Suzuki ALT125, LT125, ALT185 & LT185 SUZUKI ALT125, LT125, ALT185 AND LT185 NOTE: Metric fasteners are used throughout vehi CONDENSED SERVICE DATA ALT125D, E, F,G ALT185F MODELS LT125D, E, F,G,H LT185E, F, G,H General Engine Make... 22.2... ‘Suzuki Suzuki Engine Type . 2... a Four-Stroke: Four-Stroke; a aa me Air-Cooled Ai-Cooled Number of Cylinders 1 4 Bore .. 57.0 mm 63.0 mm. (2.244 in.) (2.480 in.) Stroke... : 48.8 mm 57.0 mm. (4.821 in.) (2.244 in.) Displacement trees 124 0c 178 cc (7.8.cu. in.) (10.9 cu. in.) Compression Ratio .... 85:1 9.0:1 Fuel Recommended Unleaded or Unleaded or Low-Lead Low-Lead Pump Octane Rating ..... 85-95 85:95 Engine Lubrication... Wet Sump; Pump Wet Sump; Pump Engine /Transmission Oil Recommendation ..... SAE 10W-40 SAE 10W-40 Forward Speeds ....-. 5 5 Reverse Speeds 1 1 Tire Size ALT Models— Front ... pce 22x 11.008 22x 11.008 Rear 22 x 11.008 22x 11.008 UT Modeis— Front : : 20 x 7.00-8 20 x 7.00-8 Rear : 22x 11.008 22x 11.008 Tire Pressures-All Models (cold) Front & Rear... 15 kPa 15 kPa (22 psi) (22 psi) Dry Weight: ALT Models... i 118 kg 125 kg (260 Ibs.) (276 Ibs.) LT Models, : 129 ko 198 kg (284 Ibs.) (304 Ibs.) Tune-Up Engine Idle Speed 1600-1600 rpm 1950-1450 rpm ‘Spark Plug: NGK D7EA D7EA Nippon Denso ound X22ES-U X22ES-U Electrode Gap... ooo 0.6-0.7 mm 0.6-0.7 mm (0.024-0.028 in.) (0.024-0.028 in.) Ignition: TYPO oe eee eae ol Breakerless Breakerless Timing 22252252 oc ‘See Text See Text 262 llvoestion® Courtesy U.S. Suzuki Motor Corp.MODELS Tune-Up (Cont.) Carburetor: Make. Model Float Height Jet Needle Clip Position Throttle Cutaway Pilot Jet... . Needle Jet Main Jet... Throttle Cable FreePlay Sizes-Clearances Valve Clearance (cold) Intake & Exhaust Valve Face Angle Valve Seat Angle Valve Seat Width Valve Stem Diameter: Intake . Exhaust Valve Guide Bore Diameter: Intake And Exhaust Valve Stem-To-Guide Clearance: Intake Exhaust Valve Spring Free Length (Min.) Inner Outer Rocker Arm Bore Diameter: Intake And Exhaust... Rocker Snatt Diameter: Intake And Exhaust Camshaft Lobe Height: Intake. . . Wear Limit Exhaust Wear Limit fusrations Courtesy US. Suzuki Motor Car, Suzuki ALT125, LT125, ALT185 & LT185 ALT125D, E, F,G LT125D, E, F, G,H Mikuni v20ss 24.8-26.8 mm (0.98-1.06 in.) 4JR39 2nd Groove From Top, 3.0 #20 0-4 #100 0.5-1.0 mm (0.02-0.04 in.) 0.08-0.13 mm (0.003-0.005 in.) 45° 45° 0.9--1 mm (0.035-0.043 in.) 5.475-5.490 mm (0.2155-0.2161 in.) 5.455-5.470 mm (0.2148-0.2153 in.) 5.500-5.512 mm (0.2165-0.2170 in.) 0.010-0.037 mm (0,0004-0,0015 in.) 0.080-0.057 mm (0.0012-0.0022 in.) 35.1 mm (1.38 in.) 39.9 mm, (1.87 in.) 12,000-12.018 mm (04724-04731 in.) 11.977-1.995 mm. (0.47 15-0.4722 in.) 32,400-2.440 mm (4.2756-1.2772 in.) 82.100 mm. (74,2638 in.) 32.400-32.440 mm (1.2756-1.2772 in.) 32.100 mm (4.2638 in.) ALT185F LT185E, F, G,H Mikuni v22ss 24.8-26.8 mm (0.98-1.06 in.) LIS 8rd Groove From Top. 2.0 #20 0-2 #118 0.5-1.0 mm (0.02-0.04 in.) 0.08-0.13 mm (0.003-0.005 in.) 45° 45° 0.9-1-1 mm (0.035-0.043 in.) 5.475-5.490 mm (0.2155-0.2161 in.) §.455-5.470 mm (0.2148-0.2153 in.) §.500-5.512 mm (0.2165-0.2170 in.) 0.010-0.087 mm (0.0004-0.0015 in.) 0.080-0.057 mi (0.0012-0.0022 in.) 35,1 mm, (1.38 in.) 39.9 mm (1.87 in.) 42.000-12.018 mm (04724-04731 in.) 11.977-11.995 mm (0.47 1-0.4722 in.) 33.780-33.820 mm (1.3299-1.3315 in.) 33.480 mm (1.3181 in.) 32.990-33.030 mm (1.2988-1,3004 in.) 32.690 mm (1.2870'n.) 263Suzuki ALT125, LT125, ALT185 & LT185 ALT125D, E, F, G MODELS LT125D, E, F, G, H Sizes-Clearances (Cont.) Camshaft Journal Diameter ........ 02.005 21.970-21.991 mm (0.8649-0.8658 in.) Camshaft Journal Clearance oo... eee eee ee 0.021-0.085 mm (0.0008-0.0022 in.) Wear Limit ateare 0.150 mm (0.0059 in.) Camshaft Runout (Max.) 0.10 mm (0.004 in.) Cylinder Head Cover Distortion (Max. ) 0.05 mm (0.002 in.) Cylinder Head Distortion (Max.) 0.05 mm (0.002 in.) Piston-to-Cylinder Wall Clearance ..... eee eeeeee 0.085-0.045 mm (0.0014-0.0018 in.) Cylinder Bore Diameter .. 57.000-57.015 mm (2.2441-2.2447 in.) ‘Wear Limit ‘57.095 mm (2.2478 in.) Cylinder Bore Distortion (Max.) 0.05 mm (0.002 in.) Piston Diameter Measured 15 mm (0.59 in.) from Skirt Bottom oo. ....ee..eesesee 56,960-56.975 mm (2.2425-2.2431 in.) Wear Limit 0.02... 0.0005 56.880 mm (2.2394 in.) Piston Pin Bore Diameter in Piston ......... 14,002-14,008 mm (0.55 13-0.5514 in.) Weer Limit 414.080 mm (0.5524 in.) Piston Pin Diameter 413.995-14.000 mm. (0.5510-0.5512 in.) Weer Limit Pa 13.980 mm (0.5504 in.) Piston Ring End Gap in Standard Bore .... 6... 0.10-0.25 mm (0,004-0.010 in.) Wear Limit ...... as 0.70 mm (0.028 in.) Piston Ring Side Clearance in Piston (Max.) Top 5 0.180 mm (0.0071 in.) IBSOOn ere tie ese 0.160 mm| (0.0059 in.) Connecting Rod Small End Bore Diameter 14.004-14.012 mm (0.5513-0.5516 in.) Wear Limit 14.040 mm (0.5528 in.) 264 ALT185F LT1856, F, G,H 21,959-21.980 mm (0.8645-0.8654 in.) 0.032-0.066 mm (0.0018-0.0026 in.) 0.150 mm: (0.0089 in.) 0.10 mm (0.004 in.) 0.05 mm (0.002 in.) 0.05 mm (0.002 in.) 0.080-0.040 mm (0.0012-0.0016 in.) 63,000-63.015 mm (2,4803-2,4809 in.) 63.100 mm. (2.4842 in.) 0.05 mm (0.002 in.) 62.965-62.980 mm, (2.4788-2.4795 in.) 62.880 mm. (2.4758 in.) 14.002-14.008 mm (0.5513-0.5514 in.) 414,030 mm (0.524 in.) 43,994-14.002 mm (0.5509-0.5513 in.) 13.980 mm (0.5504 in.) 0.10-0.25 mm (0,004-0.010 in.) 0.70 mm. (0.028 in.) 0.180 mm (0.0071 in.) (0.150 mm: (0.0059 in.) 14.006-14.014 mm (0.5514-0.5517 in.) 414.040 mm (0.5528 in.) ustrations Courasy US. Suzuki Motor Com:Suzuki ALT125, LT125, ALT185 & LT185 ALT125D, E, F,G ALT185F MODELS LT125D,E,F,G,H — LT185E,F, G,H Sizes-Clearances (Cont.) Connecting Rod Small End Side Shake (Max.) ... 