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Kawasaki Boss 175 (Eliminator 125) service manual (eng

1. http mototh com 16 10 APPENDIX Cable Wire and Hose Routing BN125 A5 Cable Wire Hose Routing 4 la oO Indicator Light Connector Move it to the right side after connected Horn Sidestand switch connector Ignition coil Regulator Rectifier Ground Lead Alternator Lead Put the connectors into the gusset after connecting them Sidestand Switch Band Left Handlebar Switch Connector Connect it in the fuel tank cover Right Handlebar Switch Connector California Model Europe Model http mototh com APPENDIX 16 11 16 12 APPENDIX Cable Wire Hose Routing BN125 A1 6 lt M 32 4 8 Vor N SANT a Wo EIS olt 2 Of JA jd Sas rie as A D T m jm ALI iz EN WA r j DN 2 6B09437BW5 http mototh com Cable Wire Hose Routing ol ll l Rear Left Turn Signal Light Tail Brake Light Rear Right Turn Signal Light Rear Fender Rear Rear Fender Front Throttle Cables Carburetor Air Vent Hose Engine Breather Hose Right Handlebar Switch Brake Hose Clutch Cable Rear Brake Light Switch Battery Vent Hose
2. 6 9 Oil Pump MVS TAU OI 6 9 Oil Pump Disassembly 5 UR 6 9 PUTS aden ty 6 10 Oil PUMP INSPECTOR 6 10 6 11 Oil Pressure Measurement pp 6 11 Relief i m Em 6 12 Relief Valve Inspection 6 12 Oil Pipe 6 13 Oil Pipe Removal 6 13 Pipe Installation 6 13 http mototh com 6 2 ENGINE LUBRICATION SYSTEM Exploded View Q 6602046 5 C http mototh com ENGINE LUBRICATION SYSTEM 6 3 Exploded View Torque No Fastener Nm kgf m ilb Remarks 1 Engine Oil Drain Plug 18 1 8 13 2 Oil Screen Cover Bolts BN125 A1 A3 9 8 1 0 87 in lb Oil Screen Cover Bolts BN125 A4 8 8 0 90 78 3 Oil Pressure Relief Valve 15 1 5 11 L 4 Oil Filter Cover Bolts BN125 A1 A3 9 8 1 0 87 in lb Oil Filter Cover Bolts BN125 A4 8 8 0 90 78 in lb 5 Oil Pump Mounting Screws 4 9 0 50 43 in lb 6 Oil Pump Assembly Screw 9 8 1 0 87 in lb 7 Oil Pipe Banjo Bolt Clutch Cover 25 2 6 19 5 8 Oil Pipe Banjo Bolt Left Crankcase 9 8 1 0 87 in lb S 9 Oil Pipe Banjo Bolt Cylinder Head 9 8 1 0 87 5 10 Pipe Mounting Bolts BN125 A1 9 8 1 0 87 in lb Oil Pipe Mounting
3. OI http mototh com 3 4 FUEL SYSTEM Exploded View Except the California Model 6C022658W5 C http mototh com FUEL SYSTEM 3 5 Exploded View Tor No Fastener 198 Remarks N m kgf m ft Ib 1 Fuel Tap Plate Screws 0 8 0 080 7 in lb 2 Fuel Tap Diaphragm Cover Screws 1 0 0 10 9 in lb 2 5 0 25 22 in lb with White Washer 3 Fuel Tap Mounting Bolts 4 9 0 50 43 in lb with Black Washer 4 Catch tank 5 Vacuum switch valve For the AT DE of BN125 A1 A2 and All Models of BN125 A3 6 For the AT CH DE of BN125 A1 and Except the EUR of BN125 A7 7 On and after EUR of BN125 A7 8 Air cleaner element OR Apply high quality foam air filter oil AT Austria CH Switzerland DE Germany EUR Europe http mototh com 3 6 FUEL SYSTEM Exploded View California Model 6002266BW5 C http mototh com FUEL SYSTEM 3 7 Exploded View Torque Fastener Remarks N m kgf m ft Ib 1 Fuel Tap Plate Screws 0 8 0 080 7 in lb 2 Fuel Tap Diaphragm Cover Screws 1 0 0 10 9 in llb 2 5 0 25 22 inb with White Washer Fuel Tap M ing Bol rae rap edits 49 0 50 43inlb with Black Washer Catch tank Vacuum switch valve Canister Separator BN125 A5 only On and after BN125 A7 Air cleaner element Apply high quality foam air filter oil O http mototh com 3
4. Hi gt P 2 SA Lite a m 255 rm lala S H 6809452BN5 http mototh com APPENDIX 16 31 Cable Wire Hose Routing Main Harness Breather Hose Secondary Air Hose Air Vent Hose Go to the fuel tank Separator Go to the canister Clamp Front http mototh com 16 32 APPENDIX Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Starter motor not rotating Starter lockout switch or neutral switch trou ble Starter motor trouble Battery voltage low Starter relay not contacting or operating Starter button not contacting Wiring open or shorted Ignition switch trouble Engine stop switch trouble Fuse blown Starter motor rotating but engine doesn t turn over Starter motor clutch trouble Torque limiter trouble Engine won t turn over Valve seizure Rocker arm seizure Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Camshaft seizure Torque limiter seizure Balancer bearing seizure No fuel flow No fuel in tank Fuel tank air vent obstructed Fuel tap v
5. Kawasaki ELIMINATOR 125 Motorcycle Service Manual http mototh com 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 Brakes Suspension Electrical System h NO B Oo RO Appendix This quick reference guide will assist you in locating a desired topic or pro cedure the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required http mototh com http mototh com Kawasaki ELIMINATOR 125 Motorcycle Service Manual 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 amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any
6. kgf cm 21 psi Rear BN125 A1 A2 Up to 185 kg 408 Ib load 175 kPa SAS 1 75 kgf cm 25 psi 125 Up to 155 kg 342 Ib load 175 kPa 1 75 kgf cm 25 psi Tread Depth Front BN125 A1 A2 4 5 mm 0 18 in BN125 A3 A5 4 0 mm 0 157 in 1 mm 0 04 in BN125 A6 4 1 mm 0 161 in Rear 7 3 mm 0 29 in 2 mm 0 08 in Standard Tires Make Type Size Front 90 90 17 49P 90 90 17 49P 90 90 17 M C 49P 130 90 15 M C 66P IRC NR67 Tube type 130 90 15 M C 66P Size 3 00 17 50P METZELER PERFECT MET77 tube type 130 90 15 665 A WARNING Use the same manufacture s tires on both front and rear wheels http mototh com WHEELS TIRES 9 5 Special Tools Rim Protector Jack 57001 1063 57001 1238 7571063ST C E 7571238ST C Bead Breaker Assembly Bearing Remover Shaft 9 57001 1072 57001 1265 75710728T C 875712655 C Bearing Driver Set Bearing Remover Head 15 x 17 57001 1129 57001 1267 7571129ST C 875712675 C http mototh com 9 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Remove the cotter pin and axle nut A e Remove the speedometer cable lower end B e Raise the front wheel B off the ground using the jack A Special Tool Jack 57001 1238 e Pull out the axle and drop the front wheel A out of the forks e Insert a wooden plate between the pads in the caliper t
7. Clean the cylinder head in a bath of high flash point sol vent e Using compressed air blow out A any particles which may obstruct the oil passage in the cylinder head e Install the valves see Valve Installation http mototh com CANC X ZZ 1972011 e D AN ZA JC 8 14010451 Cylinder Head ENGINE TOP END 4 25 Cylinder Head Warp e Clean the cylinder head see Cylinder Head Cleaning e Lay astraightedge across the lower surface of the cylinder head at the positions as shown e Use a thickness gauge A to measure the space between the straightedge B and the cylinder head Cylinder Head Warp Standard Service Limit 0 05 mm 0 002 If the cylinder head is warped more than the service limit replace it x If the cylinder head is warped less than the service limit repair the head by rubbing the lower surface on emery paper secured to a surface plate first No 200 then No 400 http mototh com 8 14010351 C 4 26 ENGINE END Valves Valve Clearance Inspection e Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter Valve Clearance Adjustment e Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter Valve Removal e Remove the cylinder head see Cylinder Head Removal Remove the rocker shafts and rocker arms see Camshaft Removal OMark and record the rocker shaf
8. Wiring Diagram ELECTRICAL SYSTEM 15 19 Rear Brake Light Switch Spark Plug Ignition Fuses 1 Lights 2 lgnition 15 15 Interlock Diode Starter Circuit Turn Signal Relay BL R _K BL Tail Brake Light 12 5 214 BK Y L Kb 8K Y LKE Rear Right Turn Signal Light 12V 21 cy Pie BK Y 071 8 Left Turn Light Rear Signal 12V 214 Regulator Crankshaft Sensor Alternator 2 Neutral Switch IGNITION SWITCH CONNECTIONS Wain Fuse 30 Battery 12V 9AH Color Code B Starter Motor Brown Chocolate L L Y amp aray Le right Green RIGHT HANDLEBAR SWITCH CONNECTIONS Front Brake Light Switch Engine Stop Switch Starter Button Headlight Switoh Color BK Color R lgnition Battery lgnition T ai 1 Ta i 12 Ta i 13 BR Li BL R R W p Brake Lever Released a Pink Purple f Po ommo w white ON a O Y Yellow 98051 17840 WIRI784CWS C http mototh com 15 20 ELECTRICAL SYSTEM Wiring Diagram BN125 A5 United States and Canada remiron frenimi on lgnition Switch Meter Light 12V 1 7W Speedometer BR ay Right Handlebar Switches 1 Front Brake Light Switch 2 Engine Stop Switch R
9. A 6809923885 C http mototh com Cable Wire Hose Routing looo n nc Rear Left Turn Signal Light Connector Tail Brake Light Connector Band Ground Lead Ignition Coil Lead Regulator Rectifier Connector CDI Unit Connector Left Handlebar Switch Connector Horn Connector Indicator Light Connector Sidestand Switch Connector Headlight Connector Front Right Turn Signal Light Connector Front Left Turn Signal Light Connector Rear Right Turn Signal Light Connector Diode Connector Starter Circuit Relay Connector Starter Relay Connector Fuse Box Connector Alternator Connector Ignition Switch Connector California Model Battery Negative Lead Turn Signal Relay Connector Right Handlebar Switch Connector Ignition Switch Connector Other Than California Model Rear Brake Switch Connector Battery Positive Lead Run the throttle sensor lead to left side Turn signal relay Run the indicator light lead from left side Starter Lead Speedometer Connector City Light Connector Europe Model Clamp Put them into the gusset after connected Connect them in the headlight housing http mototh com APPENDIX 16 19 Cable Wire Hose Routing 16 20 APP
10. http mototh com ELECTRICAL SYSTEM 15 3 Parts Location Speedometer Starter lockout switch Ignition coil Starter motor Ignition switch Crankshaft sensor Alternator Neutral switch Sidestand switch Regulator rectifier Fuse unit Starter circuit relay Starter relay Turn signal relay Battery CDI unit Front brake light switch Rear brake light switch http mototh com 15 4 ELECTRICAL SYSTEM Exploded View GP022428W5 C http mototh com ELECTRICAL SYSTEM 15 5 Exploded View Torque No Fastener q Remarks kgf m ft Ib Starter Motor Mounting Bolts 78 in lb Starter Motor Terminal Locknut 61 in lb Starter Motor Assembly Bolts 0 Stator Coil Bolts 4 113 in Ib Alternator Lead Holder Bolts 125 1 2 113 in Ib Alternator Lead Holder Bolts 125 i 78 in lb Alternator Rotor Nut BN125 A1 A2 51 Alternator Rotor Nut BN125 A3 72 Alternator Rotor Nut BN125 A4 76 Crankshaft Sensor Screws 3 9 35 in lb Ignition Coil Bolt 6 9 61 in lb Spark Plug 13 113 in lb Starter Relay Terminal Bolt 43 in lb 1 4 9 12 Starter Motor Terminal Nut 4 9 0 50 43in lb 13 Alternator Cover Damper Bolts 8 0 90 78 in lb L 4 3 8 14 Starter Motor Clutch Bolts BN125 A1 4 3 5 25 L 15 Starter Motor Clutch Bolts BN125 A2 12 1 2 104 in lb L 16 4 9 Igniter Mounting Screws 0
11. Hose Routing 16 6 APPENDIX Clean Air System 4 i eS ff View C C NE SA Ces ud IL asm O TO YEA C Ea xen 26 EAP zu gt YZ c ea cma e View B B PA v S lt lt Se 6809441BN5 http mototh com View A A Cable Wire Hose Routing 14 Vacuum Three way Joint To Fuel Air Hose Air Pipe Engine Breather Hose Air Cleaner Duct Air Cleaner Housing Vacuum Switch Carburetor Air Suction Valve Insulator Run the vacuum hose onto the left side of the duct 7 and then behind the hose 6 and car buretor 10 The mark faces upward 15 16 17 Note Positioning Mark Arrow Mark faces toward the vacuum hose Clamp APPENDIX 16 7 The position mark 15 arrow mark 16 and vacuum hose 1 shall be in line as shown http mototh com 16 8 APPENDIX Cable Wire and Hose Routing 125 1 4 6809436 5 C APPENDIX 16 9 Cable Wire Hose Routing Ignition Switch Run the ignition switch lead to the right Sidestand Switch Lead Run the sidestand switch lead to the right Body Ground lgnition Coil Alternator Lead Connector Sidestand Switch Clamp Band
12. LE ZR AG SE No SE X e NS SUE y http mototh com CRANKSHAFT TRANSMISSION 8 3 Exploded View Torque No Fastener Remarks N m kgf m ft Ib 1 Primary Gear Nut 69 7 0 51 2 Balancer Shaft Gear 78 8 0 58 EO 3 Crankcase Bolts 8 8 0 90 78 in lb 4 Crankcase Bearing Retainer Screws 4 9 0 50 43 in lb 5 Balancer Shaft 6 Balancer shaft gear 7 Crank balancer gear 8 Crankshaft EO Apply engine oil G Apply grease LG Apply liquid gasket WL Apply soap and water solution http mototh com 8 4 CRANKSHAFT TRANSMISSION Exploded View http mototh com CRANKSHAFT TRANSMISSION 8 5 Exploded View No Fastener Terduo Remarks kgf m ft lb 1 Neutral Switch 15 1 5 11 2 Shift Drum Cam Screw 4 9 0 50 43 in lb L 3 Gear Set Lever Nut 11 1 1 95 4 Sprocket Holder Bolts 12 1 2 104 in Ib 5 Shift Shaft Return Spring Pin 29 3 0 21 L 6 Shift Lever Clamp Bolt 12 1 2 104 in Ib 7 Shift Pedal Nut 30 3 1 22 EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide grease R Replacement Parts http mototh com 8 6 CRANKSHAFT TRANSMISSION Specifications Standard Service Limit Crankshaft Connecting Rod Connecting Rod Big End Side 0 20 0 35 mm 0 008 0 014 0 5 mm 0 020 in Clearan
13. Special Tool Jack 57001 1238 http mototh com HJ07007BS1 C HJ07008BS1 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 e Remove the drive chain A from the rear sprocket then remove the rear wheel B to the rear Rear Wheel Installation Apply high temperature grease seal lips and the inner circumference of the sprocket coupling see Final Drive chapter e Install the collar A on the both side of the hub e Engage the drive chain with the rear sprocket and install the rear wheel e Check the drive chain slack see Periodic Maintenance chapter e Tighten Torque Rear Axle Nut 98 N m 10 0 kgf m 72 ft Ib e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole HJ07007BS1 http mototh com WHEELS TIRES 9 9 Wheels Rims Bend the cotter pin A over the nut e Adjust the brake pedal free play see Brakes chapter e Check the rear brake effectiveness A WARNING If a full brake pedal is not obtained disassemble and inspect the br
14. o RED http mototh com SUSPENSION 12 3 Exploded View Torque No Fastener Remarks N m kgf m ft Ib Front Fork Top Plugs 23 2 3 17 Nh Front Fork Bottom Allen Bolts 20 2 0 15 Front Fork Clamp Bolt Upper 20 2 0 15 Front Fork Clamp Bolt Lower 34 3 5 25 Fork cover 125 1 5 Brake hose clamp BN125 A1 only Other than the US and CA Models Speedmeter cable guide and Brake hose guide US and CA Models Apply fork oil Apply a non permanent locking agent Apply molybdenum disulfide grease Replacement Parts CA Canada US United States lt http mototh com 12 4 SUSPENSION Exploded View GMO2092BW5 C http mototh com SUSPENSION 12 5 Exploded View Torque No Fastener 4 Remarks N m kgf m ft Ib Rear Shock Absorber Nuts and Bolts 34 3 5 25 Swingarm Pivot Nut 98 10 0 72 1 2 3 Chain guard 125 1 2 only 4 Face the manufacture s marks out http mototh com 12 6 SUSPENSION Specifications Item Standard Front Fork Per One Unit Fork Inner Tube Diameter Fork Spring Setting Air Pressure Damper Setting Fork Oil Viscosity Fork Oil Capacity Fork Oil Level Fork Spring Free Length Rear Shock Absorbers Spring Preload Gas Pressure 33 mm 1 30 Non adjustable Atmospheric p
15. 98 98 190 100 106 160 198 132 24 9 5 4 5 4 0 96 09 2 3 12 7 28 0 18 5 oo oo oo oo oo oo oo oo oo 24 5 10 6 5 7 5 5 3 6 05 217 og 09 2 40 26 30 09 2 5 26 5 18 5 5 5 12 7 5 20 106 5 20 74 22 4g 5 20111 44 8 M 500 500 500 750 500 500 _ 500 500 2 000 2 000 2 000 3000 2 000 2 000 2 000 2 000 24 9 5 3 5 9 0 96 0 ag 05 2 71 7 28 5 20 10 20 70 20 55 20 20 45 195 _ 96 280 92 220 96 130 180 92 Tester Lead Connection http mototh com ELECTRICAL SYSTEM 15 45 Ignition System Ignition System Troubleshooting Faulty Ignition Malfunctioned engine No Good Ignition System Wiring and Connector Inspection Repair or Replace Good No Good Crankshaft Sensor Inspection Replace Good Replace Faulty Crankshaft Sensor Peak Voltage Measurement Inspect 1 Peak Voltage Adapter Good 2 Crankshaft Sensor Connector v 3 Battery Voltage Ignition Coil Inspection Replace No Good Good Y Inspect No Good 1 Peak Voltage Adapter No Good Ignition Coil Peak Voltage Measurement __ 2 Ignition Coil Connector Good 3 Battery Voltage Good y Good Spark Plug Gap Inspection Adjust or Replace Good CDI Unit Inspection Replace CDI Unit Inspect 1 Battery Voltage HO RO 2 Ignition Switch hk CDI Unit
16. 9 8 1 0 87 in lb Engine Sprocket Cover Bolts BN125 A4 8 8 0 90 78 in lb 2 Engine Sprocket Cover Damper Bolts 8 8 0 90 78 in lb L 3 Torque Link Bolt and Nut 34 3 5 25 4 Rear Sprocket Nuts 26 2 7 19 5 Rear Axle Nuts 98 10 0 72 6 Sprocket Bolts 12 1 2 102 in lb 7 Face the punch mark outward 8 For DE of BN125 A1 A2 and On and after BN125 A3 of EUR Models 9 BN125 A1 A2 Models only CO Apply chain oil L Apply a non permanent locking agent R Replacement Parts DE Germany EUR Europe http mototh com 10 4 FINAL DRIVE Specifications 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 NU Chain Slack 25 40 mm 0 98 1 57 20 link Length 254 0 254 6 mm 10 00 10 02 in 259 mm 10 2 in Sprockets Rear Sprocket Warp TIR 0 4 mm 0 016 in or less TIR 0 5 mm 0 020 in N No Catalytic Converter Model NU No Catalytic Converter United Kingdom Model http mototh com FINAL DRIVE 10 5 Special Tools Bearing Driver Set Jack 57001 1129 57001 1238 7571129ST C d 7571238ST C http mototh com 10 6 FINAL DRIVE Drive Chain Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Chain Slack Adjustmen
17. Clamp Holder Band Run the throttle cables inside the right handlebar switch Run the left right rear turn signal light tail brake light leads between the stay and the rear fender http mototh com APPENDIX 16 13 16 14 APPENDIX Cable Wire Hose Routing 125 1 S 6809679885 C http mototh com APPENDIX 16 15 Cable Wire Hose Routing Throttle Cables Clutch Cable Speedometer Cable Left Handlebar Switch Harness Right Handlebar Switch Harness Sidestand Switch Holder Band Clamp BN125 A3 http mototh com 16 16 APPENDIX Cable Wire Hose Routing BN125 A1 2 i 63 o 5 CH A ond 22 ana 222224 j Die ao c yl T 2 c c SS NS aa S EF 64 67 qus vv EN WS Ta ys ae pen ds rd oS oe ee ES 6809439885 C http mototh com Cable Wire Hose Routing TIO lO TO amp 2a a a a Tail Brake Light Connector Rear Left Turn Signal Light Connector White Tape Ignition Coil Connector Body Ground Front Left Turn Signal Light Connector
18. Inlet 0 03 0 13 mm 0 001 0 005 in Service Limit Exhaust 0 38 mm 0 015 in Inlet 0 33 mm 0 013 in http mototh com GE15010781 4 28 ENGINE END Valves Valve Seat Inspection e Remove the valve see Valve Removal e Check the valve seating surface A between the valve B and valve seat C OMeasure the outside diameter D of the seating pattern on the valve seat the outside diameter is too large or too small repair the seat see Valve Seat Repair Valve Seating Surface Outside Diameter Standard Exhaust 25 5 25 7 mm 1 00 1 01 in Inlet 29 5 29 7 mm 1 16 1 17 in OMeasure the seat width E of the portion where there is no build up carbon white portion of the valve seat with a vernier caliper Good F Too Wide G Too Narrow H Uneven J x If the width is too wide too narrow or uneven repair the seat see Valve Seat Repair 8 15011752 C Valve Seating Surface Width Standard Exhaust Inlet 0 8 1 2 mm 0 03 0 05 Valve Seat Repair e Repair the valve seat with the valve seat cutters A Special Tools Valve Seat Cutter Holder 04 5 57001 1330 B Valve Seat Cutter Holder Bar 57001 1128 C For Exhaust Valve Seat Valve Seat Cutter 45 527 5 57001 1114 or 030 57001 1187 Valve Seat Cutter 327 530 57001 1120 Valve Seat Cutter 607 530 57001 1123 OValve Seat Cutter 45 30 57001 118
19. http mototh com PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart ODOMETER Whichever READING comes first x 1 000 km x 1 000 mile FREQUENCY v OPERATION Every Spark plug clean and gap 1 General lubrication perform Nuts bolts and fasteners tightness inspect e e e e Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping For higher odometer readings repeat at the frequency interval established here T Replace add adjust clean or torque if necessary AT Austria CAL California CH Switzerland DE Germany SG Singapore US United States http mototh com 2 4 PERIODIC 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 O Apply an oil to the threads and seating surface S Tighten the fasteners following the specified sequence Fastener Torque Remarks kgf m ft Ib Fuel System Upper Chamber Cover Screws 3 5 0 36 31 in lb Spring Seat Screws 0 8 0 080 7 Choke Lever Set Screw 0 8 0 080 7 in lb L Choke Lever Pivot Screw 2 0 0 20 17 in lb Pilot Air Jet 1 8 0 18 15 in lb Coasting Enricher
20. replace both pads in the caliper as a set Brake pad C Brake Pad Thickness Standard BN125 A1 A2 4 5 mm 0 177 in BN125 A3 6 0 mm 0 236 in Service Limit 1 mm 0 04 in e Install the pads and pad bolts see Brakes chapter Brake Hose and Connection Inspection e Inspect the brake hose and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it Replace the hose if any cracks B or bulges C are no ticed lighten any loose fittings http mototh com GL12002BS1 C 6110020151 o 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection e Check that the brake fluid level in the brake reservoir A is between the upper B and the lower C level line NOTE OHold the reservoir horizontal by turning the handlebar when checking brake fluid level x lf the fluid level is lower than the lower level line fill the reservoir to the upper level line in the reservoir A WARNING Do not mix two brands of fluid Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified After changing the fluid use only the same type and brand of fluid thereaft
21. ta a R BL R W BKZY BK Y High Beam Indicator BK Y BK Y Light 12V 3 4W C u R BK Neutral tad dut ae re Light 12V 3 44 La Le Turn Signal Indicator ay eY Light 12V 3 AW E gt gt 25 a Headlight ue 12V 60 554 RY 5 pa City Light 8 4 12V 4 BK Y PC BK Y T 1 1 1 1 1 1 IL RI 1 i OFF Lo Hi OFF OW PUSH FREE Li zu Ip Front Right Turn pla cy 9 Side rune Signal Light 5k Y 12V 214 Horn 12V 3 0 Left Handlebar Switches 1 Horn Button 2 Turn Signal Switch 3 Dimmer Switch Front Left Turn pid 4 Starter Lockout Switch Signal Light gt 12V 214 LEFT HANDLEBAR SWITCH CONNECTIONS rn Signal Switch Starter Lockout Switch lor Color BK Y G BK Horn Button Color BK R BK Y C o 8 8 Push Q o R Retease peru L GY Dimmer Switch Color R Y BL Y R Lo o Clutch Leve of J Released __ ommo HI a D Pulled in WIL1661AWS C http mototh com ELECTRICAL SYSTEM 15 15 Wiring Diagram Rear Brake Light Switch Fuses 2 Spark Plug i1 Lights 10 Starter Circuit Turn Signal Interlock 2 Ignition 10 Relay Relay Diode BL R 4 eri BL Tail Brake Light an 4 er Har 12V 5
22. 14 9 Fenders Front Fender Removal CAUTION Be careful not to scratch the pained surface during removal or installation e Remove the mounting bolts A and take off the front fender Front Fender Installation e Install the front fender so that the narrower side A faces forward B Rear Fender Rear Removal e Remove the seat see this chapter Raise the rear wheel off the ground using the jack see Wheels Tires chapter Special Tool Jack 57001 1238 e Pull the connectors A of the rear turn signal light and tail orake light leads e Remove the rear fender rear bolts A e Pull the rear fender rear A rearward OThe rear turn signal light and tail brake light leads come off http mototh com 14 10 Fenders Rear Fender Rear Disassembly e Remove the nuts A and take off the rear turn signal light assembly e Remove the nuts C and take off the tail brake light as sembly D Hear Fender Front Hemoval e Remove Rear Fender Rear see this chapter Drive Chain Clip Rear Brake Rod Rear End e Remove the rear axle and move the rear wheel rearward for the access to the bolts A e Remove the rear fender front A http mototh com Frame FRAME 14 11 Frame Inspection e Visually inspect the frame A for cracks dents bending or warp x lf there is any damage to the frame replace it A WARNING A repaired frame may fa
23. 8 09010851 C 8 09010951 15 36 ELECTRICAL SYSTEM Charging System Charging System Circuit BN125 A1 A2 gt L BK Y R W HE BR GPO9080BW3 C OONDOARWND Ignition switch Alternator Regulator rectifier Controller Battery Main fuse 15 Starter relay Light fuse 10 A Load http mototh com ELECTRICAL SYSTEM 15 37 Charging System Charging System Circuit BN125 A3 gt gt gt gt gt gt gt GPOS081BW3 C Ignition switch Alternator Regulator rectifier Battery Main fuse 30 A Starter relay Light fuse 15 A Load http mototh com 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 The negative side is grounded This is to prevent damage to the diodes and CDI unit A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil while the engine is running or you could receive a severe electrical shock Crankshaft Sensor Removal Installation Refer to the Stator Coil Removal Installation in the Elec t
