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ELIMINATOR 125
Motorcycle
Service Manual

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Table of Contents

   Also See for Kawasaki Eliminator 125

   Summary of Contents for Kawasaki Eliminator 125

  • Page 1 ELIMINATOR 125 Motorcycle Service Manual...
  • Page 3 Quick Reference Guide General Information Periodic Maintenance Fuel System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive 10 j Brakes 11 j Suspension 12 j Steering 13 j Frame 14 j Electrical System 15 j Appendix 16 j This quick reference guide will assist...
  • Page 5 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.
  • Page 6 LIST OF ABBREVIATIONS ampere(s) pound(s) ABDC after bottom dead center meter(s) alternating current minute(s) ATDC after top dead center newton(s) BBDC before bottom dead center pascal(s) bottom dead center horsepower BTDC before top dead center pound(s) per square inch °C degree(s) Celsius revolution direct current...
  • Page 7: Emission Control Information

    EMISSION CONTROL INFORMATION To protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi-...
  • Page 8 WE RECOMMEND THAT ALL DEALERS OBSERVE THESE PROVISIONS OF FEDERAL LAW, THE VIOLATION OF WHICH IS PUNISHABLE BY CIVIL PENALTIES NOT EXCEEDING $10,000 PER VIOLATION. TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the...
  • Page 9: How To Use This Manual

    Be alert for problems and non-scheduled ticular interest for more efficient and con- maintenance. • venient operation. Use proper tools and genuine Kawasaki Mo- • torcycle parts. Special tools, gauges, and Indicates a procedural step or work to be testers that are necessary when servicing done.
  • Page 11: Table Of Contents

    GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ........................Model Identification......................... General Specifications......................Technical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition System)... 1-13 Technical Information-Coasting Enricher................1-20 Unit Conversion Table ......................1-22...
  • Page 12: Before Servicing

    1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary.
  • Page 13: General Information

    Replacement Parts Replacement parts must be KAWASAKI genuine or recommended by KAWASAKI. Gaskets, O-rings, oil seals, grease seals, circlips or cotter pins must be replaced with new ones whenever disassembled.
  • Page 14 1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which can lead to malfunction.
  • Page 15 GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary.
  • Page 16 1-6 GENERAL INFORMATION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment.
  • Page 17: Model Identification

    GENERAL INFORMATION 1-7 Model Identification BN125-A1 (Europe) Left Side View BN125-A1 (Europe) Right Side View...
  • Page 18 1-8 GENERAL INFORMATION Model Identification BN125-A1 (Singapore) Left Side View BN125-A1 (Singapore) Right Side View...
  • Page 19: General Specifications

    GENERAL INFORMATION 1-9 General Specifications BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ Items Dimensions Overall length 2 150 mm (84.6 in.) Overall width 780 mm (30.7 in.) Overall height 1 020 mm (40.2 in.) 1 035 mm (40.8 in.) ← 1 050 mm (41.3 in.) (US, CA) 1 045 mm (41.1 in.)
  • Page 20 1-10 GENERAL INFORMATION General Specifications BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ Items Maximum torque 9.7 N·m (0.99 kgf·m, 7.2 ft·lb) @8 000 r/min ← (rpm) 9.8 N·m (1.00 kgf·m, (US)– 7.2 ft·lb) @8 000 r/min (rpm) (BN125-A7 ∼, N, NU) Carburetion system Carburetor, MIKUNI BS28 Starting system...
  • Page 21 GENERAL INFORMATION 1-11 General Specifications BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ Items Gear ratios: 2.700 (27/10) 1.705 (29/17) 1.300 (26/20) 1.090 (24/22) 0.952 (20/21) Final drive system: Type Chain drive Reduction ratio 3.066 (46/15) ← 2.800 (42/15) (BN125-A7 ∼, N, Overall drive ratio 10.708 @Top gear ←...
  • Page 22 1-12 GENERAL INFORMATION General Specifications BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ Items Trail/brake light 12 V 5/21 W Alternator: Type Single-phase AC Rated output 8.75 A/12 V @4 000 r/min (rpm): BN125-A1 15 A/14 V @8 000 r/min (rpm): BN125-A2 ∼ Specifications subject to change without notice, and may not apply to every country.
  • Page 23: Technical Information-dc-cdi (direct Current-capacitor Discharge Ignition System)

    GENERAL INFORMATION 1-13 Technical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) Description ○ Unlike the conventional CDI, the DC-CDI uses a battery instead of a magneto as a power source. ○ The DC-CDI powered by a battery generates strong ignition spark even at low engine speeds. The conventional CDI, which uses AC voltage supplied by an exciter coil, generates less ignition spark at low engine speeds.
  • Page 24 1-14 GENERAL INFORMATION Technical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) Operation The DC-CDI circuit consists of a battery , a DC-DC converter, a diode, a capacitor, an ignition timing controller, a crankshaft sensor, a thyristor, an ignition coil, a spark plug, an ignition switch, and an engine stop switch.
  • Page 25 GENERAL INFORMATION 1-15 Technical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) This sudden change in the primary current induces a primary voltage (counterelectromotive force) which is equal to the capacitor voltage (about 225 V) but against the discharging current. The primary voltage induces a high secondary voltage in the secondary coil, generating spark plug gap.
  • Page 26 1-16 GENERAL INFORMATION Technical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) Diode A diode functions as an electrical check valve. It conducts current easily from its cathode to its anode, but it will not permit current flow in the opposite direction. Since electric- ity attempts to flow from negative (–) to positive (+), a cir- cuit with a done will conduct current only when the polarity is correct, i.e., when the negative charge is applied to the...
  • Page 27 GENERAL INFORMATION 1-17 Technical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) Every time either end of the timing plate on the rotor passes by the crankshaft sensor, a pulse is generated and sent to the CDI unit, that is, two pulses are generated per one revolution of the rotor.
  • Page 28 1-18 GENERAL INFORMATION Technical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) The crankshaft sensor generates a crankshaft sensor sig- nal and sends it to the signal generator. The signal genera- tor generates A and B signals synchronized with the crank- shaft sensor signal.
  • Page 29 GENERAL INFORMATION 1-19 Technical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) (Ignition Timing Advancing) A signal and B signal in the comparator advance the igni- tion timing. The signal generator decreases A signal as the engine rpm increases from N1, to N3 as shown, but keeps B signal unchanged.
  • Page 30: Technical Information-coasting Enricher

    1-20 GENERAL INFORMATION Technical Information-Coasting Enricher The coasting enricher [A] prevents backfiring during en- gine braking by supplying a rich fuel mixture to the engine. When the motorcycle is cruising or accelerating, the engine vacuum is low, and the return spring [3] pushes the valve in its opened position [5].
  • Page 31 GENERAL INFORMATION 1-21 Technical Information-Coasting Enricher Fuel and Air Supply of Enricher System...
  • Page 32: Unit Conversion Table

    1-22 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length Prefix Symbol Power × 0.6214 mile × 3.281 mega × 1 000 000 × 0.03937 kilo × 1 000 centi × 0.01 milli × 0.001 Units of Torque micro µ...
  • Page 33: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 Periodic Maintenance Table of Contents Periodic Maintenance Chart ....Drive Chain Wear Inspection ..2-25 Torque and Locking Agent....Drive Chain Lubrication....2-26 Specifications ........Brakes..........2-26 Special Tools ........2-11 Brake Pedal Free Play Inspection 2-26 Periodic Maintenance Procedures..
  • Page 34: Periodic Maintenance Chart

    2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.The initial maintenance is vitally important and must not be neglected. * ODOMETER Whichever READING FREQUENCY comes first ×...
  • Page 35: Periodic Maintenance

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart * ODOMETER Whichever READING FREQUENCY comes first × 1 000 km ( × 1 000 mile) OPERATION Every (0.6) (4) (7.5) (12) (15) (20) (24) • • • • • • Spark plug-clean and gap † •...
  • Page 36: Torque And Locking Agent

    2-4 PERIODIC MAINTENANCE Torque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the "Remarks" column mean: L: Apply a non-permanent locking agent to the threads. M: Apply molybdenum disulfide grease.
  • Page 37 PERIODIC MAINTENANCE 2-5 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Oil Pipe Banjo Bolts M8 87 in·lb Oil Pipe Banjo Bolts M10 Oil Pipe Mounting Bolts (BN125-A1 ∼ A3) 87 in·lb Oil Pipe Mounting Bolts (BN125-A4 ∼) 0.90 78 in·lb Camshaft Bearing Holder Bolts (BN125-A1 ∼...
  • Page 38 2-6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Engine Removal/installation Engine Mounting Bolts, Nuts (M10) Engine Mounting Bolts, Nuts (M8) Engine Mounting Bracket Bolts, Nuts Engine Ground Terminal Bolt 87 in·lb Crankshaft/transmission Primary Gear Nut Balancer Shaft Gear Nut Crankcase Bolts 0.90...
  • Page 39 PERIODIC MAINTENANCE 2-7 Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Brake Pedal Bolt 87 in·lb Suspension Front Fork Top Plugs Front Fork Bottom Allen Bolts Front Fork Clamp Bolts (Upper) Front Fork Clamp Bolts (Lower) Rear Shock Absorber Nuts (Upper) Rear Shock Absorber Bolts (Lower) Swingarm Pivot Nut 10.0...
  • Page 40 2-8 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks N·m kgf·m ft·lb Turn Signal Light Holder Nuts 0.60 52 in·lb Neutral Switch Sidestand Switch Screws 0.40 35 in·lb The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts.
  • Page 41: Specifications

    PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Fuel System 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play – – – – – – Idle Speed 1 300 ±50 r/min (rpm) Air Cleaner Element Oil: Grade SE, SF or SG class –...
  • Page 42 2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit (BN125-A6 ∼) 4.1 mm (0.161 in.) 1 mm (0.04 in.) Rear 7.3 mm (0.29 in.) 2 mm (0.08 in.) Final Drive 25 ∼ 40 mm (0.98 ∼ 1.57 in.) Drive Chain Slack –...
  • Page 43: Special Tools

    PERIODIC MAINTENANCE 2-11 Special Tools Steering Stem Nut Wrench: Fork Oil Level Gauge: 57001-1100 57001-1290 Jack: 57001-1238...
  • Page 44: Periodic Maintenance Procedures

    2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose and Connection Inspection ○ The fuel hose is designed to be used throughout the mo- torcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leaks [A] or the hose to burst.
  • Page 45: Throttle Grip Free Play Adjustment

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Throttle Grip Free Play Adjustment • Loosen the locknut [A]. • Turn the adjuster [B] until the proper amount of free play can be obtained. • Tighten the locknut against the adjuster. If the throttle grip free play cannot be adjusted with the adjuster, use the cable adjusters at the lower ends of the throttle cables.
  • Page 46: Idle Speed Adjustment

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment • Start the engine and warm it up thoroughly. • Turn the idle adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range.
  • Page 47: Engine Top

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Remove the canister mounting bracket bolts [A] and re- move the brackets [B] and canister [C] together. • Disconnect the hoses from the canister. • Visually inspect the canister for cracks and other damage. If the canister has any cracks or bad damage, replace it with a new one.
  • Page 48: Cylinder Head Bolt Tightness Inspection

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cylinder Head Bolt Tightness Inspection • Check that 6 mm [A] and 9 mm [B] cylinder head bolts are tightened evenly. Standard head bolts tightening torque are shown below. Tightening Torque 6 mm Cylinder Head Bolts: 12 N·m (1.2 kgf·m, 104 in·lb) 9 mm Cylinder Head Bolts: 26 N·m (2.7 kgf·m, 19 ft·lb) Valve Clearance Inspection CAUTION...
  • Page 49: Valve Clearance Adjustment

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures Valve Clearance Adjustment If the valve clearance is not within the specified range, adjust the clearance by loosening the locknut and turning the adjusting screw. • Tighten the nuts to the specified torque and check the valve clearance again.
  • Page 50: Engine Lubrication System

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pull the clutch cable [A] tight and tighten the adjusting nuts [B] against the clutch cable bracket. • Turn the adjuster at the clutch lever until the free play is correct. • Tighten the knurled locknut at the clutch lever. WARNING Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever, or...
  • Page 51: Oil Filter Change

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Recommended Engine Oil Grade: (BN125-A1 ∼ A3): API SE, SF or SG (BN125-A4 ∼): API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity: SAE 10W-40 Capacity: 1.1 L (1.16 US qt) (When filter is not removed) 1.2 L (1.27 US qt) (when filter is removed)
  • Page 52: Oil Screen Cleaning