3.0 mm 3.0 mm (0.12 in.) (0.12 in.) Crankshaft Runout at Main Bearing Journal (Max.) 0.05 mm 0.05 mm (0.002 in.) (0.002 in.) Capacities Fuel Tank « 5.0L BOL (1.8 gal.) (2.11 gal.) Engine/ Transmission Oil See Text See Text Tightening Torques Camshaft Sprocket Bolt ...... 10-13 Nm 10-13 Nem (7.0-9.5 ft-lbs.) (7.0-9.5 ft-lbs.) ‘Clutch Hub Nut “ 40-60 N.m 60-80 N.m (29.0-43.5 fttbs.) (43.5-58.0 ft-lbs.) Cylinder Base Nut soe 7T-11N-m 7T-A1N-m (5-8 ft-tbs.) (5-8 ft.-Ibs.) Cylinder Head Cover Bolt B10 Nem 9-11N-m (6.5-7.0 ft-Ibs, ) (6.5-8.0 ft-tbs.) Cylinder Head Nut: 6mm .. if 7-11 Nem 7-11. N.m (58 ft-lbs.) (5-8 ft-lbs.) BMM eee cece 16-20 Nm 16-20 N-m (11.0-14.5 ft-lbs.) (11.0-14.5 ft-tbs.) Engine Mounting Bolts: 8mm... 5 7 28-34 N-m 28-34 N-m (20.0-24.5 ft-lbs.) (20.0-24.5 ft-lbs.) 10mm. . ¥ * 80-95 N.m 80-95 N-m (58.0-68.5 fttbs.) (58.0-68.5 ft-lbs.) Engine Sprocket Nut 80-100 N-m 100-130 N-m (58.0-72.5 ft-lbs.) (72.5-94.0 ft-lbs.) Flywheel Nut 50-60 N.m 50-60 N.m (36.0-43.5 ft-lbs.) (36.0-43.5 ft-lbs.) Front Axle Nut: ALT Models .......... 36-52 N.m 36-52 N.m (26.0-37.5 ft-tbs.) (26.0-37.5 ft-tbs.) LT Models . peers 50-80 N.m 50-80 N-m (36-58 ft.-lbs.) (36-58 ft.-Ibs.) Rear Axle Nut 85-115 N.m 85-115 N-m (61.5-83.0 ft.1bs.) (61.5-83.0 fttbs.) Wheel Retaining Nuts: Front— ALT Models 20-31 N.m 20-31 N.m (14.5-22.5 ft-lbs.) (14.5-22.5 ft-lbs.) Rear— ALT Models .. 20-31 N.m 45.65 N.m (14.5-22.5 ft-tbs.) (32.5-47.0 ft-lbs.) LT Models - i : 20-31 N-m 45-65 N-m (145-22.5 ft-lbs.) (32.5-47.0 ft-lbs.) Wheel Rim Nuts 20-31 N.m " (14.5-22.5 ft-lbs.) usrtions Courtesy U.S, Suzuki Motor Cop. 265Suzuki ALT125, LT125, ALT185 & LT185 Tightening Torques (Cont.) Marked “"7"" 4mm... 1.8-2.7 Nm (12-24 inclbs.) 5mm 2.78.1 N-m (24-54 in-bs,) 6mm 8.1-11.5 Nem (72-102 in.tbs.) 8mm 17.6-27.1 N-m (13-20 fabs.) 10mm... 39.3-58.9N-m (29.0-43.5 ft-lbs.) 12mm 68.4-98.3 N.m (50.6-72.5 ft-lbs.) 14mm. 107.7-156.6 Nem (79.5-1155 tt-lbs.) 16mm 166.7-245.4N.m (128-181 ft-lbs.) 18 mm 196.0-274.5 N-m (144.5-202.5 ft4bs.) Standard Screws: ‘Unmarked or Marked "4 4mm 0.9-2.0N-m (8.4-18.0 in-tbs.) 5mm 2.0-4.0 N.m| (18-986 inbs.) 6 mm 4.06.8 Nem (3860 in-tbs.) 8mm 9.5-15.6 N-m (84-138 in-tbs.) 40mm 21.7-34.5 N-m (16.0-25.5 ft-lbs.) 42 mm 34.5-54.2 N-m (25.5-40.0 ft-lbs.) 14mm 48.8-78.6 N-m (36-58 ft-lbs.) 16mm 78.6-127.4N-m (58-94 ft-lbs.) 18 mm 127.4-186.4 Nom (94.0-187.5 ft-lbs.) LUBRICATION All Models ENGINE AND TRANSMISSION. The engine and transmission have @ common sump and are lubricated by @ crankshaft driven oll pump. Recommended oil is @ multigrade SAE 10W-40 motor oil with an API classifica- tion of SE or SF. The sump is filled through filler plug opening (F—Fig, 6-1). Oil level should be maintained at level Fig. $6-1—Engine/tranemission sump is filed through filer ‘plug opening (F). Oll level should be maintained 2 level on ‘sight glass (G). Oil iter Is located behind side cover (C) while ‘sump Screen Is located above screen cap (8). 266 indicated on sight glass (G). Oil is drained by removing plug in underside of orankcase. Dry capacity of crank: case is 1200 mL (1.27 gt.) after an engine or transmis sion overhaul. Refiling after changing oil and oil filter requires only 1150 mL (1.22 qt.) as approximately 60 mL (0.053 qt.) of oil will be retained by crankcase cast- ings. Manufacturer recommends oil and oil fiter be changed attor the first 200 km ( 100 miles) of operation and every 1000 km (600 miles) thereafter. A sump filter screen is located above the oil drain plug and should be removed and cleaned every 2000 km (1200 miles) correspond- ing with every other oil and oil fiter change, The oil fter may be renewed after removing fiter cap (C). Insert new filter with closed end towards filter cap, Renew filter cap “O" ring and ensure filter retaining spring is properly located when installing cap. To remove ‘sump filter screen, unbolt and remove filter screen cap (S) from undemeath crankcase. Remove screen retain ing screws and withdraw acreen. Install a new “0” ring in ‘cap during reinstallation, DRIVE CHAIN. The final drive chain should be lub cated with a suitable chain lube or SAE 90 gear cil prior to each operating interval. Select chain lube designed for use on" ring type drive chains; incorrect chain lubri= cating oil may cause damage to ""O"ring seals. After every 1000 km (600 miles) of operation, the chain should be thoroughly washed in kerosene then lubricated with SAE 90 gear oil. The use of any cleaning Itratione Courtasy U.S, Suzuki Motor Corp (solutions other than kerosene may result in “O" ring seal damage. Adjust drive chain as outlined in DRIVE CHAIN AND SPROCKETS section. CABLES, LEVERS AND SHAFTS. The decompres- sion (ALT185 and LT185 models), brake, choke and throttle cables should be lubricated with motor oil every 1000 km (600 miles). Brake pedal shaft and rear axle housing should be greased every 1000 km (600 miles). Throttle lever, odometer cable, brake camshaft, front ‘wheel bearings and steering shaft should be greased every 2000 km ( 1200 miles). Do not excessively grease the brake camshaft as grease may contact brake linings reducing