24. Coil Ignition Reguletor Switch Rectifier V Spark Plug Battery 000000 09000200090 6806114BN2 http mototh com 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 If the ignition switch or the engine stop switch is turned to the OFF position the battery power supply is cut off and no spark is generated The DC DC converter in the CDI unit has a built in transformer which changes 12 V battery voltage or battery charging voltage into AC voltage The diode converts the AC voltage into about 225 V DC to charge the capacitor First step Charging the Capacitor The converter generates the current to charge the capacitor through the diode with 225 V DC During this process the current changes slowly through the primary coil winding so that the secondary coil winding goes not produce enough voltage to fire the spark plug DC DC Converter Transformer 12V DC _ gt 225V DC Capacitor Ignition Coil Battery Spark Plug 0000000 Crankshaft Sensor 6B06103BN2 Second step thyristor conducts After charging the crankshaft sensor and ignition timing contr
25. Minimum turning radius 2 5 m 8 2 ft Engine Type 4 stroke SOHC 1 cylinder Cooling system Air cooled Bore and stroke 55 x 52 4 mm 2 2 x 2 1 in Displacement 124 cm 7 6 cu in Compression ratio 9 6 1 Maximum horsepower 8 8 kW 12 PS lt 99 500 r min rpm US 8 5 kW 11 6 PS 9 500 r min rpm BN125 A7 N NU http mototh com 1 10 GENERAL INFORMATION General Specifications Carburetion system Starting system Ignition system Timing advance Ignition timing Items 125 1 2 125 4 125 5 Maximum torque 9 7 N m 0 99 7 2 ft lb 98 000 r min rpm 9 8 N m 1 00 kgf m US 7 2 ft lb 98 000 r min rpm BN125 A7 N NU Carburetor MIKUNI BS28 Electric starter DC CDI Electronically advanced analog From 10 BTDC 1 300 r min rpm to 30 BTDC 4 500 r min rpm From 10 BTDC 1 300 r min rpm to 35 BTDC 4 500 r min rpm US CA CAL Spark plug NGK CR7E CR7E or U22ESR N 125 4 05 Valve timing Inlet Open 23 BTDC Close 57 ABDC Duration 260 Exhaust Open 64 BBDC Close 16 ATDC Duration 260 Lubrication system Forced lubrication wet sump Engine oil Grade SE SF or SG BN125 A3 API SE SF or SG API SH SJ or SL with JASO MA Viscosity SAE10W 40 Capacity 1 4 L 1 48 US qt when engine is completely dry Drive Train Primary reduction
26. NOTE ODo not lower the middle line below the bottom edge of the carburetor body If the gauge is lowered and then raised again the fuel level measured shows somewhat higher than the actual fuel level If the gauge is lowered too far dump the fuel out of it into suitable container and start the procedure over again e Read the fuel level in the gauge and compare to the spec ification Service Fuel Level Standard 1 3 mm 0 04 0 12 in below from the mating surface of the float bowl e Tighten the drain plug turn the fuel tap to the OFF position and remove the fuel level gauge xIf the fuel level is incorrect adjust it see Service Fuel Level Adjustment http mototh com 6606010152 C Carburetor FUEL SYSTEM 3 13 Service Fuel Level Adjustment A 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 this includes any appliance with a pilot light Remove the carburetor and drain the fuel into a suitable container e Remove the float bowl screws A and float bowl e Slide out the pivot pin A and remove the float B e When removing and installing the pivot pin note the fol lowings OBe careful not to snap the pin holder leg C OWhen removing it tap D the left end of the pin OWhen installin
27. Pressure DE of the 45 53 kPa 340 400 mmHg 6 5 7 7 lt BN125 A1 2 and other psi than the CAL CAL 41 52 kPa 310 390 mmHg 6 0 7 5 Camshaft Cam Height Exhaust 39 348 39 464 mm 1 5491 1 5537 in 39 25 mm 1 545 in Inlet 39 707 39 823 mm 1 5633 1 5678 in 39 61 mm 1 559 in Camshaft Runout TIR 0 02 mm 0 0008 in or less TIR 0 1 mm 0 004 in Rocker Arm Inside diameter 13 000 13 018 mm 0 5118 0 5125 in 13 05 mm 0 514 in Rocker Shaft Diameter 12 983 12 994 mm 0 5111 0 5116 in 12 96 mm 0 510 in Cylinder Head Cylinder Compression Usable range 960 1 470 kPa 9 8 15 0 kgf cm 139 213 psi 500 r min rpm Cylinder Head Warp Valves Valve Clearance Exhaust 0 15 0 19 mm 0 006 0 007 in Inlet 0 08 0 12 mm 0 003 0 005 in Valve Head Thickness Exhaust 0 9 1 1 mm 0 035 0 043 in 0 5 mm 0 02 in Inlet 0 6 0 8 mm 0 024 0 031 in 0 4 mm 0 01 in Valve Stem Bend TIR 0 01 mm 0 0004 in or less TIR 0 05 mm 0 002 in Valve Stem Diameter Exhaust 4 455 4 470 mm 0 1754 0 1760 in 4 44 mm 0 175 in Inlet 4 475 4 490 mm 0 1762 0 1768 in 4 46 mm 0 176 in Valve Guide Inside Diameter Exhaust 4 500 4 512 mm 0 1772 0 1776 in 4 57 mm 0 180 in Inlet 4 500 4 512 mm 0 1772 0 1776 in 4 57 mm 0 180 in Valve valve Guide Clearance Wobble Method Exhaust 0 14 0 19 m
28. Top 0 77 0 79 mm 0 0303 0 0311 in 0 70 mm 0 028 Second 0 77 0 79 mm 0 0303 0 0311 0 70 mm 0 028 Piston Ring End Top 0 15 0 30 mm 0 006 0 012 in 0 60 mm 0 024 Second 0 30 0 45 mm 0 012 0 018 in 0 70 mm 0 028 in Oil 0 20 0 70 mm 0 008 0 028 in 1 0 mm 0 04 in AT Austria CAL California CH Switzerland DE Germany N No Catalytic Converter Model NU No Catalytic Converter United Kingdom Model http mototh com 4 8 END Specifications Cam Height Camshaft Runout GE11012281 GE11061781 Cam Height A Valve Head Thickness GE15011281 C GE15004BS1 C Dial Gauge A Valve Stem Diameter A Valve Head Thickness B 45 C http mototh com 4 9 Special Tools Compression Gauge 20 kgf cm Valve Seat Cutter 327 530 57001 221 57001 1120 7570221ST C 875711205 C Valve Spring Compressor Assembly Valve Seat Cutter 32 535 57001 241 57001 1121 7570241ST C 8 5711215 C Piston Pin Puller Assembly Valve Seat Cutter 607 30 57001 910 57001 1123 9 7570910ST C 7571123ST C Valve Seat Cutter 45 527 5 Valve Seat Cutter Holder Bar 57001 1114 57001 1128 T5711148T C 7571128ST C Valve Seat Cutter 45 532 Valve Spring Compressor Adapter 22 570
29. Woodruff Key Primary Gear Installation e Fit the woodruff key B securely in the slot before in stalling the primary gear A e Install the spring washer A with the concave side facing to the crankcase Install the clutch e Temporarily tighten the primary gear nut B GF15000BS1 C e Using the gear holder A hold the primary gear as shown e Tighten the primary gear nut B Torque Primary Gear Nut 69 7 0 kgf m 51 ft Ib Special Tool Gear Holder m1 75 57001 1015 e Install the clutch cover see Clutch Cover Installation http mototh com ENGINE LUBRICATION SYSTEM 6 1 Engine Lubrication System Table of Contents Exploded ERE 6 2 Engine OI NAE are a 6 4 jer ep crue ccr 6 5 Speglal Oog S PT O I 6 6 Engine Oll arid Oil Filter rper t io e pt e eng E duree ZA 6 7 Oil Level me M E 6 7 m 6 7 OIL FITS Change tr ae Sut EAE 6 7 OIE SOROS 6 8 Oi Sereen Removal Roue Eme 6 8 Oil Screen InstallatlOn 6 8 PUMP etin tof Moo aud tea 6 9 Oil Pump
30. e Turn out the drain plug A a few turns and drain the float bowl Front B Special Tool Carburetor Drain Plug Wrench Hex 3 57001 1269 e Check to see if water or dirt comes out e Tighten the drain plug and turn the fuel tap to the ON position Torque Carburetor Drain Plug 2 0 N m 0 20 kgf m 17 in Ib If any water or dirt appears during the above inspection clean the fuel system see Carburetor Cleaning and Fuel Tank Cleaning Carburetor Removal A 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 this includes any appliance with a pilot light Remove Fuel Tank see Fuel Tank Removal Throttle Cable Lower Ends A Move back the air cleaner housing see Air Cleaner Hous ing Removal Lh Wins p rm http mototh com FUEL SYSTEM 3 15 Carburetor e Loosen the carburetor holder clamp A and air cleaner duct clamp e 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 e Take out the carburetor e Stuff pieces of lint free clean cloth into the carburetor holder and the air cleaner duct to keep dirt out of the en gine and air cleaner A WARNING If dirt or dust is allowed to pass through into the carburetor t
31. measure the arcing distance again with the spark plug cap removed from the ignition coil Remove the cap by turning it counterclock wise x lf the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug cap http mototh com GP10144BS2 C ELECTRICAL SYSTEM 15 41 Ignition System 00000 050 5 00020252520 x If the coil tester is not available the coil be checked for a broken or badly shorted winding with the hand tester NOTE OThe hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage e Measure the primary winding resistance as follows OConnect the hand tester between the coil terminals e Measure the secondary winding resistance as follows ORemove the plug cap OConnect the tester between the spark plug leads Measure primary winding resistance A Measure secondary winding resistance B Ignition Coil C GP10143BS1 C the tester does not read as specified replace the coil Ignition Coil Winding Resistance Primary Windings 0 09 0 13 Q x 1 0 Secondary Windings 3 8 5 8 x 1 e Visually inspect the secondary winding lead x If it shows any damage replace the coil Ignition Coil Primary Peak Voltage NOTE OBe sure the battery is fully charged e Remov
32. 0 25 22 in lb http mototh com 2 6 PERIODIC MAINTENANCE Torque and Locking Agent Torque Fastener Remarks Engine Removal installation Engine Mounting Bolts Nuts M10 44 4 5 33 Engine Mounting Bolts Nuts M8 25 2 5 18 Engine Mounting Bracket Bolts Nuts 25 2 5 18 Engine Ground Terminal Bolt 9 8 1 0 87 Crankshaft transmission Primary Gear Nut 69 7 0 51 Balancer Shaft Gear Nut 78 8 0 58 O Crankcase Bolts 8 8 0 90 78 in Ib Crankcase Bearing Retainer Screws 4 9 0 50 43 in lb Neutral Switch 15 1 5 11 Shift Drum Screw 4 9 0 50 43 in lb L Gear Set Lever Nut 11 1 1 95 in Ib Engine Sprocket Holder Bolts 12 1 2 104 in Ib Shift Return Spiring Pin Bolt 29 3 0 21 L Shift Lever Clamp Bolt 12 1 2 104 in Ib Shift Pedal Nut 30 3 1 22 Wheels tires Front Axle Nut 78 8 0 58 Rear Axle Nut 98 10 0 72 Tire Air Valve Nuts 1 5 0 15 13 in lb Spoke Nipples 2 0 3 9 0 20 0 40 17 35 in lb Final Drive Engine Sprocket Cover Bolts BN125 A1 9 8 1 0 87 in lb Engine Sprocket Cover Bolts BN125 A4 8 8 0 90 78 in lb Engine Sprocket Cover Damper Bolts 8 8 0 90 78 L Torque Link Bolt and Nut 34 3 5 25 Rear Sprocket Nut 26 2 7 19 Rear Axle Nut 98 10 0 72 Engine Sprocket Holder Bolts 12 1 2 104 in Ib Brakes Brake Disc Bolt 27 2 8 20 Caliper Mounting Bolts 25 2 5 18 Caliper Holder Shaft Bolt 18 1 8 13 Caliper Pad Bolts 18 1 8 13 Caliper Bleed Valve
33. 19 http mototh com Steering Stem STEERING 13 7 Steering Stem Installation e 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 All the steel balls are the same size e Put on the upper inner race and steering stem cap A and insert the steering stem into the head pipe e Install the stem nut B so that the recessed side C faces down e When the races are replaced with new ones tighten the stem nut to 20 N m 2 0 kgf m 14 5 ft lb of torque with the stem nut wrench A to settle the races in place To tighten the stem nut to the specified torque hook the wrench on the stem nut and pull the wrench at the hole with 108 N 11 kgf of force B in the direction shown e Loosen the stem nut and adjust the steering see this chapter e Install the turn signal light unit OThe left turn signal light unit has an L mark A on it and the right turn signal light unit has an R mark B OTighten Torque Turn Signal Light Holder Nuts 5 9 N m 0 60 kgf m 52 in Ib e Run the throttle cables A clutch cable B and turn sig nal light leads C as shown Front D http mototh com GNO70305S1 GN05030281 C GNO4010281 13 8 STEERING Steering Stem e Install the front fork see Suspension chapter NOTE Olnst
34. 21 Rear Right Turn me Signal Light 6 12Y 21 6 Rear Left Turn Signal Light Seay 12V 218 BK Y 5L BK Y Regulator Rectifier Main Fuse 15 sss sss 4 Starter Battery Alternator Relay 12V 8AH Crankshaft Neutral sensor Switch Br Brown Chocolate De Dark Green 8 creen Lev sray IGNITION SWITCH CONNECTIONS RIGHT HANDLEBAR SWITCH CONNECTIONS o Orange pe eal le rait3 Front Brake Light SwitchlEngine Stop Switch Starter Button Headlight Switch T or BR ay Pink um Purple OFF Push OFF Red FUA Released zo pa RUN Omimo Released 98051 18614 WIRIG661AWS C http mototh com 15 16 ELECTRICAL SYSTEM Wiring Diagram BN125 A2 Singapore and BN125 A4 United States BR parra Ignition Switch ay ALLL BL mae R R W Meter Light 12V 1 78 Speedometer R BL R W BK Y BK Y Right Handlebar Switches i Front Brake Light Switch 2 Engine Stop Switch 3 Starter Button High Beam Indicator Light 12V 3 4W Y 5k EE R BK R BK Neutral Indicator C BL W Light 12V 3 4W LG 16 i i Gy GY Turn Signal Indicator 6 Light 12V 3 4W Headlight nee 12V 60 5548 t Right
35. 33 Engine Mounting Bolts Nuts M8 25 2 5 18 Engine Mounting Bracket Bolts Nuts 25 2 5 18 Engine Ground Terminal Bolt 98 1 0 87 in lb http mototh com 7 4 ENGINE REMOVAL INSTALLATION Special Tool Jack 57001 1238 7571238ST C http mototh com ENGINE REMOVAL INSTALLATION 7 5 Engine Removal Installation Engine Removal e Place the jack A under the frame to lift the rear wheel B off the ground Special Tool Jack 57001 1238 e Squeeze the brake lever slowly and hold it with a band A A WARNING Be sure to hold the front brake when removing the engine or the motorcycle may fall over It could cause an accident and injury e Drain the engine oil see Periodic Maintenance chapter e Remove Side Covers and Seat see Frame chapter Fuel Tank see Fuel System chapter e Disconnect the cables and wiring leads from the engine Alternator Lead Connector A Engine Ground Lead B Electric Starter Motor Cable Terminal C Spark Plug Cap Breather Tube e Remove Muffler see Engine Top End chapter Cylinder Head Bracket A Carburetor B see Fuel System chapter Shift Pedal see Crankshaft Transmission chapter Chain Cover and Engine Sprocket see Final Drive chap ter Clutch Cable Lower End see Clutch chapter http mototh com GHO4023BS1 C 7 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation Remove Engine Mounting Bolts A Engine
36. 75 kgf cm 25 psi BN125 A3 Up to 155 kg 342 Ib load 175 kPa 1 75 kgf cm 25 psi Tread Depth Front BN125 A1 A2 4 5 mm 0 18 in 1 mm 0 04 in 125 A5 4 0 mm 0 157 in 1 mm 0 04 in http mototh com 2 10 PERIODIC MAINTENANCE Specifications ltem Standard Service Limit 125 6 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 Drive Chain Slack 20 Link Length Brakes Brake Lever Free Play Brake Pedal Free Play Shoe Lining Thickness Brake Fluid Grade Brake Pad Lining Thickness BN125 A1 A2 BN125 A3 Brake Light Timing Front Rear Suspension Oil Viscosity Oil Capacity Par Unit Completely Dry When Changing Oil Oil Level Fully Compressed Without Main Spring 25 40 mm 0 98 1 57 in 254 0 254 6 mm 10 00 10 02 in Non adjustable 20 30 mm 0 79 1 18 in 3 85 4 15 mm 0 152 0 163 in DOT4 4 5 mm 0 177 in 6 0 mm 0 236 in Pulled on On after about 10 mm 0 39 in of pedal travel SHOWA SS 8 or equivalent 191 2 5 mL 6 46 0 085 US oz Approx 165 mL 5 58 US oz 218 2 mm 8 58 0 08 in 259 mm 10 2 in 2 mm 0 08 in 1 mm 0 04 1 mm 0 04 in Electrical system Spark Plug Gap Battery Electrolyte Level 0 7 0 8 mm 0 028 0 031 in Between level lines http mototh com PERIODIC MAINTENANCE 2 11 Special Tools Steer
37. 8 21 Transmission Shift Drum Removal Installation e Refer to the Crankcase Disassembly Installation in the Crankshaft Transmission chapter Shift Fork Bending e 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 90 A A 6113014581 C Shift Fork Gear Groove Wear e Measure the thickness of the shift fork ears A and mea sure the width B of the gear grooves o Shift Fork Ear Thickness f Standard 4 9 5 0 mm 0 193 0 197 in Service Limit 4 8 mm 0 189 in e Gear Groove Width Standard 5 05 5 15 mm 0 199 0 203 in Service Limit 5 25 mm 0 207 in x If the thickness of a shift fork ear is less than the service limit the shift fork must be replaced x If the gear groove is worn over the service limit the gear must be replaced Shift Fork Guide Pin Drum Groove Wear e Measure the diameter of each shift fork guide pin A and measure the width B of each shift drum groove Shift Fork Guide Pin Diameter Standard 5 9 6 0 mm 0 232 0 236 in Service Limit 5 8 mm 0 228 in 6113010781 Shift Drum Groove Width Standard 6 05 6 20 mm 0 238 0 244 in Service Limit 6 3 mm 0 248 in xIf the guide pin on any shift fork is less than the service limit the fork must be replaced x If any shift drum groove is worn over the service li
38. 8 FUEL SYSTEM Specifications Item Standard Throttle Grip Free Play 2 3 mm 0 08 0 12 in 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 Service Fuel Level 1 3 mm 0 04 0 12 in below from the bottom edge of the of the carburetor body skirt Float Height 19 4 2 mm 0 76 0 08 in Main Jet 105 125 US CA 122 5 BN125 A7 N NU Needle Jet No 0 8 807 0 8M 891 US CA 0 7M 891 BN125 A7 N NU Jet Needle Mark 4DH24 3 4 17 1 US CA 4031 2 BN125 A7 NU Pilot Jet Slow Jet 30 32 5 US CA and BN125 A7 N NU Pilot Air Jet Slow Air Jet 95 90 US CA 70 BN125 A6 US CA and BN125 A7 N NU Throttle Valve 110 105 US CA and BN125 A7 N NU Air Cleaner Element Oil High quality foam air filter oil Grade API SE SF or SG class Viscosity SAE30 CA Canada CH Switzerland US United States N No Catalytic Converter Model NU No Catalytic Converter United Kingdom Model http mototh com Specifications Pilot screw Plug 05 Pilot air jet Jet needle D Throttle valve E Pilot jet F Needle jet G Main jet H Float I Valve seat J Valve needle K http mototh com FUEL SYSTEM 3 9 6006062052 C 3 10 FUEL SYSTEM Special Tools Fuel Level Gauge Carburetor Drain Plug Wrench Hex 3 57001 1017 57001 1
39. Bolts BN125 A4 8 8 0 90 78 in lb Oil Filler Plug 2 5 0 25 22 inib EO Apply engine oil Apply grease L Apply a non permanent locking agent R Replacement parts S Follow the specific tightening sequence http mototh com 6 4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart GG04010BW4 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 Air Cleaner Housing 6 Crankshaft Oil seal A Oil Flow 7 Oil Pipe Banjo Bolts B Blowby Gas 8 Camshaft http mototh com ENGINE LUBRICATION SYSTEM 6 5 Specifications tem Standard Engine Oil Grade BN125 A1 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 Between upper and lower level lines Oil Pressure Measurement Oil Pressure 94 000 r min rpm 13 32 kPa 0 13 0 33 kgf cm 1 8 4 7 psi Temperature 90 194 http mototh com 6 6 ENGINE LUBRICATION SYSTEM Special Tools Oil Pressure Gauge 5 kgf cm Oil Pressure Gauge Adapter M10 x 1 25 57001 125 57001 1182 1570125 C 875711825 http mototh com ENGINE LUBRICATION SYSTEM 6 7 Engine Oi
40. Connector Rear Right Turn Signal Light Connector Tie with the stay by the band after connected California Model http mototh com APPENDIX 16 21 16 22 APPENDIX Cable Wire and Hose Routing BN125 A5 NN WS gt SS e SN CELK gt gt WS 6809928885 C http mototh com Cable Wire Hose Routing P N S S S S a St Connector Fuse Box Connector Battery Positive Lead Clamp Turn Signal Relay Alternator Connector Battery Negative Lead Band CDI Unit Connector Ignition Coil Lead Run the indicator light lead from left side Connect them in the headlight housing City Light Connector Europe Model lgnition Switch Connector Put them into the gusset after connected Rear Brake Switch Connector Right Handlebar Switch Connector Starter Lead Battery Starter Circuit Relay California Model http mototh com APPENDIX 16 23 16 24 APPENDIX Cable Wire Hose Routing Evaporative Emission Control System BN125 A5 California Model 6809449BN5 http mototh com Cable Wire Hose Routing 1a Fuel Separator Canister Vacuum Switch Valve Air Cleaner Housing Label Blue
41. Cylinder Removal 11 13 Master Cylinder Installation 11 13 Master Cylinder Disassembly 11 13 Master Cylinder Assembly 11 14 Master Cylinder Inspection Visual I iS DOG GI 11 14 Front 11 15 http mototh com Brake Disc Removal Brake Disc Installation Brake Disc Wear Brake Disc Warp Brake Fluid Brake Fluid Level Inspection Brake Fluid Change Brake Line Bleeding Brake Hose Brake Hose Removal Installation Brake Hose Inspection Rear Brake Pedal and Brake Cable Brake Pedal Position Inspection Adjustment Brake Pedal Free Play Inspection Adjustment Brake Pedal Removal Brake Pedal Installation Brake Cable Removal Brake Cable Installation Brake Cable Lubrication Rear Brake Panel and Drum Brake Panel Removal Brake Panel Installation Brake Panel Disassembly Brake Panel Assembly Brake Panel Inspection Brake Shoe Lining Wear toe teens Brake Shoe Springs Inspection Brake Drum Wear Inspection 11 2 BRAKES Exploded View 3 OT TS 1a http mototh com BRAKES 11 3 Exploded View T
42. Do not remove any bearings for lubrication If any bearings are removed they will need to be replaced with new ones e Pack the front hub bearings with good quality bearing grease Turn the bearings around by hand a few times to make sure the grease is distributed evenly inside the bearings NOTE OSince the rear hub bearing are packed with grease and sealed lubrication is not required http mototh com http mototh com Final Drive Table of Contents Exploded View Specifications Special Tools Drive Chain Chain Slack Inspection Chain Slack Adjustment Wear Inspection Lubrication Drive Chain Removal Drive Chain Installation Sprocket Coupling Engine Sprocket Removal Engine Sprocket Installation Rear Sprocket Removal Rear Sprocket Installation Sprocket Wear Sprocket Warp Inspection Coupling Removal Coupling Installation Coupling Bearing Removal Coupling Bearing Installation Coupling Bearing Wear Lubrication Damper Inspection http mototh com FINAL DRIVE 10 1 10 2 10 4 10 5 10 6 10 6 10 6 10 6 10 6 10 6 10 6 10 7 10 7 10 7 10 8 10 8 10 8 10 8 10 8 10 9 10 9 10 9 10 9 10 9 10 2 FINAL DRIVE Exploded View http mototh com FINAL DRIVE 10 3 Exploded View Torque No Fastener Remarks Nm ftlb 1 Bolts 125 1
43. Environmental Protection Agency and California Air Resources Board Addi tionally Kawasaki has incorporated an evaporative emission control system 3 in compliance with applicable regulations of the California Air Resources Board on vehicles sold in California only 1 Crankcase Emission Control System This system eliminates the release of crankcase vapors into the atmosphere Instead the vapors are routed through an oil separator to the inlet side of the engine While the engine is operating the vapors are drawn into combustion chamber where they are burned along with the fuel and air supplied by the carburetion system 2 Exhaust Emission Control System This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle The fuel ignition and exhaust systems of this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutant levels The exhaust system of this model motorcycle manufactured primarily for sale in California in cludes a catalytic converter system 3 Evaporative Emission Control System Vapors caused by fuel evaporation in the fuel system are not vented into the atmosphere In stead fuel vapors are routed into the running engine to be burned or stored in a canister when the engine is stopped Liquid fuel is caught by a vapor separator and returned to the fuel tank The Clean Air Act which is the Federal law covering motor ve
44. Front Right Turn Signal Light Connector Join connectors in the headlight unit Speedometer Light Connector Headlight Connector Rear Right Turn Signal Light Connector Interlock Diodes Starter Circuit Relay Connector Starter Relay Connector Regulator Rectifier Connector Fuse Box Connector Turn Signal Relay Connector Battery Negative Lead Alternator Connector CDI Unit Left Handlebar Switch Connector Right Handlebar Switch Connector Rear Brake Light Switch Connector lgnition Switch Connector Indicator Light Connector Sidestand Light Connector Horn Connector Battery Positive Lead CDI Unit Connector Battery Right Handlebar Switch Lead Connector City Light Connector Europe Model Band Clamp Starter Lead Rear Brake Light Switch Turn Signal Relay http mototh com APPENDIX 16 17 16 18 APPENDIX Cable Wire Hose Routing BN125 A3 A4 0 3 QO OQ D 8 999 NV f llo cc e aA L mmn Sle P G 60 mc ee I fp WY z SANNAR NN 1 3 9 9 7 77 02222 7 727727777 7777 N Le E dh 1 22 2 44 aN IL REI ML GL si 2 TRE 2 OUD 49 9 69 62 69 7 0909 69 2 Lae 4 09090 690900000208 G 89 WX 2 i N TORN rae 155 e