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the O-ring [A] with new one. • Apply grease to the O-ring and the grommet [B]. • Install the cover [C] and tighten the cover bolts. Torque - Oil Filter Cover Bolts (BN125-A1 ∼...
  • Page 53: Wheels/tires

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Wheels/Tires Spoke Tightness Inspection • Check that all the spokes are tightened evenly. If spoke tightness is uneven or loose, tighten the spoke nipples evenly. Torque - Spoke Nipples: 2.0 ∼ 3.9 N·m (0.20 ∼ 0.40 kgf·m, 17 ∼...
  • Page 54: Air Pressure Inspection/adjustment

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Pressure Inspection/Adjustment • Remove the air valve cap. • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  • Page 55: Tire Wear Inspection

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Tire Wear Inspection As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn).
  • Page 56: Drive Chain Slack Adjustment

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Set the motorcycle up on its center stand. ○ Rotate the rear wheel to find the position where the chain is tightest. ○ Measure the vertical movement (chain slack) [A] midway between the sprockets. If the chain slack exceeds the standard, adjust it.
  • Page 57: Drive Chain Wear Inspection

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Bend the cotter pin [A] over the nut [B]. • Check the rear brake effectiveness. WARNING If the axle and torque link nuts are not securely tightened and the cotter pin and snap pin are not installed, an unsafe riding condition may result.
  • Page 58: Drive Chain Lubrication

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Lubrication • The chain should be lubricated with a lubricant which will both prevent the exterior from rusting and also absorb shock and reduce friction in the interior of the chain. If the chain is especially dirty, it should be washed in diesel oil or kerosene, and afterward soaked in a heavy oil.
  • Page 59: Brake Shoe Lining Wear Inspection

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Check that the front brake cam lever [A] comes to an 80° ∼ 90° angle [C] with the rear brake rod [B] when the rear brake is fully applied. If it does not, remove the adjusting nut [D] and lever, then adjust the rear brake cam lever angle.
  • Page 60: Brake Fluid Level Inspection

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection • Check that the brake fluid level in the brake reservoir [A] is between the upper [B] and the lower [C] level line. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level.
  • Page 61: Brake Line Bleeding

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Remove the clear plastic hose. • Install the reservoir cap. • Tighten the bleed valve, and install the rubber cap. Torque - Caliper Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb) Front Brake Reservoir Cap Screws: 2.5 N·m (0.25 kgf·m, 22 in·lb) •...
  • Page 62 2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ The fluid level must be checked often during the bleed- ing operation and replenished with fresh brake fluid as necessary. If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will have entered the line.
  • Page 63: Brake/master Cylinder Cup And Dust Seal Replacement

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Brake/Master Cylinder Cup and Dust Seal Replacement • Refer to the Master Cylinder section in the Brakes chapter for Brake/Master Cylinder Cup and Dust Seal Replace- ment. Caliper Piston/Dust Seals Replacement • Refer to the Calipers section in the Brakes chapter for Caliper Piston/Dust Seals Replacement.
  • Page 64: Suspension

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Oil Change • Remove the front fork (see Suspension chapter). • Hold the outer tube vertically in a vise. • Unscrew the top plug out of the inner tube. • Remove: Spacer [A] Fork Spring Seat [B] Fork Spring [C]...
  • Page 65: Front Fork Oil Leak Inspection

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Install the fork spring [A] with the smaller end facing [B] downward. • Install: Fork Spring Seat Spacer • Repeat the same procedure for another front fork. • Install the front fork (see Suspension chapter). Front Fork Oil Leak Inspection •...
  • Page 66: Steering

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection • Check the steering. ○ Lift the front wheel off the ground using the jack [A]. Special Tool - Jack: 57001-1238 ○ With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop.
  • Page 67: Steering Stem Bearing Lubrication

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem (see Steering chapter). • Using a high-flash point solvent, wash the upper and lower steel balls. • Wipe all the old grease off the upper and lower outer races.
  • Page 68: General Lubrication

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○...
  • Page 69: Nut, Bolt, And Fastener Tightness Inspection

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness Inspection Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○...
  • Page 71 FUEL SYSTEM 3-1 Fuel System Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... 3-10 Throttle Grip and Cables ......................3-11 Free Play Inspection ......................3-11 Free Play Adjustment......................3-11 Throttle Cable Installation ....................3-11 Throttle Cable Lubrication and Inspection ................ 3-11 Carburetor ..........................
  • Page 72: Exploded View

    3-2 FUEL SYSTEM Exploded View...
  • Page 73 FUEL SYSTEM 3-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Upper Chamber Cover Mounting Screws 0.36 31 in·lb Spring Seat Screws 0.080 7 in·lb Choke Lever Set Screw 0.080 7 in·lb Choke Lever Pivot Screw 0.20 17 in·lb Pilot Air Jet 0.18 15 in·lb Coasting Enricher Cover Screws...
  • Page 74 3-4 FUEL SYSTEM Exploded View Except the California Model...
  • Page 75 FUEL SYSTEM 3-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Tap Plate Screws 0.080 7 in·lb Fuel Tap Diaphragm Cover Screws 0.10 9 in·lb 0.25 22 in·lb with White Washer Fuel Tap Mounting Bolts 0.50 43 in·lb with Black Washer 4.
  • Page 76 3-6 FUEL SYSTEM Exploded View California Model...
  • Page 77 FUEL SYSTEM 3-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Fuel Tap Plate Screws 0.080 7 in·lb Fuel Tap Diaphragm Cover Screws 0.10 9 in·lb 0.25 22 in·lb with White Washer Fuel Tap Mounting Bolts 0.50 43 in·lb with Black Washer 4.
  • Page 78: Specifications

    3-8 FUEL SYSTEM Specifications Item Standard 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Throttle Grip Free Play Carburetor Make, Type MIKUNI BS28 Idle Speed 1 300 ±50 r/min (rpm) Pilot Screw (Turns Out) 1 5/8 3.0 (BN125-A7 ∼, N, NU) (US, CA, CH) –...
  • Page 79 FUEL SYSTEM 3-9 Specifications Pilot screw [A] Plug [B] (US, CA, CH) Pilot air jet [C] Jet needle [D] Throttle valve [E] Pilot jet [F] Needle jet [G] Main jet [H] Float [I] Valve seat [J] Valve needle [K]...
  • Page 80: Special Tools

    3-10 FUEL SYSTEM Special Tools Fuel Level Gauge: Carburetor Drain Plug Wrench, Hex 3: 57001-1017 57001-1269...
  • Page 81: Throttle Grip And Cables

    FUEL SYSTEM 3-11 Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Grip Free Play Inspection in the Pe- riodic Maintenance chapter. Free Play Adjustment • Refer to the Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter. Throttle Cable Installation •...
  • Page 82: Carburetor

    3-12 FUEL SYSTEM Carburetor Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter. Idle Speed Adjustment • Refer to the Idle Speed Adjustment in the Periodic Main- tenance chapter. Service Fuel Level Inspection WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions.
  • Page 83: Service Fuel Level Adjustment

    FUEL SYSTEM 3-13 Carburetor Service Fuel Level Adjustment WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 84: Fuel System Cleanliness Inspection

    3-14 FUEL SYSTEM Carburetor Fuel System Cleanliness Inspection WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 85: Carburetor Installation

    FUEL SYSTEM 3-15 Carburetor • Loosen the carburetor holder clamp [A] and air cleaner duct clamp. • Pull the carburetor out of the air cleaner duct end [B], and then pull it out of the carburetor holder [C] from the vehicle’s right side.
  • Page 86 3-16 FUEL SYSTEM Carburetor • Remove: Upper Chamber Cover [A] Vacuum Piston and Diaphragm CAUTION During carburetor disassembly, the careful not to damage the diaphragm. Never use a sharp edge to remove the diaphragm. • Remove the spring seat screws [D]. •...
  • Page 87: Carburetor Assembly

    FUEL SYSTEM 3-17 Carburetor • Remove the coasting enricher cover. • Remove the diaphragm [A]. Carburetor Assembly • Turn in the pilot screw [A] fully but not tightly, and then back it out the same number of turn counted during dis- assembly.
  • Page 88: Carburetor Cleaning

    3-18 FUEL SYSTEM Carburetor • Align the diaphragm tang [A] with the notch in the upper chamber, and fit the diaphragm sealing lip into its groove. • After installing the upper chamber cover, check that the vacuum piston slides up and down smoothly without bind- ing in the carburetor bore.
  • Page 89: Carburetor Inspection

    FUEL SYSTEM 3-19 Carburetor Carburetor Inspection WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 90 3-20 FUEL SYSTEM Carburetor • Check the tapered portion [A] of the pilot screw [B] for wear or damage. If the pilot screw is worn or damaged on the tapered por- tion, it will prevent the engine from idling smoothly. Re- place it.
  • Page 91: Air Cleaner

    FUEL SYSTEM 3-21 Air Cleaner Air Cleaner Element Removal • Remove the left side cover. • Remove the element cover [A]. Front [B] • Pull out the air cleaner element [A]. • Push a clean, lint-free towel into the air cleaner housing to keep dirt or other foreign material from entering.
  • Page 92: Air Cleaner Housing Removal

    3-22 FUEL SYSTEM Air Cleaner Air Cleaner Housing Removal • Remove: Side Covers and Seat (see Frame chapter) Fuel Tank (see Fuel Tank Removal) Battery (see Electrical System) and Battery Seat [A] Breather Hose of Air Cleaner Starter Relay [B] Fuse Case [C] Starter Circuit Relay [D] Housing Mounting Bolts [E] and Screws [F]...
  • Page 93: Fuel Tank

    FUEL SYSTEM 3-23 Fuel Tank Fuel Tank Removal WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 94: Fuel Tank Cleaning

    3-24 FUEL SYSTEM Fuel Tank Fuel Tank Cleaning WARNING Clean the tank in a well-ventllated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank.
  • Page 95: Fuel Tap Inspection

    FUEL SYSTEM 3-25 Fuel Tank Fuel Tap Inspection • Remove the fuel tap. • Check the fuel tap filter screen [A] for any breaks or dete- rioration. If the fuel tap screens have any breaks or are deterio- rated, they may allow dirt to reach the carburetor, causing poor running.
  • Page 96: Evaporative Emission Control System ( California Model Only)

    3-26 FUEL SYSTEM Evaporative Emission Control System ( California Model Only) The Evaporative Emission Control System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals specified by the Pe- riodic Maintenance Chart.
  • Page 97: Separator Operation Test

    FUEL SYSTEM 3-27 Evaporative Emission Control System ( California Model Only) Separator Operation Test WARNING Gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks;...
  • Page 99 ENGINE TOP END 4-1 Engine Top End Table of Contents Exploded View........Cylinder Head Cleaning ....4-24 Specifications ........Cylinder Head Warp..... 4-25 Special Tools ........Valves ..........4-26 Clean Air System (For AT, CH, DE of Valve Clearance Inspection ..4-26 BN125-A1 ∼...
  • Page 100: Exploded View

    4-2 ENGINE TOP END Exploded View...
  • Page 101: Engine Top End

    ENGINE TOP END 4-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Valve Adjusting Cap Bolts (BN125-A1 ∼ A3) 87 in·lb Valve Adjusting Cap Bolts (BN125-A4 ∼) 0.90 78 in·lb Camshaft Chain Cover Bolts (BN125-A1 ∼ A3) 87 in·lb Camshaft Chain Cover Bolts (BN125-A4 ∼) 0.90 78 in·lb Cylinder Head Bolts (M9)
  • Page 102 4-4 ENGINE TOP END Exploded View...
  • Page 103 ENGINE TOP END 4-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb 1 Camshaft Bearing Holder Bolts (BN125-A1 ∼ A3) 87 in·lb Camshaft Bearing Holder Bolts (BN125-A4 ∼) 0.90 78 in·lb 2 Camshaft Sprocket Bolts 104 in·lb 3 Camshaft Chain Holder Screw 0.50 43 in·lb 4 Camshaft Chain Guide Bolt...
  • Page 104: Specifications

    4-6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air Sytem Vacuum Switch Valve Closing Open → Close – – – Pressure: 45 ∼ 53 kPa (340 ∼ 400 mmHg, 6.5 ∼ 7.7 – – – (AT, CH, DE, of the BN125-A1 ∼...
  • Page 105 ENGINE TOP END 4-7 Specifications Item Standard Service Limit Width: 0.8 ∼ 1.2 mm (0.03 ∼ 0.05 in.) Exhaust – – – 0.8 ∼ 1.2 mm (0.03 ∼ 0.05 in.) Inlet – – – Valve Spring Free Length: Exhaust 43.51 mm (1.713 in.) 42.1 mm (1.66 in.) Inlet 43.51 mm (1.713 in.)
  • Page 106 4-8 ENGINE TOP END Specifications Cam Height Camshaft Runout Valve Stem Bend Cam Height [A] Valve Head Thickness Dial Gauge [A] Valve Stem Diameter [A] Valve Head Thickness [B] 45° [C]...
  • Page 107: Special Tools

