1974-1977 Suzuki GT125 Service Manual (80 Pages)
Complete maintenance and repair guide for Suzuki GT125 twins. Covers engine, transmission, carburetors, electrical systems and detailed troubleshooting. Factory specifications and step-by-step overhaul procedures.
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Sample pages from the 1974-1977 Suzuki GT125 Service Manual (80 Pages) manual
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Models Covered & Key Technical Specifications
Suzuki GT125 — 1974–1977 Integrated Documentary Manual | GT125 Series Compendium
- Approved Cold Start Limits: 124 cc displacement corresponds to the two-cylinder engine displacement Matrix.
- Factory Velocity Specs: For optimal horsepower delivery, 16 bhp at 9500 rpm achieves the rated maximum engine output Standards.
- Verified Enclosure Specs: The compression chamber is calibrated to 6.8:1 — defines the combustion pressure ratio Margin.
- Designated Fastener Specs: The spark plug electrode requires 0.024–0.028 in. (0.6–0.7 mm) is rated at the correct ignition gap Protocol.
- Essential Tolerance Values: Oil tank capacity reaches 2.1 pints (1.2 litres) is standardized to the fuel supply reservoir Architecture.
- Operational Thermal Rating: Ignition timing of 22° BTDC or 1.95 mm piston travel — signifies the firing advance threshold Norms.
Professional Workshop Service Manual & Technical Specifications
Commercial Performance Training Manual: Motorcycle Maintenance Mastery: Suzuki GT125 Manual Knowledge-Base
Repair-Classification: Suzuki GT125 (1974–1977 models) // Repair-Classification: Two-stroke Engine / Transmission Systems Logic // Architecture-Focus: Professional workshop documentation with complete specifications.
| Specification | Operational-Logic | Calibration-Spec |
|---|---|---|
| Engine Overview | 124 cc twin-cylinder two-stroke configuration | Complete bore and stroke data documented |
| Transmission System | Five-speed gearbox with primary and secondary reduction | Gear ratios and capacity specifications provided |
| Electrical Components | 12V AC alternator with negative earth system | Contact-breaker points, fuse ratings, and bulb specifications included |
| Brake Systems | Front hydraulic disc and rear drum configuration | Torque specifications and adjustment procedures documented |
| Suspension and Steering | Telescopic front forks with adjustable bearings | Trail angles, castor specifications, and bearing configurations listed |
Repair procedures are structured around five critical engine requirements: fuel-air mixture induction, cylinder transfer, compression, ignition timing, and exhaust discharge. The document covers engine disassembly and reassembly processes, detailing piston removal, ring inspection, crankshaft bearing assessment, and selector drum alignment. The manual addresses transmission subsystem operation, including clutch basket removal, gear selector linkage dismantling, and countershaft bearing extraction. System operation descriptions cover primary reduction mechanisms, gearbox engagement procedures, and kickstart assembly function. The documentation addresses carburettor configuration, consisting of twin Mikuni units with float chamber management, jet selection, and needle positioning. Assembly instructions are detailed for crankcase separation and rejoining, with numbered bolt sequencing to ensure proper component alignment and oil-seal integrity.
Disassembly instructions are documented for the complete electrical system, encompassing contact-breaker point access, alternator rotor extraction, and neutral indicator switch removal. The manual documents torque specifications for the engine mounting studs to ensure proper structural alignment. Wear limits are specified for cylinder bore dimensions, piston-to-bore clearance, and friction disc thickness, enabling technicians to assess component serviceability. Each chapter within the manual provides sequential photographs paired with detailed text explanations, supporting readers through multi-step procedures without requiring external technical references.
The manual incorporates a comprehensive troubleshooting section addressing engine starting failures, performance degradation, electrical faults, and mechanical noise diagnosis. Routine maintenance schedules are itemized across four service intervals (500, 2000, 4000, and 6000 miles), specifying component checks, fluid changes, and adjustment procedures at each stage. A daily and weekly inspection system is provided to maintain optimal operating conditions between major service events. Reference data includes ignition timing marks, contact-breaker gap tolerances, and spark plug electrode specifications. Safety guidance addresses fuel handling, electrical hazard mitigation, and workshop equipment requirements, establishing proper preparation techniques before undertaking major mechanical work.
The document includes wiring diagrams and electrical circuit schematics for troubleshooting system faults, alongside detailed illustrations of brake pad replacement, front fork oil drainage, and chain tension adjustment procedures. Component location guides support rapid identification of service points and access routes throughout the motorcycle frame. The manual provides detailed specifications for all service fluids, including recommended oil grades for engine, transmission, and hydraulic applications, with capacity information for each system.
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