45. Label Red Hose with blue stripe Hose Hose Hose with white stripe White Paint Mark White Paint Mark with blue stripe with red stripe http mototh com APPENDIX 16 25 Cable Wire Hose Routing 16 26 APPENDIX California Model Evaporative Emission Control System BN125 A5 http mototh com APPENDIX 16 27 Cable Wire Hose Routing 1 Vacuum Switch Valve 2 Go to the fuel tap 3 Carburetor Holder 4 Separator http mototh com 16 28 APPENDIX Cable Wire Hose Routing Evaporative Emission Control System BN125 A5 California Model ae ie 552077 6 A zr RS J QN 7 m TS WH A SS Z 2 z MER x BEER A ee LM http mototh com APPENDIX 16 29 Cable Wire Hose Routing 1 Run the ignition coil primary lead under the throttle cables secondary air hose and breather hose Go To Left Side Separator Go To The Fuel Tank Breather Hose Secondary Air Hose Air Vent Hose Throttle Cables Vacuum Switch Valve 10 Carburetor Holder 11 Canister 12 Go To Left Side 13 Clamp 14 Knob of clip shall be installed downward http mototh com 16 30 APPENDIX Cable Wire Hose Routing Evaporative Emission Control System BN125 A5 California Model Had
46. Light Timing Inspection Turn on the ignition switch The brake light should go on when the front brake is ap plied does not replace the switch Rear Brake Light Timing Inspection e Turn on the ignition switch Check the operation of the rear brake light switch by de pressing the brake pedal e f it does not as specified adjust the brake light timing Brake Light Timing Standard On After about 10 mm 0 39 in of pedal travel A Rear Brake Light Timing Adjustment e While holding the switch body turn the adjusting nut A to adjust the switch CAUTION To avoid damaging the electrical connections in side the switch be sure that the switch body does not turn during adjustment NOTE OBrake light turns on sooner as the switch body rises B and turns on later as the switch body lowers C Brake Cable Replacement e Whenever the brake cable is removed lubricate it e With the cable disconnected at both ends the cable should move freely A within the cable housing If cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable http mototh com 6004020281 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Oil Change e Remove the front fork see Suspension chapter e Hold the outer tube vertically in a vise e Unscrew the top plug out of the inne
47. Operation 3 onic Replace Faulty Parts 4 http mototh com 15 46 ELECTRICAL SYSTEM Ignition System Ignition System Circuit BN125 A1 A2 gt NGC ve ek MV Z gt gt c mo 3 6P x gt W Y ay BK Y G BK R a W I BL BK a W Y G W 9 BK Y L BK Y GPi0i46BWN3 C Neutral switch Interlock diodes Sidestand switch Starter lockout switch Engine stop switch lgnition fuse 10 A lgnition switch Regulator rectifier Crankshaft sensor CDI unit lgnition coil Spark plug Battery Main fuse 15 A 2a RONM http mototh com ELECTRICAL SYSTEM 15 47 Ignition System Ignition System Circuit BN125 A3 J ia a gt lt ta Y G BK G W W Y Y G G W LG BK BR 4 Y R BL w 8L w GPi0i147BW3 C Ignition switch Starter lockout switch Crankshaft sensor Interlock diodes Sidestand switch Ignition fuse 15 A Engine stop switch Neutral switch CDI unit 10 Ignition coil 11 Spark plug 12 Main fuse 30 A 13 Battery 14 Regu
48. Remove the crankshaft jig e Install the crankcase bolts A in the left crankcase half B and tighten them starting with the nearest ones to the crankshaft then farther ones Torque Crankcase Bolts 8 8 Nm 0 90 kgf m 78 in Ib http mototh com 8 12 CRANKSHAFT TRANSMISSION Crankcase Check to see that the crankshaft drive shaft and output shaft all turn freely in the neutral position x 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 e Put the end of the woodruff key A into the inside of the ball bearing B so that the key can seat securely e Apply a non permanent locking agent to the shift drum cam screw A and tighten it Torque Shift Drum Cam Screw 4 9 N m 0 50 kgf m 43 in Ib e Install the gear set lever B and tighten the nut C Torque Gear Set Lever Nut 11 N m 1 1 kgf m 95 in Ib e Install the external shift mechanism D see this chapter e Check to see that gears shift smoothly from 1st to 5th gear and 5th to 1st while spinning the output shaft e Set the shift drum in the neutral position e Replace the O ring A on the output shaft with a new one e Apply grease to the inside of the output shaft collar B e Insert the collar with the oil groove end C facing in e Install the removed parts see appropriate chapters http mototh com CRAN
49. Remove the fuel tap e Check the fuel tap filter screen A for any breaks or dete rioration x lf the fuel tap screens have any breaks or are deterio rated they may allow dirt to reach the carburetor causing poor running Replace the fuel tap lf the fuel tap leaks or allows fuel to flow when it is at On or RES position without engine running replace the amp damaged gasket B or O ring C 89090 10157 Torque Fuel Plate Screws 0 8 N m 0 080 kgf m 7 in Ib Fuel Tap Diaphragm Cover Screws 1 0 N m 0 10 kgf m 9 in Ib http mototh com 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 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 Parts Removal Installation A 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 this includes any appliance with a pilot light CAUTION If gasoline solvent water or any other liquid enters the canister the canister s vapor absorbing capac ity is greatly reduced If the canister does become conta
50. Shaft 57001 1075 N 875710755 C Head Pipe Outer Race Driver 51 5 57001 1076 8757107697 6 Head Pipe Outer Race Driver 46 5 57001 1106 Steering Stem Nut Wrench 8 5711065 C 57001 1100 57 ST571100ST 57001 1238 7571238ST C http mototh com Steering STEERING 13 5 Steering Inspection e Refer to the Steering Inspection in the Periodic Mainte nance chapter Steering Adjustment e Refer to the Steering Adjustment in the Periodic Mainte nance chapter http mototh com 13 6 STEERING Steering Stem Steering Stem Removal e Loosen the steering stem head bolt A e 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 e Loosen the turn signal light holder bolts and nuts B e Remove the nuts A and take off the headlight body B e Remove Steering Stem Head Bolt A Steering Stem Head B Front Fork C see Suspension chapter ORemove the steering stem head with the meter unit and handlebar left installed e Push up on the stem base A and remove the stem nut C with the steering stem nut wrench B then remove the steering stem Special Tool Steering Stem Nut Wrench 57001 1100 e Remove Lower Inner Race and Steel Balls 20 Steering Stem Cap A Upper Inner Race and Steel Balls
51. Special Tool Outside Circlip Pliers 57001 144 A e Do not reuse the removed circlips http mototh com 8 20 CRANKSHAFT TRANSMISSION Transmission Transmission Assembly e Replace any circlips removed with new ones Olnstall the circlips A so that the opening B is aligned with a spline groove C Olnstall the toothed washer D so that the teeth E are not aligned with the opening of the circlip e The drive shaft gears can be recognized by size the gear with the smallest diameter is 1st gear and the largest one is 5th gear Be sure that all parts are put back in the cor rect sequence and all circlips and washers are properly in place e The output shaft gears can be recognized by size the gear with the largest diameter is 1st gear and the small est one is 5th gear Be sure that all parts are put back in the correct sequence and all circlips and washers are properly in place e Check that each gear spins or slides freely on the trans mission shafts without binding after assembly 6113068851 C SHbHOOODDOOE 9 6113144883 C 1 Circlip 6 Collar 2 Circlip 7 Drive Gear 3rd and 4th 3 Washer 8 Drive Gear 5th 4 Toothed Washer 5 Drive Gear 2nd 9 Drive Shaft 10 Output Gear 2nd http mototh com 11 Output Gear 4th 12 Output Gear 3rd 13 Output Gear 5th 14 Output Gear Low 15 Output Shaft CRANKSHAFT TRANSMISSION
52. Terminal Ground When transmission is in neutral O o When transmission is not in neutral http mototh com ELECTRICAL SYSTEM 15 65 Fuse Main Fuse 15 Removal Remove the right side cover See Frame chapter e Disconnect the starter relay connector e Pull out the main fuse B from the starter relay A with needle nose pliers Main Fuse 15 A Inspection e Remove the fuse see Fuse Removal e Inspect the fuse element x lf it is blown out replace the fuse Before replacing a blown fuse always check the amperage in the affected circuit If the amperage is equal to or greater than the fuse rating check the wiring and related components for a short circuit Housing A Fuse Element B Terminals C Blown Element D CAUTION When replacing a fuse be sure the new fuse matches the specified fuse rating for that circuit Installation of a fuse with a higher rating may cause damage to wiring and components 8 20000151 C Fuse 10 Removal e Remove the right side cover see Frame chapter e Open the fuse case A and remove the fuses B Fuse 10 A Installation x lf a fuse fails during operation inspect the electrical sys tem to determine the cause and then replace it with a new fuse or proper amperage CAUTION The fuse case has 10 A fuses only Do not use the fuse other than 10 A fuse http mototh com 15 66 ELECTRICAL SYSTEM Fuse Fus
53. The maximum difference in gauge reading is the crankshaft runout Standard TIR 0 03 mm 0 0012 in or less Service Limit TIR 0 07 mm 0 003 in lf the runout at either point exceeds the service limit re place the crankshaft assembly with a new one or align the crankshaft so that the runout falls within the service limit http mototh com NO 6105072851 6105073851 8 14 CRANKSHAFT TRANSMISSION Crankshaft e First correct the horizontal misalignment by striking the projecting crank half A with a plastic soft lead or brass hammer as shown e Recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit 6105074BS1 Next correct the vertical misalignment by either driving a wedge A in between the crank halves or by squeezing them in a vice depending on the nature of the misalign ment 2 CAUTION Do not hammer the crank half at the point 6105004852 C http mototh com CRANKSHAFT TRANSMISSION 8 15 Balancer Shaft Gear Balancer Shaft Gear Removal e Remove Alternator Rotor see Electrical System chapter Clutch Cover see Clutch chapter e 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 e Remove the balancer shaft gear D a long with the woodruff key Balancer Shaft Ge
54. W R BL R W BK Y BK Y 3 8tarter Button ee xx ESTY 55 22 oo NS Lo m aan High Beam Indicator BK Y BK Y Light 12V 3 40 Ou RIIK Neutral Indicator BR BL N Light 12V 3 4W LG La Turn Signal Indicator 4 yu 1 1 Light 12V 3 4W E o az zo gt zz R BK T Headlight BK Y 12V 60 55W R Y ae iz PUSH FREE OFF Front Right Turn 6 plg cy Signal Light 8K Y ald 5k t Side Stand 12V 21W Left Handlebar Switches Switch Horn 1 Button 12V 3 0A 9 Turn Signal Switch 3 Dimmer Switch 4 Starter Lockout Switch Front Left Turn Pid amp Signal Light BK Y bLal 5k Y 12V 21W LEFT HANDLEBAR SWITCH CONNECTIONS Sidestand Switch Horn Button Turn Signal Switch Bimmer Switch Starter Lockout EE 6 1 6v ee roe Color push ommo p om co o j Release OFF Push Released Pulled 211084 5 C http mototh com ELECTRICAL SYSTEM 15 21 Wiring Diagram Rear Brake Light Switch Fuses Spark Plug 1 Lights 15 Starter Circuit Interlock 2 Ignition 15A Relay Turn Signal Diode Relay EI 221 BL R _K BL BK Y Kj BkK Y R LKE GY Fe 6 put 5ikxv Fe BK Y 746 Alternator Sta
55. Y G W G W OConnect the hand tester as shown in the table OStart the engine ORun it at 4 000 r min rpm of the engine speed ONote the voltage readings Special Tool Hand Tester 57001 1394 Alternator Output Voltage BN125 A1 A2 Meter Connections Reading Range Meter to Meter to 4 000 rpm 50 V AC Pink lead Engine ground 37 V or more Alternator Output Voltage 125 Meter Connections Reading Range Meter to Meter to 4 000 rpm Yellow lead 38 V or more 250 V AC Yellow lead x lf the output voltage shows the value in the table the alter nator operates properly A much lower reading than the value in the table indicates that the alternator is defective http mototh com 15 34 ELECTRICAL SYSTEM Charging System Check the stator resistance as follows OStop the engine OConnect the hand tester as shown in the table ONote the resistance readings Stator Coil Resistance BN125 A1 A2 Tester i Reading Range Meter to Meter to x10 Pink lead Engine ground 01 080 Stator Coil Resistance 125 Tester Connections Reading Range Meter to Meter to x10Q Yellow lead Yellow lead 03 090 x lf there is more resistance than shown in the table or no hand tester reading infinity the stator has an open lead and must be replaced Much less than this resistance means the st
56. and O rings after disassembly can reduce sealing per formance Remove old gaskets and clean the sealing surfaces thoroughly so that no gasket material or other material remains Install new gaskets and replace used O rings when re assembling Liquid Gasket Locking Agent For applications that require Liquid Gasket or a Locking agent clean the surfaces so that no oil residue remains be fore applying liquid gasket or locking agent Do not apply them excessively Excessive application can clog oil pas sages and cause serious damage http mototh com 33020128 5 08020148 5 08020158 5 E Before Servicing GENERAL INFORMATION 1 5 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 Replace with new ones whenever removed Press bearings with the manufacturer and size marks facing out Press the bearing into place by putting pressure on the correct bearing race as shown Pressing the incorrect race can cause pressure between the inner and outer race and result in bearing damage Oil Seal Grease Seal Do not remove pressed oil or grease seals unless removal is necessary Replace with new ones whenever removed Press new
57. clutch holder Special Tool Clutch Holder 57001 1243 Torque Clutch Hub Nut 98 N m 10 0 kgf m 72 ft Ib e Install the spring seat B and then the spring C with the concave side facing to the clutch cover e When installing the friction plates and steel plates first in stall the friction plate A whose inside diameter is larger than the others and then install a steel plate D and alter nating them CAUTION If new dry friction plates and steel plates are in stalled apply engine oil to the surfaces of each plate to avoid clutch plate seizure e Apply molybdenum disulfide grease to the pusher ends A and install the thrust bearing e Tighten the clutch spring bolts Torque Clutch Spring Bolts 8 8 Nm 0 90 kgf m 78 in Ib Friction and Steel Plate Damage Wear e Visually inspect the friction and steel plates for signs of seizure overheating discoloration or uneven wear e Measure the thickness of the friction plates A at several points x If any plates show signs of damage or if they have worn past the service limit replace them with new ones Friction Plate Thickness Standard 2 92 3 08 mm 0 115 0 121 in Service Limit 2 8 mm 0 11 in Friction and Steel Plate Warp e Place friction plate or steel plate B on a surface plate and measure the gap between the surface plate A with a thickness gauge C The gap is the amount of friction or steel plate warp x If any plate
58. 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 diode s cathode NOTE OThis manual doesn t use the conventional current flow concept but the electron theory current flow concept current is supposed to flow negative to positive in this text Thyristor SCR Current will flow from the cathode to anode but will not flow in the reverse direction The thyristor differs from a diode in two respects a even though a voltage of the cor rect polarity negative to cathode may be applied the thyris tor will not conduct until a signal is applied to the gate input lead b once started it will not stop conducting even if the gate lead signal voltage stops until the cathode to anode voltage is removed or reversed The crankshaft sensor is installed on the alternator cover so that it will be close to the alternator rotor One side of the crankshaft sensor core has a permanent magnet and the other side has a coil to signal the CDI unit Crankshaft Sensor A Alternator Rotor B Timing Plate C Output Voltage D http mototh com Diode A anode K cathode 6806105851 C Diode Current Flow No current flows Current flows A C C 6806106851 C Thyristor Current Flow A anode K cathode G gate 8
59. filter is to be changed replace it with a new one e Check the gasket at the drain plug for damage Replace the gasket with a new one e After draining install the drain plug and gasket Torque Engine Oil Drain Plug 18 N m 1 8 kgf m 13 ft Ib e Pour in the specified type and amount of engine oil through the oil filler http mototh com SEEMS F PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures Recommended Engine Oil Grade 125 1 API SE SF or SG 125 4 API SE SF or SG SJ or SL with JASO MA Viscosity SAE 10W 40 Capacity 1 1 L 1 16 US qt 20 10 0 10 20 30 40 0 When filter is not removed 143 50 8 85 10 2809010851 1 2 L 1 27 US qt when filter is removed 1 4 L 1 48 US qt when engine is completely dry NOTE OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions your riding area e Install the oil filler plug Torque Filler Plug 2 5 N m 0 25 kgf m 22 in Ib e Check the oil level see Engine Lubrication chapter Oil Filter Change e Drain the engine oil see Engine Oil change e Remove the oil filter cover bolts A and cover B e Take off the filter e Remove the spring Front C e Replace the filter A with a new one e Install the spring B e Install the new filter so t
60. fork legs balanced for motorcycle stability Fork Spring Free Length Standard 398 5 mm 15 7 in Service Limit 391 mm 15 4 in http mototh com 6 04041351 Rear Shock Absorbers SUSPENSION 12 13 Spring Preload Adjustment e 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 1 2 3 4 5 Spring Tension Stronger A WARNING If a pair of adjusters are not adjusted equally han dling may be impaired and a hazardous condition may result Removal e Raise the rear wheel off the ground Special Tool Jack 57001 1238 Unscrew the upper mounting nut and lower mounting bolts A and remove the rear shock absorber B Installation e Install the rear shock absorbers e Tighten the rear shock absorber nuts and bolts Torque Rear Shock Absorber Mounting Nut and Bolt 34 3 5 kgf m 25 ft Ib http mototh com 12 14 SUSPENSION Swingarm Swingarm Removal e 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 e Pull out the swingarm pivot shaft and remove the swingarm A e Separate the drive chain Swingarm Installation e Apply plenty of grease t
61. if necessary remove the pilot screw as follows e Replace the O ring with a new one OFor the Swiss United States and Canada models pry out the pilot screw plug with an awl or other suitable tool e Turn in the pilot screw and count the number of turns until it seats fully but not tightly and then remove the screw Use this number of turns to set the screw to its original position during assembly NOTE OA carburetor has different turns out of the pilot screw for each individual unit When setting the pilot screw use the turns out determined during disassembly Use the specification in this manual only if the original num ber is unknown e Remove Float Bowl Float Pivot Pin A Float B with Float Valve Needle Pilot Jet C Main Jet D e Push the needle jet A out from the inside of the carbure tor bore with your finger http mototh com 6606010551 C Carburetor FUEL SYSTEM 3 17 e Remove the coasting enricher cover e Remove the diaphragm A Carburetor Assembly e Turn in the pilot screw A fully but not tightly and then back it out the same number of turn counted during dis assembly e For the Swiss United States and Canada models drive in a new plug B in the pilot screw hole of the carburetor body C as shown CAUTION Do not force the needle jet and main jet or over tighten them They could be damaged requiring re placement e Tighten Torque M
62. is not available disassemble the caliper before the brake hose is removed see Caliper Disas sembly Caliper Installation e Install the caliper and brake hose lower end OReplace the washers that are on each side of hose fitting with new ones Tighten Torque Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft Ib Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib Check the fluid level in the brake reservoir e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage WARNING not attempt to drive the motorcycle until brake lever is obtained by pumping the brake lever until the pads against the disc The brake will not function on the first application of the lever if this is not done Caliper Disassembly e Remove the caliper see Caliper Removal e Remove the pads and spring see Brake Pad Removal e Using compressed air remove the pistons OLightly apply compressed air to the hose joint opening WARNING To avoid serious injury never place your fingers or palm inside the caliper opening If you apply com pressed air into the caliper the piston may crush your hand or fingers http mototh com GLO5081BS1 Caliper BRAKES 11 9 Olnsert a wooden board A 5 mm 0 2 in thick inside the caliper opening OApply compressed air B to the banjo bolt hole to allow the pis
63. is not specified one check the battery voltage ignition switch and ignition fuse e Set the hand tester to the x 1 kO range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 x 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 http mototh com 8 10010251 C 15 44 ELECTRICAL SYSTEM Ignition System CDI Unit Internal Resistance BN125 A1 A2 Tester Lead Connection Unit 18 5 74 3 13 3 13 4 1 16 4 19 76 5 20 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 GP10145BS1 C CDI Unit Internal Resistance BN125 A3 Unit Tester Lead Connection deme i 2 3 4 5 6 7 8 9 10 nal 1 30 925 30 80 32 5 55 67 5 30 65 150 370 150 320 160 220 270 150 26 24 3 3 4 5 2 96 8 38 05 2 13 7 28 0 18 3 245 245 475 25 265 40 47 5 33
64. marked side out unit it bot toms out Special Tool Bearing Driver Set 57001 1129 B Coupling Bearing Wear Lubrication e See the Inspection and Lubrication sections of the rear hub bearings in Wheels Tires chapter Damper Inspection e Remove the rear wheel coupling and inspect the rubber dampers A e Replace the damper if it appears damaged or deterio rated http mototh com GK05010281 GK05008BS1 C GK05010581 C http mototh com BRAKES 11 1 Brakes Table of Contents Exploded View 11 2 Specifications 11 6 Special Tools pp 11 7 Caliper 11 8 Caliper Removal 11 8 Caliper Installation 11 8 Caliper Disassembly 11 8 Caliper Assembly 11 9 Caliper Fluid Seal Damage 11 10 Caliper Dust Seal Friction Boot tige 11 11 Caliper Cylinder 11 11 Caliper Holder Shaft Wear 11 11 Front Brake Pads 11 12 Brake Pad Removal BN125 A1 PD 11 12 Brake Pad Removal BN125 A3 p 11 12 Brake Pad Installation BN125 A1 zl co rp 11 12 Brake Pad Installation BN125 A3 T MM S NM PER 11 12 Brake Pad Wear Inspection 11 12 Master Cylinder 11 13 Master
65. mototh com GE04017BS1 C GEO4018BS1 C GE04085BS1 C 4 14 ENGINE 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 Retightening the mounting bolts from this position could damage the tensioner and the camshaft chain Once the bolts are loosened the tensioner must be removed and reset as described in Camshaft Chain Tensioner Installation Do not turn over the crankshaft while the tensioner is re moved This could upset the cam chain timing and damage the valves Remove the chain tensioner cap A together with O ring Remove the mounting bolts and take off the camshaft chain tensioner Camshaft Chain Tensioner Installation e While compressing the push rod A turn C it clockwise with a suitable screwdriver B until the rod stops CAUTION Do not turn the rod counterclockwise at installation This could detach the rod and the tensioner cannot be reinstalled e While holding the rod in position with the screwdriver or a holder plate A install the tensioner on the cylinder block NOTE To make the procedure easy use a holder plate to keep the rod fro