    ENGINE TOP END 4-9 Special Tools Compression Gauge, 20 kgf/cm²: Valve Seat Cutter, 32°- 30: 57001-221 57001-1120 Valve Spring Compressor Assembly: Valve Seat Cutter, 32° - 35: 57001-241 57001-1121 Piston Pin Puller Assembly: Valve Seat Cutter, 60°- 30: 57001-910 57001-1123 Valve Seat Cutter, 45°- 27.5: Valve Seat Cutter Holder Bar: 57001-1114...
  • Page 108 4-10 ENGINE TOP END Special Tools Fork Oil Level Gauge: Valve Guide Arbor, 4.5: 57001-1290 57001-1331 Compression Gauge Adapter, M10 × 1.0: Valve Guide Reamer, 4.5: 57001-1317 57001-1333 Valve Seat Cutter Holder, 4.5: Valve Seat Cutter, 60° - 33: 57001-1330 57001-1334 ○...
  • Page 109: Clean Air System (for At, Ch, De Of Bn125-a1 ~ A2 And Other Than The Cal)

    ENGINE TOP END 4-11 Clean Air System (For AT, CH, DE of BN125-A1 ∼ A2 and other than the CAL) AT: Austria CAL: California CH: Switzerland DE: Germany Air Suction Valve Installation • Install the air suction valve so that its number [A] of the read faces outside and downward.
  • Page 110: Vacuum Switch Valve Unit Test

    4-12 ENGINE TOP END Clean Air System (For AT, CH, DE of BN125-A1 ∼ A2 and other than the CAL) Vacuum Switch Valve Unit Test • Remove the vacuum switch valve (see Vacuum Switch Valve Removal). • Connect a commercially available vacuum gauge [A] and syringe [B] (or fork oil level gauge) to the vacuum hoses as shown.
  • Page 111: Clean Air System (california Model)

    ENGINE TOP END 4-13 Clean Air System (California Model) Vacuum Switch Valve Test • Remove the vacuum switch valve. • Connect the vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown. Special Tool - Fork Oil Level Gauge : 57001–1290 Air Flow [C] •...
  • Page 112: Camshaft Chain Tensioner

    4-14 ENGINE TOP END Camshaft Chain Tensioner Camshaft Chain Tensioner Removal CAUTION This is a non-return type cam chain tensioner. The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner, do not take out the mounting bolts only halfway.
  • Page 113 ENGINE TOP END 4-15 Camshaft Chain Tensioner • Install the O-ring in the tensioner body. • Install the tensioner so that the arrow mark [B] faces up- ward, and tighten the mounting bolts. Torque - Chain Tensioner Mounting Bolts (BN125-A1 ∼ A3): 9.8 N·m (1.0 kgf·m 87in·lb) (BN125-A4 ∼): 8.8 N·m (0.90 kgf·m 87in·lb) •...
  • Page 114: Camshaft

    4-16 ENGINE TOP END Camshaft Camshaft Removal • Remove: Fuel Tank [A] (see Fuel System chapter) Camshaft Chain Cover [B] Valve Adjusting Caps [C] • Holding the camshaft center bolt [A] with a wrench, loosen the camshaft sprocket bolts [B]. •...
  • Page 115: Camshaft Installation

    ENGINE TOP END 4-17 Camshaft • Using a screw [A] (M5 × P0.8 mm), remove the rocker shafts [B]. ○ Mark the rocker shafts so that they can be installed later in the same position. • Remove: Rocker Arms [A] Camshaft Bearing Holder [B] ○...
  • Page 116: Camshaft Chain Removal

    4-18 ENGINE TOP END Camshaft • Install the camshaft bearing holder [A]. • Apply engine oil to the rocker shaft surface and cam por- tion of the rocker arm, and then install them at the original position. ○ Install the rocker shafts [B] so that the screw threads face outward.
  • Page 117: Camshaft Chain Installation

    ENGINE TOP END 4-19 Camshaft • Remove the crank balancer gear [A]. Special Tool - Outside Circlip Pliers: 57001-144 ○ Stuff a clean cloth into the hole [B] so that the balancer damper springs will not fall into it. • Remove the camshaft chain holder [A], and pull the camshaft chain [B] upward.
  • Page 118 4-20 ENGINE TOP END Camshaft ○ Align the three punch marks [D] on the balancer shaft gear [A], crank balancer gear [B], and coupling [C]. • Install the alternator (see Electrical System chapter). • Align the punch mark [A] on the crankcase with the “T” mark [B] on the rotor.
  • Page 119: Cylinder Head

    ENGINE TOP END 4-21 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged • Warm up the engine thoroughly. • Stop the engine. • Remove: Fuel Tank (see Fuel System chapter) Spark Plug Owner’s Tool - Spark Plug Wrench, Hex 16: 92110-1172 [A] •...
  • Page 120: Cylinder Head Removal

    4-22 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove: Fuel Tank (see Fuel System chapter) Exhaust Pipe [A] (see Muffler Removal) Carburetor [B] (see Fuel System chapter) Oil Pipe [C] (see Engine Lubrication chapter) Spark Plug Cap Ignition Coil CDI Unit (see Electrical System chapter) •...
  • Page 121: Cylinder Head Installation

    ENGINE TOP END 4-23 Cylinder Head Cylinder Head Installation • Install: Dowel Pins [A] New Cylinder Head Gasket [B] • Apply molybdenum disulfide grease to the threads of the 9 mm cylinder head bolts [1 ∼ 4], and engine oil to both sides of the washers.
  • Page 122: Cylinder Head Assembly

    4-24 ENGINE TOP END Cylinder Head Cylinder Head Assembly • Install the rubber dampers as shown. Dampers [A] Fins [B] Front [C] Cylinder Head Cleaning • Remove the cylinder head (see Cylinder Head Removal). • Remove the valves (see Valve Removal). •...
  • Page 123: Cylinder Head Warp

    ENGINE TOP END 4-25 Cylinder Head Cylinder Head Warp • Clean the cylinder head (see Cylinder Head Cleaning). • Lay a straightedge across the lower surface of the cylinder head at the positions as shown. • Use a thickness gauge [A] to measure the space between the straightedge [B] and the cylinder head.
  • Page 124: Valves

    4-26 ENGINE TOP END Valves Valve Clearance Inspection • Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment • Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Removal • Remove the cylinder head (see Cylinder Head Removal). •...
  • Page 125: Valve Guide Installation

    ENGINE TOP END 4-27 Valves Valve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). CAUTION Do not heat the cylinder head with a torch. This will warp the cylinder head.
  • Page 126: Valve Seat Inspection

    4-28 ENGINE TOP END Valves Valve Seat Inspection • Remove the valve (see Valve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
  • Page 127 ENGINE TOP END 4-29 Valves Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair. Therefore the cutter must not be used for other purposes than seat repair. 2. Do not drop or shock the valve seat cutter, or the dia- mond particles may fall off.
  • Page 128 4-30 ENGINE TOP END Valves • Measure the outside diameter of the seating surface with a vernier caliper. If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
  • Page 129 ENGINE TOP END 4-31 Valves If the seat width is too wide, make the 60° grind [A] de- scribed below. If the seat width is within the specified range, lap the valve to the seat as described below. • Grind the seat at a 60° angle until the seat width is within the specified range.
  • Page 130 4-32 ENGINE TOP END Valves...
  • Page 131: Cylinder, Piston

    ENGINE TOP END 4-33 Cylinder, Piston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) • Tap lightly up the cylinder [A] with a plastic mallet to sep- arate from the crankcase. • Remove the cylinder base gasket. Piston Removal •...
  • Page 132 4-34 ENGINE TOP END Cylinder, Piston ○ When installing the piston pin snap ring, compress it only enough to install it and no more. CAUTION Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.
  • Page 133: Cylinder Wear

    ENGINE TOP END 4-35 Cylinder, Piston • Apply engine oil to the cylinder bore. • Position the piston ring openings. • Install the cylinder [B] while compressing [A] the piston rings with your thumbs. • Install the removed parts. Cylinder Wear •...
  • Page 134: Piston/cylinder Clearance

    4-36 ENGINE TOP END Cylinder, Piston Piston/Cylinder Clearance • Subtract the piston diameter from the cylinder inside di- ameter to get the piston/cylinder clearance. Piston/Cylinder Clearance 0.025 ∼ 0.052 mm (0.0010 ∼ 0.0020 in.) Standard: If the piston/cylinder clearance is less than the specified range, use a smaller piston or increase the cylinder inside diameter by honing.
  • Page 135: Piston Ring Thickness

    ENGINE TOP END 4-37 Cylinder, Piston Piston Ring Thickness • Measure the piston ring thickness. ○ Use a micrometer to measure at several points around the ring. Piston Ring Thickness (Top, Second) 0.77 ∼ 0.79 mm (0.0303 ∼ 0.0311 in.) Standard: Service Limit: 0.70 mm (0.028 in.)
  • Page 136: Carburetor Holder

    4-38 ENGINE TOP END Carburetor Holder Carburetor Holder Installation • Apply grease to the O-ring [A], and install the carburetor holder. ○ Take care not to pinch the O-ring. • Tighten: Torque - Carburetor Holder Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 137: Muffler

    ENGINE TOP END 4-39 Muffler WARNING To avoid a serlous burn, do not remove the muffler when the engine is still hot. Wait until the muffler cools down. Muffler Removal • loosen the muffler body clamp bolt [A]. • Remove the muffler body mounting bolt and nut [B]. •...
  • Page 139 CLUTCH 5-1 Clutch Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Clutch Lever and Cable ......................Clutch Lever Free Play Inspection ..................Clutch Lever Free Play Adjustment .................. Clutch Lever Installation....................Clutch Cable Removal ...................... Clutch Cable Installation ....................Clutch Cable Lubrication....................
  • Page 140: Exploded View

    5-2 CLUTCH Exploded View...
  • Page 141 CLUTCH 5-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Clutch Hub Nut 10.0 Clutch Spring Bolt 0.90 78 in·lb Clutch Cover Bolts (BN125-A1 ∼ A3) 87 in·lb Clutch Cover Bolts (BN125-A4 ∼) 0.90 78 in·lb Oil Seal Retaining Plate Bolts (BN125-A1 ∼ A3) 87 in·lb Oil Seal Retaining Plate Bolts (BN125-A4 ∼) 0.90...
  • Page 142: Specifications

    5-4 CLUTCH Specifications Item Standard Service Limit 2 ∼ 3 mm (0.08 ∼ 0.12 in.) Clutch Lever Free Play – – – Clutch 2.92 ∼ 3.08 mm (0.115 ∼ 0.121 in.) Friction Plate Thickness 2.8 mm (0.11 in.) Friction and Steel Plate Warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) Clutch Spring Free Length...
  • Page 143: Special Tools

    CLUTCH 5-5 Special Tools Gear Holder, m1.75: Clutch Holder: 57001-1015 57001-1243...
  • Page 144: Clutch Lever And Cable

    5-6 CLUTCH Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. Clutch Lever Free Play Inspection • Refer to the Clutch Lever Free Play Inspection in the Pe- riodic Maintenance chapter.
  • Page 145: Clutch Cover

    CLUTCH 5-7 Clutch Cover Clutch Cover Removal • Drain the engine oil (see Periodic Maintenance chapter). • Remove: Front Footpeg Oil Pipe Banjo Bolt [A] • Screw the clutch lever adjuster in completely so as to give the clutch cable plenty of play. •...
  • Page 146: Clutch Cover Assembly

    5-8 CLUTCH Clutch Cover • With the shaft pulled a little out of the cover, turn the lever until it becomes hard to turn. ○ The release lever should have about 11 mm (0.43 in.) [A] clearance between the lever and the washer. •...
  • Page 147: Clutch Removal

    CLUTCH 5-9 Clutch Clutch Removal • Remove the clutch cover (see Clutch Cover Removal). NOTE ○ If the primary gear is to be removed, remove the pri- mary gear nut before clutch removal (see Primary Gear Removal). • Remove: Clutch Spring Bolts [A] with Springs Clutch Spring Plate [B] Ball Bearing and Pusher [C] Friction Plates and Steel Plates...
  • Page 148: Friction And Steel Plate Damage, Wear

