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Muffler (expansion Chamber, Silencer); Expansion Chamber Removal; Expansion Chamber Installation Notes; Sil Ence R Packing Change - Kawasaki KX125 1990 Service Manual

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4
·
16 ENGINE TOP END
Pis
ton,
Piston
Pin,
Connecting Rod Wea
r
Inspec
tion
Visually
inspect
the
snap
ring
still
fitted in
place.
*
If the ring
shows
weakness or
deformation.
replace
the
ring.
Also
if
the pin hole
groove
shows
exces-
sive
wear,
replace
the
piston.
Measure the
diameter
of
the
piston
pin
with
a
micro-
meter.
*
11
the
piston
pin d iameter is
less than the service
limit at any
point,
replace
the piston
pin.
Using
a cylinder gauge, measure the
diameter
of
both
of
piston pin holes
in
the
piston and
the
in-
side
diameter
of
the
connecting rod
small
end.
*
If
either
piston
pin
hole
diameter
exceeds
the
service
limit.
replace
the
piston.
*
If
the
connecting
rod
small end inside diameter
ex-
ceeds
the
service
limit. replace
the
crankshaft
as-
sembly.
Piston
PIn
Diameter
KX125:
Standard:
15.995-
16.000
mm
Senllce Umk
:
KX250:
Standanl:
SenllceUmk:
15.96
mm
17.99
5-
18.000
mm
18.96
mm
PIston
PIn
Hole
Diameter
KX125:
Standard:
16.000
-
16.020
mm
SenllceUmk:
KX250:
Standard:
SenllceUmk:
16 .07
mm
18.000
-
18.020
mm
18.07
mm
Smal
End
Inskte DIameter
KX1 25
:
Standard:
21 ,003
-
21.014 mm
Service
lintt:
21.06 mm
KX250:
Standard:
22.003
-
22.014 mm
SenllceUmk:
22.06 mm
A.
Snap
Ring
B.
PistCKl
Pin
Muffler (Expansion
Chamber.
Silencerl
Expansion Chamber Removal
-
Remove
the
right
side
cover.
-
Remove the
silencer.
A.
Silencer
B.
Mounting Bolts
-
Remove
the exhaust
pipe
holding
springs.
-
Remove the
muffler
damper mounting bolt,
and
pull off the expansion
chamber
toward the
front
A.
Muffler Damper
Mounting Bolt
B.
Exhaust
Pipe Holding
Springs
Expansion
Chamber
Installation Notes
-
Installation
is
the
reverse
of
removal.
-
Scrape
any
carbon out
of
the expansion chamber.
-
Check
the
exhaust ().rings
for
signs
of
damage.
If
necessary,
replace them with new
ones.
Silencer
Packing
Change
Replace
the silencer packing
if
the exhaust
noise
becomes
too
loud
or the
engine
performance
drops.
-
Remove
the inner pipe mounting
bolts,
and
pull the
inner
pipe
out
toward
the
rear.

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