66. narrow side C of the screen going first e Install the new gasket and oil screen cover e Tighten the oil screen cover bolts Torque Oil Screen Cover Bolts BN125 A1 9 8 N m 1 0 kgf m 87 in Ib 125 4 8 8 N m 0 90 kgf m 78 in Ib http mototh com GGO5000BS1 6005014851 C PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Wheels Tires Spoke Tightness Inspection e Check that all the spokes are tightened evenly x 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 35 in Ib e Check the rim runout A WARNING If any spoke breaks it should be replaced immedi ately A missing spoke places an additional load on the other spokes which will eventually cause other spokes to break Rim Runout Inspection e Place the jack under the frame so that the front rear wheel off the ground Special Tool Jack 57001 1238 e Inspect the rim for small cracks dents bending or warp ing x If there is any damage to the rim it must be replaced e Remove the wheels and set them on the suitable jig e Set a dial gauge to the side of the rim and rotate the rim to measure axial runout A The difference between the highest and lowest dial readings is the amount of runout e Set a dial gauge to the outer circumference of the rim and rotate the rim to measure radial runout B The d
67. not be less than the minimum in order to avoid piston seizure Piston Ring Piston Ring Groove Wear e Check for uneven groove wear by inspecting the ring seat ing The rings should fit perfectly parallel to groove surfaces If not replace the piston and all the piston rings e With the piston rings in their grooves make several mea surements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Top 0 03 0 07 mm 0 0012 0 0028 in Second 0 02 0 06 mm 0 0008 0 0024 in Service Limit Top 0 17 mm 0 0067 in Second 0 16 mm 0 0063 in x lf the piston ring groove clearance is greater than the ser vice limit measure the ring thickness and groove width as follows to decide whether to replace the rings the piston or both Piston Ring Groove Width e Measure the piston ring groove width OUse a vernier caliper at several points around the piston Piston Ring Groove Width Standard Top 0 82 0 84 mm 0 0323 0 0331 in Second 0 81 0 83 mm 0 0319 0 0327 in Service Limit Top 0 92 mm 0 0362 in Second 0 91 mm 0 0358 in xf the width of any of the two grooves is wider than the service limit at any point replace the piston http mototh com 8 16020851 ENGINE END 4 37 Cylinder Piston Piston Ring Thickness Measure the piston ring thickness OUse a micrometer to measure at several points around the rin
68. oil seals with manufacture and size marks facing out Make sure the seal is aligned properly when installing Apply specified grease to the lip of seal before installing the seal Circlips Cotter Pins Replace circlips or cotter pins that were removed with new ones Take care not to open the clip excessively when in stalling to prevent deformation http mototh com Gare 5 080720138 5 f 08020198 5 Grease GB02046BS1 C 08020708 5 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 Sey cation points are called out throughout this manual apply raw Jl the specific oil or grease as specified fA d d Bonz E Direction of Engine Rotation 4s When rotating the crankshaft by hand the free play 14 amount of rotating direction will affect the adjustment Ro tate the crankshaft to positive direction clockwise viewed from output side FA B020728 5 Electrical Leads A two color lead is identified first by the primary color and then the stripe color Unless instructed otherwise electrical Y R leads must be connected to those of the same color Instrument Use a meter that has enough accuracy for an accurate measurement Read the manufacture s instructions thor oughly before using the
69. piston CAUTION Do not reuse snap rings as removal weakens and deforms them They could fall out and score the cylinder wall e Remove the piston pin Special Tools Piston Pin Puller Assembly 57001 910 A Adapter B Remove the piston e Carefully spread the ring opening with your thumbs and then push up on the opposite side A of the ring to remove it Remove the 3 piece oil ring with your thumbs in the same manner Cylinder Piston Installation NOTE Olf a new piston or cylinder is used check piston to cylin der clearance see Piston Cylinder Clearance and use new piston ring e Apply engine oil to the inner surface of the connecting rod small end e The triangular mark on the piston head must point toward the front of the engine e Fit a new piston pin snap ring into the side of the piston so that the ring opening A does not coincide with the slit B of the piston pin hole http mototh com GE16022BS1 C GE16023BS1 C GE16031BS1 C 4 34 ENGINE END Cylinder Piston OWhen 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 NOTE OThe oil ring rails have no top or bottom e Install the oil ring expander A in the bottom piston ring groove so the ends B butt togeth
70. point solvents to clean the carburetor CAUTION Do not use compressed air on an assembled carbu retor or the floats may be crushed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbu retor with a cleaning solution This will prevent damage to or deterioration of the parts The carburetor body has plastic parts that can not be removed Do not use a strong carburetor cleaning solution which could attack these parts instead use a mild high flash point cleaning solu tion safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged e Disassemble the carburetor e Immerse all the metal parts in a carburetor cleaning solu tion Rinse the parts in water e When the parts are clean dry them with compressed air e Blow through the air and fuel passages with compressed air e Assemble the carburetor http mototh com Carburetor FUEL SYSTEM 3 19 Carburetor Inspection A 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 this includes any appliance with a pilot light e Remove the carburetor e Before disassembling the carburetor check the fuel level see Fuel Level
71. ports clean with compressed air e Check the piston return springs H for any damage x lf the spring is damaged replace it http mototh com 6107010451 C Front Brake Disc BRAKES 11 15 Disc Removal Remove the wheel see Wheels Tires chapter e Unscrew the mounting bolts and take off the disc Brake Disc Installation e Install the brake disc on the wheel so that the marked side A faces out e Tighten Torque Brake Disc Mounting Bolts B 27 N m 2 8 kgf m 20 ft Ib Brake Disc Wear e Visually inspect the disk Replace the disc if it shows any damage or crack e Measure the thickness of the disc A at the point where it has worn the most x If the disc has worn past the service limit replace it B Measuring Area Brake Disc Thickness Standard 3 8 4 2 mm 0 150 0 165 in 4 3 4 7 mm 0 169 0 185 in BN125 A3 Norway and Spain BN125 A4 Service Limit 3 5 mm 0 138 in 4 0 mm 0 157 in BN125 A3 Norway and Spain BN125 A4 Brake Disc Warp e Using a jack raise the wheel off the ground see Wheels Tires chapter Special Tool Jack 57001 1238 OFor front disc inspection turn the handlebar fully to one side e Set up a dial gauge against the disc B as shown measure disc runout while turning A the wheel by hand x If runout exceeds the service limit replace the disc Disc Runout Standard Less than 0 12 mm 0 008 in or
72. system Type Gear Reduction ratio 3 666 77 21 Clutch type Wet multi disc Transmission Type 5 speed constant mesh return shift http mototh com GENERAL INFORMATION 1 11 General Specifications ems BNi2 amp Ai A2 25 3 4 BNI2SAS Gear ratios 1st 2 700 27 10 2nd 1 705 29 17 ard 26 20 4th 1 090 24 22 5th 0 952 20 21 Final drive system Type Chain drive Reduction ratio 3 066 46 15 lt 2 800 42 15 BN125 A7 NU Overall drive ratio 10 708 gear 9 778 Top gear BN125 A7 N NU Frame Type Double cradle Caster rake angle 34 Trail 121 mm 4 8 in 119 mm 4 7 125 4 05 Rim Size Front 17 x 1 85 Rear 15 x 2 75 Front tire Type Tube type Size 90 90 17 49 Rear tire Type Tube type Size 130 90 15 66 Front suspension Type Telescopic fork Wheel travel 130 mm 5 1 in 140 mm 5 5 in Rear suspension Type Swingarm Wheel travel 60 mm 2 4 in 80 mm 3 1 in 75 mm 3 0 in BN125 A2 Brake type Front Single disc Rear Drum Electrical Equipment Battery 12 V9 Ah Headlight Type Semi sealed beam Bulb 12 V 60 55 W http mototh com 1 12 GENERAL INFORMATION General Specifications ltems BN125 A1 A2 BN125 A3 A4 125 5 Trail brake light 12 V 5 24 W Alterna
73. 01 1115 57001 1202 ST571115ST C 875712025 C http mototh com 4 10 ENGINE END Special Tools Fork Oil Level 57001 1290 ST571290ST C Compression Adapter 10 1 0 57001 1317 7571317ST C Valve Seat Cutter Holder 4 5 57001 1330 7571330ST C Valve Guide Arbor 4 5 57001 1331 875713315 C Valve Guide Reamer 4 5 57001 1333 7571333ST C Valve Seat Cutter 60 33 57001 1334 875713345 6 OValve Seat Cutter 32 33 57001 1199 can also be used instead of Valve Seat Cutter 32 35 57001 1121 OValve Seat Cutter 45 630 57001 1187 also be used instead of Valve Seat Cutter 45 27 57001 1114 http mototh com ENGINE END 4 11 Clean Air System For AT CH DE of 125 1 A2 and other than the CAL AT Austria CAL California CH Switzerland DE Germany Air Suction Valve Installation e Install the air suction valve so that its number A of the read faces outside and downward e Tighten Torque Air Suction Valve Cover Bolts BN125 A1 9 8 N m 1 0 kgf m 87 in Ib 125 4 8 8 N m 0 90 kgf m 78 Air Suction Valve Inspection e Refer to the Air Suction Valve Inspection in the Periodic Maintenance chapter Vacuum Switch Valve Removal e Remove the right side cover see Frame chapter e Remove the hose A from the air cle
74. 06107851 C 6806108851 C 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 2 one revolution of the rotor One is positive pulse A and d the other is a negative pulse be n Flywheel B Rotation Output Voltage Corresponds to timing plate length GBO6109BS2 C The crankshaft sensor a signal generator and voltage comparators determine the ignition timing in the ignition timing controller The power supply circuit is the power source for the signal generator and the voltage comparators Ignition Timing Controller Power Supply Circuit Signal Generator Crankshaft Signal Thyristor Sensor Comparator B Signal 6806110BN2 http mototh com 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 signals synchronized with the ET shaft sensor signal These signals are shown in the figure One Revoluti on That is to say the signal generator changes the crank Advance Anele sh
75. 15 10 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Capacity Electrolyte Level Specific Gravity of Electrolyte Charging System Type BN125 A1 A2 BN125 A3 Charging Voltage Stator Coil Resistance Regulator rectifier 12V9 Ah between level lines 1 280 0 01 20 68 F Single phase AC Three phase AC 14 15 V engine speed 4 000 r min rpm night in the text AC Lighting Voltage Lighting Coil Resistance BN125 A1 A2 BN125 A3 Ignition System Crankshaft Sensor Resistance BN125 A1 A2 BN125 A3 Crankshaft Sensor Peak Voltage Ignition Coil 3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage Spark Plug Spark Plug Type Standard Option Spark Plug Gap Spark Plug Cap Resistance Type BN125 A1 A2 Single phase all wave rectifier ees 125 Three phase all wave rectifier Se Resistance in the text pit AC Lighting System Alternator Type BN125 A1 A2 Single phase AC peius BN125 A3 Three phase AC Sa 11 16 V engine speed 4 000 r min rpm 0 1 0 8 Y Ground 0 3 0 9 Y Y 180 280 x 100 190 290 x 100 3 6 V or more 6 mm or more 0 09 0 13 O x 1 Q 3 8 5 8 kO x 1 110 V or more NGK CR7E or ND U24ESR N 0 7 0 8 mm 0 028 0 031 in 3 75 6 25 x 1 Electric Starter System Starter Motor Brush L
76. 16 57001 1262 or Owner s Tool 92110 1172 Spark Plug Cleaning Inspection e Refer to the Spark Plug Cleaning Inspection in the Peri odic Maintenance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Gap Inspection in the Periodic Maintenance chapter CDI Unit Removal OThe hand tester can check the CDI unit for a broken or badly shorted winding but it is a shortcut method which cannot inspect the precise condition of the CDI unit e Remove Fuel Tank see Fuel System chapter CDI Unit screws A and Bolts B CDI Unit C e Disconnect the connectors from the CDI unit http mototh com Ignition System ELECTRICAL SYSTEM 15 43 CDI Unit Inspection CAUTION When inspecting the CDI Unit A observe the fol lowing to avoid damage to the CDI Unit Do not disconnect the CDI Unit with the ignition switch on This may damage the CDI Unit Do not disconnect the battery leads while the engine is run ning This may damage the CDI Unit CDI Unit Operation Check e Remove the fuel tank see Fuel System chapter e Disconnect the connectors A from the CDI Unit e Set the hand tester B to the 25V DC range and connect it to the connector come from harness side as follows Tester terminal D R lead Tester terminal C BK Y lead Special Tool Hand Tester 57001 1394 e Turn the ignition switch on and read the voltage CDI Unit Operation Voltage Battery Voltage x If the tester reading
77. 23 2 23 2 24 http mototh com Drive Chain Wear Inspection Drive Chain Lubrication Brakes Brake Pedal Free Play Inspection Brake Shoe Lining Wear Inspection Brake Pad Wear Inspection Brake Hose and Connection Inspection Brake Fluid Level Inspection Brake Fluid Change Brake Line Bleeding Brake Master Cylinder Cup and Dust Seal Replacement Caliper Piston Dust Seals Replacement Brake Light Switch Inspection Brake Cable Replacement Suspension Front Fork Oil Change Front Fork Oil Leak Inspection Rear Shock Absorber Oil Leak Inspection Swingarm Pivot Lubrication Steering Steering Inspection Steering Adjustment Steering Stem Bearing Lubrication Electrical System Battery Electrolyte Level Inspection Spark Plug Cleaning Inspection Spark Plug Gap Inspection General Lubrication Lubrication Nut Bolt and Fastener Tightness Inspection Tightness Inspection 2 25 2 26 2 26 2 26 2 27 2 27 2 27 2 28 2 28 2 29 2 31 2 31 2 31 2 31 2 32 2 32 2 33 2 33 2 33 2 34 2 34 2 34 2 35 2 35 2 35 2 35 2 35 2 36 2 36 2 37 2 37 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 x 1 000 km x 1 000 mile v 1
78. 269 7571017ST C 875712695 http mototh com Throttle Grip and Cables FUEL SYSTEM 3 11 Free Play Inspection e Refer to the Throttle Grip Free Play Inspection in the Pe riodic Maintenance chapter Free Play Adjustment e Refer to the Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter Throttle Cable Installation e Install the throttle cable in accordance with the Cable Wire and Hose Routing section in the Appendix chapter e Install the upper ends of the throttle cables in the grip after installing the lower ends of the throttle cable on the carburetor e Tighten Torque Handlebar Switch Housing Screws 3 4 N m 0 35 kgf m 30 in Ib e After Installation adjust the cable properly WARNING Operation with incorrectly routed or improperly ad justed cables could result in an unsafe riding con dition Throttle Cable Lubrication and Inspection e Whenever the cable are removed or in accordance with the Periodic Maintenance Chart lubricate the throttle cable see General Lubrication in Periodic Maintenance chapter e Apply a thin coating of grease to the cable upper end e Use the pressure cable lubber to lubricate the cable e With the cable disconnected at both ends the cable should move freely in the cable housing xIf the cable movement is not free after lubricating if the cable is frayed or if the housing is kinked replace the cable http mototh c
79. 3 Fuel Tank Inspection 3 23 Fuel Tank Cleaning 3 24 Fuel Tap Removal 3 24 Fuel Tap Installation 3 24 Fuel Tap Inspection 3 25 Evaporative Emission Control System California Model Only 3 26 Parts Removal Installation 3 26 Hose Inspection 3 26 Separator Inspection 3 26 Separator Operation Test 3 27 Canister Inspection 3 27 http mototh com 3 2 FUEL SYSTEM Exploded View eT gt emit http mototh com FUEL SYSTEM 3 3 Exploded View Torque No Fastener Nm kgf m Remarks 1 Upper Chamber Cover Mounting Screws 3 5 0 36 31 in lb 2 Spring Seat Screws 0 8 0 080 7 in lb 3 Choke Lever Set Screw 0 8 0 080 7 in lb L 4 Choke Lever Pivot Screw 2 0 0 20 17 in lb 5 Pilot Air Jet 1 8 0 18 15 in lb 6 Coasting Enricher Cover Screws 2 0 0 20 17 in lb 7 Pilot Jet 0 8 0 080 7 in lb 8 Main Jet 1 8 0 18 15 in lb 9 Float Valve Holder Screw 2 0 0 20 17 in lb 10 Plunger 3 9 0 40 35 in lb 11 Float Bowl Screws 2 0 0 20 17 in lb 12 Carburetor Drain Plug 2 0 0 20 17 in lb 13 Throttle cable accelerator A Throttle cable decelerator Plug CA CH US Pilot screw Valve needle Needle jet Float Jet needle BN125 A1 A2 BN125 A3 CL Apply cable lubricant G Apply grease L Apply a non permanent locking agent CA Canada CH Switzerland US United States PO PO NM HH ASH A Ss
80. 3B 0138 http mototh com W2RO138AWS C 15 24 ELECTRICAL SYSTEM Precautions of important precautions that musts when servicing electrical systems Learn ob serve all the rules below not reverse the battery cable connections This will burn out the diodes on the electrical parts OAlways check battery condition before condemning other parts of an electrical system A fully charged battery is a must for conducting accurate electrical system tests OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTo prevent damage to electrical parts do not disconnect the battery cables or any other electrical connections when the ignition switch is on or while the engine is running OBecause of the large amount of current never keep the starter button pushed when the starter motor will not turn over or the current may burn out the starter motor wind ings ODo not use a meter or indicator illumination bulb rated for other than voltage or wattage specified in the wiring diagram as the meter or indicator panel could be warped by excessive heat radiated from the bulb OTake care not to short the leads that are directly con nected to the battery positive terminal to the chassis ground OTroubles may involve one or in some cases all items Never replace a defective part without de
81. 50 43 1 17 Crankshaft sensor 18 Regulator rectifier 19 Ignition coil 20 CDI unit 21 Battery 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 http mototh com 15 6 ELECTRICAL SYSTEM Exploded View http mototh com ELECTRICAL SYSTEM 15 7 Exploded View Fastener ES Neutral Switch Sidestand Switch Screws 0 40 35 in lb L Handlebar Switch Housing Screws 3 4 0 35 30 in lb 2 Ignition switch Turn signal relay Starter circuit relay Interlock diode Fuse case BN125 A1 Rear brake light switch Sidestand switch Meter unit Apply a non permanent locking agent http mototh com 15 8 ELECTRICAL SYSTEM Exploded View http mototh com ELECTRICAL SYSTEM 15 9 Exploded View ts to ain Turn Signal Light Holder Nuts 0 60 52 Headlight unit Turn signal lights Tail brake light Canada and United Kingdom Models BN125 A6 Other than Canada and United Kingdom Models United Kingdom Model only BN125 A6 ONOaAKR WM http mototh com
82. 6 12 18 24 30 36 OPERATION Every 0 6 4 7 5 15 20 24 Fuel hose connections inspectt e Throttle grip play inspect Idle speed inspect Air cleaner element clean t Evaporative emission control system CAL inspect 1 Air suction valve inspect AT CH DE SI US Cylinder head bolt tightness inspect Valve clearance inspect Clutch adjust Engine oil change 6 month e Oil filter replace e e Oil screen clean Spoke tightness rim runout inspect e wear inspect Drive chain slack inspect 1 000 km Drive chain wear inspect Drive chain lubricate 600 km Brake pedal free play inspect Brake lining or pad wear inspect e Brake hose connections inspect e Brake fluid level inspect month jo Brake fluid change 2 years Brake master dust Caliper fluid seal and dust seal replace 4 years 4 years Brake light switch inspect 1 e Brake cable replace 2 years Front fork oil change 2 years Front fork oil leak inspect Rear shock absorber oil leak inspect Swingarm pivot lubricate N Steering inspect Steering stem bearing lubricate 2 years Battery electrolyte level inspect 6 months
83. 6 Clutch Lever Free Play Inspection 5 6 Clutch Lever Free Play Adjustment 5 6 Clutch Lever Installation 5 6 Clutch Cable Removal 5 6 Clutch Cable Installation 5 6 Clutch Cable Lubrication 5 6 Clutch Cover 5 7 Clutch Cover Removal 5 7 Clutch Cover Installation 5 7 Clutch Cover Assembly 5 8 Clutch 5 9 i Fed Eu 5 9 Clatch Installation Mii 5 9 Friction and Steel Plate Damage Wear Nt 5 10 Friction and Steel Plate Warp terrere naps 5 10 Clutch Spring Free Length Measurement nennen 5 11 Clutch Housing Finger Damage cde Miete uo lia p Sp BR ax Mo ctos etd 5 11 Gluten eub Spline dag to cm tton qe pda thia ead DH cx dapes sona 5 11 Primary cuo 5 12 Primary Gear Removal 5 12 Primary Gear Installation http mototh com 5 2 CLUTCH Exploded View Qo Q AB n F 0 0 QU 6 02038 5 http mototh com CLUTCH 5 3 Exploded View Torque Fastener kgf m itib Remarks 1 Clutch Hub Nut 98 10 0 72 2 Spring Bolt 8 8 0 90 78 in lb 3 Clutch Cover Bolts BN125 A1 9 8 1 0 87 in lb Clutch Cover Bolts BN125 A4 8 8 0 90 78 in lb 4 Seal Retaining Plate Bolts BN125 A1 9 8 1 0 87 in lb Oil Se
84. 7 can also be used instead of Valve Seat Cutter 45 627 5 57001 1114 For Inlet Valve Seat Valve Seat Cutter 457 532 57001 1115 Valve Seat Cutter 327 535 57001 1121 or 33 57001 1199 Valve Seat Cutter 607 533 57001 1334 OValve Seat Cutter 32 33 57001 1199 can also be used instead of Valve Seat Cutter 32 635 57001 1121 the manufacturer s instructions are not available use the following procedure http mototh com Valves ENGINE TOP END 4 29 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 diamond particles may fall off 3 Do not fail to apply engine oil to the valve seat cutter before grinding the seat surface Also wash off ground particles sticking to the cutter with washing oil NOTE ODo not use a wire brush to remove the metal particles from the cutter It will take off the diamond particles 4 Setting the valve seat cutter holder in position operate the cutter in one hand Do not apply too much force to the diamond portion NOTE OPrior to grinding apply engine oil to the cutter and during the operation wash off any ground particles sticking to the cutter with washing oil 5 After use wash it with washing oil and apply thin layer of engine oil before storing Marks Stamped on the Cutter The marks stamp
85. 8 SeabHemovalz AE EE 14 8 Seatlnstallationi zs ne ATA ce eu IM 14 8 14 9 Front Fender POST 14 9 Front Fender Installation Nt 14 9 Redan Fender Rear datas teo ee oe 14 9 Rear Fender Rear Disassembly pp 14 10 Rear Fender Eront Removal eee tee e Noel A 14 10 laic 14 11 Frame INsp ction Rm 14 11 http mototh com 14 2 Exploded View P http mototh com Exploded View FRAME 14 3 Torque No Fastener Remarks N m kgf m ft Ib 1 Front Footpeg Bolts 23 2 3 17 O Apply oil http mototh com 14 4 Exploded View SG amp US Other than SG amp US Other than SG amp US N 2 ceo o V 6002103 5 http mototh com 14 5 Exploded View IT Italy SG Singapore US United States BN125 A4 http mototh com 14 6 Special 57001 1238 Jack e a e N Lr pud http mototh com 14 7 Side Covers Left Side Cover Removal e Remove the screws A e Pull B the front part
86. 9 13 9 13 http mototh com 9 2 WHEELS TIRES Exploded View PLP a PD 9 SN http mototh com WHEELS TIRES 9 3 Exploded View Torque No Fastener i Tie ArVave Nuts 15 os imb HERE NN ERE Spoke Nipples 2 0 3 9 0 20 0 40 17 35in lb Front Axle Nut 78 8 0 58 Rear Axle Nut 98 10 0 72 5 For DE of BN125 A1 A2 and On and after BN125 A3 of EUR Models G Apply grease R Replacement Parts WL Apply soap and water solution or rubber lubricant DE Germany EUR Europe http mototh com 9 4 WHEELS TIRES Specifications Axle Rumout 100 mm 3 9 Tires Air Pressure When Cold Front BN125 A1 A2 Up to 185 kg 408 Ib load 150 kPa 1 5 kgf cm 21 psi Item Standard Service Limit Wheels Rims Rim Size Front 17 x 1 85 15 x 2 75 SS 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 0 2 mm 0 008 in TIR 0 1 mm 0 004 in or less BN125 A1 A2 BN125 A3 A5 BN125 A6 Rear BN125 A1 A2 BN125 A3 Replacement Tires Front Rear DUNLOP D404F tube type IRC NF53 Tube type IRC NF53 Tube type DUNLOP D404 tube type Make Type METZELER PERFECT ME77 tube type BN125 A3 Up to 155 kg 342 Ib load 150 kPa 1 5