    5-10 CLUTCH Clutch • Install the washer [A] as shown. Crankcase Side [B] • Tighten the clutch hub nut [C], while holding the clutch hub with the clutch holder. Special Tool - Clutch Holder: 57001-1243 Torque - Clutch Hub Nut: 98 N·m (10.0 kgf·m, 72 ft·lb) •...
  • Page 149: Clutch Spring Free Length Measurement

    CLUTCH 5-11 Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 35.0 mm (1.38 in.) Service Limit: 34.0 mm (1.34 in.) Clutch Housing Finger Damage...
  • Page 150: Primary Gear

    5-12 CLUTCH Primary Gear Primary Gear Removal • Remove the clutch cover (see Clutch Cover Removal). • Using the gear holder [A], hold the primary gear and loosen the primary gear nut [B]. Special Tool - Gear Holder, m1.75: 57001-1015 •...
  • Page 151 ENGINE LUBRICATION SYSTEM 6-1 Engine Lubrication System Table of Contents Exploded View........................Engine Oil Flow Chart......................Specifications ......................... Special Tools .......................... Engine Oil and Oil Filter......................Oil Level Inspection......................Engine Oil Change......................Oil Filter Change ....................... Oil Screen..........................Oil Screen Removal ......................Oil Screen Installation .......................
  • Page 152: Exploded View

    6-2 ENGINE LUBRICATION SYSTEM Exploded View...
  • Page 153 ENGINE LUBRICATION SYSTEM 6-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Oil Drain Plug Oil Screen Cover Bolts (BN125-A1 ∼ A3) 87 in·lb Oil Screen Cover Bolts (BN125-A4 ∼) 0.90 78 in·lb Oil Pressure Relief Valve Oil Filter Cover Bolts (BN125-A1 ∼ A3) 87 in·lb Oil Filter Cover Bolts (BN125-A4 ∼) 0.90...
  • Page 154: Engine Oil Flow Chart

    6-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart 1. Oil screen 9. Drive Shaft 2. Oil pump 10. Output Shaft 3. Clutch Cover Oil Passage 11. Camshaft Chain Tunnel 4. Oil Pressure Relief Valve 12. Engine Breather Hose 5. Oil Filter 13.
  • Page 155: Specifications

    ENGINE LUBRICATION SYSTEM 6-5 Specifications Item Standard Engine Oil Grade: (BN125-A1 ∼ A3) API SE, SF or SG (BN125-A4 ∼) API SE, SF or SG API SH, SJ or SL with JASO MA Viscosity SAE 10W-40 Capacity 1.1 L (1.16 US qt) (when filter is not removed) 1.2 L (1.27 US qt) (when filter is removed) 1.4 L (1.48 US qt) (when engine is completely dry) Level...
  • Page 156: Special Tools

    6-6 ENGINE LUBRICATION SYSTEM Special Tools Oil Pressure Gauge, 5 kgf/cm²: Oil Pressure Gauge Adapter, M10 × 1.25: 57001-125 57001-1182...
  • Page 157: Engine Oil And Oil Filter

    ENGINE LUBRICATION SYSTEM 6-7 Engine Oil and Oil Filter WARNING Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury. Oil Level Inspection • Situate the motorcycle so that it is vertical.
  • Page 158: Oil Screen

    6-8 ENGINE LUBRICATION SYSTEM Oil Screen Oil Screen Removal • Refer to the Oil Screen Cleaning in the Periodic Mainte- nance chapter. Oil Screen Installation • Refer to the Oil Screen Cleaning in the Periodic Mainte- nance chapter.
  • Page 159: Oil Pump

    ENGINE LUBRICATION SYSTEM 6-9 Oil Pump Oil Pump Removal • Remove the clutch cover (see Clutch chapter). • Remove the mounting screws [A] and remove the oil pump assembly [B]. ○ Turn the pump gear so that the pump mounting screws can be removed through the pump gear holes.
  • Page 160: Oil Pump Assembly

    6-10 ENGINE LUBRICATION SYSTEM Oil Pump Oil Pump Assembly • Install the oil pump gear [A]. • Fill the rotors [B] with engine oil. • Install the cover and tighten the oil pump assembly screw. Torque - Oil Pump Assembly Screw: 9.8 N·m (1.0 kgf·m, 87 in·lb) •...
  • Page 161: Oil Pressure

    ENGINE LUBRICATION SYSTEM 6-11 Oil Pressure Oil Pressure Measurement • Remove the air suction valve [A] (see Engine Top End chapter). • Replace the oil pipe banjo bolt of the clutch cover [B] with the oil pressure gauge adapter (special tool) [C]. If the oil pressure gauge adapter bottoms out, add washer(s) (P/N: 11009-1105) [D] under the adapter.
  • Page 162: Relief Valve

    6-12 ENGINE LUBRICATION SYSTEM Relief Valve Relief Valve Inspection • Remove the relief valve from the clutch cover. • Check to see if the valve [A] slides smoothly when push- ing in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
  • Page 163: Oil Pipe

    ENGINE LUBRICATION SYSTEM 6-13 Oil Pipe Oil Pipe Removal • Remove: Oil Pipe Banjo Bolts (Cylinder Head) [A] Oil Pipe Banjo Bolt (Clutch Cover) [B] Oil Pipe Mounting Bolt [C] • Remove: Engine Sprocket Cover (see Final Drive chapter) Oil Pipe Banjo Bolt (Left Crankcase) [A] •...
  • Page 165 ENGINE REMOVAL/INSTALLATION 7-1 Engine Removal/Installation Table of Contents Exploded View........................Special Tool ..........................Engine Removal/Installation ....................Engine Removal........................ Engine Installation......................
  • Page 166: Exploded View

    7-2 ENGINE REMOVAL/INSTALLATION Exploded View...
  • Page 167 ENGINE REMOVAL/INSTALLATION 7-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Mounting Bolts, Nuts (M10) Engine Mounting Bolts, Nuts (M8) Engine Mounting Bracket Bolts, Nuts Engine Ground Terminal Bolt 87 in·lb...
  • Page 168: Special Tool

    7-4 ENGINE REMOVAL/INSTALLATION Special Tool Jack: 57001-1238...
  • Page 169: Engine Removal/installation

    ENGINE REMOVAL/INSTALLATION 7-5 Engine Removal/Installation Engine Removal • Place the jack [A] under the frame to lift the rear wheel [B] off the ground. Special Tool - Jack: 57001-1238 • Squeeze the brake lever slowly and hold it with a band [A].
  • Page 170: Engine Installation

    7-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation • Remove: Engine Mounting Bolts [A] Engine Mounting Bracket Bolts [B] ○ Pull out the mounting bolts while lifting the engine. • Lift up the engine and move it to the right side of the frame. •...
  • Page 171 ENGINE REMOVAL/INSTALLATION 7-7 Engine Removal/Installation If the engine sprocket is hard to install, remove the master link and the clip from the drive chain, and then install the engine sprocket. ○ Install the clip [A] so that the open end [B] of the "U" points in the opposite direction of chain rotation [C].
  • Page 173 CRANKSHAFT/TRANSMISSION 8-1 Crankshaft/Transmission Table of Contents Exploded View........Starter Motor Clutch Assembly ..8-16 Specifications ........Starter Motor Clutch Inspection ... 8-16 Special Tools and Sealant ....Torque Limiter Inspection..... 8-16 Crankcase ......... External Shift Mechanism....8-17 Crankcase Disassembly ....Shift Pedal Height Adjustment ..
  • Page 174: Exploded View

    8-2 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 175 CRANKSHAFT/TRANSMISSION 8-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Primary Gear Nut Balancer Shaft Gear Nut Crankcase Bolts 0.90 78 in·lb Crankcase Bearing Retainer Screws 0.50 43 in·lb 5. Balancer Shaft 6. Balancer shaft gear 7. Crank balancer gear 8.
  • Page 176 8-4 CRANKSHAFT/TRANSMISSION Exploded View...
  • Page 177 CRANKSHAFT/TRANSMISSION 8-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Neutral Switch Shift Drum Cam Screw 0.50 43 in·lb Gear Set Lever Nut 95 in·lb Engine Sprocket Holder Bolts 104 in·lb Shift Shaft Return Spring Pin Shift Lever Clamp Bolt 104 in·lb Shift Pedal Nut EO: Apply engine oil.
  • Page 178: Specifications

    8-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rod 0.20 ∼ 0.35 mm (0.008 ∼ 0.014 in.) Connecting Rod Big End Side 0.5 mm (0.020 in.) Clearance 0.005 ∼ 0.017 mm (0.0002 ∼ 0.0007 in.) Connecting Rod Big End Radial 0.07 mm (0.003 in.) Clearance Crankshaft Runout...
  • Page 179: Special Tools And Sealant

    CRANKSHAFT/TRANSMISSION 8-7 Special Tools and Sealant Outside Circlip Pliers: Crankshaft Jig: 57001-144 57001-1174 Gear Holder, m1.75: Crankcase Splitting Tool Assembly: 57001-1015 57001-1362 Bearing Driver Set: Kawasaki Bond (Liquid Gasket-Silver): 57001-1129 92104-002...
  • Page 180: Crankcase

    8-8 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Disassembly • Remove: Clutch (see Clutch chapter) Primary Gear (see Clutch chapter) Starter Motor (see Electrical System chapter) Alternator (see Electrical System chapter) Balancer Shaft Gear (see Balancer Shaft Gear Re- moval) Crank Balancer Gear (see Engine Top End chapter) [A] •...
  • Page 181: Crankcase Assembly

    CRANKSHAFT/TRANSMISSION 8-9 Crankcase • Remove the transmission shaft [A], gears and balancer shaft from the right crankcase half [B]. • Remove: Shift Drum Cam Screw [A] Shift Drum Cam [B] Woodruff Key [C] Shift Drum [D] Gear Set Lever [E] •...
  • Page 182 8-10 CRANKSHAFT/TRANSMISSION Crankcase • Press the damper [A] into the crankcase with the bearing drier set. Special Tool - Bearing Driver Set: 57001-1129 • Chip off the old gasket from the mating surfaces of the crankcase halves and clean them off with a high-flash point solvent.
  • Page 183 • Apply liquid gasket to the mating surface [B] of the left crankcase half. Sealant - Kawasaki Bond (Liquid Gasket-Silver): 92104 -002 • Using a suitable tool on the left crankcase to press around the hole for the crankshaft, fit the crankcase halves to- gether with a press on the tool.
  • Page 184 8-12 CRANKSHAFT/TRANSMISSION Crankcase • Check to see that the crankshaft, drive shaft, and output shaft all turn freely (in the neutral position). If the crankshaft will not turn, probably the crankshaft is not centered; Tap the mount portion [A] of the crankcase with a plastic hammer to reposition it.
  • Page 185: Crankshaft

    CRANKSHAFT/TRANSMISSION 8-13 Crankshaft Crank Balancer Gear Removal/Installation • Refer to Camshaft Chain Removal/Installation in the En- gine Top End chapter. Crankshaft Removal • Refer to the Crankcase Disassembly in this chapter. Crankshaft Installation • Refer to the Crankcase Assembly in this chapter. Crankshaft Disassembly If the crankshaft is damaged, replace it as a set.
  • Page 186 8-14 CRANKSHAFT/TRANSMISSION Crankshaft • First correct the horizontal misalignment by striking the projecting crank half [A] with a plastic, soft lead, or brass hammer as shown. • Recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit. •...
  • Page 187: Balancer Shaft Gear

    CRANKSHAFT/TRANSMISSION 8-15 Balancer Shaft Gear Balancer Shaft Gear Removal • Remove: Alternator Rotor (see Electrical System chapter) Clutch Cover (see Clutch chapter) • Using the gear holder, hold the primary gear [A] and loosen the balancer shaft gear nut [B]. Special Tool - Gear Holder, m1.75: 57001-1015 [C] •...
  • Page 188: Starter Motor Clutch

    8-16 CRANKSHAFT/TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal and Installation in the Electrical System chapter. Starter Motor Clutch Disassembly • Remove the alternator rotor [A] (see Electrical System chapter). • Hold the alternator rotor with the flywheel holder [B] and remove the starter motor clutch bolts [C].
  • Page 189: External Shift Mechanism

    CRANKSHAFT/TRANSMISSION 8-17 External Shift Mechanism Shift Pedal Height Adjustment • Adjust the length of the shift linkage rod so that the dis- tance between the shift pedal [A] and the front left footpeg [B] shall be 26.5 ∼ 29.5 mm (1.04 ∼ 1.16 in.) [C]. Then, the length [D] of the shift linkage rod will be approximately 141 mm (5.55 in.) as illustrated.
  • Page 190: External Shift Mechanism Inspection