braking ability, AIR CLEANER ELEMENT All Models ‘The air cleaner element should be removed and cleaned every 1000 km (600 miles). To remove air cleaner element, first remove seat and element cover, Remove element retaining pin and withdraw element. Carefully separate foam element from frame. Thoroughly clean element in a suitable nonflammable solvent. Compress element between hands to remove solvent. Saturate element in clean motor cil. Compress element to remove excess oil. Reinstall element by reversing removal procedure, FUEL SYSTEM All Models CARBURETOR. Models ALT125 and LT125 are equipped with a Mikuni VM20SS carburetor while Models ALT185 and LT185 are equipped with a Mikuni VM22SS carburetor. Refer to CONDENSED SERVICE DATA for carburetor specifications. Fig. $8-2—On ALT125 and ALT185 models, throttle cable adjuster is located adjacent to handlebar ae shown. On LT 125 and LT185 model, adjuster is located above engine adjacent to frame. On all models loosen locknut (L) and rotate adjuster (A) {0 adjust throttle cable free play. Ilustrations Courtesy US. Suzuki Motor Cor, Suzuki ALT125, LT125, ALT185 & LT185 Betore performing carburetor adjustments, the throttle cable should be adjusted to provide 0.5-1.0 mm (0.02-0.04 in.) free play at idle position, To adjust, loos- fen locknut (L—Fig. 86-2) and rotate adjuster (A) as required. Free play can be measured at cable guide on top of carburetor. Initial setting of idle mixture screw (18—Fig. S6-3) is 194 turns aut on ALT125 and LT125 madels or 2% turns ‘out on ALT185 and LT185 models from a lightly seated position. Rotating idle mixture screw counterclockwise will richen mixture while clockwise rotation will lean rix- ture. Final adjustment should be made with engine at normal operating temperature and running, Adjust idle speed screw so engine idles at 1500-1600 rom on ALT125 and LT126 models or 1360-1450 rpm on ALT185 and LT185 models. On all models, adjust idle mixture screw so highest idle is achieved and readjust idle speed screw fo recommended rpm. After adjusting ‘carburetor, check throttle cable adjustment as previously described When servicing carburetor, observe the following: On Models ALT125 and LT125, clip (6—Fig. $6-4) should bbe in second groove from top of jet needle (7). On Models ALT186 and LT185, clip (6) should be in third ‘groove from top of jet needle (7). On all models, float height should be 24.8-26.8 mm. (0.98-1.06 in.). To check float height, remave float bowl and invert carbure- tor. Measure the distance (A—Fig. S6-5) between bot- tom of float and gasket surface on carburetor body, Adjust float by bending float arm tang, FUEL PUMP. All models are equipped with a dia phragm type fuel pump located adjacent to fuel tank. Alternating pressure and vacuum inside intake manifold is directed to one side of fuel pump diaphragm via hose, During vacuum pulse, diaphragm draws fuel through inlet ccheck valve into fuel chamber. During pressure pulse, diaphragm reduces fuel chamber volume moving fuel through outlet check valve If fuel delivery to carburetor is interrupted, first elimi- nate other sources of difficulty such as insufficient fuel, clogged fuel strainers, cracked or split hoses or loose pump housing retaining screws before servicing fuel ump. When servicing pump, defective or questionable parts should be renewed. Diaphragm should be renewed if deterioration is evident. Fig. $6-3—Installed view of carburetor used on ALT {85 and LT185 models showing location of idle speed screw (17), idle ‘mixture screw (18) and priming pumo (33). 267Suzuki ALT125, LT125, ALT185 & LT185 FUEL STRAINER. All models are equipped with a fusl strainer located in each fuel tank outlet. The strainer ‘should be removed and cleaned every 2000 km (1200 miles). On ALT185 and LT185 models, the fuel tank ‘must be removed from vehicle to withdraw strainers from tank. Fig. $6-4—Exploded view of Mikuni VIM22SS carburetor used ‘On ALT 185 and LT 185 models. Carburetor used on ALT 125 and LT125 models fs similar except starter vaive limiter (15) t= ‘absent. 2 Sommer 12 washer 23, et vate retinar 2 cap 18. Spin 24, ome ate 5 Gamer 14 Stor sae 25. Sew 4 Spine 1, State vale witer 26, Fox! pn 5 Reta 48, Washer 27 Row . detnosdiecip 17. Me spoe screw 28. Chock bl retaher 2 Sets 1 kteriawe sew 29, Sesh ba 1 Twotwcido 40. Patt 0. Gasket 9. Boer 20, Needle jt 3 De 10. Gomme 2 Maint 2, Fa! bow 11 Cabcue 22) Int ae £8. reing pump 268 IGNITION AND ELECTRICAL All Models SPARK PLUG. Standard recommended spark plug is NGK D7EA or Nippon Denso X22ES-U. Spark plug elec trode gap should be 0.8-0.7 mm (0.024-0.028 in.) Spark plug should be removed, cleaned and electrode ‘gap set every 2000 km ( 1200 miles) and renewed every ‘5000 km (3100 miles) IGNITION. All models are equipped with a capacitor discharge, pointless electronic ignition system. The igni- tion system consists of the flywheel, a magneto coil located underneath flywheel, an extemally mounted pick- up coil, a CDI module attached to front frame tube, an ignition coil located adjacent to module, a spark plug and lan engine stop switch. Ignition timing should occur at 10° BTDC with engine operating at 2000 rpm and below and at 30° BTDC at 3500 rpm and above. Retr to Fig. S6-6 for view of timing marks. {ignition malfunction occurs, check condition of spar plug, all wires and connections before trouble-shooting ignition circuit. Using Suzuki pocket tester number (09900-25002 or a suitable chmmeter, refer to the follow- ing test specifications and procedures to aid trouble- shooting ‘Fig. $8-5—Flost level (A) should be 24.8-26.8 mm (0.08-1.06 in.). Bend float arm tang to adjust float level. Fig. $6-5—View of ignition timing marke typical of all models. ‘Note that 10° and 20° marks are before ‘op dead center. Mustrations Courtesy US. Sums Motor Com.