87. ARNING If the axle nut and torque link nut are not securely tightened an unsafe riding condition may result e Turn the wheel measure the chain slack again at the tight est position and readjust if necessary e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole http mototh com HJ07007BS1 PERIODIC MAINTENANCE 2 25 Periodic Maintenance Procedures eBend the cotter over the nut 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 e Tighten the chain adjuster locknuts Drive Chain Wear Inspection e Remove the chain cover see Final Drive chapter e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links x If there is any irregularity replace the drive chain Lubricate the drive chain if it appears dry Stretch the chain taut by hanging 98 10 kg 20 Ib weight A on the chain Measure the length of 20 links on the straight part of the chain from the pin center of the 1st pin to the pin center of the 21s
88. BO6112BS4 C gt Ignition Timing deg BTDC Advance Flat Flat Engine Speed gt 8 06113851 C 1 20 GENERAL INFORMATION Technical Information Coasting Enricher 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 The passage 6 is open and the air runs through the pilot jet 7 for better atomization During engine braking a high vacuum is generated behind the butterfly valve 11 This draws the diaphragm 2 against the return spring 8 to close the valve 12 and then the passage 6 The mixture becomes rich to prevent backfiring because the amount of air is reduced During Cruising or Acceleration During Engine Braking 19 0 9 D mf 0 SA A A 2 d 222 Z N NZ A 2 E 7 AG 22227 7 2 in BEA d 5 22 d On m BW ay LA Fuel Float M EZ 8 Float gt Bow f Bow Low Vacuum High Vacuum 2 Air Flow au I NA NA AA lost Rich ZA I ez CCZZZZZZZZZZZZZZZZZZZZZZZZZZZZZLL fA f 1 9 Slow
89. C and take the gasket out of the bottom of the outer tube Special Tools Fork Cylinder Holder Handle 57001 183 D Fork Cylinder Holder Adapter 57001 1011 E e Take the cylinder unit out of the inner tube e Remove the dust seal A from the outer tube with a screw driver e Remove the retaining ring A from the outer tube with a screwdriver http mototh com GM04004BS1 C 6 04146851 C 12 10 SUSPENSION Front Fork e 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 e Take out the cylinder base out of the outer tube e Remove the guide bushings A washer B and oil seal C from the inner tube Fork Assembly e Check the O ring on the top plug and replace it with a new one e Replace the following parts with new ones after removal Dust Seal A Retaining Ring B Oil Seal C Inner Guide Bushing D Outer Guide Bushing E Bottom Allen Bolt Gasket F e Put the cylinder unit A with the spring into the inner tube B protruding from the inner tube and install the cylinder base C onto the bottom end of the cylinder unit Olnstall the cylinder base with the tapered end D up e Install the inner tube cylinder unit and cylinder base as a set into the outer tube e Install
90. CTRICAL SYSTEM Ignition System Ignition Timing Engine speed Head timing mark A aligns with 1 300 100 r min rpm mark B on camshaft sprocket x If the ignition timing is incorrect inspect the CDI unit and the crankshaft sensor Ignition Coil Removal e Remove the fuel tank see Fuel System chapter e Disconnect the primary winding leads from the ignition coil e Remove the mounting bolt A e Take off the ignition coil B Ignition Coil Installation e Tighten the ignition coil bolt Torque Ignition Coil Bolt 6 9 Nm 0 70 kgf m 61 in Ib Olnstall the ignition coil noting the position of the ground terminal A and primary winding leads Terminal B BL BK Lead Terminal C BK Y Lead Ignition Coil Inspection e Remove the ignition coil see this chapter e Measure the arcing distance with the suitable commer cially available coil tester A to check the condition of the ignition coil B e Connect the ignition coil with the spark plug cap left at tached at the end of the spark plug lead to the tester in the manner prescribed by the manufacturer and measure the arcing distance A WARNING To avoid extremely high voltage shocks do not touch the coil body or leads x If the distance reading is less than the specified value the ignition coil or spark plug cap is defective Ignition Coil Arcing Distance 6 mm or more To determine which part is defective
91. Clutch Inspection e Remove the alternator cover see Electrical System chap ter e Turn the starter gear A by hand The starter gear should turn clockwise B freely but should not turn counterclock wise C by the starter clutch function the starter motor clutch does not operate as it should or if it makes noise disassemble the starter motor clutch and visually inspect the clutch parts If there is any worn or damaged part replace it e Visually inspect the starter gear and crankshaft x If the sliding surface A is worn or damaged replace the starter gear and or crankshaft Torque Limiter Inspection e Remove the torque limiter A and visually inspect it x lf the limiter has any wear discoloration or other damage replace it as a unit http mototh com I gt F CRANKSHAFT TRANSMISSION 8 17 External Shift Mechanism Shift Pedal Height Adjustment e 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 E 18 6 Shift Pedal Removal Remove the engine sprocket cover A see Final Drive chapter e Remove the clamp bolt e Remove the shift lever C from the shift shaft NOTE OWhen installing the shift lever onto the shift shaft ali
92. Cover Screws 2 0 0 20 17 in lb Pilot Jet 0 8 0 080 7 in lb Main Jet 1 8 0 18 15 in lb Float Valve Holder Screw 2 0 0 20 17 in lb Choke Plunger Cap 3 9 0 40 35 in lb Float Bowl Screws 2 0 0 20 17 in lb Carburetor Drain Plug 2 0 0 20 17 in lb Fuel Tap Plate Screws 0 8 0 080 7 Fuel Tap Diaphragm Cover Screws 1 0 0 10 9 in lb Fuel Tap Mounting Bolts White Washer 2 5 0 25 22 Fuel Tap Mounting Bolts Black Washer 4 9 0 50 43 in lb Engine Top End Valve Adjusting Cap Bolts Bn125 A1 A3 9 8 1 0 87 Valve Adjusting Cap Bolts BN125 A4 8 8 0 90 78 in lb Camshaft Chain Cover Bolts BN125 A1 A3 9 8 1 0 87 in lb Camshaft Chain Cover Bolts BN125 A4 8 8 0 90 78 in Ib Cylinder Head Bolts M9 26 2 7 19 OM S washer Cylinder Head Bolts M6 12 1 2 104 in Ib S Camshaft Chain Cover Damper Bolts 9 8 1 0 87 in lb BN125 A1 Camshaft Chain Cover Damper Bolts 8 8 0 90 78 in Ib BN125 A4 Spark plug 13 1 3 9 5 Cylinder Head Blank Cap Bolt BN125 A1 9 8 1 0 87 Cylinder Head Blank Cap Bolt BN125 A4 8 8 0 90 78 in lb Carburetor Holder Bolts 9 8 1 0 87 in lb Air Suction Valve Cover Bolts BN125 A1 A3 9 8 1 0 87 Air Suction Valve Cover Bolts BN125 A4 8 8 0 90 78 in lb Cylinder Head Plug 4 9 0 50 43 Vacuum Hose Fitting 5 9 0 60 52 in lb http mototh com PERIODIC MAINTENANCE 2 5 Torque and Locking Agent Pipe Banjo Bolts 8 Oil Pipe Banjo Bolts M10 Oil Pipe Mo
93. ENDIX BN125 A5 AXI A n n 9 P3 12772022000 7229177 1 NE 4446 224 e SA dam d MEO _ wie WU aaa spans oo et LL 0 X 45 NT Wem SS z Zi 7 AU 0 _ TUN l San Eu i E H NE SS 00 9 O 08809927845 C http mototh com Cable Wire Hose Routing 2 lt a a Rear Left Turn Signal Light Connector Tail Brake Light Connector Band White Tape Ground Lead Regulator Rectifier Connector Ignition Coil Lead Left Handlebar Switch Connector Horn Connector Indicator Light Connector Sidestand Switch Connector Front Left Turn Signal Light Connector Front Right Turn Signal Light Connector Headlight Connector Speedometer Connector City Light Connector Europe Model Ignition Switch Connector Rear Brake Switch Connector Right Handlebar Switch Connector CDI Unit Connector Alternator Connector Battery Negative Lead Connector Turn Signal Relay Connector Fuse Box Connector Starter Relay Connector Starter Circuit Relay Connector Diode
94. ION Do not scrape off the deposits with a scraper as this could damage the rubber requiring replacement of the suction valve assembly http mototh com GE04062381 C 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cylinder Head Bolt Tightness Inspection Check that 6 mm A and 9 mm 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 Ib 9 mm Cylinder Head Bolts 26 Nm 2 7 kgf m 19 ft lb Valve Clearance Inspection CAUTION If valve clearance is left unadjusted wear will even tually cause the valves to remain party open which lowers performance burns the valves and the valve seats and may cause serious engine damage NOTE O Valve clearance must be checked and adjusted when the engine is cold at room temperature e Remove Valve Adjusting Caps A Camshaft Chain Cover B e Turn the camshaft center bolt A counterclockwise with a wrench OMaking sure that the inlet valve opens and then closes start to turn the bolt in the same direction until the mark C on the camshaft sprocket aligns with the timing mark B on the cylinder head This shows that the piston TDC is at the end of the compression stroke e Using athickness gauge A measure the valve clearance between the adjusting screw and valve stem Measure the clearance for both valv
95. Inspection Move the starter plunger lever up and down to check that the starter plunger moves smoothly x lf the starter plunger does not work properly replace the plunger level and or the carburetor e Turn the throttle cable pulley to check that the throttle valve A moves smoothly and return by spring face x If the throttle valve does not move smoothly replace the carburetor e Disassemble the carburetor see Carburetor Disassem bly e Clean the carburetor see Carburetor Cleaning e Check that the diaphragm A on the vacuum piston is in good condition If any of the diaphragm is not in good condition replace them e Check the plastic tip A of the float valve needle B It should be smooth without any grooves scratches or tears x lf the plastic tip is damaged C replace the needle e Push the rod D in the other end of the float valve needle and then release it E x f the rod does not spring out replace the float valve nee dle http mototh com 6606040551 C 3 20 FUEL SYSTEM Carburetor Check the tapered portion of the pilot screw for wear or damage x If the pilot screw is worn or damaged on the tapered por tion it will prevent the engine from idling smoothly Re place it e Check that the vacuum piston A moves smoothly in the carburetor body The surface of the piston must not be excessively worn the vacuum piston does not move smoothly o
96. KSHAFT TRANSMISSION 8 13 Crankshaft Crank Balancer Gear Removal Installation Refer to Camshaft Chain Removal Installation in the En gine Top End chapter Crankshaft Removal e Refer to the Crankcase Disassembly in this chapter Crankshaft Installation e Refer to the Crankcase Assembly in this chapter Crankshaft Disassembly If the crankshaft is damaged replace it as a set Not for sale to each part of the crankshaft Connecting Rod Big End Seizures e In case of seizure replace the crankshaft assembly Connecting Rod Big End Radial Clearance e Support the crankshaft with both side and place dial gauge A against the connecting rod big end e Push B the connecting rod first towards the gauge and then in the opposite direction The difference between two gauge readings is the radial clearance Connecting Rod Big End Radial Clearance Standard 0 005 0 017 mm 0 0002 0 0007 in Service Limit 0 07 mm 0 003 in x If the radial clearance exceeds the service limit replace the crankshaft assembly Connecting Rod Big End Side Clearance Measure connecting rod big end side clearance A Connecting Rod Big End Side Clearance Standard 0 20 0 35 mm 0 008 0 014 in Service Limit 0 50 mm 0 020 in x lf the clearance exceeds the service limit replace the crankshaft assembly Crankshaft Runout e Supporting the crankshaft from both side place a dial gauge as shown and turn the crankshaft slowly
97. L SYSTEM Lighting System Turn Signal Light Circuit BN125 A6 PARK BATTERY CC 1 Om a BK Y DLL oss BK Y BK Y GP12082BWN3 Turn signal indicator light Turn signal relay lgnition fuse 15 A Front right turn signal light Front left turn signal light Rear right turn signal light Rear left turn signal light Turn signal switch lgnition switch Starter relay Main fuse 30 A Battery http mototh com ELECTRICAL SYSTEM 15 63 Meter Gauge Indicator Unit Speedometer Removal e Remove the speedometer cable upper end A Remove the meter unit by taking off the mounting bolts 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 Speedometer Disassembly e Remove Speedometer see this chapter Screws A Screw B and Knob C e To remove the wedge base type bulb A then pull the bulb out of the socket CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for other than voltage or wattage specified in the wiring dia gram Indicator Unit Removal Installation e Remove the bolts A and indicator unit B fro
98. Locknut Starter Motor Terminal Nut Starter Relay Terminal Bolt Starter Motor Assembly Bolts Starter Motor Mounting Bolts Starter Motor Clutch Bolts BN125 A1 Starter Motor Clutch Bolts BN125 A2 Headlight Body Screws Handlebar Switch Housing Screws A2 13 3 9 6 9 4 9 8 8 8 8 69 98 104 13 13 8 8 6 9 4 9 4 9 3 4 8 8 34 12 2 9 3 4 4 5 Hand tight or 0 50 3 5 2 0 0 35 2 0 3 5 2 3 1 3 0 40 0 70 0 50 0 90 0 90 7 0 10 0 10 6 1 3 1 3 0 90 0 70 0 50 0 50 0 35 0 90 3 5 1 2 0 30 0 35 33 Hand tight or 43 in lb 25 15 30 in lb 15 25 113 in lb 5 16 61 in lb 43 in lb 78 16 78 51 72 76 113 in lb 113 78 16 61 16 43 in lb 43 in lb 30 in lb 78 in lb 25 104 in lb 26 16 30 in lb http mototh com 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Threads dia mm 3 4 4 9 6 5 9 7 8 8 14 19 10 25 34 12 44 61 14 73 98 16 115 155 18 165 225 20 225 325 Fastener Remarks N m Turn Signal Light Holder Nuts 59 Neutral Switch 15 Sidestand Switch Screws 3 9 L 0 35 0 50 0 60 0 80 1 4 1 9 2 6 3 5 4 5 6 2 7 4 10 0 11 5 16 0 17 0 23 0 23 33 http mototh com The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a s
99. Mainte nance chapter Oil Filter Change e Refer to the Oil Filter Change in the Periodic Maintenance chapter http mototh com 6 8 ENGINE LUBRICATION SYSTEM Oil Screen Oil Screen Removal e Refer to the Oil Screen Cleaning in the Periodic Mainte nance chapter Oil Screen Installation e Refer to the Oil Screen Cleaning in the Periodic Mainte nance chapter http mototh com ENGINE LUBRICATION SYSTEM 6 9 Oil Pump Pump Removal e Remove the clutch cover see Clutch chapter e Remove the mounting screws A and remove the oil pump assembly B OTurn the pump gear so that the pump mounting screws can be removed through the pump gear holes Oil Pump Installation e Replace the O rings with new ones e Install the O rings A e Install the dowel pin B e Install the oil pump assembly e Tighten Torque Oil Pump Mounting Screws A 4 9 N m 0 50 kgf m 43 in Ib e Install the clutch cover see Clutch chapter Oil Pump Disassembly e Remove Oil Pump see this chapter Circlip and Washer A Oil Pump Assembly Screw B e Remove the oil pump cover C 6009000851 C e Remove Inner Rotor A Outer Rotor ES 9 NN 6009010151 http mototh com 6 10 ENGINE LUBRICATION SYSTEM Oil Pump Pump Assembly e Install the oil pump gear A e Fill the rotors B with engine oil e Install the cover and tighten the oil pump assembly scr
100. Mounting Bracket Bolts B OPull out the mounting bolts while lifting the engine e Lift up the engine and move it to the right side of the frame e Remove the engine A from the vehicle right side Engine Installation e Insert the mounting bolts from the left side of the engine and install the nuts on the right side e Tighten the engine mounting bolts with the specified torque Torque Engine Mounting Bolts Nuts M10 A 44 N m 4 5 kgf m 33 ft lb Engine Mounting Bolts Nuts M8 B 25 N m 2 5 kgf m 18 ft lb Engine Mounting Bracket Bolts 25 N m 2 5 kgf m 18 ft lb Cylinder Head Bracket Bolts Nuts 25 N m 2 5 kgf m 18 ft lb e Install the drive chain A and engine sprocket B http mototh com GHO4010281 ENGINE REMOVAL INSTALLATION 7 7 Engine Removal Installation x 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 Olnstall the clip A so that the open end B of the U points in the opposite direction of chain rotation C e Install the engine ground cable A as shown Run the cable near the mounting boss B e Tighten Torque Engine Ground Terminal Bolt 9 8 Nm 1 0 kgf m 87 in Ib e Run the cables hoses and leads according to the Cable Wire and Hose Routing section of the Appendix chapter e Install the removed parts see appropriate chapters e Adjust Throttle Cable see Fu
101. NGINE END Valves Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose make seating area smooth and round Measure Seat Outside Diameter Tool Vernier Caliper Purpose check seat outside diameter against specification Results Too small Machinist s dye on seat 45 Grind Tool 45 Cutter Purpose increase outside diameter of seat area to specification 32 Grind Tool 32 Cutter reduce outside diameter Measure Seating seat area to specification Tool Vernier Caliper Purpose check seat width against specification Too narrow Too wide 45 Grind Machinist s dye on seat Tool 45 Cutter Purpose increase width of seat area beyond specification to increase outside diameter 60 Grind Tool 60 Cutter Purpose reduce seat width to specification Tool Valve lapper grinding compound Purpose perfectly match valve and seat are check valve head for damage GEI5093B http mototh com Cylinder Piston ENGINE TOP END 4 33 Cylinder Removal e 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 e Remove the cylinder see Cylinder Removal e Place a clean cloth under the piston and remove the pis ton pin snap ring A from the outside of the
102. Passage Slow Passage EN 1 Pilot Air Jet 1 7 Pilot Jet 2 Diaphragm 8 Pilot Air Jet 2 3 Return Spring 9 Pilot Screw 4 Cover 10 Air Cleaner Housing 5 Valve Opened 11 Butterfly Valve Throttle Valve 6 Passage 12 Valve Closed http mototh com GENERAL INFORMATION 1 21 Technical Information Coasting Enricher Fuel and Air Supply of Enricher System Fuel Tank Float sin Air Cleaner Pilot Jet Fuel LZZ Mixture Pilot Air Jet2 Ai Carburetor HE Slow Passage Bore Bypass Outlet X Pilot Screw Engine 6806015282 http mototh com 1 22 GENERAL INFORMATION Unit Conversion Table Prefixes for Units Units of Length Symbol Power km x 0 6214 mile mega M 1 000 000 m x 3 281 ft centi C 0 01 milli m 0 001 0 000001 Units of Torque N m x 0 1020 kgf m Nm x 0 7376 ft lb Units of Mass 2 E kg x 2 205 Ib x 7 233 9 0 03527 02 kgf m x 8680 Units of Volume Units of Pressure L x 0 2642 gal US kPa x 0 01020 kgf cm L x 0 2200 gal imp kPa x 0 1450 L x 1 057 qt US kPa x 07501 kgf cm x 9807 kPa L x 2 113 x pint US kgf cm x 14 22 p L x 186 Qfpint imp cmHg x 1 33 kPa mL x 0 03381 oz US mL x 0 02816 oz imp mL x 0 06102 cu in Units of Speed km h x 0 6214 mph Units of Force gt RI x Units of Pow
103. R BL W Light 12V 3 4W 16 LG Turn Signal Indicator pu zd Light 12V 3 48 gt x 555 3 11111 gt gt sp cosa Ss Headlight 12 60 551 Hi City Light z 12V4W N m 12V5W NU Dther than United States and Canada O Loden Front Right n 9 Signal Light BK Y BK Y 12V 21W Left Handlebar Switches Horn 1 Button 12V 3 0 9 Turn Signal Switch 3 Dimmer Switch 4 Starter Lockout Switch Front Left Turn Signal Light BK Y BK Y 12V 2194 W2L0138AW5 C http mototh com Wiring Diagram ELECTRICAL SYSTEM 15 23 Rear Brake Light Switch Spark Plug Fuses 1 Lights 2 lenition 15 Starter 15 Circuit Turn Relay m Interlock Diode ition kj n Signal Tail Brake Light 12V 5 21W Regulator Rectifier Alternator 2 Crankshaft Side Stang Neutral Sensor Switeh Se FER Starter Motor IGNITION SWITCH CONNECTIONS BK Y DL BK Y Battery 12V 9 RIGHT HANDLEBAR SWITCH CONNECTIONS Color Code Stack gt flue Green Front Brake Light Switch Engins Stop Switch Starter Button eotor y R Gotorlon e on al Orange Pink pu Purple Brake Lever OFF Push Pulled In a Released Released RUN a White Y Yellow 88052 11424 114
104. RAKES Rear Brake Pedal Brake Cable Brake Pedal Position Inspection Adjustment gt Check that the brake pedal A is in the correct position Pedal Position C Standard About 80 mm 3 15 in above footpeg top x If it is incorrect adjust the brake pedal position e Loosen the locknut A and turn the adjusting bolt B until the brake pedal is correctly positioned e Tighten the locknut Check Rear Brake Light Switch Timing see Electrical System chapter Brake Pedal Free Play see Brake Pedal Free Play In spection NOTE Olf the pedal position cannot be adjusted by turning the adjusting bolt the brake pedal may be deformed or in correctly installed Brake Pedal Free Play Inspection Adjustment e Refer to the Brake Pedal Free Play Check in the Periodic Maintenance chapter Brake Pedal Removal e Remove the adjusting nut from the end of the brake rod and take off the joint and brake rod from the brake cam lever e Remove Bands A Cover B Front Footpeg Mounting Bolts C e Remove Cotter Pin and Joint Pin A Brake Cable Nut B Brake Pedal Bolts C Rear Brake Light Switch Spring D http mototh com Rear Brake Pedal Brake Cable BRAKES 11 19 Remove the brake pedal A and return spring Brake Pedal Installation e Apply grease to the brake pedal pivot e Temporarily install the brake return spring onto the brake shaft and hook the spr
105. Spark Plug 13 N m 1 3 kgf m 113 in Ib The following table should be consulted if the obtainable compression reading is not within the us able range Problem Diagnosis Remedy Action Cylinder Carbon accumulation on piston and in Remove the carbon deposits and replace compression combustion chamber possibly due to damaged parts if necessary is higher than damaged valve stem oil seal and or usable range damaged piston oil rings This may be indicated by white exhaust smoke Incorrect cylinder head gasket Replace the gasket with a standard part thickness Cylinder Gas leakage around cylinder head Replace damaged gasket and check compression cylinder head warp is lower than condition of valve seating Repair if necessary usable range Incorrect valve clearance Adjust the valve clearance Incorrect piston cylinder clearance Replace the piston and or cylinder Piston seizure Inspect the cylinder and liner and replace repair the cylinder and or piston as necessary Bad condition of piston ring and or Replace the piston and or the piston rings piston ring grooves http mototh com 4 22 ENGINE END Cylinder Head Cylinder Head Removal e 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 e Remo
106. Spark Plug Gap 0 7 0 8 mm 0 028 0 031 in http mototh com GNO7010381 C 8 08010251 C 9 0 0 0 9 0 9 0 9 DSS SS 222727 lt gt 8 10012851 C 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Pivots Lubricate with Motor Oil Sidestand Brake Pedal Clutch Lever Points Lubricate with Grease Throttle Inner Cable Upper Ends A Speedometer Inner Cable Clutch Inner Cable Upper End Brake Lever Grease the lower part of the inner cable sparingly Apply silicone grease Cables Lubricate with Cable Lubricant Throttle Inner Cable Clutch Inner Cable e Lubricate the cables by seeping the oil between the cable and housing OThe cable may be lubricated by using a commercially available pressure cable lubricator with an aerosol cable lubricant e With the cable disconnected at the both ends the cable should move freely A within the cable housing x If cable movement is not free after lubricating if the cable is
107. TOP END 4 27 Valve Guide Installation Apply oil to the valve guide outer surface before installa tion e Heat the area around the valve guide hole to about 120 150 C 248 302 F CAUTION Do not heat the cylinder head with torch This will warp the cylinder head Soak the cylinder head and heat the oil e Drive the valve guide in from the top of the head using the valve guide arbor until the circlip stops the guide from going in too far Special Tool Valve Guide Arbor 4 5 57001 1331 e Ream the valve guide with valve guide reamer A even if the old guide is reused Special Tool Valve Guide Reamer 4 5 57001 1333 Valve to Guide Clearance Measurement Wobble Method If a small bore gauge is not available inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below e Insert a new valve A into the guide B and set a dial gauge against the stem perpendicular to it as close as possible to the cylinder head mating surface e Move the stem back and forth C to measure valve valve guide clearance e Repeat the measurement in a direction at a right angle to the first x If the reading exceeds the service limit replace the guide NOTE OThe reading is not actual valve valve guide clearance because the measuring point is above the guide Valve Valve Guide Clearance Wobble Method Standard Exhaust 0 14 0 19 mm 0 006 0 007 in
