CLEANING with a wet chamois or cloth and allow it
Washing the Motorcycle to dry in the shade.
When washing the motorcycle, follow the
instruction below:
1. Remove dirt and mud from the motorcy- CAUTION
cle with running water. You may use a Cleaning with any alkaline or strong acid
soft sponge or brush. Do not use hard cleaner gasoline, brake fluid, or any
materials which can scratch the paint. other solvent will damage the motorcy-
2. Wash the entire motorcycle with mild cle parts.
detergent or car wash soap using a
sponge or soft cloth. The sponge or cloth Clean only with soft cloth and warm
should be frequently soaked in the soap water with mild detergent.
solution.
NOTE: Avoid spraying or allowing water to

flow over the following places:
• Ignition switch
• Spark plug
• Fuel tank cap
• Carburetor
8-2

Waxing the Motorcycle Inspection after Cleaning
After washing the motorcycle, waxing and For extended life of your motorcycle, lubri-
polishing are recommended to further pro- cate according to “LUBRICATION POINTS”
tect and beautify the paint. section.
• Only use waxes and polishes of good
quality.
• When using waxes and polishes, WARNING
observe the precautions specified by the Wet brakes can cause poor braking per-
manufacturers. formance and may lead to an accident.
Avoid a possible accident by expecting

longer stopping distances after washing
your motorcycle. Apply brakes several
times to let heat dry the brake shoes.
Follow the procedures in the “INSPECTION

BEFORE RIDING” section to check your
motorcycle for any problems that may have
arisen during your last ride.
8-3

STORAGE PROCEDURE FUEL
If the motorcycle is to be left unused for 1. Fill the fuel tank to the top with fuel.
extended period of time for winter storage or 2. Drain the carburetor or run the engine for
any other reason, the machine needs spe- a few minutes until the stabilized gaso-
cial servicing requiring appropriate materi- line fills the carburetor.
als, equipment and skill. For this reason,
Suzuki recommends that you trust this
maintenance work to your Suzuki dealer. If
WARNING
you need to service the machine for storage Fuel and fuel vapor are highly flammable
yourself, follow the general guidelines as fol- and toxic. You can be burned or poi-
lows. soned when handling fuel.
MOTORCYCLE When draining the carburetor:
Clean the entire motorcycle. Place the • Stop the engine and keep flames,
motorcycle on the centre stand on a firm, flat sparks, and heat sources away.
surface where it will not fall over. Turn the • Drain fuel only outdoors or in a well-
handlebars all the way to the left and lock ventilated area.
the steering, and remove the ignition key. • Do not smoke.
• Avoid breathing fuel vapor.
• Keep children and pets away.
• Dispose of drained fuel properly.
8-4

ENGINE TYRE
1. Pour one tablespoon of motor oil into the Inflate the tyres to the normal specifications.
spark plug hole. Reinstall the spark plug
and crank the engine a few times. EXTERNAL
2. Drain the engine oil thoroughly and fill • Spray all vinyl and rubber parts with rub-
the crankcase with the fresh engine oil ber preservative.
all the way up to the filler hole. • Spray the unpainted surfaces with rust
preventative.
BATTERY • Coat the painted surfaces with car wax.
1. Remove the battery from the motorcycle.
NOTE: Be sure to remove the negative ter-

minal first, then remove the positive termi-
nal.
2. Clean the outside of the battery with a

mild detergent and remove any corro-
sion from the terminals and wiring har-
ness connections.
3. Store the battery in a room above freez-
ing.
8-5

PROCEDURE DURING STORAGE PROCEDURE FOR RETURNING TO
Once a month, recharge the battery with a SERVICE
specified charging rate (Ampere). Standard • Clean the entire motorcycle.
charging rate is 0.5A × 5 to 10 hours. • Reinstall the battery.
NOTE: Make sure that the battery vent hose

is routed properly. Be sure to connect the
positive terminal first, then connect the neg-
ative terminal.
• Remove the spark plug. Turn the engine

a few times by putting the transmission
in top gear and turning the rear wheel.
Reinstall the spark plug.
• Drain the engine oil thoroughly. Replace
the oil filter with a new one and pour
fresh oil as outlined in this manual.
• Adjust the pressure of tyres as described
in the TYRE section.
• Lubricate all places as instructed in this
manual.
• Do the “INSPECTION BEFORE
RIDING” as listed in this manual.
8-6

SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length........................................................................ 1780 mm
Overall width ......................................................................... 650 mm
Overall height........................................................................ 1125 mm
Wheelbase............................................................................ 1250 mm
Ground clearance ................................................................. 160 mm
ENGINE
Type ...................................................................................... Four-stroke, air-cooled, OHC
Number of cylinder................................................................ 1
Bore ...................................................................................... 53.5 mm
Stroke.................................................................................... 55.2 mm
Displacement ........................................................................ 124 cm3
Compression ratio................................................................. 9.6 : 1
Carburetor............................................................................. VM18, single
Air cleaner............................................................................. Non-woven fabric element
Starter system ...................................................................... Electric and Primary kick
Lubrication system................................................................ Wet sump

DRIVE TRAIN
Clutch.................................................................................... Dry shoe, automatic, centrifugal type
Gearshift pattern ................................................................... Automatic
Reduction ratio...................................................................... Variable change (2.645 – 0.802)
Final reduction ratio .............................................................. 7.576 (42/17 × 46/15)
Drive system ......................................................................... V-belt drive
CHASSIS
Front suspension .................................................................. Telescopic, coil spring, oil damped
Rear suspension ................................................................... Swingarm type, coil spring, oil damped
Steering angle....................................................................... 45° (right & left)
Caster ................................................................................... 26°
Trail ....................................................................................... 82 mm
Turning radius ....................................................................... 1.95 m
Front brake............................................................................ Drum brake
Rear brake ............................................................................ Drum brake
Front tyre size ....................................................................... 90/100-10 53J, tube type
Rear tyre size........................................................................ 90/100-10 53J, tube type