    8-18 CRANKSHAFT/TRANSMISSION External Shift Mechanism • Turn the shift drum and position the neutral groove [A] as shown. • Remove the shift shaft [D] while pushing [C] the shift mechanism arm [B] toward the shaft. External Shift Mechanism Inspection • Examine the shift shaft [A] for any damage.
  • Page 191: Transmission

    CRANKSHAFT/TRANSMISSION 8-19 Transmission Transmission Shaft Removal • Split the crankcase (see Crankcase Disassembly). • Pull out the shift rod [A] allowing the shift fork guide pins to free from the shift drum [B]. • Remove the shift forks [C]. • Remove the shift drum.
  • Page 192: Transmission Assembly

    8-20 CRANKSHAFT/TRANSMISSION Transmission Transmission Assembly • Replace any circlips removed with new ones. ○ Install the circlips [A] so that the opening [B] is aligned with a spline groove [C]. ○ Install the toothed washer [D] so that the teeth [E] are not aligned with the opening of the circlip.
  • Page 193: Shift Drum Removal/installation

    CRANKSHAFT/TRANSMISSION 8-21 Transmission Shift Drum Removal/Installation • Refer to the Crankcase Disassembly/Installation in the Crankshaft/Transmission chapter. Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of gear when under power.
  • Page 194: Ball Bearing, And Oil Seal

    8-22 CRANKSHAFT/TRANSMISSION Ball Bearing, and Oil Seal Ball Bearing Replacement CAUTION Do not remove the ball bearings unless it is neces- sary. Removal may damaged them. • Using a press or puller, remove the ball bearing. NOTE ○ In the absence of the above mentioned tools, satisfac- tory results may be obtained by heating the case to ap- proximately 93°C (200°F) max, and tapping the bearing in or out.
  • Page 195 WHEELS/TIRES 9-1 Wheels/Tires Table of Contents Exploded View........................Specifications ......................... Special Tools .......................... Wheels (Rims) ........................Front Wheel Removal ....................... Front Wheel Installation ....................Rear Wheel Removal......................Rear Wheel Installation..................... Wheel Inspection ......................Spoke Inspection ......................Rim Inspection ........................Axle Inspection........................Tires............................
  • Page 196: Exploded View

    9-2 WHEELS/TIRES Exploded View...
  • Page 197 WHEELS/TIRES 9-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Tire Air Valve Nuts 0.15 13 in·lb 2.0 ∼ 3.9 0.20 ∼ 0.40 17 ∼ 35 in·lb Spoke Nipples Front Axle Nut Rear Axle Nut 10.0 5. For DE of BN125-A1 ∼ A2 and On and after BN125-A3 of EUR Models G: Apply grease.
  • Page 198: Specifications

    9-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Size: Front 17 × 1.85 – – – Rear 15 × 2.75 – – – Rim Runout (with tire installed): Axial TIR 0.8 mm (0.03 in.) or less 2 mm (0.08 in.) Radial TIR 1.0 mm (0.04 in.) or less 2 mm (0.08 in.)
  • Page 199: Special Tools

    WHEELS/TIRES 9-5 Special Tools Rim Protector: Jack: 57001-1063 57001-1238 Bead Breaker Assembly: Bearing Remover Shaft, 9: 57001-1072 57001-1265 Bearing Driver Set: Bearing Remover Head, 15 × 17: 57001-1129 57001-1267...
  • Page 200: Wheels (rims)

    9-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove the cotter pin and axle nut [A]. • Remove the speedometer cable lower end [B]. • Raise the front wheel [B] off the ground using the jack [A]. Special Tool - Jack: 57001-1238 •...
  • Page 201: Rear Wheel Removal

    WHEELS/TIRES 9-7 Wheels (Rims) • Fit the fork leg stop [A] between the speedometer gear housing stop [B] and install the front wheel. • Install the axle from the right side and tighten the axle nut. Torque - Front Axle Nut: 78 N·m (8.0 kgf·m, 58 ft·lb) •...
  • Page 202: Rear Wheel Installation

    9-8 WHEELS/TIRES Wheels (Rims) • Remove: Chain Cover Cotter Pin [A] and Axle Nut [B] Torque Link Bolt, Nut (rear) [C] Brake Adjusting Nut [D] • Remove the brake rod [E] from the brake cam lever [F]. • Remove the drive chain [A] from the rear sprocket, then remove the rear wheel [B] to the rear.
  • Page 203: Wheel Inspection

    WHEELS/TIRES 9-9 Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. • Adjust the brake pedal free play (see Brakes chapter). • Check the rear brake effectiveness. WARNING If a full brake pedal is not obtained, disassemble and inspect the brake parts.
  • Page 204: Tires

    9-10 WHEELS/TIRES Tires Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection/Adjustment in the Pe- riodic Maintenance chapter. Tire Inspection • Refer to the Tire Wear Inspection in the Periodic Mainte- nance chapter. Tire Removal • Remove the following. Wheel (see this chapter) Brake Disc (front) Brake Panel (rear)
  • Page 205: Tire Installation

    WHEELS/TIRES 9-11 Tires ○ For easier removal, always drop the tire bead opposite the valve stem into the rim well [A], and pry the tire bead a little at a time. • Do the same for the other side of the tire, then remove the rim from the tire.
  • Page 206: Hub Bearings (wheel Bearings)

    9-12 WHEELS/TIRES Hub Bearings (Wheel Bearings) Removal • Remove the wheel, and take out the following. Speedometer Gear (from front hub) [A] Collars [B] Grease Seals [C] ○ Use a screwdriver for the grease seal removal. • Remove the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down.
  • Page 207: Inspection

    WHEELS/TIRES 9-13 Hub Bearings (Wheel Bearings) Inspection ○ Since the hub bearings are made to extremely close tol- erances, the clearance cannot normally be measured. NOTE ○ Do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones.
  • Page 209 FINAL DRIVE 10-1 Final Drive Table of Contents Exploded View........................10-2 Specifications ......................... 10-4 Special Tools .......................... 10-5 Drive Chain..........................10-6 Chain Slack Inspection ..................... 10-6 Chain Slack Adjustment....................10-6 Wear Inspection ........................ 10-6 Lubrication ........................10-6 Drive Chain Removal ......................10-6 Drive Chain Installation .....................
  • Page 210: Exploded View

    10-2 FINAL DRIVE Exploded View...
  • Page 211 FINAL DRIVE 10-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Engine Sprocket Cover Bolts (BN125-A1 ∼ A3) 87 in·lb Engine Sprocket Cover Bolts (BN125-A4 ∼) 0.90 78 in·lb Engine Sprocket Cover Damper Bolts 0.90 78 in·lb Torque Link Bolt and Nut Rear Sprocket Nuts Rear Axle Nuts 10.0...
  • Page 212: Specifications

    10-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Standard Chain: Make/type: ENUMA CHAIN (BN125-A1 ∼ A2) – – – Joint Endless EK428SH-R DAIDO (BN125-A3 ∼ ) Joint Endless DID424HG Link: 132 links – – – 130 links (BN125-A7 ∼, N, NU) –...
  • Page 213: Special Tools

    FINAL DRIVE 10-5 Special Tools Bearing Driver Set: Jack: 57001-1129 57001-1238...
  • Page 214: Drive Chain

    10-6 FINAL DRIVE Drive Chain Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter. Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter. Wear Inspection • Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter.
  • Page 215: Sprocket, Coupling

    FINAL DRIVE 10-7 Sprocket, Coupling Engine Sprocket Removal • Remove the engine sprocket cover bolts [A] and sprocket cover [B]. • Remove the engine sprocket bolts [A]. • Pull the engine sprocket [A] off the output shaft along with the chain. Engine Sprocket Installation •...
  • Page 216: Rear Sprocket Removal

    10-8 FINAL DRIVE Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheels/Tires chapter). • Remove the drive chain (see Drive Chain Removal). • Remove the rear sprocket nuts [A] and separate the rear sprocket [B] from the coupling. Rear Sprocket Installation •...
  • Page 217: Coupling Installation

    FINAL DRIVE 10-9 Sprocket, Coupling Coupling Installation • Grease [A] the following and install the coupling. Coupling Grease Seal Lips. Coupling Internal Surface • Install the rear sprocket and the coupling (see this chap- ter). • Install the rear wheel (see Wheels/Tires chapter). Coupling Bearing Removal •...
  • Page 219 BRAKES 11-1 Brakes Table of Contents Exploded View........11-2 Brake Disc Removal ....11-15 Specifications ........11-6 Brake Disc Installation ....11-15 Special Tools ........11-7 Brake Disc Wear ......11-15 Caliper ..........11-8 Brake Disc Warp ......11-15 Caliper Removal ......11-8 Brake Fluid ........
  • Page 220: Exploded View

    11-2 BRAKES Exploded View...
  • Page 221 BRAKES 11-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Disc Bolts Caliper Mounting Bolts Caliper Holder Shaft Bolts Caliper Pad Bolts Caliper Bleed Valve 0.80 69 in·lb Brake Hose Banjo Bolts Brake Lever Pivot Bolt 0.60 52 in·lb Brake Lever Pivot Bolt Locknut 0.60 52 in·lb...
  • Page 222 11-4 BRAKES Exploded View...
  • Page 223 BRAKES 11-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Brake Pedal Bolt 87 in·lb Torque Link Bolt and Nut G: Apply grease. R: Replacement Parts...
  • Page 224: Specifications

    11-6 BRAKES Specifications Item Standard Service Limit Front Brake Pad Lining Thickness: 4.5 mm (0.177 in.) (BN125-A1 ∼ A2) 1 m (0.04 in.) 6.0 mm (0.236 in.) (BN125-A3 ∼ ) 1 m (0.04 in.) 3.8 ∼ 4.2 mm (0.150 ∼ 0.165 in.) Disk Thickness 3.5 mm (0.138 in.) 4.3 ∼...
  • Page 225: Special Tools

    BRAKES 11-7 Special Tools Inside Circlip Pliers: Jack: 57001-143 57001-1238...
  • Page 226: Caliper

    11-8 BRAKES Caliper Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose Removal/Installation).
  • Page 227: Caliper Assembly

    BRAKES 11-9 Caliper ○ Insert a wooden board [A] 5 mm (0.2 in.) thick inside the caliper opening. ○ Apply compressed air [B] to the banjo bolt hole to allow the pistons [C] to protrude and stop at the wooden board. ○...
  • Page 228: Caliper Fluid Seal Damage

    11-10 BRAKES Caliper • Apply brake fluid to the inside of the cylinders and to the outside of the pistons and push the pistons [A] into the cylinders. • Check the friction boot [B] and dust boot [C] and replace them with new ones if they are damaged.
  • Page 229: Caliper Dust Seal/friction Boot Damage

    BRAKES 11-11 Caliper Caliper Dust Seal/Friction Boot Damage • Check that the dust seal and friction boot [C] are not cracked, worn, swollen, or otherwise damaged. • If they show any damage, replace it. Caliper Piston and Cylinder Damage • Visually inspect the piston [D] and cylinder surfaces for damage.
  • Page 230: Front Brake Pads

    11-12 BRAKES Front Brake Pads ∼ Brake Pad Removal (BN125-A1 • Remove the caliper with the hose attached. • Remove: Caliper Pad Bolts [A] Outer Pad [B] • Remove the inner pad (piston side pad) [C]. ∼ Brake Pad Removal (BN125-A3 •...
  • Page 231: Master Cylinder

    BRAKES 11-13 Master Cylinder Master Cylinder Removal • Remove the brake fluid from the reservoir with a syringe or other suitable device. • Disconnect the front brake light switch connectors [A]. • Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation).
  • Page 232: Master Cylinder Assembly

    11-14 BRAKES Master Cylinder Master Cylinder Assembly • Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
  • Page 233: Front Brake Disc

    BRAKES 11-15 Front Brake Disc Brake Disc Removal • Remove the wheel (see Wheels/Tires chapter). • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Page 234: Brake Fluid

    11-16 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in Periodic Main- tenance chapter. Brake Fluid Change • Refer to the Brake Fluid Change in Periodic Maintenance chapter. Brake Line Bleeding • Refer to the Brake Line Bleeding in Periodic Maintenance chapter.
  • Page 235: Brake Hose

    BRAKES 11-17 Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
  • Page 236: Rear Brake Pedal And Brake Cable

    11-18 BRAKES Rear Brake Pedal and Brake Cable Brake Pedal Position Inspection/Adjustment • Check that the brake pedal [A] is in the correct position. Pedal Position [C] Standard: About 80 mm (3.15 in.) above footpeg top If it is incorrect, adjust the brake pedal position. •...
  • Page 237: Brake Pedal Installation