108. Turn EAd cy al Light BK Y Pad 5k v 23W i OFF m gt lt 296558 11 IT DE Un zi 05222 i5 i E oa 5 1 a H 1 PUSH FREE 1 1 1 cee 9 Side Stand Left Handlebar Switches Switch Horn 1 Button 12V 3 0A 2 Turn Signal Switch 3 Dimmer Switch 4 5 Lockout Switch Front Left Turn gt 6 Signal Light BK Y p eK Y 12V 234 LEFT HANDLEBAR SWITCH CONNECTIONS Sidestand Switch Horn Turn Signal Switch Dimmer Switch Starter Lockout Switch Color Clutch Lever W1L1783CW5 C http mototh com ELECTRICAL SYSTEM 15 17 Wiring Diagram Rear Brake Light Switch Fuses Spark Plug 1 Lights 15 Starter Circuit Interlock 2 Ignition 15 Turn Signal LA Diode KT BL R KJ BL Light R Lik Rear Right Gy Pie cy Signal Light 6 12V 23 Rear Left 4 Signal Light 12V 23 gt Main Fuse Alternat i ernator km 128 44 m sk Black Crankshaft et Blue Chocolate DG Park Green e ereen ay oray Light Blue IGNITION SWITCH CONNECTIONS RIGHT HANDLEBAR SWITCH CONNECTIONS 9 Front Brake Light Switch Engine Sto
109. Valves ENGINE TOP END 4 31 x lf the seat width is too wide make the 60 grind A de scribed below x If the seat width is within the specified range lap the valve to the seat as described below e Grind the seat at a 60 angle until the seat width is within the specified range OTo make the 60 grind fit 60 cutter into the holder and slide it into the valve guide OTurn the holder while pressing down lightly OAfter making the 60 grind return to the seat width mea surement step above Correct Width B e Lap the valve to the seat once the seat width and O D are within the ranges specified above OPut a little coarse grinding compound on the face of the valve in a number of places around the valve head OSpin the valve against the seat until the grinding com pound produces a smooth matched surface on both the seat and the valve ORepeat the process with a fine grinding compound Lapper A Valve Seat B Valve C e The seating area should be marked about in the middle of the valve face x If the seat area is not in the right place on the valve check to be sure the valve is the correct part If it is it may been refused too much replace it e Be sure to remove all grinding compound before assem bly e When the engine is assembled be sure to adjust the valve clearance see Valve Clearance Adjustment http mototh com GE15012381 C GE15012081 4 32 E
110. Wipe oil off the outer circumference of the rotor e Hold the alternator rotor A steady with the flywheel holder B and remove the rotor nut C Special Tool Flywheel Holder 57001 1313 CAUTION Do not hold the timing plate D of the alternator rotor This can damage the timing plate http mototh com 15 32 ELECTRICAL SYSTEM Charging System e Using the flywheel puller and rotor puller remove the alternator rotor C from the crankshaft Special Tools Flywheel Puller M30 1 5 57001 1191 Rotor Puller M16 M18 M20 M22 x 1 5 57001 1216 OHolding the flywheel puller screw in the rotor puller while tapping the head of the rotor puller with a hammer and remove the alternator rotor e Remove the starter gear D Alternator Rotor Installation e Apply oil to the crankshaft journal A e Using a cleaning fluid clean off any oil or dirt on the fol lowing portions and dry them with a clean cloth Crankshaft Tapered Portion B Alternator Rotor Tapered Portion C e Install the starter gear A e Install the woodruff key B securely in the slot of the crankshaft e Install the alternator rotor D so that the woodruff key fits in the groove C of the rotor e Tighten Torque Alternator Rotor Nut BN125 A1 A2 69 N m 7 0 kgf m 51 ft Ib BN125 A3 98 N m 10 0 kgf m 72 ft Ib BN125 A4 104 N m 10 6 kgf m 76 ft lb Special Tool Flywheel Holder 57001 1313 e Install the altern
111. a 1 22 http mototh com 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion 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 This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following Battery Ground Before completing any service on the motorcycle discon nect the battery cables from the battery to prevent the en gt j gine from accidentally turning over Disconnect the ground E ND cable first and then the positive When completed b 20 f i jn with the service first connect the positive cable to the 8 Z positive terminal of the battery then the negative mL ble the negative terminal DISASSEMBLY ASSEMBLY WU2U748 Edges of Parts Lift large or heavy parts wearing gloves to prevent injury from possible sharp edges on the parts Solvent Use a high flush point solvent when cleaning parts High flush point solvent should be used according to directions of the solvent manufacturer anwa E Cleaning vehicle before disassembly y Clean the vehicle thoroughly
112. actory in the assembled state so if replaced they must be replaced as a set e Apply soap and water solution around the engine damper A before pressing it into the crankcase 6104136851 CAUTION Do not apply engine oil to prevent rubber damper deterioration http mototh com 8 10 CRANKSHAFT TRANSMISSION Crankcase e Press the damper A into the crankcase with the bearing drier set Special Tool Bearing Driver Set 57001 1129 e Chip off the old gasket from the mating surfaces of the crankcase halves and clean them off with a high flash point solvent e Using compressed air blow out the oil passages in the crankcase halves A WARNING Clean the engine parts in a well ventilated area and take care that there are no sparks or flame any where near the working area this includes any ap pliance with a pilot light Do not use gasoline or a low flash point solvent to clean parts A fire or ex plosions could result e Support the crankcase bearing boss with a suitable re tainer A e Using a press and the bearing driver set C install new bearings B until they bottoms out Special Tool Bearing Driver Set 57001 1129 CAUTION Support the crankcase bearing boss when the bear ings are pressed or the crankcase could be dam aged e Press the output shaft bearing A in the left crankcase half B so that the sealed side C faces to the oil seal Spec
113. acuum hose clogged Fuel tap clogged Fuel line clogged Float valve clogged Engine flooded Fuel level in carburetor float bowl too high Float valve worn or stuck open Starting technique faulty When flooded crank the engine with the throttle fully opened to allow more air to reach the engine No spark spark weak Battery voltage low Ignition switch not on Engine stop switch turned off Clutch lever not pulled in or gear not in neu tral Spark plug dirty broken or gap malad justed http mototh com Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect CDI unit trouble Neutral starter lockout switch or sidestand switch trouble Crankshaft sensor trouble Ignition coil trouble Ignition or engine stop switch shorted Wiring shorted or open Fuse blown Fuel air mixture incorrect Pilot screw and or idle adjusting screw mal adjusted Pilot jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter jet clogged Compression Low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Poor Running at Low S
114. adlight fuse 15 A http mototh com 15 58 ELECTRICAL SYSTEM Lighting System Headlight Circuit BN125 A6 ON PARK Tmn 2 e usuriw os BR BR BR BATTERY W W R BK R BK gt m Ha 7 R BK BK Y R Y C R W D 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 e Remove the tail brake light lens A NO GP12081BW2 C e Push the bulb A in the socket turn it counterclockwise B and pull it out http mototh com Lighting System ELECTRICAL SYSTEM 15 59 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 e Push the bulb in turn it clockwise and replace it It should lock in position Tighten the lens screws Be careful not to overtighten them Turn Signal Relay Inspection e Remove the right side cover See Frame chapter Connect one 12 V battery and turn signal lights as indi cated in the figure and count how many times the lights flash for one minute Turn Signal Relay A Turn Signal Lights B 12 V Battery C x lf the lights do not flash as specified replace the turn sig nal relay Testing Turn Signal Relay Load The Number of Turn times Signal Lights Wantage N my Lig
115. aft sensor signal into A and B signals Range A Signal Voltage B Signal GB06111BS2 C http mototh com 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 A and B signals are shown with the signals overlapped The comparator compares A signal with B signal When A signal voltage becomes equal to or less than B signal voltage the comparator sends a trigger signal to the gate in the thyristor firing the spark plug The intersection point between A and B signals indicates the timing when the spark plug fires This point moves left the timing advances as the engine rpm increases from N1 to N3 as shown Before or after advancing period the ignition timing is de termined by the crankshaft sensor signal and the ignition timing remains constant The figure shows the advancing chart http mototh com One revolution Crankshaft Sensor Signal Time A Signal 4 Signal MAN gt ANa Aep A Thyristor Gate Signal N3 N2 Ni Ts Ti Time Advance E gt 62 8 Crank Angle 30 10 deg BTDC or 35 G
116. ain Jet 1 8 N m 0 18 kgf m 15 in Ib Pilot Jet 0 8 N m 0 080 kgf m 7 in Ib e Put the float valve needle into the valve seat e Before installing the float insert the tang on the float plate through the clip A on the valve needle e Press the pivot pin B into the holder leg and float e Set the float height as specified see Service Fuel Level Adjustment e Slip the jet needle A through the hole in the center of the vacuum piston B and put the spring seat C on the top of the needle e Tighten the spring seat screws D Torque Spring Seat Screw 0 8 Nm 0 080 kgf m 7 in Ib http mototh com 6606010351 C 6606010551 C 3 18 FUEL SYSTEM Carburetor e Align the diaphragm tang A with the notch in the upper chamber and fit the diaphragm sealing lip into its groove e After installing the upper chamber cover check that the vacuum piston slides up and down smoothly without bind ing in the carburetor bore e Tighten Torque Upper Chamber Cover Screws 3 5 0 36 kgf m 31 in Ib Float Bowl Screws 2 0 N m 0 20 kgf m 17 in lb Coasting Enricher Screws 2 0 N m 0 20 kgf m 17 in Ib Carburetor Cleaning A WARNING Clean the carburetor in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash
117. ain Slack Inspection e Check to see that the notches A on the alignment indi cators on both sides are in the same relative position at the rear end B of the hole in each swingarm x If they are not adjust the chain slack and align them A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition NOTE OClean the chain if it is dirty and lubricate it if it appears dry http mototh com 6J05010781 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Set the motorcycle on its center stand ORotate the rear wheel to find the position where the chain is tightest OMeasure the vertical movement chain slack A midway between the sprockets x If the chain slack exceeds the standard adjust it Chain Slack Standard 25 40 mm 0 98 1 57 in Drive Chain Slack Adjustment e Remove the cotter pin A from the rear axle nut e Loosen Torque Link Nut B Rear Axle Nut C Both Chain Adjuster Locknuts D e Turn both chain adjusters E evenly until the drive chain has the correct amount of slack e Check to see that notches on the alignment indicators are in the same relative position on both sides WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Torque Rear Axle Nut 98 N m 10 0 kgf m 72 ft Ib Torque Link Nut 34 N m 3 5 kgf m 25 ft lb A W
118. ake parts Worn parts cause lock of the brake or loss of braking Wheel Inspection Raise the front rear wheel off the ground Special Tool Jack 57001 1238 Spin the wheel lightly and check for roughness or binding If roughness or binding is found replace the hub bearings Spoke Inspection e Refer to the Spoke Tightness Inspection in the Periodic Maintenance chapter Rim Inspection e Refer to the Rim Runout Inspection in the Periodic Main tenance chapter Axle Inspection e Visually inspect the front or rear axle for damage x If the axle is damaged or bent replace it e Place the axle on the V blocks that are 100 mm 3 9 in A apart and set a dial gauge B on the axle at a point halfway between the blocks Turn C the axle to measure the runout The difference between the highest and low est dial readings is the amount of runout If axle runout exceeds the service limit replace the axle Axle Runout 100 mm 3 9 in Standard TIR 0 1 mm 0 004 in or less Service Limit 0 2 mm 0 008 in http mototh com HJ07008BS1 C 6J04018BS1 C 9 10 WHEELS TIRES Tires Air Pressure Inspection Adjustment e Refer to the Air Pressure Inspection Adjustment in the Pe riodic Maintenance chapter Tire Inspection e Refer to the Tire Wear Inspection in the Periodic Mainte nance chapter Tire Removal e Remove the following Wheel see this chapter Brake Disc fron
119. al Retaining Plate Bolts BN125 A4 8 8 0 90 78 in lb 5 Cover Damper Bolt 8 8 0 90 78 in lb L 6 Starter Lockout Switch Screws 1 0 0 10 9 in lb 7 Primary Gear Nut 69 7 0 11 8 Oil Pressure Relief Valve 15 1 5 11 L 9 Starter lockout switch CL Apply cable lubricant EO Apply engine oil G Apply grease L Apply a non parmanent locking agent M Apply molybdenum disulfide grease http mototh com 5 4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 2 3 mm 0 08 0 12 in Clutch Friction Plate Thickness Friction and Steel Plate Warp Clutch Spring Free Length 2 92 3 08 mm 0 115 0 121 in 2 8 mm 0 11 in 0 2 mm 0 008 in or less 0 3 mm 0 012 in 35 0 mm 1 38 in 34 0 mm 1 34 in http mototh com CLUTCH 5 5 Special Tools Gear Holder m1 75 Clutch Holder 57001 1015 57001 1243 gt 8 5710155 6 7571243ST C http mototh com 5 6 CLUTCH Clutch Lever Cable Due to friction plate wear and clutch cable stretch over along period of use the clutch must be adjusted in accor dance with the Periodic Maintenance Chart Clutch Lever Free Play Inspection e Refer to the Clutch Lever Free Play Inspection in the Pe riodic Maintenance chapter Clutch Lever Free Play Adjustment e Refer to the Clutch Lever Free Play Adjustment in the Periodic Maintenance chapter Clutch Lever Installati
120. all 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 4 5 kgf m 33 ft lb Front Fork Clamp Bolts Lower 34 3 5 kgf m 25 ft lb e Install the removed parts Do not impede the handlebar turning by routing the cables harnesses and hoses improperly see Gen eral Information chapter e Check and adjust the following items Throttle Cables see Fuel System chapter Clutch Cable Rear View Mirrors e Check the front brake effectiveness WARNING Do not attempt ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brakes will not function on the first application of the lever if this is not done Steering Stem Warp e Whenever the steering stem A is removed or if the steer ing cannot be adjusted for smooth action check the steer ing stem for straightness x If the steering stem is bent replace the steering stem http mototh com GNO5010181 C STEERING 13 9 Steering Stem Bearing Steering Stem Bearing Removal xIf the bearing is damaged remove it e 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 opposit
121. and then install them at the original position Olnstall the rocker shafts B so that the screw threads face outward e Replace the rocker shaft bolt washers with new ones e Install Cylinder Head Bolts see Cylinder Head Installation Rocker Shaft Bolts e Tighten Torque Camshaft Bearing Holder Bolts BN125 A1 A3 9 8 N m 1 0 kgf m 87 in Ib 125 4 8 8 N m 0 90 kgf m 78 in Ib Rocker Shaft Bolts 8 8 Nm 0 90 kgf m 78 in Ib e Engage the camshaft sprocket A with the chain B Then align the T mark C on the sprocket with the timing mark D on the cylinder head NOTE OPull the tension side exhaust side of the chain up to remove slack Torque Camshaft Sprocket Bolts 12 N m 1 2 kgf m 104 prem E I et 8 11010351 C e Install the camshaft chain tensioner see Camshaft Chain Tensioner Installation e Check the valve clearance see Periodic Maintenance chapter Tighten Torque Camshaft Chain Cover Bolts BN125 A1 9 8 N m 1 0 kgf m 87 in Ib 125 4 8 8 N m 0 90 kgf m 78 in Ib Camshaft Chain Removal e Remove Camshaft Sprocket A see Camshaft Removal but do not remove the valve adjusting caps Alternator see Electrical System chapter http mototh com ENGINE END 4 19 Camshaft Remove the crank balancer gear A Special Tool Outside Circlip Pliers 57001 144 OStuff a clean cloth into
122. aner housing e Pull the damper B upward to cleaner the stopper C e Remove Pipe D Vacuum Hose Vacuum Switch Valve E Vacuum Switch Valve Installation e Install the hose A to air suction valve so that the mark B on it faces upward e Align the vacuum pipe C the arrow mark D on the damper E and the mark F on the air hose G to air cleaner Clamps H Vacuum Switch Valve I Face the tabs J as shown e Route the hoses correctly see Appendix chapter http mototh com 8 04010152 4 12 ENGINE END Clean Air System For DE of 125 1 2 and other than the CAL Vacuum Switch Valve Unit Test e 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 Special Tool Fork Oil Level Gauge 57001 1290 Air Flow C e Gradually raise the vacuum lower the pressure applied to the vacuum switch valve and check the valve opera tion When the vacuum is low the vacuum switch valve should permit air to flow When the vacuum raises to valve closing pressure it should stop air flow If the vacuum switch valve does not operate as described replace it with a new one NOTE O To check air flow through the vacuum switch valve just blow through the air cleaner hose Vacuum Switch Valve Closing Pressure Open Close Standa
123. any damage e Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage x lf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube e Temporarily assemble the inner and outer tubes and pump them back and forth manually to check for smooth operation x If you feel binding or catching the inner and outer tubes must be replaced WARNING straightened outer fork tube fail possibly causing accident Replace badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it http mototh com ee d 8 04041251 C 8 04013851 8 04010351 C 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 x lf 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
124. ar Installation e Fit the woodruff key A securely into the groove then install the balancer shaft gear B e Align the timing marks A on the balancer shaft gear and the crank balancer gear Balancer Shaft Gear Nut B e Using the gear holder hold the primary gear A as shown e Apply oil to the threads and seating surface of the bal ancer shaft gear nut e Tighten the balancer shaft gear nut B Torque Balancer Shaft Gear Nut 78 N m 8 0 kgf m 58 ft lb Special Tool Gear Holder m1 75 57001 1015 e Install Alternator Rotor see Electrical System chapter Alternator Cover see Electrical System chapter Clutch Cover see Clutch chapter http mototh com 8 16 CRANKSHAFT TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal Installation e Refer to the Alternator Rotor Removal and Installation in the Electrical System chapter Starter Motor Clutch Disassembly e Remove the alternator rotor A see Electrical System chapter Hold the alternator rotor with the flywheel holder and remove the starter motor clutch bolts C Special Tool Flywheel Holder 57001 1313 Remove the starter motor clutch D Starter Motor Clutch Assembly e Apply a non permanent locking agent to the threads of the starter motor clutch bolts A and tighten them Torque Starter Motor Clutch Bolts 125 1 34 N m 3 5 kgf m 25 ft Ib BN125 A2 12 N m 1 2 kgf m 104 in Ib Starter Motor
125. aring is noisy does not spin smoothly or has any rough spots replace it Oil Seal Inspection e Inspect the oil seals Replace it if the lips are misshapen discolored indicating that the rubber has deteriorated hardened or otherwise damaged http mototh com 6114060581 6113014951 C 5 5 9 1 Wheels Tires Table of Contents Exploded VIGW due dad 9 2 jer P 9 4 Special lool m E 9 5 Wheels RIMS 9 6 Front Wheel Removal LS 9 6 Front Wheel InstallaliOht sii tete Rear Wheel Removal PEE Hear Wheel 9 8 Wheel 9 9 SPOKE INSOSCHOM eC 9 9 M m 9 9 h iAzoeiy m 9 9 9 10 Air Pressure Inspection Adjustment nennen 9 10 TIRE INS DOCH 9 10 Mire Removal dea def 9 10 Existe CLIE 9 11 Hub Bearings Wheel Bearings pp 9 12 FHemoVal4 3 acta E A SE 9 12 Installation MEE 9 12 INS pecho M Xv
126. at rain water is drawn in through the air cleaner or if engine oil is blown back drain the housing e Visually check the catch tank A if the water or oil accu mulates in the tank any water or oil accumulates in the tank drain it by taking off the drain plug B at the lower end of the drain hose e Install the catch tank with the arrow C on it pointing up ward e Be sure to install the plug firmly Be sure to install the plug in the drain hose after draining Oil could drain from the open hose and get on the tires which could cause an accident and injury http mototh com M ce g c dp 0 6607010251 3 22 FUEL SYSTEM Air Cleaner Air Cleaner Housing Removal e 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 e Remove the element cover A and element e Move back B the air cleaner housing e Remove the carburetor C see this chapter e Remove the air cleaner housing A from the vehicle s right side Front B Air Cleaner Housing Installation e Be sure to fit the engine breather hose and draining hoses into the air cleaner housing http mototh com FUEL SYSTEM 3 23 Fuel Tank Fuel Tank Removal A WARNING Gasoline is extremely flammabl
127. ator cover see this chapter Stator Coil Removal e Remove Alternator Cover see this chapter Stator Coil Bolts A Crankshaft Sensor Screws B Holders C e Remove the stator coil D and the crankshaft sensor E from the alternator cover http mototh com Charging System ELECTRICAL SYSTEM 15 33 Stator Coil Installation Tighten Torque Stator Coil Bolts A 13 Nm 1 3 kgf m 113 in Ib Crankshaft Sensor Screws B 3 9 N m 0 40 kgf m 35 in Ib Alternator Lead Holder Bolts BN125 A3 8 8 N m 0 90 kgf m 78 in Ib BN125 A1 2 13 N m 1 3 kgf m 113 in Ib 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 A short or open in one of the coil wires will result in either a low output or no output at all A loss in rotor magnetism which may be caused by dropping or hitting the alternator by leaving it near an electromagnetic field or just by aging will result in low output e To check the alternator output voltage do the following procedures ODisconnect the alternator connector A Using an auxil iary wires connect the following leads in the connectors for engine operation L G W Y W
128. ator is shorted and must be replaced xlf the stator coil has normal resistance but the voltage check showed the alternator to be defective then the rotor magnets have probably weakened and the rotor must be replaced Regulator Rectifier Inspection e Remove Right Side Cover see Frame chapter Regulator Rectifier A e Disconnect the connector B from the regulator rectifier e Set the hand tester to the x 1 kO range and make the measurements shown in the table Special Tool Hand Tester 57001 1394 x lf 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 Regulator Rectifier Internal Resistance BN125 A1 A2 Unit Tester Lead Connection Terminal L L 2 10 100 10 100 oo oo Tester Lead Connection L Y Lead E BK Y Lead A P Lead B W Lead L E A B 8 09010251 http mototh com Charging System ELECTRICAL SYSTEM 15 35 Regulator Rectifier Internal Resistance BN125 A3 Unit Tester Lead Connection Terminal W Y Y Y BK Y oo oo Y co C Y 2 co BK Y Tester Lead Conn