ELECTRICAL
Ignition type .......................................................................... Electronic ignition (CDI)
Spark plug............................................................................. NGK CR6HSA or CHAMPION P-RZ9HC
Battery .................................................................................. 12V 18kC (5 Ah)/10HR
Generator.............................................................................. Single-phase A.C. generator
Fuse...................................................................................... 10A
Headlight............................................................................... 12V 35/35W
Brake light/Taillight ................................................................ 12V 21/5W
Turn signal light..................................................................... 12V 10W × 2
License plate light ................................................................. 12V 5W
High beam indicator light ...................................................... 12V 1.7W
Turn signal indicator light ...................................................... 12V 1.7W × 2
CAPACITIES
Fuel tank ............................................................................... 6.0 L
Engine oil, oil change ........................................................... 900 ml
with filter change................................................. 1000 ml
overhaul .............................................................. 1050 ml

INDEX
A E
ACCESSORY INSTALLATION AND ENGINE OIL........................................... 6-22
PRECAUTION SAFETY TIPS ................. 1-2 ENGINE OIL AND GEAR OIL .................. 3-2
AIR CLEANER ....................................... 6-14 ENGINE STALLING ................................. 7-4
ALLOW THE ENGINE OIL TO CIRCULATE
BEFORE RIDING..................................... 4-3 F
AVOID CONSTANT LOW SPEED........... 4-3 FUEL ........................................................ 3-2
FUEL HOSE........................................... 6-22
B FUEL SUPPLY CHECK ........................... 7-2
BATTERY .............................................. 6-10 FUEL TANK CAP ................................... 2-13
BRAKES ................................................ 6-33 FUSE...................................................... 6-50
BREAKING IN THE NEW TIRES............. 4-3
G
C GEAR OIL .............................................. 6-29
CARBURETOR...................................... 6-30 GEARSHIFT LEVER.............................. 2-15
CENTRE STAND ................................... 2-19
CHOKE KNOB ....................................... 2-14 H
COOLING FAN FILTER......................... 6-32 HELMET HOLDERS .............................. 2-17
HOOK..................................................... 2-18

I M
IGNITION SWITCH ..................................2-5 MAINTENANCE SCHEDULE .................. 6-2
IGNITION SYSTEM CHECK ....................7-4 MAXIMUM THROTTLE OPENING
INSPECTION BEFORE RIDING ..............4-4 RECOMMENDATION.............................. 4-2
INSTRUMENT PANEL .............................2-7 MODIFICATION....................................... 1-4
MOTORCYCLE CLEANING .................... 8-2
K
KEY ..........................................................2-5 O
KICK STARTER LEVER.........................2-15 OBSERVE YOUR FIRST AND
MOST CRITICAL SERVICE .................... 4-4
L
LEFT HANDLEBAR..................................2-8 P
LIGHT BULB REPLACEMENT...............6-41 PROCEDURE DURING STORAGE ........ 8-6
LOCATION OF PARTS ............................2-2 PROCEDURE FOR RETURNING TO
LUBRICATION POINTS ...........................6-8 SERVICE ................................................. 8-6

R T
RIGHT HANDLEBAR............................. 2-11 TOOLS ..................................................... 6-6
TRUNK................................................... 2-16
S TYRES ................................................... 6-38
SAFE RIDING RECOMMENDATION FOR
MOTORCYCLE RIDERS ......................... 1-4 V
SERIAL NUMBER LOCATION ................ 1-6 VARY THE ENGINE SPEED ................... 4-2
SPARK PLUG ........................................ 6-18
STARTING OFF....................................... 5-4
STARTING THE ENGINE........................ 5-2
STOPPING AND PARKING..................... 5-5
STORAGE PROCEDURE ....................... 8-4
Total page: 112

Part No. 99011-33G50-01A
September, 2007 TK EN
SUZUKI MOTORCYCLE INDIA PRIVATE LIMITED
K8 Village Kherki, Badshahapur,

N, H, -8 Link Road, Gurgaon (Haryana) Printed in India

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SUZUKI MOTORCYCLE INDIA © COPYRIGHT SUZUKI MOTORCYCLE

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ACCESSORY INSTALLATION AND PRECAUTION SAFETY TIPS ................. 1-2

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Use extreme caution when selecting and

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INSPECTION BEFORE RIDING BE EXTRA SAFETY CONSCIOUS ON

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Please write down the numbers in the box

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1 Rear brake lever 5 Throttle grip

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This motorcycle comes equipped with a

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HIGH BEAM INDICATOR LIGHT 3

NOTE: If a turn signal light is not operating

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REAR BRAKE LEVER 1

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Always use the turn signals when you

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FRONT BRAKE LEVER 1

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If the engine does not start after several

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The fuel tank cap is located under the seat.

Never fill the fuel above the bottom of

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• Stop the engine and keep flames,

NOTE: Refer to the RIDING TIPS section of

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Be sure the kick starter lever is returned

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Place helmets as shown, or seat may not be

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Never carry a helmet fastened to a hel-

Hook the helmet ring to the helmet holders

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To use the hook, turn the hook and open the

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To place the motorcycle on the centre stand,

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Be careful not to spill any fuel when fill-

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Initial 800 km Less than 1/2 throttle