‘To check condition of CDI module, first remove module ‘rom vehicle. Use tester or ohmmeter in conjunction with test chart shown in Fig. S6-7. Renew CDI module it required. To check condition of magneto coil and pickup coil, separate blue wire from pickup coil and black/red wire from magneto coil to CDI module. Attach one tester lead. to pickup coil end of blue wire and remaining tester lead to vehicle ground. Resistance reading should be approxi- mately 130-200 ohms. Attach one tester lead to magneto coil end of black/red wire and remaining tester lead to ground. Resistance reading should be approximately 360-450 ohms. ‘To check condition of ignition coil, separate black wire connector from coil to CD ignition module and remove high tension wire from spark plug. Attach one tester lead to black wire and remaining lead to coll ground. Primary coil resistance reading should be approximately 0.5-1.5 ohms. Attach one tester lead to high tension wire and remaining lead to coil ground. Secondary coil resistance reading should be approximately 15k-25k ohms. LIGHT CIRCUIT. All models are equipped with a light- ing coil located underneath the flywheel. On ALT125 and LT125 models, the lighting coil should produce 5.5-8.0, volts to provide voltage to the 6 volt 25 watt headlight and 6 volt 5 watt tailight. On ALT 185 and LT185 models, the lighting coil is regulated and should produce 9-14 volts to provide voltage to the 12 volt 35/35 watt head- light and 12 volt 5 watt taillight, On all models the lighting coil can be statically checked using Suzuki pocket tester 09900-26002 or a suitable ohmmeter. Separate yellow/red wire connector ‘rom lighting coil to light switch and attach one tester lead 10 coil side of wire and remaining lead to vehicle ground. + Tester lead piack/| stack fpiack Liana Rasa ned! | entice fretion 5 &| black A B | Ct | ate | pier Sintec alrea | I | J Gj a : Brack ifmice| 1 | K | 6 c Suzuki ALT125, LT125, ALT185 & LT185 Resistance reading should be approximately 0.2.0.8 ohms. ‘An operational check can be performed using Suzuki pocket tester 09900-25002 or a suitable voltmeter as follows: Remove headlight and attach tester positive lead to yellow wire and tester negative lead to black/white wire. Set lighting switch to on position, and on ALT185 and LT185 models, set dimmer switch in high beam posi- tion. On ALT126 and LT125 models, run engine at 3000 rpm and then at 8000 rpm while observing tester. Light- ing coilis satistactory if voltage reading is within the limits of 6.6:8.0 volts. On ALT185 and LT185 models, run engine at 2000 rpm and then above 2000 rpm while observing tester. Lighting coil and regulator are satisfac tory if voltage reading is within the limits of 9-14 volts, WIRING. If wiring requires repair, always use replace: ment wire of the same gage. Wires should be routed away from areas of extreme heat or sharp edges. Plastic tie straps should be used to retain wires in their original gS bow Fig. $6-8—Wiring diagram for all ALT125 models and LT125 ‘models except for Model LT 125H. 8 tack 1. Hesston & Gray 8 Era sop ston WW tga Yeon 5 Sour BIR in wth rd car & gator cal rw. Bact win wn acer + EDimecie Yel wee sac 8 Nona vetio, V | Yo | WG Fig. S6-7—Use chart shown above and values listed below to test concition of CD ignition module. All values are approxima tions. 1A 1904-1704 ons 6 Testa neal souls 5. eter ors H, Open atau! 26edok tne 1 Claes reat 070k sme Soak aime stations Courtesy US, Suzuki Motor Corp. Fig. $6-3—wiring diagram for Model LT125H. Refer to legend in Fig. S6-8 for identification of components and wiring color codes except for ignition ewitch (12). 269Suzuki ALT125, LT125, ALT185 & LT185 Positions to prevent short circuiting. Refer to Fig. S6-8, Fig. 6-9, Fig. S6-10 or Fig. S6-11 for schematic wiring diagram pertaining to 2 particular model FASTENERS All Models After the first 200 km (100 miles) of operation and ‘every 1000 km (600 mriles) thereafter the cylinder head, cylinder, exhaust system engine mounts and all chassis ‘huts oF bolts should be retightened. Refer to TIGHTEN- ING TORQUES section of CONDENSED SERVICE DATA for torque specifications. VALVE SYSTEM All Models The valves are actuated via rocker arms by a single overhead camshaft. Camshatt is timed and driven by a roller drive chain from left end of crankshaft. Valve clear- Fig. $8-10—Wiring diagram for all ALT185 models and LT 185 ‘modele except for Model LT185H, Refer to legend in Fig. S6-8 or identification of components and wiring color codes except for dimmer switch (10) and voltage regulator (11). ig, S6-11—Wiring dlagram for Model LT 185H. Refer to legend ‘in Fis. $0-8 for identification of components and wiring color ‘codes except for dimmer switch ( 10), voltage regulator (11) ‘and combination ignition ight switeh (13). 