129. badly worn or if it shows any damage replace it http mototh com CRANKSHAFT TRANSMISSION 8 19 Transmission Transmission Shaft Removal Split the crankcase see Crankcase Disassembly e Pull out the shift rod A allowing the shift fork guide pins to free from the shift drum B Remove the shift forks e Remove the shift drum Pull out the drive shaft D and output shaft E together with their gears meshed Transmission Shaft Installation e Apply engine oil to the sliding portions of every gear and bearing e Install the drive shaft and output shaft B in the right crankcase with their gears A meshed e Apply a small amount of engine oil to the shift fork fingers and fit each shift fork into the groove of the proper gear e The shift forks can be identified by their shape or number Install them noting the direction shown OThe drive shaft fork A is the shortest and install it with its mark 65 B facing the engine left side Olnstall the output shaft fork C with its mark 64 D facing the engine left side Olnstall the left output shaft fork E as shown e Fit each shift fork guide pin into the corresponding groove in the shift drum e Apply a small amount of engine oil to the shift rod and slide them into the shift forks e Assemble the crankcase see Crankcase Assembly Transmission Disassembly e Remove the transmission shafts e Remove the circlips washers then gears
130. before disassembly Dirt or y other foreign materials entering into sealed areas during ve hicle disassembly can cause excessive wear and decrease performance of the vehicle GAAP E http mototh com GENERAL INFORMATION 1 3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly Storage of Removed Parts After all the parts including subassembly parts have been a cleaned store the parts in a clean area Put a clean cloth xj CM or plastic sheet over the parts to protect from any foreign SAREE 2 2 materials that collect before re assembly ISS CoN 2 A HF TAMRE Inspection Reuse of worn or damaged parts may lead to serious ac cident Visually inspect removed parts for corrosion discol ES oration other damage Refer the appropriate sections 4 of this manual for service limits on individual parts Replace Y the parts if has been found or if the part is be yond its service limit X 020098 5 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 SI 8 Assembly Order S In most cases assem
131. beyond the service limit Drum Inside Diameter Standard 130 00 130 16 mm 5 118 5 124 in Service Limit 130 75 mm 5 148 in http mototh com 6112014851 C 8112010151 http mototh com SUSPENSION 12 1 Suspension Table of Contents Exploded i CE 12 2 jr eum 12 6 seJ olete fe MI foro rcc 12 7 Front FOTK ML 12 8 mmteae 12 8 Fork Removal EE 12 8 RMON 12 8 Fork Bisassemb y 12 9 Fork ASSermbly siens he Dt 12 10 Inner Tube Outer Tube Inspection 12 11 Spring Inspeotlort adim re eb oe site 12 12 Rear SMOCK ADS ORD GIS M cC 12 13 Spring Preload Adjustment 12 13 Removal 12 13 Installation 12 13 Swingarm 12 14 Swingarm Removal 12 14 Swingarm Installation 12 14 Swingarm Bearing Removal 12 14 Swingarm Bearing Installation 2141298 Swingarm Pivot Check 12 15 Swingarm Bearing Sleeve Inspection 12 15 http mototh com 12 2 SUSPENSION Exploded View 2 2 0 yi a ji K fo 5 ol 1 0 00 GD EN au uu
132. bility use only the recommended standard tires for replacement in flated to the standard pressure Use the same man ufacturer s tires on both front and rear wheels NOTE OReplace the rim band with a new one whenever the tire is replaced e Position the tire on the rim so that the air valve A is at the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire Tighten Torque Tire Air Valve Nut 1 5 N m 0 15 kgf m 13 in Ib Brake Disc Bolts 27 N m 2 8 kgf m 20 ft lb e Check the tire rotation mark A on the front rear tire and install it on the rim accordingly NOTE O The direction of the tire rotation B is shown by an arrow on the tire sidewall http mototh com GJO5056BS1 C 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 OUse a screwdriver for the grease seal removal e Remove the hub bearings A CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Special Tools Bearing Remover Shaft 9 57001 1265 B Bearing Remover Head 15 x 17 57001 1267 C Installation e Before installing the wheel bearings blow any dirt or for eign particles out of the hub with compre
133. bly order is the reverse of disassem bly however if assembly order is provided in this Service x a wie E Manual follow the procedures given p o ON Y lt ML gt Gaby C NN A a cw t wr 08020118 5 http mototh com 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 Conversely when loosening the bolts nuts or screws first loosen all of them by about a quar ter turn and then remove them If the specified tightening sequence is not indicated tighten the fasteners alternating diagonally Tightening Torque Incorrect torque applied to a bolt nut or screw may lead to serious damage Tighten fasteners to the specified torque using a good quality torque wrench Often the tightening sequence is followed twice initial tightening and final tightening with torque wrench Force Use common sense during disassembly and assembly excessive force can cause expensive or hard to repair dam age When necessary remove screws that have a non permanent locking agent applied using an impact driver Use a plastic faced mallet whenever tapping is necessary Gasket O ring Hardening shrinkage or damage of both gaskets
134. ccelerator cable all the way in e Tighten the locknut securely against the adjuster e Adjuster either lower nuts A of the accelerator cable or the decelerator cable until the correct throttle grip free play is obtained x If the free play cannot be adjusted with the lower adjusting nuts use the adjuster at the upper end of the cable again e Check that the throttle pulley B stops C against the idle adjusting screw A with the throttle grip closed Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides If handlebar movement changes the idle speed the throt tle cable may be improperly adjusted or incorrectly routed or damaged Be sure to correct any of these conditions before riding see Cable Wire and Hose Routing section in Appendix chapter A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition e Check idle speed x lf the idle speed is out of the specified range adjust it Idle Speed Standard 1 300 50 r min rpm http mototh com 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment Start the engine and warm it up thoroughly e Turn the idle adjusting screw A until the idle speed is correct OOpen and close the throttle a few times to make sure that the idle speed is within the specified range Readjust i
135. ce Connecting Rod Big End Radial 0 005 0 017 mm 0 0002 0 0007 in 0 07 mm 0 003 in Clearance Crankshaft Runout TIR 0 03 mm 0 0012 in or less TIR 0 07 mm 0 003 in Transmission Shift Fork Ear Thickness 4 9 5 0 mm 0 193 0 197 in 4 8 mm 0 189 in Gear Shift Fork Groove Width 5 05 5 15 mm 0 199 0 203 in 5 25 mm 0 207 in Shift Fork Guide Pin Diameter 5 9 6 0 mm 0 232 0 236 in 5 8 mm 0 228 in Shift Drum Groove Width 6 05 6 20 mm 0 238 0 244 in 6 3 mm 0 248 in http mototh com CRANKSHAFT TRANSMISSION 8 7 Special Tools Sealant Outside Circlip Pliers Crankshaft Jig 57001 144 57001 1174 p 7570144ST C 875711745 C Gear Holder m1 75 Crankcase Splitting Tool Assembly 57001 1015 57001 1362 1571015 6 875713625 Bearing Driver Set Kawasaki Bond Liquid Gasket Silver 57001 1129 92104 002 7571129ST C 879200025 C http mototh com 8 8 CRANKSHAFT TRANSMISSION Crankcase Crankcase Disassembly e 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 e Remove the engine see Engine Removal Installation chapter e Set the engine on a clean surface and hold the engine steady while pa
136. cer Gear Hetroval epa tata a 8 17 Removal Installation 8 13 External Shift Mechanism Crankshaft Removal 8 13 Inspection CM 8 18 Crankshaft Installation 8 13 Transmission pp Crankshaft Disassembly 8 13 Transmission Shaft Removal Connecting Rod Big End Transmission Shaft Installation 8 19 8 13 Transmission Disassembly 8 19 Connecting Rod Big End Radial Transmission Assembly 8 20 8 13 Shift Drum Removal Installation 8 21 Connecting Rod Big End Side Shift Fork Bending 8 21 2 enin nra ona 8 13 Shift Fork Gear Groove Wear 8 21 Crankshaft Runout 8 13 Shift Fork Guide Pin Drum Balancer Shaft 8 15 Groove 8 21 Balancer Shaft Gear Removal 8 15 Gear Dog and Gear Dog Hole Balancer Shaft Gear Installation 8 15 Damage 8 21 Starter Motor Clutch 8 16 Ball Bearing and Oil Seal 8 22 Starter Motor Clutch Ball Bearing Replacement 8 22 Removal Installation 8 16 Ball Bearing Wear 8 22 Starter Motor Clutch Disassembly 8 16 Oil Seal Inspection 8 22 http mototh com 8 2 CRANKSHAFT TRANSMISSION Exploded View N
137. d lower steel balls e Wipe all the old grease off the upper and lower outer races e Visually check the races and balls Replace the bearing assemblies if they show wear or damage e Apply grease liberally to the upper and lower races and stick the steel balls A in place with grease e Install the steering stem see Steering chapter and ad just the steering see Steering Adjustment Electrical System Battery Electrolyte Level Inspection e Visually check the electrolyte level in the battery If the level line of electrolyte any cell is below the lower level line A on the battery case add distilled water only to that cell until the level is at the upper level line B CAUTION Ordinary tap water is not a substitute for distilled water and will shorten the life of the battery Spark Plug Cleaning Inspection Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool xIf the spark plug center electrode A and or side elec trode B are corroded or damaged or if the insulator C is cracked replace the plug e Use the standard spark plug or its equivalent Spark Plug Gap Inspection e Measure the gap D with a wire type thickness gauge xIf the gap is incorrect carefully bend the side electrode with a suitable tool to obtain the correct gap
138. der holes e Install Pad Spring A Caliper Holder B Pads and Caliper Pad Bolts e Tighten Torque Caliper Pad Bolts 18 N m 1 8 kgf m 13 ft Ib e Install the caliper see Caliper Installation Caliper Fluid Seal Damage The fluid seal piston seal A is placed around the pis ton to maintain clearance between the pad and the disc If the seal is in a poor condition it could lead the pad to wear excessively or the brake to drag which may cause the tem perature of the disc or the brake fluid to increase e Replace the fluid seal if it exhibits any of the conditions listed below OBrake fluid leakage around the pad OBrakes overheat OConsiderable difference in inner and outer pad wear OSeal and piston are stuck together xIf the fluid seal is replaced replace the dust seal B as well Also replace all seals every other time the pads are changed http mototh com 125 2 6105084851 C 6105087851 C Caliper BRAKES 11 11 Caliper Dust Seal Friction Boot Damage e Check that the dust seal and friction boot C are not cracked worn swollen or otherwise damaged e f they show any damage replace it Caliper Piston and Cylinder Damage e Visually inspect the piston D and cylinder surfaces for damage Replace the caliper if the cylinder and piston are badly scored or rusty Caliper Holder Shafts E Caliper Holder Shaft Wear The caliper body must slide smoothly on t
139. e Remove Ignition Coil A Left Cylinder Head Bolts B Rocker Shaft Bolts C ODiscard the rocker shaft bolt washers http mototh com E11010481 Camshaft ENGINE TOP END 4 17 e Using a screw A M5 P0 8 mm remove the rocker shafts B OMark the rocker shafts so that they can be installed later in the same position e Remove Rocker Arms A Camshaft Bearing Holder B OMark the rocker arms so that they can be installed later in the same position Pull out the camshaft A CAUTION The crankshaft may be turned while the camshaft is removed Always pull the chain taut while turning the crankshaft This avoids kinking the chain on the lower crankshaft sprocket A kinked chain could damage both the chain and the sprocket Camshaft Installation e Blow through the oil passage B with compressed air A e Apply engine oil to all cam parts journal and bearing Olf the camshaft is replaced with a new one apply a thin coat of molybdenum disulfide grease to the new cam part surfaces and journal e Install the camshaft with the cam portion A down and the hole B up http mototh com lt tn 2 L 1 Y 1 IIT 7 a 4 18 ENGINE END Camshaft e Install the camshaft bearing holder A e Apply engine oil to the rocker shaft surface and cam por tion of the rocker arm
140. e MO Apply molybdenum disulfide oil The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 1 R Replacement Parts S Follow the specific tightening sequence AT Austria CAL California CH Switzerland DE Germany http mototh com 4 4 ENGINE END Exploded View http mototh com ENGINE END 4 5 Exploded View Torque No Fastener kat Remarks 1 Camshaft Bearing Holder Bolts BN125 A1 9 8 1 0 87 Camshaft Bearing Holder Bolts BN125 A4 8 8 0 90 78 in lb 2 Camshaft Sprocket Bolts 12 1 2 104 in lb 3 Camshaft Chain Holder Screw 4 9 0 50 43 in lb 4 Camshaft Chain Guide Bolt 8 8 0 90 78 in lb 5 Chain Tensioner Mounting Bolts BN125 A1 9 8 1 0 87 Chain Tensioner Mounting Bolts BN125 A4 8 8 0 90 78 6 Chain Tensioner Cap 4 9 0 50 43 in lb 7 Valve Adjusting Screw Locknut 15 1 5 11 8 Rocker Shaft Bolts 8 8 0 90 78 in lb 9 Muffler Body Mounting Nut 15 1 5 11 M Apply molybdenum disulfide grease MO Apply molybdenum disulfide oil The molybdenum disulfide oil is a mixture of engine oil and molybdenum disulfide grease with a weight ratio 10 1 R Replacement parts http mototh com 4 6 ENGINE END Specifications ltem Standard Service Limit Clean Air Sytem Vacuum Switch Valve Closing Close
141. e 10 Inspection e Inspect the fuse element x If it is blown out replace the fuse Fuse Element A Blown Element B GP20000BS1 http mototh com APPENDIX 16 1 Appendix Table of Contents Gable Wire and Hose Routing pp 16 2 Troubleshooting G de Tc 16 32 http mototh com 16 2 APPENDIX Cable Wire and Hose Routing BN125 A1 http mototh com Cable Wire Hose Routing Crankshaft Sensor Oil Pipe Clamp Run the alternator lead under the oil pipe Alternator Lead Run the neutral switch lead so that it shall not out of guide rib Guide Rib Neutral Switch Turn Signal Relay Engine Ground Lead Holder Carburetor Drain Hose Battery Vent Hose http mototh com APPENDIX 16 3 16 4 APPENDIX Cable Wire and Hose Routing BN125 A1 Sa LT eme dO sue 27 YESS oc UN GPS 6809440885 http mototh com APPENDIX 16 5 Cable Wire Hose Routing CDI Unit lgnition Coil Lead Engine Breather Hose To Fuel Tap Insulator Run the ignition coil lead under the engine breather hose Clamp Install the hose as shown Other than AT DE SG CH Models AT Austria CH Switzerland DE Germany SG Singapore http mototh com Cable Wire
142. e Camshaft Hole Inside Diameter Standard BN125 A1 A6 12 000 12 027 mm 0 472 0 474 in BN125 A7 and A8 15 000 15 027 mm 0 591 United States Models 0 592 in Service Limit BN125 A1 A6 12 15 mm 0 478 in BN125 A7 and A8 15 15 mm 0 596 in United States Models xIf they are exceed the service limit replace the affected parts of them Brake Shoe Lining Wear Inspection e Refer to the Brake Shoe Lining Wear Inspection in the Periodic Maintenance chapter http mototh com EUN Rear Brake Drum BRAKES 11 23 Brake Shoe Springs Inspection e Visually inspect the brake shoe springs for breaks or dis tortion x lf the springs are damaged in any way replace them e Measure the free length of the brake shoe springs If either is stretched beyond the service limit replace both springs Brake Shoe Springs Free Length Standard Long 44 5 45 5 mm 1 752 1 791 in Short 32 5 mm 1 280 in Service Limit Long 47 2 mm 1 86 in Short 34 1 mm 1 34 in Brake Drum Wear Inspection e Remove the rear wheel see Wheels Tires chapter e Remove the brake panel e Measure the inside diameter A of the drum OUse calipers and measure at several points any measurement is greater than the service limit re place the wheel hub xIf the drum is worn unevenly or scored lightly turn the drum on a brake drum lathe or replace the wheel hub Do not turn the drum
143. e 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 this includes any appliance with a pilot light e Remove the seat and side covers see Frame chapter e Remove the fuel tank mounting bolts A e Turn the fuel tap to the OFF or RES position e Pull the hose off the tap e Disconnect the indicator light lead connector A e Remove the fuel tank e Drain the fuel tank OPlace a suitable container under the fuel tank OTurn the fuel tap to the PRI position to drain the fuel into the container Fuel Tank Installation e Read the above WARNING e Check the rubber dampers A on the frame xIf the dampers are damaged or deteriorated replace them e Route the hose and leads correctly e Connect the indicator light connector e Be sure the hose are clamped securely Fuel Tank Inspection e Remove the hoses from the fuel tank and open the tank cap e Check to see if the breather pipe and water drain pipe in tank are not clogged x If they are clogged remove the tank and drain it and then blow pipes free with compressed air CAUTION Do not apply compressed air to the air vent holes in the tank cap This could cause damage and clog ging of the labyrinth in the cap http mototh com 3 24 FUEL SYSTEM Fuel Tank Fuel Tank Cleaning A WARNING Clean the tank i
144. e engine sprocket so that the punch mark A face the outward e Tighten the engine sprocket bolts Torque Engine Sprocket Bolts 12 1 2 kgf m 104 in Ib NOTE OWhen tightening the holder bolts hold the rear brake on e Install the engine sprocket cover and tighten the bolts with specified torque Torque Engine Sprocket Cover Bolts BN125 A1 A3 9 8 N m 1 0 kgf m 87 in Ib BN125 A4 8 8 0 90 kgf m 78 in Ib e Run the alternator leads crankshaft sensor leads A and neutral switch leads B as shown Run under the oil pipe C Guide Rib D e Adjust the drive chain see Periodic Maintenance chap ter http mototh com GKO5037BS1 10 8 FINAL DRIVE Sprocket Coupling Rear Sprocket Removal e Remove the rear wheel see Wheels Tires chapter e Remove the drive chain see Drive Chain Removal e Remove the rear sprocket nuts A and separate the rear sprocket B from the coupling Rear Sprocket Installation e Install the sprocket with the tooth number marking A out ward e Tighten the rear sprocket nuts Torque Rear Sprocket Nuts 26 Nm 2 7 kgf m 19 ft Ib Sprocket Wear e Visually inspect the engine and rear sprocket teeth x lf the teeth are worn as illustrated replace the sprockets and inspect the drive chain see Periodic Maintenance chapter NOTE O Sprocket wear is exaggerated for illustration Worn Tooth Engine Sprocket A Worn Tooth Rear Sproc
145. e race to drive it out e Hammer the bottom A of the lower inner race with a chisel OUsing a suitable bar pry out the inner race from the stem Grease Seal B Lower Inner Race C Steering Stem Bearing Installation e Replace the bearing outer races with new ones e Apply grease to the outer races and drive them into the head pipe at the same time Special Tools Head Pipe Outer Race Press Shaft 57001 1075 A Head Pipe Outer Race Driver 051 5 57001 1076 C Head Pipe Outer Race Driver 446 5 57001 1106 B e Replace the stem bearing inner race with new ones e Apply grease to the lower inner race A and drive it onto the stem B Special Tools Steering Stem Bearing Driver 57001 137 C Steering Stem Bearing Driver Adapter 34 5 57001 1074 D Steering Stem Bearing Wear Damage e Remove the steering stem see this chapter e Using a high flash point solvent wash the bearings clean of grease and dirt and examine the races and balls e Visually check the balls or races x If the balls or races are worn or if either race is dented replace both races and all the balls for that bearing as a set Steering Stem Bearing Lubrication e Refer to the Steering Stem Bearing Lubrication in the Pe riodic Maintenance chapter http mototh com GNO7030181 C GNO7030381 C 13 10 STEERING Handlebar Handlebar Removal 125 1 2 e Remove Throttle Cables A see Fue
146. e the fuel tank see Fuel System chapter e Remove the spark plug cap e Measure the ignition coil primary peak voltage as follows e Install the new spark plug A into the removed spark plug cap F and ground it onto the engine e Connect the peak voltage adapter B into the hand tester C and set it to the x 250 V DC range Adapter black lead Ignition coil primary lead terminal D Adapter red lead Ignition coil ground terminal Ignition Coil E Battery G CDI Unit IC Igniter A WARNING To avoid extremely high voltage shock do not touch the spark plug or tester connection 6 10062851 C http mototh com 15 42 ELECTRICAL SYSTEM Ignition System e Turn the ignition switch and engine stop switch on e 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 Repeat the measurement 5 or more times Ignition Coil Primary Peak Voltage Standard 110 V or more Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B the reading is less than the specified value check the following Ignition Coil see Ignition Coil Inspection Crankshaft Sensor see Crankshaft Sensor Inspection CDI Unit see CDI Unit Inspection Spark Plug Hemoval e Remove the spark plug cap e Remove the spark plug using the 16 mm plug wrench A Special Tools Spark Plug Wrench Hex
147. ection Charging Voltage Inspection Check the battery condition see Battery section e Warm up the engine to obtain actual alternator operating conditions Check that the ignition switch is turned off and connect the hand tester as shown in the table Special Tool Hand Tester 57001 1394 Charging Voltage Tester Connections Reading Range Tester to Tester to 25 V DC Battery Battery 14 15 e Turn on the ignition switch and start the engine and note the voltage readings at various engine speeds with the headlight turned on and then turned off The readings should show nearly battery voltage when the engine speed is low and as the engine speed rises the readings should also rise But they must be kept under the specified voltage e Turn off the ignition switch to stop the engine and discon nect the hand tester x If the charging voltage is kept between the values given in the table the charging system is considered to be working normally x f the output voltage is much higher than the values spec ified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open x If the charging voltage does not rise as the engine speed increases then the regulator rectifier is defective or the alternator output is insufficient for the loads Check the alternator and regulator rectifier to determine which part is defective http mototh com Y W
148. ed on the back of the cutter A represent the following DU 9 Cutter angle DO 5 ode ue Outer diameter of cutter C Operating Procedures e Clean the seat area carefully e Coat the seat with machinist s dye e Fit a 45 cutter into the holder and slide it into the valve guide e Press down lightly on the handle and turn it right or left Grind the seating surface only until it is smooth CAUTION Do not grind the seat too much Overgrinding will reduce valve clearance by sinking the valve into the head If the valve sinks too far into the head it will be impossible to adjust the clearance and the cylin der head must be replaced http mototh com 8 15011851 C 4 30 ENGINE END Valves Measure the outside diameter of the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind until the diameter is within the spec ified range Widened Width A of engagement by machining with 45 cutter Ground Volume B by 32 cutter 32 C Correct Width D Ground Volume E by 60 cutter 60 F Measure the outside diameter or the seating surface with a vernier caliper x If the outside diameter of the seating surface is too small repeat the 45 grind A until thediamter is within the spec ified range Original Seating Surface B NOTE ORemove all pitting of flaws from 45 ground s