    BRAKES 11-19 Rear Brake Pedal and Brake Cable • Remove the brake pedal [A] and return spring [B]. Brake Pedal Installation • Apply grease to the brake pedal pivot. • Temporarily install the brake return spring onto the brake shaft and hook the spring onto the brake pedal. •...
  • Page 238: Brake Cable Installation

    11-20 BRAKES Rear Brake Pedal and Brake Cable • Remove: Cotter Pin and Joint Pin Brake Cable Nut [A] • Remove the silencer (see Engine Top End chapter). • Remove the adjusting nut on the end of the brake rod, and take off the joint pin and brake rod from the brake cam lever.
  • Page 239: Rear Brake Panel And Drum

    BRAKES 11-21 Rear Brake Panel and Drum Brake Panel Removal • Remove the rear wheel (see Wheels/Tires chapter). • Separate the brake panel from the wheel hub. Brake Panel Installation • Fit the brake panel into the rear wheel, and then install the rear wheel (see Wheels/Tires chapter).
  • Page 240: Brake Panel Inspection

    11-22 BRAKES Rear Brake Panel and Drum • Install the brake cam seal and fit the indicator [A] on the serration so that it points to the extreme right of the US- ABLE RANGE [B]. • Install the cam lever in its original position on the camshaft, and tighten its bolt.
  • Page 241: Brake Shoe Springs Inspection

    BRAKES 11-23 Rear Brake Panel and Drum Brake Shoe Springs Inspection • Visually inspect the brake shoe springs for breaks or dis- tortion. If the springs are damaged in any way, replace them. • Measure the free length of the brake shoe springs. If either is stretched beyond the service limit, replace both springs.
  • Page 243 SUSPENSION 12-1 Suspension Table of Contents Exploded View........................12-2 Specifications ......................... 12-6 Special Tools .......................... 12-7 Front Fork ..........................12-8 Fork Oil Change........................ 12-8 Fork Removal........................12-8 Fork Installation......................... 12-8 Fork Disassembly ......................12-9 Fork Assembly ........................12-10 Inner Tube, Outer Tube Inspection ................... 12-11 Spring Inspection ......................
  • Page 244: Exploded View

    12-2 SUSPENSION Exploded View...
  • Page 245 SUSPENSION 12-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Fork Top Plugs Front Fork Bottom Allen Bolts Front Fork Clamp Bolt (Upper) Front Fork Clamp Bolt (Lower) 5. Fork cover (BN125-A1 ∼ A5) 6. Brake hose clamp (BN125-A1 only) 7.
  • Page 246 12-4 SUSPENSION Exploded View...
  • Page 247 SUSPENSION 12-5 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Rear Shock Absorber Nuts and Bolts Swingarm Pivot Nut 10.0 3. Chain guard (BN125-A1 ∼ A2 only) 4. Face the manufacture’s marks out.
  • Page 248: Specifications

    12-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner Tube Diameter 33 mm (1.30 in.) Fork Spring Setting Non-adjustable Air Pressure Atmospheric pressure (non-adjustable) Damper Setting Non adjustable Fork Oil Viscosity SHOWA SS-8 or equivalent Fork Oil Capacity 191 ±2.5 mL (6.46 ±0.085 US oz.) (completely dry) approx.
  • Page 249: Special Tools

    SUSPENSION 12-7 Special Tools Fork Cylinder Holder Handle: Fork Outer Tube Weight: 57001-183 57001-1218 Fork Cylinder Holder Adapter: Front Fork Oil Seal Driver: 57001-1011 57001-1219 Oil Seal & Bearing Remover: Jack: 57001-1058 57001-1238 Bearing Driver Set: Hook Wrench (Owner’s Tool): 57001-1129 92110-1143...
  • Page 250: Front Fork

    12-8 SUSPENSION Front Fork Fork Oil Change • Refer to the Front Fork Oil Change in the Periodic Main- tenance chapter. Fork Removal If the fork leg is to be disassembled, loosen the top plug beforehand. To loosen the fork top plug, loosen the fork upper clamp bolts.
  • Page 251: Fork Disassembly

    SUSPENSION 12-9 Front Fork • Check the front brake effectiveness after installation. WARNING Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brake will not function to the first application of the lever if this is not done.
  • Page 252: Fork Assembly

    12-10 SUSPENSION Front Fork • Use the fork outer tube weight [A] to separate the outer tube [B] from the inner tube [C]. Holding the inner tube by hand, pull the outer tube several times to pull out the inner tube. Special Tool - Fork Outer Tube Weight: 57001-1218 •...
  • Page 253: Inner Tube, Outer Tube Inspection

    SUSPENSION 12-11 Front Fork • Apply molybdenum disulfide grease to the oil seal lips and install the washer and oil seal [A] into the outer tube. Special Tool - Front Fork Oil Seal Driver: 57001-1219 [B] • Install the retaining ring and dust seal by hand. •...
  • Page 254: Spring Inspection

    12-12 SUSPENSION Front Fork Spring Inspection • Since the fork spring [A] becomes shorter as it weakens, check its free length [B] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of the replacement spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced for motorcycle stability.
  • Page 255: Rear Shock Absorbers

    SUSPENSION 12-13 Rear Shock Absorbers Spring Preload Adjustment • To adjust the spring force, turn the adjuster on each shock absorber to the desired position. Owner’s Tool - Hook Wrench: 92110-1143 [A] Spring Preload Adjustment Adjuster Position Spring Tension → Stronger WARNING If a pair of adjusters are not adjusted equally, han- dling may be impaired and a hazardous condition...
  • Page 256: Swingarm

    12-14 SUSPENSION Swingarm Swingarm Removal • Remove: Chain Cover Rear Wheel (see Wheels/Tires chapter) Rear Shock Absorber Lower Mounting Bolts [A] (see this chapter) Silencer [B] (see Engine Top End chapter) Brake Cable [C] (see Brakes chapter) Pivot Nut [D] Front [E] •...
  • Page 257: Swingarm Pivot Check

    SUSPENSION 12-15 Swingarm Swingarm Pivot Check • Remove: Rear Wheel (see Wheels/Tires chapter) Rear Shock Absorber Bolts • Move the swingarm up and down to check for abnormal friction, and push and pull it to check for bushings play [A]. A small amount of play on the pivot is normal and no corrective action is needed.
  • Page 259 STEERING 13-1 Steering Table of Contents Exploded View........................13-2 Special Tools .......................... 13-4 Steering ..........................13-5 Steering Inspection ......................13-5 Steering Adjustment......................13-5 Steering Stem......................... 13-6 Steering Stem Removal ....................13-6 Steering Stem Installation ....................13-7 Steering Stem Warp......................13-8 Steering Stem Bearing ......................
  • Page 260: Exploded View

    13-2 STEERING Exploded View BN125-A1 ∼...
  • Page 261 STEERING 13-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Steering Stem Head Bolts Steering Stem Nut Hand-tight Hand-tight Hand-tight or 4.9 or 0.50 or 43 in·lb Handlebar Nuts Handlebar Weight Screws – – – Handlebar Switch Housing Screws 0.35 30 in·lb Front Fork Clamp Bolts (Lower) Front Fork Clamp Bolts (Upper)
  • Page 262: Special Tools

    13-4 STEERING Special Tools Steering Stem Bearing Driver: Head Pipe Outer Race Driver, 46.5: 57001-137 57001-1106 Steering Stem Bearing Driver Adapter, 34.5: Steering Stem Nut Wrench: 57001-1074 57001-1100 Head Pipe Outer Race Press Shaft: Jack: 57001-1075 57001-1238 Head Pipe Outer Race Driver, 51.5: 57001-1076...
  • Page 263: Steering Inspection

    STEERING 13-5 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter. Steering Adjustment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter.
  • Page 264: Steering Stem

    13-6 STEERING Steering Stem Steering Stem Removal • Loosen the steering stem head bolt [A]. • Open the headlight body and pull off the connectors in the headlight body (see Electrical System chapter). • Remove the clutch cable upper end and lead connector. •...
  • Page 265: Steering Stem Installation

    STEERING 13-7 Steering Stem Steering Stem Installation • Apply grease to the upper and lower outer races in the head pipe so that the steel balls will stick in place during stem insertion. Install the upper steel balls (23) [A] and lower steel balls (23).
  • Page 266: Steering Stem Warp

    13-8 STEERING Steering Stem • Install the front fork (see Suspension chapter). NOTE ○ Install the front fork at the correct position. Tighten the fork upper clamp bolts [A] first, next the stem head bolt [B], last the fork lower clamp bolts. Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb) Steering Stem Head Bolt: 44 N·m (4.5 kgf·m, 33...
  • Page 267: Steering Stem Bearing

    STEERING 13-9 Steering Stem Bearing Steering Stem Bearing Removal If the bearing is damaged, remove it. • To remove the outer races [A] pressed in the head pipe, insert a bar [C] into the head pipe [B], and hammer evenly around the circumference of the opposite race to drive it out.
  • Page 268: Handlebar

    13-10 STEERING Handlebar Handlebar Removal (BN125-A1/A2) • Remove: Throttle Cables [A] (see Fuel System chapter) Brake Master Cylinder [B] (see Brakes chapter) Left Handlebar Switch Housing [C] Clutch Cable Upper End [D] Speedometer Unit [E] (with Cable) • Remove the handlebar nuts [A] and take off the handle- bar.
  • Page 269: Handlebar Installation (bn125-a3 ~ )

    STEERING 13-11 Handlebar • The front half of the right and left switch housings [A] has a small projection [B]. Fit the projection into the small hole [C] in the handlebar. • Install the handlebar switch housing. • Tighten: Torque - Handlebar Switch Housing Screws: 3.4 N·m (0.35 kgf·m, 30 in·lb) ∼...
  • Page 271 FRAME 14-1 Frame Table of Contents Exploded View........................14-2 Special Tool ..........................14-6 Side Covers ..........................14-7 Left Side Cover Removal ....................14-7 Left Side Cover Installation ....................14-7 Right Side Cover Removal....................14-7 Right Side Cover Installation..................... 14-7 Seat ............................14-8 Seat Removal ........................
  • Page 272: Exploded View

    14-2 FRAME Exploded View...
  • Page 273 FRAME 14-3 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Front Footpeg Bolts O: Apply oil.
  • Page 274 14-4 FRAME Exploded View...
  • Page 275 FRAME 14-5 Exploded View IT: Italy SG: Singapore US: United States (BN125-A4 ∼)
  • Page 276: Special Tool

    14-6 FRAME Special Tool Jack: 57001-1238...
  • Page 277: Side Covers

    FRAME 14-7 Side Covers Left Side Cover Removal • Remove the screws [A]. • Pull [B] the front part of the left side cover outward to clear the stopper. • Pull [C] the cover rearward to clear the hook, and remove Left Side Cover Installation •...
  • Page 278: Seat

    14-8 FRAME Seat Seat Removal • For the models other than the Singapore and U.S.A. mod- els, remove the bolts [A] and loosen the bolts [B] on both sides. • Remove the pad assembly [C]. • For the Singapore and U.S.A. models remove the bolts [A], cover [B], and collar [C] on both sides.
  • Page 279: Fenders

    FRAME 14-9 Fenders Front Fender Removal CAUTION Be careful not to scratch the pained surface during removal or installation. • Remove the mounting bolts [A] and take off the front fender [B]. Front Fender Installation • Install the front fender so that the narrower side [A] faces forward [B].
  • Page 280: Rear Fender Rear Disassembly

    14-10 FRAME Fenders Rear Fender Rear Disassembly • Remove the nuts [A] and take off the rear turn signal light assembly [B]. • Remove the nuts [C] and take off the tail/brake light as- sembly [D]. Rear Fender Front Removal •...
  • Page 281: Frame

    FRAME 14-11 Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WARNING A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
  • Page 283 ELECTRICAL SYSTEM 15-1 Electrical System Table of Contents Parts Location........15-2 Starter Motor Removal....15-48 Exploded View........15-4 Starter Motor Installation....15-48 Specifications ........15-10 Starter Motor Disassembly... 15-48 Special Tools and Sealant ....15-12 Starter Motor Assembly ....15-49 Wiring Diagram .........
  • Page 284: Parts Location

    15-2 ELECTRICAL SYSTEM Parts Location...
  • Page 285 ELECTRICAL SYSTEM 15-3 Parts Location 1. Speedometer 2. Starter lockout switch 3. Ignition coil 4. Starter motor 5. Ignition switch 6. Crankshaft sensor 7. Alternator 8. Neutral switch 9. Sidestand switch 10. Regulator/rectifier 11. Fuse unit 12. Starter circuit relay 13.
  • Page 286: Exploded View