270 lance should be adjusted after the first 200 km (100 miles) of operation and every 1000 km (600 miles) thereafter. Valve clearance should be adjusted with engine cold, To adjust valve clearance, first remove seat, front frame cover, spark plug, valve adjustment caps and manual starter. Rotate crankshaft until "T" mark (TOC— Fig. $6-6) on flywheel aligns with stationary mark (M) (on crankcase and piston is on compression stroke. To ensure piston is on compression stroke, rotate crank- shaft % turn past TDC while observing intake valve. If valve movement is indicated, rotate crankshaft one {ull revolution and align timing marks again. Clearance between racker arm adjusting screw and valve stem should be 0.08-0.13 mm (0.003-0.005 in.) for both intake and exhaust valves. Clearance is adjusted by loosening locknut (L—Fig. $6-13) and turning screw (A). Be sure to recheck adjustment after locknuts have been tightened, Ater performing valve clearance adjustment, check ‘and adjust decompression control. Actuate control lever on right handlebar. Adjust the cable at (A—Fig. S6-14) 'S0 decompression lever (D) just contacts cylinder head cover. CAM CHAIN All Models ‘Cam chain tension should be adusted after the first 200 km (100 miles) of operation and every 1000 km (600 miles) thereafter. Cam chain tension is adjusted with piston at TDC on compression stroke. Align timing marks as previously described in VALVE SYSTEM sec- tion to set piston at TOC on compression stroke; however ‘or cam chain tension adjustment, make sure flywheel is rotated in normal operation direction (counterclockwise) ‘only. Loosen locknut (L—Fig. S6-18) and back out set ‘screw (S) one complete revolution to release tensioner Bush rod. Spring in tensioner mechanism automatically Fig. S6-13—Clearance between valve stem and adjusting screw (A) should be 0.08-0.13 mm (0.008-0.005 in.) for both intake ‘and exhaust valves, IMusrations Courtesy US. Suaui Motor Corp,adjusts cam chain tension. Tighten set screw and secure with locknut. ‘Cam chain noise atter adjustment may be caused by a stuck tensioner push rod. Remove tensioner retaining cam screws (C) and withdraw the unit. Loosen set ‘screw and clean tensioner with @ suitable solvent. Lubri- cate tensioner push rod with clean motor oil. Actuate push rod several times to ensure smooth movement. Reinstall tensioner and adjust as previously described. CLUTCH All Models. All models are equipped with two types of automatt- cally actuated clutches assembled into one unit and fitted to right end of crankshaft. One type is @ two-shoe centrit- gal clutch actuated by engine rpm. The other type is a ‘muttiple-dise clutch actuated by the gear shift lever. Dur- ing gear selection, a lever attached to end of gear shift shaft simultaneously disengages the multiple-disc clutch to permit smooth transmission operation. The clutch should be adjusted after the first 200 km (100 miles) of operation and every 2000 km (1200 miles) thereafter. To adjust clutch, remove cover (C— Fig. $6-16) on right side of crankcase. Loosen locknut (L-Fig. S6-17). Tur adjusting screw (8) in stopping just as internal resistance is felt, then back screw out '% tum. Secure adjusting screw while tightening locknut. To check clutch operation, first adjust clutch as pre- Viously described. Ensure oil level is correct and engine is at operating temperature. Attach a suitable tachometer. Select low gear and slowly accelerate engine while observing meter. Initial engagement should begin at Fig. $6-14—Decomoression lever (D) should just contact ‘cylinder head cover when engaged. Adjust cable at (A). Fig. $0-15—Following procedure outlined In text, loosen lock- ‘nut (L) and set screw (8) to adjust cam chain tension. Iustrationt Courtesy US. Suzukl Motor Corp Suzuki ALT125, LT125, ALT185 & LT185, 1800-2200 rpm. Next, with transmission still in low gear, ook up brakes and momentarily open the throttle, Do not ‘maintain open throttie longer than 10 seconds. Engine ‘speed should be held to 3200-3600 rpm on models prior to 1986 and 3300-3700 rpm on 1986 and 1987 models, ‘Any results other than specified may indicate disassem- bly and repair of clutch unit is required. MANUAL STARTER All Models R&R AND OVERHAUL. Refer to Fig. S6-18 for exploded view of starter used on ALT125 and LT125 ‘models or to Fig. S6-19 for exploded view of starter used fon ALT185 and LT185 models. On all models, starter may be removed as a complete unit from vehicle after removing four starter housing retaining cap screws. Refer Fig. S6-18—Remove side cover (C) to obtain access to clutch ‘agjusting serow. Fig, $8-17—View of clutch adjusting screw (S) and locknut (L). Refer to text for adjustment procedure. anSuzuki ALT125, LT125, ALT185 & LT185 to appropriate exploded view and disassemble starter as follows: If starter spring remains under tension, pull start- ‘er rope and hold rope pulley (7) with notch in pulley adjacent to rope outlet. Pull rope back through outlet so it engages notch in pulley and allow pulley to slowly unwind. Remove "E” ring or retaining nut (1) and disas- semble unit. Be careful when removing rewind spring (8); a rapidly uncoiling starter spring could cause seri= ous injury. Fig, $6-16-—Exploded view of manual starter used on ALT125 ‘and L125 models. 5 retin late © Stare paw 8 Sener rousno 4. 5ere0 1 Rope pallor 10-Foe ‘Fig. S0-19—Exploded view of manusl starter used on ALT1ES ‘and L185 model. ay Sore 8. Sener hing 2 Prcon plate 8 Specse 10 Pose, 4 Pret gue 7 Rope pulley 11 Starter pout + Sprague owing Pe 272 Rewind spring is wound in a clockwise direction in starter housing. Rope is wound on rope pulley in a clock- wise direction as viewed with pulley in housing. Reas- semble starter assembly by reversing Gisassembly pro- cedure. To place tension on rewind spring, pass rope through rope outlet in housing and install rope handle. Pull rope out and hold pulley so notch in pulley is adjacent to rope outlet. Pull a loop of rope back through outlet between notch in pulley and housing. Turn rope pulley Clockwise three or four complete revolutions to place tension on spring. Do not place more tension on rewind spring than is necessary to draw rope handle up against housing, FRONT AXLE ASSEMBLY Models ALT125 And ALT185 R&R AND OVERHAUL. Refer to Fig. S6-20 for an exploded view of front axle assembly used on ALT185 Fig. $6-20—Exploded view of steering and front axle sesembly used on ALT185 models. Front axle assombly used on ALT125. ‘models is similar. 12. Stang stom & oy 1 Sta bas at 2. Fork cap siren 13, Cote pn 8. Stem head tackot 14 Sa nt 4 Seana sem ma 15. Rut spacer 5 disteoe 1. Spacer © Quer ace 17 Sea Basing bate (22) 18 Bawing & enerrece 19: Hab mere 20. Baring spacer 10. Boarng bate (18) 21. Ave 1 Oatorrace 22. Wet ut iusrstions Courtesy US. Suns Motor Corp.models. Front axle assembly used on ALT125 models is ‘similar. To remove front wheel, remove cotter pin (13) ‘and unscrew axle nuts (14). Suitably support vehicle and remove front wheel and axle assembly. Remove ‘spacers (16) from both sides of axle shaft (21) and withdraw axle shaft from hub (19). Remove wheel retaining nuts (22) and separate wheel hub and wheel, Drive seals (17), bearings (18) and spacer (20) from hub if necessary, Inspect bearings and axle for wear. Bearings should be Packed with a good quality wheel bearing grease. To reassemble, reverse disassembly procedure while noting the following: On ALT125 models, install the frst bearing into nonstudded side of hub. On ALT185 models, install the first bearing into threaded stud side of hub. On all models, seals (17) are installed with open sides toward bearings. Apply grease to seal lips before inserting spac- ers (16). Tighten wheel retaining nuts (22) to 2031 Nem (14,5-22.5 ft-lbs.) torque and axle retaining nuts (14) to 36-52 N.m (26.0-87.5 ft-lbs.) torque. Models LT125 And LT185 R&R AND OVERHAUL. Refer to Fig. S6-21 for an exploded view of front axle assembly used on LT125 ‘models or to Fig. S6-22 for front axle assembly used on LT185 models. To remove either wheel hub (35), Femove front wheel and axle nut (38). Pull wheel hub {rom spindle (30). Do not lose spacer (36). Drive seals (82), bearings (33) and spacer (34) from hub if neces- sary. To reassemble, reverse disassembly procedure while noting the following: Install the inner bearing (33) into hub first. Seals (32) are installed with open sides toward bearings (33). Tighten axle nut (38) to 50-80 N.m (38.0-58.0 ft-lbs.) torque. On LT125 models, tighten ‘wheel retaining nuts to 20-31 N.m (14.5-22.5 ft-lbs.) torque. On LT185 models, tighten wheel retaining nuts to 45-65 N-m (32.5-47.0 ft-lbs.) torque STEERING Models ALT125 And ALT185 ADJUSTMENT. The steering should be checked and adjusted after the first 200 km (100 miles) of operation and every 1000 km (600 miles) thereafter. To adjust, remove handlebars and steering stem head bracket (3— Fig. S6-20). Using tool 09940-14911 or equivalent, tighten steering stem nut (4) to 40-50 N.m (29-36 ft Ibs.) torque, Pivot the fork lock-to-lock several times to ‘seat the bearings, then loosen stem nut ¥%-Me turn. Install ‘stem head bracket and tighten stem heed retaining nut (1) and cap screws (2) to 35-55 N.m (25.5-40.0 ft.- lbs.) torque. Recheck adjustment Imstrations Courtesy U.S. Suzukl Motor Corp Suzuki ALT125, LT125, ALT185 & LT185 R&R AND OVERHAUL. To remove steering assembly, remove front wheel as outlined in FRONT AXLE ASSEM- BLY section. Remove front fender, fender extension and headlight. Disconnect wiring within headlight housing and carefully pull wiring harness from housing. Remove head- light housing and handlebars, Unless handlebars require complete removal, do not detach control cables or levers, Unbolt and remove steering stem head bracket (3— Fig. $6-20). Using tool 09940-14911 or equivalent, unscrew stem nut (4) and remove steering stem and fork assembly from frame being careful not to lose bear- ing balls (7 and 10) Drive upper and lower bearing inner races (8 and 9) from head pipe using a suitable drift. Lower bearing outer race (11) can be removed by carefully driving a suitable wedge between bearing and bearing seat. Inspect and renew any questionable components. Bearing inner races (8 and 9) should be installed using too! 09941- 34513 or equivalent. Use a good quality grease to lubri- cate and retain bearing balls (7 and 10) in position dur- ing installation. Upper bearing contains 22 loose bearing balls (7) while lower bearing contains 18 loose bearing balls (10). Adjust steering stem as outlined in ADJUST: MENT section. Models LT125 And LT185 ADJUSTMENT. The toe-in should be checked and adjusted after the first 200 km ( 100 miles) of operation and every 1000 km (600 miles) thereafter. Prior to toe- in adjustment, inspect steering assembly for damaged or Fig. $8-21—Exploded view of steoring and front axle assembly used on L125 models. Refer to Fig. 86-22 for parts identiies- tion, 