    15-4 ELECTRICAL SYSTEM Exploded View...
  • Page 287 22. Starter relay 23. Starter clutch (BN125-A1) 24. Other than United States and Canada Models EO: Apply engine oil. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. Si: Apply silicone grease. SS: Apply silicone sealant (Kawasaki Bond: 56019-120).
  • Page 288 15-6 ELECTRICAL SYSTEM Exploded View...
  • Page 289 ELECTRICAL SYSTEM 15-7 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Neutral Switch Sidestand Switch Screws 0.40 35 in·lb Handlebar Switch Housing Screws 0.35 30 in·lb 4. Ignition switch 5. Turn signal relay 6. Starter circuit relay 7. Interlock diode 8.
  • Page 290 15-8 ELECTRICAL SYSTEM Exploded View...
  • Page 291 ELECTRICAL SYSTEM 15-9 Exploded View Torque Fastener Remarks N·m kgf·m ft·lb Headlight Body Screws 0.30 26 in·lb Turn Signal Light Holder Nuts 0.60 52 in·lb 3. Headlight unit 4. Turn signal lights 5. Tail/brake light 6. Canada and United Kingdom Models (BN125-A6 ∼ ) 7.
  • Page 292: Specifications

    15-10 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Capacity 12 V 9 Ah – – – Electrolyte Level between level lines – – – Specific Gravity of Electrolyte 1.280 ±0.01 @20°C (68°F) – – – Charging System Type: (BN125-A1/A2) Single-phase AC –...
  • Page 293 ELECTRICAL SYSTEM 15-11 Specifications Item Standard Service Limit Switches Rear Brake Light Switch Timing ON after about 10 mm (0.39 in.) pedal travel – – –...
  • Page 294: Special Tools And Sealant

    Special Tools and Sealant Flywheel Puller, M30 × 1.5: Flywheel Holder: 57001-1191 57001-1313 Rotor Puller, M16/M18/M20/M22 × 1.5: Hand Tester: 57001-1216 57001-1394 Timing Light: Peak Voltage Adapter: 57001-1241 57001-1415 Spark Plug Wrench, Hex 16: Kawasaki Bond (Silicone Sealant): 57001-1262 56019-120...
  • Page 295: Wiring Diagram

    ELECTRICAL SYSTEM 15-13 Wiring Diagram Dummy Page...
  • Page 296 15-14 ELECTRICAL SYSTEM Wiring Diagram BN125-A1...
  • Page 297 ELECTRICAL SYSTEM 15-15 Wiring Diagram...
  • Page 298 15-16 ELECTRICAL SYSTEM Wiring Diagram BN125-A2 ∼ (Singapore) and BN125-A4 (United States)
  • Page 299 ELECTRICAL SYSTEM 15-17 Wiring Diagram...
  • Page 300 15-18 ELECTRICAL SYSTEM Wiring Diagram BN125-A2 ∼ A5 (Europe)
  • Page 301 ELECTRICAL SYSTEM 15-19 Wiring Diagram...
  • Page 302 15-20 ELECTRICAL SYSTEM Wiring Diagram BN125-A5 (United States and Canada)
  • Page 303 ELECTRICAL SYSTEM 15-21 Wiring Diagram...
  • Page 304 15-22 ELECTRICAL SYSTEM Wiring Diagram BN125-A6 ∼ (US, CA, N, NU)
  • Page 305 ELECTRICAL SYSTEM 15-23 Wiring Diagram...
  • Page 306: Precautions

    15-24 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○...
  • Page 307 ELECTRICAL SYSTEM 15-25 Precautions ○ Electrical Connectors Connectors [A] Connectors [B]...
  • Page 308: Electrical Wiring

    15-26 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor, replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, looseness and damage. If the connector is corroded or dirty, clean it carefully.
  • Page 309: Battery

    ELECTRICAL SYSTEM 15-27 Battery Battery Removal/Installation • Remove: Right Side Cover (see Frame chapter) Battery Holder • Disconnect the battery negative (–) cable [A] first, and then the positive (+) cable [B]. Front [C] • When installing the battery, connect the positive (+) cable [A] first and then the negative cable [B].
  • Page 310: Initial Charging

    15-28 ELECTRICAL SYSTEM Battery Initial Charging WARNING Keep the battery away from sparks and open flames during charging, since the battery gives off an ex- plosive gas mixture of hydrogen and oxygen. When using a battery charger, connect the battery to the charger before turning on the charger.
  • Page 311: Ordinary Charging

    ELECTRICAL SYSTEM 15-29 Battery Ordinary Charging • Remove the battery (see Battery Removal). • If any of the cells are low, fill them to the LOWER level line with distilled water only. The electrolyte will expand during charging, and the level will rise. WARNING Keep the battery away from sparks and open flames during charging, since the battery gives off an ex-...
  • Page 312 15-30 ELECTRICAL SYSTEM Battery Battery Charging Rate/Time Table (12 V 9 Ah)
  • Page 313: Charging System

    ELECTRICAL SYSTEM 15-31 Charging System Alternator Cover Removal • Drain the engine oil (see Engine Lubrication System chapter). • Remove: Engine Sprocket Cover (see Final Drive chapter) Alternator Lead Connector [A] • Remove: Alternator Cover Bolts [A] Alternator Cover [B] •...
  • Page 314: Alternator Rotor Installation

    15-32 ELECTRICAL SYSTEM Charging System • Using the flywheel puller [A] and rotor puller [B], remove the alternator rotor [C] from the crankshaft. Special Tools - Flywheel Puller, M30 × 1.5: 57001-1191 Rotor Puller, M16/M18/M20/M22 × 1.5: 57001 -1216 ○ Holding the flywheel puller, screw in the rotor puller while tapping the head of the rotor puller with a hammer and remove the alternator rotor.
  • Page 315: Stator Coil Installation

    Apply silicone sealant to the circumference of the alterna- tor lead grommet [C], and fit the grommet into the notch of the cover securely. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Alternator Inspection There are three types of alternator failures: short, open (wire burned out), or loss in rotor magnetism.
  • Page 316: Regulator/rectifier Inspection

    If the tester readings are not as specified, replace the regulator/rectifier. CAUTION Use only Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a mugger or a meter with a large-capacity battery is used, the regulator/rectifier will be damaged.
  • Page 317: Charging Voltage Inspection

    ELECTRICAL SYSTEM 15-35 Charging System Regulator/Rectifier Internal Resistance (BN125-A3 ∼) Unit: kΩ Tester (+) Lead Connection Terminal BK/Y – ∞ ∞ ∞ ∞ 0.5 ∼ 10 – ∞ ∞ ∞ 0.5 ∼ 10 (−)* ∞ – ∞ ∞ 0.5 ∼ 10 ∞...
  • Page 318 15-36 ELECTRICAL SYSTEM Charging System Charging System Circuit (BN125-A1/A2) 1. Ignition switch 2. Alternator 3. Regulator/rectifier 4. Controller 5. Battery 6. Main fuse 15 A 7. Starter relay 8. Light fuse 10 A 9. Load...
  • Page 319 ELECTRICAL SYSTEM 15-37 Charging System Charging System Circuit (BN125-A3 ∼) 1. Ignition switch 2. Alternator 3. Regulator/rectifier 4. Battery 5. Main fuse 30 A 6. Starter relay 7. Light fuse 15 A 8. Load...
  • Page 320: Ignition System

    15-38 ELECTRICAL SYSTEM Ignition System CDI Unit Connectors [A] CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent CDI unit damage. Do not install the battery back- wards.
  • Page 321: Ignition Timing Inspection

    ELECTRICAL SYSTEM 15-39 Ignition System • Set the hand tester [B] to the × 25 V DC range, and con- nect it to the peak voltage adapter [C] as shown in the diagram. • Connect the black lead of the adapter to W/Y lead and red lead to G/W lead in the crankshaft sensor connector [A].
  • Page 322: Ignition Coil Removal

    15-40 ELECTRICAL SYSTEM Ignition System Ignition Timing Engine speed Head timing mark [A] aligns with: 1 300 ±100 r/min (rpm) “T” mark [B] on camshaft sprocket If the ignition timing is incorrect, inspect the CDI unit and the crankshaft sensor. Ignition Coil Removal •...
  • Page 323: Ignition Coil Primary Peak Voltage

    ELECTRICAL SYSTEM 15-41 Ignition System If the coil tester is not available, the coil can be checked for a broken or badly shorted winding with the hand tester. NOTE ○ The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. •...
  • Page 324: Spark Plug Removal

    15-42 ELECTRICAL SYSTEM Ignition System • Turn the ignition switch and engine stop switch on. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission gear in neutral to measure the igni- tion coil primary peak voltage. •...
  • Page 325: Cdi Unit Inspection

    If the tester readings are not as specified, replace the CDI unit. CAUTION Use only Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or meter with a large-capacity battery is used, the CDI unit will be damaged.
  • Page 326 (–)*: Tester (–) Lead Connection CAUTION Use only Hand Tester 57001-1394 for this test. A tester other than the Kawasaki Hand Tester may show different readings. If a megger or meter with a large-capacity battery is used, the CDI unit will be damaged.
  • Page 327 ELECTRICAL SYSTEM 15-45 Ignition System Ignition System Troubleshooting...
  • Page 328 15-46 ELECTRICAL SYSTEM Ignition System Ignition System Circuit (BN125-A1/A2) 1. Neutral switch 2. Interlock diodes 3. Sidestand switch 4. Starter lockout switch 5. Engine stop switch 6. Ignition fuse 10 A 7. Ignition switch 8. Regulator/rectifier 9. Crankshaft sensor 10. CDI unit 11.
  • Page 329 ELECTRICAL SYSTEM 15-47 Ignition System Ignition System Circuit (BN125-A3 ∼) 1. Ignition switch 2. Starter lockout switch 3. Crankshaft sensor 4. Interlock diodes 5. Sidestand switch 6. Ignition fuse 15 A 7. Engine stop switch 8. Neutral switch 9. CDI unit 10.
  • Page 330: Electric Starter System

    15-48 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body. Tapping the shaft or body could damage the motor. • Remove: Oil Pipe (see Engine Lubrication System chapter) • Slide back the rubber cap. •...
  • Page 331: Starter Motor Assembly

    ELECTRICAL SYSTEM 15-49 Electric Starter System • Remove the terminal locknut [A] and terminal bolt [B], and then remove the brush with the brush plate from the yoke. Starter Motor Assembly • Replace the O-rings with new ones. • Apply a thin coat of grease to the oil seal [A] and needle bearing [B].
  • Page 332: Brush Inspection

    15-50 ELECTRICAL SYSTEM Electric Starter System Brush Inspection • Measure the length [A] of each brush. If any is worn down to the service limit, replace the carbon brush holder assembly [B]. Starter Motor Brush Length 9.5 ∼ 10.5 mm (0.37 ∼ 0.41 in.) Standard: Service Limit: 8 mm (0.31 in.)
  • Page 333: Brush Lead Inspection

    ELECTRICAL SYSTEM 15-51 Electric Starter System Brush Lead Inspection • Using the × 1 Ω hand tester range, measure the resis- tance as shown. Terminal Bolt and Positive Brush [A] Brush Plate and Negative Brush [B] Special Tool - Hand Tester: 57001-1394 If there is not close to 0 Ω, the brush has an open.
  • Page 334: Starter Circuit Relay Inspection

    15-52 ELECTRICAL SYSTEM Electric Starter System Starter Circuit Relay Inspection • Remove: Right Side Cover (see Frame chapter) Starter Circuit Relay • Connect the hand tester [A] and 12 V battery [B] as shown. Relay Coil Terminal [1] and [2] Relay Switch Terminal [3] and [4] If the relay [C] does not work as specified, the relay is defective.
  • Page 335 ELECTRICAL SYSTEM 15-53 Electric Starter System Electric Starter Circuit (BN125-A1/A2) 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Starter circuit relay 5. Ignition fuse 10 A 6. Starter lockout switch 7. Interlock diodes 8. CDI unit 9. Starter motor 10.
  • Page 336 15-54 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit (BN125-A3 ∼) 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Starter circuit relay 5. Ignition fuse 15 A 6. Starter lockout switch 7. Interlock Diodes 8. CDI unit 9.
  • Page 337: Lighting System

    ELECTRICAL SYSTEM 15-55 Lighting System Headlight Beam Horizontal/Vertical Adjustment • Turn the horizontal adjuster [A] on the headlight with a screwdriver in or out until the beam points straight ahead. ○ Turn the horizontal adjuster clockwise to face the head- light left.
  • Page 338: Ac Lighting Voltage Inspection