273See nn Suzuki ALT125, LT125, ALT185 & LT185 ‘excessively worn components. It service to steering assembly is required, refer to R&R AND OVERHAUL sec- tion, To check toe“, inflate tires to recommended pressure of 15 kPa (2.2 psi). Position vehicle on a flat smooth ‘surface and set handlebars straight forward. Using a suit- able tape measure, measure the distance between right ‘and left tire centerlines on back side of tires (B—Fig '$6-23) and record measurement. Locate the same tire centerline points on front side of tires (F) and record ‘measurement. On LT125 models, the front measurement should be 7-9 mm (0.28-0.95 in.) less than rear meas- urement on models prior to 1986 and 5-11 mm (0.20- 0.43 in.) on 1986 and 1987 models. On LT185 models, the front measurement should be 13.5-16.5 mm (0.60- 0.65 in.) less than rear measurement on models prior to 1986 and 9-15 mm (0.35-0.59 in.) on 1986 and 1987 ‘models. On all models, note that the distance from a projected vehicle centertine to left (L) and right (R) tire Ccenterlines should also be equal 4. Storing sat Dust soa! 18. Cotter an 2 Cap ser 8, Lowerbusting 6, Tadd 3 Wrene 10. “O"rg 17 Lect 1 Sham holder 1S: Dost sa 8 Ton ahs ray 12 Waster 18. Cap screw 5 Cote pin 13. Loatwacer 20. Shock absorber 7 Seal tale 4 ta 21 using 274 2a To adjust toesin, loosen tie rod locknuts (17—Fig. S6- 21 or Fig, $6-22) on both left and right tie rods. Tie rod fends (16) and locknuts (17) color coded yellow have | left-hand throads. Rotate adjusters (18) in equal incre- ‘ments to maintain equal vehicle centerline to left and right tire conteriine distances. Tighten tie rod locknuls to 25-35 Nem (180-256 ft-lbs) torque. R&R AND OVERHAUL. Refer to Fig, S6-21 for an exploded view of steering assembly used on LT125 mod- tls or to Fig. $6-22 for exploded view of steering assem- bly used on LT185 models. Removal and disassembly of steering components is evident after inspection of unit ‘and referral to an appropriate exploded view. During reassembly, renew all colter pins. Lubricate all friction points with @ good quality grease, Tighten steering shaft clamp cap screws (2) to 18-28 Nom (13-20 ft-lbs.), steering shatt lower nut (14) 10 22-35 N.m (16.0-25.5 ft-lbs.) and tie rod retaining nuts and spindle cap screws. (28) to 40-60 N.m (29.0-43.5 ft-lbs.) torque. Fig. $6-22— Exploded view of steering, suspension and front axle assembly used on LT 185 models. 8 Lente an 22 Spndectpsoen 34 Beata acer Upper warbone sem 20. Sone 38. Seacer usta 3%. Spacer 37 Washer (Cap stew 22. Soa 38. Ase Spe neser 8. Beaton 38. Cate sin stations Courtesy U8. Sucuki Motor Corp.BRAKES All Models ADJUSTMENT. All models are equipped with a two- shoe internal expanding drum brake mounted on rear axle and actuated by either left handlebar lever or right brake pedal. The brakes should be checked and adjusted after the frst 200 km (100 miles) and every 1000 km (600 mites) thereafter. To properly check and adjust brake system, first actuate brake pedal and measure free travel at end of pedal, Free travel should be 20-30 mm (0.8-1.2 in.) and is adjusted by rotating pedal adjuster (P—Fic. S6-24) After adlusting brake pedal, check brake lever adjust- ment, Remove protective cover from lever and measure brake lever free travel. Lever should have S-7 mm (0.1 0.3:in) of tree travel between lever base and bracket as, measured at (F—Fig. S6-25). To adjust, turn adiuster (A) on brake lever completely in, then rotate lever adius- ter (L—Fig. $6-24) located at rear brake as required. ‘Additional adjustment is possibie by turning adjuster (A— Fig. $6.25). All models are equipped with a brake lining weer indi- cator (Fig, $6-24) on axle housing o externally deter- mine brake lining weer limit. To externally check brake lining wear, apply the breke and note the location of index mark (M) on brake cam lever in relationship to stationary indicator (I). if mark does not rotate beyond wear indicator (I), brake linings may be considerea satisfactory. F oT R }——_ 5 ——| Fig, $6-23—Toowin should be 7-9 mm (9/92-11/92 In.) on 17125 models prior to 1986 and 5-11 mm (0.20-0.43 in.) on 1986 and 1967 models. Toe-in should be 13.5-16.5 mm (17782-21732 in.) on LT195 models prior to 1986 and 9-15 ‘mm (0.35-0.59 I.) on 1986 and 1987 models. Refer fo text for ‘measuring procedure. Ietrations Courtety US. Survki Motor Cor. Suzuki ALT125, LT125, ALT185 & LT185 R&R AND OVERHAUL. To remove rear brake shoes ‘or inspection or renewal, first suitably support rear of vehicle and remove right rear axle nut. Pull tire, wheel ‘and hub off axle as an assembly. Remove the drum retaining nuts (1 and 2—Fig. S6-26). Unbolt and withdraw brake drum cover (4). Slide brake drum (6) off axle. Carefully extract the brake shoes (6) and springs (7) from backing plate. Brake shoes should be renewed if linings are worn to 1.5 mm (0.06 in.) of less. Brake drum should be re- newed if inside diameter exceeds 160.7 mm (5.93 in.) Reinstall brake shoes by reversing removal procedure while noting the following: Lightly coat brake camshaft and pin with grease. If dust seal “3) requires renewal, ‘coat outer perimeter of new seal with Loctite or equiva: lent. On ALT185 and LT185 models, install seal into brake drum cover with arrow marked side of seal facing — 2 ie gS {ae Fig. $8-24—View of brake lever adjuster (L.), pedal adjuster (P) and brake lining wear indicator marke (Ai) and (1) typical of all models. Fig. $6-25—Brake lever should have 3-7 mm (0.1-0.3 In.) of {ree travel measured at (F). Tuin adjuster (A) completely in ‘and adjust a (L—Fig. $6-24). 278Suzuki ALT125, LT125, ALT185 & LT185 ‘ut and centered in notched portion of cover bore. On all ‘models, install brake cover with drain opening down and tighten cap screws to 4-7 N.m (36-60 in.-Ibs.) torque. Install and tighten inner drum nut (2) t0 60-80 N-m (36-58 ft-lbs.) torque. While securing inner drum nut, install and tighten outer drum nut (1) to 160-200 N-m. (118.5-144.5 ft-lbs.) torque, Tighten axle nut to 85-115 N-m (61.5-83.0 ft-lbs.) torque and secure with a new cotter pin. Adjust brake as outlined in ADJUSTMENTS paragraphs. SUSPENSION Model LT185 Model LT185 is equipped with a double wishbone type front suspension and oil dampened shock absorbers, ‘Shock absorber load setting is not adjustable. Refer to Fig. $6-22 for exploded view of suspension components. ‘The suspension components should be periodically inspected for excessive wear or damage. When renewing bushings (21 and 25), coat outside of bushing with Loo- tite or equivalent, then carefully press bushing into sus- pension arm. Upper and lower suspension arm inner cap ‘screws (23) should be tightened to 40-60 N-m (29.0- 43.5 ft-lbs.) torque while the outer cap screws (26) should be tightened to 70-100 N.m (50.5-72.5 ft-lbs.) torque. Shock absorber retaining cap screws (19) should be tightened 10 40-60 N-m (29.0-43.5 ft-lbs.) torque, 12. Ale housing 21. “Ona 2 bearing pacer 25 beseng 26. Seal 27. Housing cap stew 20. ote 29. Socket mounting farae 50. Flange sopra DRIVE CHAIN AND SPROCKETS All Models ADJUSTMENT. The drive chain should be inspected ‘and adjusted every 1000 km (600 miles). Improper ‘maintenance and neglect can cause early failure of both drive chain and sprockets. Drive chain free play should be 10-20 mm (0.39-0.79 in,) measured midway be- ‘tween sprockets, To adjust free play, first remove bottom ‘uard plate to obtain access to chain tensioner. Loosen chain tensioner retaining cap screw and reposition ten- sioner as required. Tighten chain tensioner retaining cap Screw to 70-100 N.m (50.5-72.5 ft-lbs.) torque, Refer to LUBRICATION section for drive chain lubrica- tion requirements, R&R AND OVERHAUL. To remove drive chain and ‘sprockets, remove seat, rear fender and bottom guard plate. Suitably support rear of vehicle and remove left axle nut (30—Fig. S6-27). Slide tie, wheel and hub from axle as an assembly. Loosen chain tensioner retaining cap screw (8) and slacken drive chain, Release chain case clamps and remove the two retaining nuts, then withdraw case. Remove tensioner (10) clamp bolt and ‘snap ring (11). Pull chain tensioner (10) off tensioner ‘arm (9). Unbolt and remove chain catcher (3). Remove sprocket retaining nut (6) and lockwasher (5). Pull sprocket (4) from drive shaft (1) and withdraw sprock- ‘et and chain. Bend back tabs on lock plates (26) and Fig. 86-26—Exploded view of brakes and resy axle assambly used on ALT 185 and LT185 ‘models. ALT125 and LT125 models are similar, 276 Iusrations Courtesy US, Suzukl Motor Corp.remove cap screws (27). Slide rear sprocket assembly (17 through 25) off axle. Remove cotter pins (17) and » nuts (18). Separate rear driven sprocket components. Carefully examine front, rear and tensioner sprockets: for excessive wear. Wor sprockets will usually have a hooked profile. A good test is to place a new chain on a Used sprocket and check the fit. Wear on sprocket sides indicates misalignment. If sprockets require renewal due to weer, always renew drive chain, Inspect remaining ‘components and renew any that are damaged or worn excessivaly. ‘Standard chain on ALT125 and LT125 models is either @ DLD. 428V or Takasago RK428 HMO with 90 links. ‘Standard chain on ALT 185 and LT 185 models is either a D..D. 520VS or Takasago RK520 SMO with 72 links. On ‘ALT125 and LT125 models standard drive sprocket has 1 Courtertat 8 Cham catoner 4 me spocet 5 Waser 8. Gap seron 8. Tenstner am 1: Chan tnsonar 1) Sea 18 Spacer 14, Tersner sprocket 16. Step na 4, Cater pn 19. Washer 20. Spacer 2. nor socket ite 22. Dane 25. Ree sprectet 26 ute srt ae 26, Lock te 27, Mountra tage cap stew 20. Wel ho 25. Wheel nat 2. halen 3, Coterpa Suzuki ALT125, LT125, ALT185 & LT185 18 teeth while standard rear sprocket has 49 teeth. On ALT185 and LT185 models, standard drive sprocket has 12 teeth while standard rear sprocket has 38 teeth. Reinstall by reversing removal procedure while noting the following: Renew all lock plates and cotter pins. Apply Loctite or equivalent to threads on rear sprocket cap screws (25) and tighten cap screws (25) and nuts (18) to 8-12 N-m (8.0°8.5 ft-lbs.) torque, Secure nuts with new cotter pins (17). Apply Loctite or equivalent to rear sprocket assembly retaining cap screws (27) and tighton screws to 40-60 N-m (29.0-48.6 ft-1bs.) torque Bend lock plates (26) up around cap screw heads. Install chain tensioner (10) on tensioner arm (@) with index punch mark on end of arm shatt centrally located in split on chain tensioner (10). Adjust chain tension 2s outlined in ADJUSTMENT paragraphs, Fig. $6-27—Exploded view of final drive sprockets, chain tensioner and related compo 32 Cap ‘nonts used on ALT 185 and LT185 models. ALT25 and LT 125 models ae similar. tystratons Courtesy US, Suzuk! Motor Corp, 27