    15-56 ELECTRICAL SYSTEM Lighting System • Replace the headlight bulb [A]. CAUTION When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode.
  • Page 339 ELECTRICAL SYSTEM 15-57 Lighting System Headlight Circuit (BN125-A1/A2) 1. High beam indicator light 4. Alternator 2. Headlight 5. Regulator/rectifier 3. Dimmer switch 6. Headlight switch Headlight Circuit (BN125-A3 ∼ A5) 1. High beam indicator light 5. Alternator 2. Headlight 6. Regulator/rectifier 3.
  • Page 340: Tail/brake Light Bulb Replacement

    15-58 ELECTRICAL SYSTEM Lighting System Headlight Circuit (BN125-A6∼) 1. High beam indicator light 2. Headlight 3. Dimmer switch 4. Alternator 5. Regulator/rectifier 6. Ignition switch 7. Headlight fuse 15 A Tail/Brake Light Bulb Replacement • Remove the tail/brake light lens [A]. •...
  • Page 341: Turn Signal Relay Inspection

    ELECTRICAL SYSTEM 15-59 Lighting System • With the front pin [A] down, insert the new bulb by aligning the front pin with the groove [B] in the walls of the socket. • Push the bulb in, turn it clockwise, and replace it. It should lock in position.
  • Page 342 15-60 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit (BN125-A1/A2) 1. Turn signal indicator light 2. Turn signal relay 3. Ignition fuse 10 A 4. Front right turn signal light 5. Front left turn signal light 6. Rear right turn signal light 7.
  • Page 343 ELECTRICAL SYSTEM 15-61 Lighting System Turn Signal Light Circuit (BN125-A3 ∼ A5) 1. Turn signal indicator light 2. Turn signal relay 3. Ignition fuse 15 A 4. Front right turn signal light 5. Front left turn signal light 6. Rear right turn signal light 7.
  • Page 344 15-62 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit (BN125-A6∼) 1. Turn signal indicator light 2. Turn signal relay 3. Ignition fuse 15 A 4. Front right turn signal light 5. Front left turn signal light 6. Rear right turn signal light 7.
  • Page 345: Meter, Gauge, Indicator Unit

    ELECTRICAL SYSTEM 15-63 Meter, Gauge, Indicator Unit Speedometer Removal • Remove the speedometer cable upper end [A]. • Remove the meter unit [C] by taking off the mounting bolts [B]. CAUTION Place the meter so that the face is up. If a meter is left upside down or sideways for any length of time, it will malfunction.
  • Page 346: Switches And Sensors

    15-64 ELECTRICAL SYSTEM Switches and Sensors Front Brake Light Switch Inspection • Refer to the Front Brake Light Switch Inspection in the Periodic Maintenance chapter. Rear Brake Light Timing Inspection • Refer to the Rear Brake Light Timing Inspection in the Periodic Maintenance chapter.
  • Page 347: Fuse

    ELECTRICAL SYSTEM 15-65 Fuse Main Fuse 15 A Removal • Remove the right side cover (see Frame chapter). • Disconnect the starter relay connector. • Pull out the main fuse [B] from the starter relay [A] with needle nose pliers. Main Fuse 15 A Inspection •...
  • Page 348: Fuse 10 A Inspection

    15-66 ELECTRICAL SYSTEM Fuse Fuse 10 A Inspection • Inspect the fuse element. If it is blown out, replace the fuse. Fuse Element [A] Blown Element [B]...
  • Page 349 APPENDIX 16-1 Appendix Table of Contents Cable, Wire, and Hose Routing ....................16-2 Troubleshooting Guide ......................16-32...
  • Page 350 16-2 APPENDIX Cable, Wire, and Hose Routing BN125-A1 ∼...
  • Page 351 APPENDIX 16-3 Cable, Wire, and Hose Routing 1. Crankshaft Sensor 2. Oil Pipe 3. Clamp 4. Run the alternator lead under the oil pipe. 5. Alternator Lead 6. Run the neutral switch lead so that it shall not out of guide rib. 7.
  • Page 352 16-4 APPENDIX Cable, Wire, and Hose Routing BN125-A1 ∼...
  • Page 353 APPENDIX 16-5 Cable, Wire, and Hose Routing 1. CDI Unit 2. Ignition Coil Lead 3. Engine Breather Hose 4. To Fuel Tap 5. Insulator 6. Run the ignition coil lead under the engine breather hose. 7. Clamp 8. Install the hose as shown. 9.
  • Page 354 16-6 APPENDIX Cable, Wire, and Hose Routing Clean Air System...
  • Page 355 APPENDIX 16-7 Cable, Wire, and Hose Routing 1. Vacuum Hose 2. Three-way Joint 3. To Fuel Tap 4. Air Hose 5. Air Pipe 6. Engine Breather Hose 7. Air Cleaner Duct 8. Air Cleaner Housing 9. Vacuum Switch 10. Carburetor 11.
  • Page 356 16-8 APPENDIX Cable, Wire, and Hose Routing BN125-A1 ∼ A4...
  • Page 357 APPENDIX 16-9 Cable, Wire, and Hose Routing 1. Ignition Switch 2. Run the ignition switch lead to the right. 3. Sidestand Switch Lead 4. Run the sidestand switch lead to the right. 5. Body Ground 6. Ignition Coil 7. Alternator Lead Connector 8.
  • Page 358 16-10 APPENDIX Cable, Wire, and Hose Routing BN125-A5 ∼...
  • Page 359 APPENDIX 16-11 Cable, Wire, and Hose Routing 1. Indicator Light Connector (Move it to the right side after connected.) 2. Horn 3. Sidestand switch connector 4. Ignition coil 5. Regulator/Rectifier 6. Ground Lead 7. Alternator Lead 8. Put the connectors into the gusset after connecting them. 9.
  • Page 360 16-12 APPENDIX Cable, Wire, and Hose Routing BN125-A1 ∼...
  • Page 361 APPENDIX 16-13 Cable, Wire, and Hose Routing 1. Rear Left Turn Signal Light 2. Tail/Brake Light 3. Rear Right Turn Signal Light 4. Rear Fender Rear 5. Rear Fender Front 6. Throttle Cables 7. Carburetor Air Vent Hose 8. Engine Breather Hose 9.
  • Page 362 16-14 APPENDIX Cable, Wire, and Hose Routing BN125-A1 ∼...
  • Page 363 APPENDIX 16-15 Cable, Wire, and Hose Routing 1. Throttle Cables 2. Clutch Cable 3. Speedometer Cable 4. Left Handlebar Switch Harness 5. Right Handlebar Switch Harness 6. Sidestand Switch 7. Holder 8. Band 9. Clamp 10. BN125-A3 ∼...
  • Page 364 16-16 APPENDIX Cable, Wire, and Hose Routing BN125-A1 ∼ A2...
  • Page 365 APPENDIX 16-17 Cable, Wire, and Hose Routing 1. Tail/Brake Light Connector 2. Rear Left Turn Signal Light Connector 3. White Tape 4. Ignition Coil Connector 5. Body Ground 6. Front Left Turn Signal Light Connector 7. Front Right Turn Signal Light Connector 8.
  • Page 366 16-18 APPENDIX Cable, Wire, and Hose Routing BN125-A3 ∼ A4...
  • Page 367 APPENDIX 16-19 Cable, Wire, and Hose Routing 1. Rear Left Turn Signal Light Connector 2. Tail/Brake Light Connector 3. Band 4. Ground Lead 5. Ignition Coil Lead 6. Regulator/Rectifier Connector 7. CDI Unit Connector 8. Left Handlebar Switch Connector 9. Horn Connector 10.
  • Page 368 16-20 APPENDIX Cable, Wire, and Hose Routing BN125-A5 ∼...
  • Page 369 APPENDIX 16-21 Cable, Wire, and Hose Routing 1. Rear Left Turn Signal Light Connector 2. Tail/Brake Light Connector 3. Band 4. White Tape 5. Ground Lead 6. Regulator/Rectifier Connector 7. Ignition Coil Lead 8. Left Handlebar Switch Connector 9. Horn Connector 10.
  • Page 370 16-22 APPENDIX Cable, Wire, and Hose Routing BN125-A5 ∼...
  • Page 371 APPENDIX 16-23 Cable, Wire, and Hose Routing 1. Diode Connector 2. Fuse Box Connector 3. Battery Positive Lead 4. Clamp 5. Turn Signal Relay 6. Alternator Connector 7. Battery Negative Lead 8. Band 9. CDI Unit Connector 10. Ignition Coil Lead 11.
  • Page 372 16-24 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Control System (BN125-A5 ∼ : California Model)
  • Page 373 APPENDIX 16-25 Cable, Wire, and Hose Routing 1. Fuel Tank 2. Separator 3. Canister 4. Vacuum Switch Valve 5. Air Cleaner Housing 6. Label (Blue) 7. Label (Red) 8. Hose (with blue stripe) 9. Hose (with blue stripe) 10. Hose (with red stripe) 11.
  • Page 374 16-26 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Control System (BN125-A5 ∼ : California Model)
  • Page 375 APPENDIX 16-27 Cable, Wire, and Hose Routing 1. Vacuum Switch Valve 2. Go to the fuel tap 3. Carburetor Holder 4. Separator...
  • Page 376 16-28 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Control System (BN125-A5 ∼ : California Model)
  • Page 377 APPENDIX 16-29 Cable, Wire, and Hose Routing 1. Run the ignition coil primary lead under the throttle cables, secondary air hose and breather hose. 2. Go To Left Side 3. Separator 4. Go To The Fuel Tank 5. Breather Hose 6.
  • Page 378 16-30 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Control System (BN125-A5 ∼ : California Model)
  • Page 379 APPENDIX 16-31 Cable, Wire, and Hose Routing 1. Main Harness 2. Breather Hose 3. Secondary Air Hose 4. Air Vent Hose 5. Go to the fuel tank 6. Separator 7. Go to the canister 8. Clamp 9. Front...
  • Page 380: Troubleshooting Guide

    16-32 APPENDIX Troubleshooting Guide NOTE Spark plug cap or high tension wiring trou- ○ This is not an exhaustive list, giving every possible cause for each problem listed. It Spark plug cap shorted or not in good con- is meant simply as a rough guide to assist tact the troubleshooting for some of the more Spark plug incorrect...
  • Page 381 APPENDIX 16-33 Troubleshooting Guide Fuel level in carburetor float bowl too high Fuel level in carburetor float bowl too high or too low or too low Fuel tank air vent obstructed Needle jet bleed holes or needle jet clogged Carburetor holder loose Air cleaner clogged, poorly sealed, or miss- Air cleaner duct loose Fuel tap clogged...
  • Page 382: Abnormal Engine Noise

    16-34 APPENDIX Troubleshooting Guide Fuel/air mixture incorrect: Jumps out of gear: Main jet clogged or wrong size Shift fork ear worn, bent Fuel level in carburetor float bowl too low Gear groove worn Carburetor holder loose Gear dogs and/or dog holes worn Air cleaner duct loose Shift drum groove worn Air cleaner poorly sealed, or missing...
  • Page 383: Abnormal Drive Train Noise

    APPENDIX 16-35 Troubleshooting Guide Abnormal Drive Train Noise: Fuel level in carburetor float bowl too low Clutch noise: Air cleaner duct loose Clutch rubber damper weak or damaged Air cleaner O-ring damaged Clutch housing finger/friction plate tang Air cleaner poorly sealed or missing clearance excessive Handling and/or Stability Clutch housing gear worn...
  • Page 384: Battery Trouble

    16-36 APPENDIX Troubleshooting Guide Battery Trouble: Disc warped Contaminated pad Battery discharged: Brake fluid deteriorated Battery faulty (e.g., plates sulphated, Primary or secondary cup damaged in mas- shorted through sedimentation, elec- ter cylinder trolyte insufficient) Brake master cylinder scratched inside Battery leads making poor contact Drum brake: Load excessive (e.g., bulb of excessive...
  • Page 385 MODEL APPLICATION Year Model Beginning Frame No. BN125A000001 or 1998 BN125-A1 JKABN125AAA000001 BN125A016001 or 1999 BN125-A2 JKABN125AAA016001 2000 BN125-A3 JKABN125AADA00001 □ 2001 BN125-A4 JKABNRA1 1DA00574 □ JKABNRA1 2DA04626 or 2002 BN125-A5 JKABN125AADA04626 □ JKABNRA1 3DA08070 or 2003 BN125-A6 JKABN125AADA08170 □ JKABNRA1 4DA09073 or 2004...

Comments to this Manuals

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  • Dave Smith Sep 09, 2016 07:08:
    Son just bought one always nigglly bits to sort out
  • John king Mar 02, 2016 08:59:
    I need a manual for repair and services but I need to know if the ignition switch had to be replaced and u brought one but it only heads three wires coming from it but the old one has 6 wires what do I wire to what to the new ignition switch