149. el System chapter Clutch Cable see Clutch chapter Drive Chain see Final Drive chapter e Fill the engine with engine oil see Engine Lubrication System chapter e Adjust the idle speed see Fuel System chapter e Check the clutch operation e Check the brake effectiveness A WARNING Do not attempt to drive 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 on the first application of the lever if this is not done A WARNING If a full brake pedal is not obtained disassemble and inspect the brake parts Worn parts can cause lock of the brake or loss of braking http mototh com GK04002BS1 C 8 04010152 C http mototh com CRANKSHAFT TRANSMISSION 8 1 Crankshaft Transmission Table of Contents Exploded VieW pp 8 2 Starter Motor Clutch Assembly 8 16 Specifications 8 6 Starter Motor Clutch Inspection 8 16 Special Tools and Sealant 8 7 Torque Limiter Inspection 8 16 8 8 External Shift Mechanism 8 17 Crankcase Disassembly 8 8 Shift Pedal Height Adjustment 8 17 Crankcase Assembly 8 9 Shift Pedal Removal 8 17 Crankshaft 2 aen 8 13 External Shift Mechanism Crank Balan
150. ength Commutator Diameter 9 5 10 5 mm 0 37 0 41 in 27 95 28 05 mm 1 10 1 11 in 8 mm 0 31 in 27 mm 1 06 in http mototh com ELECTRICAL SYSTEM 15 11 Specifications tem Standard Switches Rear Brake Light Switch Timing ON after about 10 mm 0 39 in pedal travel http mototh com 15 12 ELECTRICAL SYSTEM Special Tools and Sealant Flywheel Puller M30 x 1 5 57001 1191 875711915 6 Rotor Puller 16 18 20 22 x 1 5 57001 1216 875712165 C Timing Light 57001 1241 7571241ST C Spark Plug Wrench Hex 16 57001 1262 875712625 C Flywheel Holder 57001 1313 7571313ST C Hand Tester 57001 1394 7571394ST C Peak Voltage Adapter 57001 1415 Ne 7 Kawasaki Bond Silicone Sealant 56019 120 875601205 C http mototh com ELECTRICAL SYSTEM 15 13 Wiring Diagram Dummy Page http mototh com 15 14 ELECTRICAL SYSTEM Wiring Diagram 125 1 Ignition Switch I Meter 12V Light 1 78 Speedometer orron PARK ignition cl Bare 0 Joa BR BL R W Po Ri 1 ght Handlebar Switches Front Brake Light Switch Engine Starter top Switch Button Headlight Switch gt 2 ee xx ee gt Ex 8 5 zz en z N N Sa gee a gt
151. er Recommended Disc Brake Fluid Grade DOT4 Brake Fluid Change e Level the brake fluid reservoir e Remove the reservoir e Remove the rubber cap from the bleed valve A on the Caliper e Attach a clear plastic hose B to the bleed valve and run the other end of the hose into a container e Fill the reservoir with fresh specified brake fluid e Change the brake fluid as follows NOTE OThe fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes Open the bleed valve A Pump the brake lever and hold it B Close the bleed valve C Release the brake lever D http mototh com 0513054852 C PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures e Remove the clear plastic hose e Install the reservoir cap e Tighten the bleed valve and install the rubber cap Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib Front Brake Reservoir Cap Screws 2 5 N m 0 25 kgf m 22 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage If necessary bleed the air from the lines see Brake Line Bleedi
152. er e Install the oil ring steel rails one above the expander and one below it OSpread the rail with your thumbs but only enough to fit the rail over the piston ORelease the rail into the bottom piston ring groove e Do not mix up the top ring and second ring e Install the second ring C so that the RN mark D faces up e Install the top ring A so that the R mark B faces up e Install Dowel Pins A New Oylinder Base Gasket B e The piston ring openings must be positioned as shown in the figure The openings of the oil ring steel rails must be about 30 40 of angle from the opening of the top ring Top Ring A Second Ring B Oil Ring Steel Rails C Oil Ring Expander D Triangular Mark E http mototh com 8 16013051 GE16060481 Opening Position 30 901490 90 NE e FI GE16068BS1 ENGINE END 4 35 Cylinder Piston eApply engine oil to the cylinder bore Position the piston ring openings e Install the cylinder B while compressing A the piston rings with your thumbs e Install the removed parts Cylinder Wear Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment at each of the three locations total of six measure ments shown in the figure 10 mm 0 39 in A 40 mm 1 57 in B 20 mm 0 79 in C x If any of the cylinder inside diam
153. er 57001 1394 x If there is a high resistance or no reading gt between any two segments a winding is open and the starter motor must be replaced e Using the highest hand tester range measure the resis tance between the segments and the shaft B x If there is any reading at all the armature has a short and the starter motor must be replaced NOTE OEven if the foregoing checks show the armature to be good it may be defective in some manner not readily detectable with the hand tester If all other starter motor and starter motor circuit components check good but the starter motor still does not turn over or only turns over weakly replace the starter motor with a new one http mototh com GP11047BS1 GP11049BS1 Electric Starter System ELECTRICAL SYSTEM 15 51 Brush Lead Inspection e Using the x 1 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 x If there is not close to 0 the brush has an open Re place the terminal bolt assembly and or the brush holder assembly Brush Plate and Terminal Bolt Inspection e Using the highest hand tester range measure the resis tance as shown Terminal Bolt and Brush Plate A Terminal Bolt and Negative Brush Holder B Terminal Bolt and End Cover C Special Tool Hand Tester 57001 1394 x If there is any read
154. er kg 9 807 N kW x 1 360 PS PS x 0 7355 kw PS x 0 9863 HP Units of Temperature 9 C 40 OR 5 F 40 cde 5 9 oF oF 4 32 68 104 176 212 248 284 40 20 0 20 i40 60 80 100 120 140 160 180 200 1220 240 260 280 300 320 40 20 0 20 1 40 60 i 80 400 i 420 1140 160 17 8 4 4 267 48 9 71 1 933 116 138 oC C http mototh com PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart Torque and Locking Agent Specifications Special Tools Periodic Maintenance Procedures Fuel System Fuel Hose and Connection Inspection Throttle Grip Free Play Inspection Throttle Grip Free Play Adjustment Idle Speed Inspection Idle Speed Adjustment Air Cleaner Element Cleaning Evaporative Emission Control System Inspection CAL Engine Top Air Suction Valve Inspection Cylinder Head Bolt Tightness Inspection Valve Clearance Inspection Valve Clearance Adjustment Clutch Clutch Lever Free Play Inspection Clutch Lever Free Play Adjustment Engine Lubrication System Engine Oil Change Oil Filter Change Oil Screen Cleaning Wheels Tires Spoke Tightness Inspection Rim Runout Inspection Air Pressure Inspection Adjust ment Tire Wear Inspection Final Drive Drive Chain Slack Inspection Drive Chain Slack Adjustment 2 2 2 4 2 9 2 11 2 12 2 12 2 16 2 16 2 17 2 17 2 17 2 17 2 18 2 18 2 19 2 20 2 21 2 21 2 21 2 22 2 23 2
155. er end facing B downward e Install Fork Spring Seat Spacer e Repeat the same procedure for another front fork e Install the front fork see Suspension chapter Front Fork Oil Leak Inspection e Visually inspect the front forks A for oil leakage scoring or scratches on the outer surface of the inner tubes Replace or repair any defective parts if necessary Rear Shock Absorber Oil Leak Inspection e Visually inspect the rear shock absorbers A for oil leak age x If they are oil leaked one unit feels weaker than the other replace both shock absorber as a set Swingarm Pivot Lubrication e Remove the swingarm see Suspension chapter e Using high flash point solvent wash the following parts and apply plenty of molybdenum disulfide grease them Needle Bearings A Grease Seals B Sleeve C Swingarm Pivot Shaft except for threads D OThis prevents the shaft and the bolt from rusting or seiz ing http mototh com E KB 6514009851 6514033851 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection e Check the steering OLift the front wheel off the ground using the jack A Special Tool Jack 57001 1238 OWith 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 x If the wheel bind
156. ery is rated at 9 Ah and the recommended charging rate is 0 9 A CAUTION If the battery is not given a full initial charging it will discharge in a few weeks After that it can not be charged by supplemental charging Always remove the battery from the vehicle for charging If the battery is charged while still in stalled battery electrolyte may spill and corrode the frame or other parts of the vehicle Do not use a high rate battery charger as is typi cally employed at automotive service stations un less the charger rate can be reduced to the level re quired Charging the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charging rates also cause the plates to shed active material Deposits will accumulate and can cause internal shorting If the temperature of the electrolyte rises above 45 113 F during charging reduce the charging rate to lower the temperature and increase charg ing time proportionately e Turn the charger off then disconnect it from the battery e Check battery voltage Battery voltage should be 12 13 V http mototh com Battery ELECTRICAL SYSTEM 15 29 Ordinary Charging e Remove the battery see Battery Removal e f any of the cells are low fill them to the LOWER level line with distilled water only The electrolyte will expand during chargin
157. es at a time Valve Clearance when cold Standard Inlet 0 08 0 12 mm 0 0031 0 0047 in Exhaust 0 15 0 19 mm 0 0059 0 0075 in http mototh com PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Valve Clearance Adjustment xIf the valve clearance is not within the specified range adjust the clearance by loosening the locknut and turning the adjusting screw e Tighten the nuts to the specified torque and check the valve clearance again Torque Valve Adjusting Screw Locknut 15 N m 1 5 kgf m 11 ft lb e Install the valve adjusting caps with their up marks A up Torque Valve Adjusting Cap Bolts BN125 A1 9 8 N m 1 0 kgf m 87 in Ib 125 4 8 8 N m 0 90 kgf m 78 in Ib Clutch Clutch Lever Free Play Inspection e Check that the clutch cable upper end is fully seated in the adjuster A e Pull the clutch lever B just enough to take up the free play C OMeasure the gap free play between the lever and the lever holder x If the gap free play is too wide the clutch may not re lease fully If the gap is too narrow the clutch may not engage fully In either case adjust it Clutch Lever Free Play Standard 2 3 mm 0 08 0 12 in Clutch Lever Free Play Adjustment A WARNING To avoid a serious burn never touch the engine or exhaust pipe during clutch adjustment e Slide back the dust cover e Loosen both adjuster nut
158. eter measurements ex ceeds the service limit replace the cylinder Cylinder Inside Diameter Standard 55 000 55 012 mm 2 1654 2 1658 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 55 10 mm 2 169 or 0 05 mm 0 002 in difference between any two measurements Piston Wear e Measure the outside diameter A of each piston 5 mm 0 20 in B up from the bottom of the piston at a right angle to the direction of the piston pin x If the measurement is under service limit replace the pis ton Piston Diameter Standard 54 960 54 975 mm 2 1638 2 1644 in A 54 968 54 982 mm 2 1641 2 1646 in GE16010181 BN125 A7 N NU N No Catalytic Converter Model NU No Catalytic Converter United Kingdom Model Service Limit 54 81 mm 2 158 in http mototh com 4 36 ENGINE END Cylinder Piston Piston Cylinder Clearance e Subtract the piston diameter from the cylinder inside di ameter to get the piston cylinder clearance Piston Cylinder Clearance Standard 0 025 0 052 mm 0 0010 0 0020 in x lf the piston cylinder clearance is less than the specified range use a smaller piston or increase the cylinder inside diameter by honing x f the piston cylinder clearance is greater than specified range use a larger piston x If only a piston is replaced the clearance may exceed the standard slightly But it must
159. ew Torque Oil Pump Assembly Screw 9 8 N m 1 0 kgf m 87 in Ib e Install the washer circlip e Replace the O rings with new ones e Check that the pump gear turns freely after assembly Pump Inspection e Disassemble the oil pump see Oil Pump Disassembly e Visually inspect the oil pump body outer and inner rotors and cover x If there is any damage or uneven wear replace the rotors cover body or the oil pump assembly http mototh com 6009001851 C ENGINE LUBRICATION SYSTEM 6 11 Oil Pressure Oil Pressure Measurement Remove the air suction valve A see Engine Top End chapter e Replace the oil pipe banjo bolt of the clutch cover B with the oil pressure gauge adapter special tool C xlf the oil pressure gauge adapter bottoms out add washer s P N 11009 1105 D under the adapter e Attach the oil Pressure gauge E Special Tools Oil Pressure Gauge 5 kgf cm 57001 125 Oil Pressure Gauge Adapter M10 x 1 25 57001 1376 e Install the air suction valve see Engine Top End chapter e Start the engine and warm up the engine thoroughly e Run the engine at the specified speed and read the oil pressure gauge If the oil pressure is much lower than the standard check the oil pump crankshaft oil seal of the clutch cover and oil pump relief valve x f the reading is much higher than the standard check the oil pump screen and the oil filter first and oil pas
160. f necessary Front B Air Cleaner Element Cleaning NOTE Oln dusty areas the element should be cleaned more frequently than the recommended interval OAfter riding through rain or on muddy roads the element should be cleaned immediately OSince repeated cleaning opens the pores of the foam element replace it with a new one in accordance with the Periodic Maintenance Chart Also if there is a break in the element material or any other damage to the ele ment replace the element with a new one A WARNING Clean the element in a well ventilated area and make sure that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element e Remove the air cleaner element see Fuel System chap ter e Clean the element in a bath of high flash point solvent and then dry it with compressed air or by shaking it Visually check the element for tears or breaks and replace the damaged element with a new one e After cleaning saturate the element with SE SF or SG class SAE 30 oil squeeze out excess oil e Wrap the element A in a clean rag B and squeeze it as dry as possible Evaporative Emission Control System Inspection CAL Canister Inspection e Remove the canister cover A http mototh com PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures e Remove the cani
161. f m 13 ft Ib e Instal the caliper see Caliper Installation A WARNING Do not attempt to drive 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 on the first application of the lever if this is not done Brake Pad Wear Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter http mototh com Master Cylinder BRAKES 11 13 Master Cylinder Removal Remove the brake fluid from the reservoir with a syringe or other suitable device e Disconnect the front brake light switch connectors A Remove the banjo bolt to disconnect the brake hose from the master cylinder see Brake Hose Removal In stallation OWhen removing the brake hose temporarily secure the end of the brake hose to same high place to keep fluid loss to a minimum Unscrew the clamp bolts A and take off the master cylin der B as an assembly with the reservoir brake lever and brake switch installed OWhen removing the master cylinder take care not to spill the brake fluid on the painted or plastic parts CAUTION Immediately wash away any brake fluid that spills Master Cylinder Installation e Set the master cylinder to match its mating face to the punched mark A of the handlebar e The master cylinder clamp must be installed with the ar row mark B faced upward e Tighten the uppe
162. f m 87 in Ib BN125 A4 8 8 N m 0 90 kgf m 78 Oil Pipe Banjo Bolts A M10 25 N m 2 5 kgf m 18 ft Ib M8 9 8 N m 1 0 kgf m 87 in Ib Oil Pipe Mounting Bolts B BN125 A1 9 8 N m 1 0 kgf m 87 in Ib BN125 A4 8 8 N m 0 90 kgf m 78 Cylinder Head Mounting Bolts 25 N m 2 5 kgf m 18 in Ib e Install Carburetor see Fuel System chapter Exhaust pipe see Muffler Removal Fuel Tank see Fuel System chapter http mototh com 4 24 ENGINE END Cylinder Head Cylinder Head Assembly e Install the rubber dampers as shown Dampers A Fins B Front C 66 HAL LI CE ES ES ENS at HENN 4 CELLEN O TOT EOE ml TRS F IW SS NS 0 Plea gt I N ES lt 0 2 m O 2 4 IW NAIC 6 140102 3 Cylinder Head Cleaning e Remove the cylinder head see Cylinder Head Removal e Remove the valves see Valve Removal e Wash the head with a high flash point solvent e Scrape the carbon out of the combustion chamber and exhaust port with a suitable tool
163. fler ENGINE TOP END 4 39 WARNING To avoid serlous burn do not remove the muffler when the engine is still hot Wait until the muffler cools down Muffler Removal e loosen the muffler body clamp bolt A Remove the muffler body mounting bolt and nut Remove the muffler body A backward e Remove the exhaust pipe mounting bolt e Remove Exhaust Pipe Holder Nuts A Exhaust Pipe B NOTE OWhen removing the muffler body and exhaust pipe as sembly do not loosen the muffler body clamp bolt Muffler Installation e Check the exhaust pipe holder gasket for sings of dam age lf necessary replace the gasket with a new Check the gasket A of the clamp for sings of damage and that it fits in place securely x If necessary replace the gasket with a new one e Tighten Torque Muffler Body Mounting Nut 15 N m 1 5 kgf m 11 ft lb First tighten all the bolts and nuts to a snug fit Next tighten the exhaust pipe holder nuts evenly to avoid exhaust leaks e Lastly tighten the rest of the bolts and clamp bolt securely e Thoroughly warm up the engine wait until the engine cools down and then retighten the exhaust pipe holder nuts and the clamp bolt securely http mototh com http mototh com CLUTCH 5 1 Table of Contents Exploded View 5 2 Specifications 5 4 Special Tools 5 5 Clutch Lever and Cable 5
164. frayed B or if the cable housing is kinked C replace the cable http mototh com 6004011481 C 6004020281 Periodic Maintenance Procedures PERIODIC MAINTENANCE 2 37 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 OFor the engine fasteners check the tightness of them when the engine is cold at room temperature x lf there are loose fasteners retighten them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table in this section For each fastener first loosen it by 1 2 turn then tighten it x lf cotter pins are damaged replace them with new ones Nut Bolt and Fastener to be checked Wheels Front Axle Nut Rear Axle Nut Cotter Pin Rear Axle Nut Final Drive Chain Adjuster Locknuts Rear Sprocket Nuts Brakes Brake Lever Pivot Nut Brake Pedal Cotter Pin Brake Rod Joint Cotter Pin Torque Link Nut Brake Cam Lever Nut Caliper Mounting Bolts Front Master Cylinder Clamp Bolts Suspension Front Fork Clamp Bolts Front Fender Bolts Rear Shock Absorber Bolts and Nuts Swingarm Pivot Nut Steering Stem Head Bolt Handlebar Holder Clamp Nuts Engine Throttle Cable Ad
165. g Piston Ring Thickness Top Second Standard 0 77 0 79 mm 0 0303 0 0311 in Service Limit 0 70 mm 0 028 in x If any of the measurements is less than the service limit on either of the rings replace all the rings NOTE OWhen using new rings in a used piston check for un even groove wear The rings should fit perfectly parallel to the groove sides If not replace the piston Piston Ring End Gap e Place the piston ring A inside the cylinder using the pis ton to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low Measure the gap between the ends of the ring with a thickness gauge Piston Ring End Gap Standard 0 15 0 30 mm 0 006 0 012 A seleodassl o Second 0 30 0 45 mm 0 012 0 018 in Cil 0 20 0 70 mm 0 008 0 028 in Service Limit Top 0 6 mm 0 024 in Second 0 7 mm 0 028 in Cil 1 0 mm 0 04 in xIf the end gap of either ring is greater than the service limit replace all the rings http mototh com 4 38 ENGINE END Carburetor Holder Carburetor Holder Installation e Apply grease to the O ring A and install the carburetor holder OTake care not to pinch the O ring e Tighten Torque Carburetor Holder Bolts 9 8 Nm 1 0 kgf m 87 in Ib e Install the insulator B so that its recess aligns with the boss A on the carburetor holder http mototh com Muf
166. g and the level will rise A 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 This proce dure prevents sparks at the battery terminals which could ignite any battery gases Connect a charger to the battery BEFORE plugging it in or turning it on Set the charging rate and time according to the battery condition previously determined using the Battery Charg ing Rate Time Table e Check the electrolyte level after charging CAUTION Always remove the battery from the vehicle for charging If the battery is charged while still in stalled battery electrolyte may spill and corrode the frame or other parts of the vehicle Do not use a high rate battery charger as is typi cally employed at automotive service stations un less the charger rate can be reduced to the level re quired Charging the battery at a rate higher than specified may ruin the battery Charging at a high rate causes excess heat which can warp the plates and cause internal shorting Higher than normal charging rates also cause the plates to shed active material Deposits will accumulate and can cause internal shorting If the temperature of the electrolyte rises above 45 113 F during charging reduce the charging rate to lower the temperat
167. g it press E the right end of the pin Front F e Bend the tang A on the float arm very slightly to change the float height e Drive in the pivot pin to install the float C e Remove the float chamber gasket e Measure the float height D tilting the carburetor so that the tang on the float just touches the needle rod in the float valve Olncreasing the float height lowers the fuel level and de creasing the float height raises the fuel level Float Bowl Mating Surface A Float Valve Needle Rod contacted but unloaded B Float Height Standard 19 4 2 mm 0 76 0 08 in NOTE ODo not push the needle rod in during float height mea surement e Assemble the carburetor and recheck the fuel level xIf the fuel level cannot be adjusted by this method the float or the float valve is damaged http mototh com GCOG095BS1 C 6606010451 C 6006013781 C 3 14 FUEL SYSTEM Carburetor Fuel System Cleanliness Inspection WARNING Gasoline is extremely flammable and 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 this includes any appliance with a pilot light Connect a suitable hose to the fitting at the bottom of the carburetor float bowl e Run the lower end of the hose into a suitable container e Turn the fuel tap to the PRI position
168. g size Jet needle or needle jet worn Air jet clogged http mototh com Engine oil level too high Engine oil viscosity too high Drive train trouble Air suction valve trouble AT DE SG CH Vacuum switch valve trouble AT DE SG Ch Balancer mechanism malfunctioning Coasting enricher trouble Overheating Firing incorrect Spark plug dirty broken or gap malad justed Spark plug incorrect CDI unit trouble 16 34 APPENDIX Troubleshooting Guide Fuel air mixture incorrect Main jet clogged or wrong size Fuel level in carburetor float bowl too low Carburetor holder loose Air cleaner duct loose Air cleaner poorly sealed or missing Air cleaner O ring damaged Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Clutch slipping Engine oil level too high Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate Engine oil level too low Engine oil poor quality or incorrect Clutch Operation Faulty Clutch slipping No clutch lever play Clutch inner cable catching Clutch cable unadjusted Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch release mechanism trouble Clutch hub or housing unevenly worn Clutch not disengaging properly Clutch lever play excessive Clutch plate warped or too rough Clutch spring compression uneven Engine oil deteriorated Engine oil viscosity too high Engine oil level to
169. garm Bearing Sleeve Inspection CAUTION Do not remove the bearing for inspection Removal may damage them e Visually inspect the swingarm needle bearing A OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring inspect the bearing in the swingarm for abrasion color change or other damage x If there is any doubt as to the condition of any of the nee dle bearings or sleeves B replace all the sleeves and needle bearings as a set http mototh com 8 06010251 http mototh com STEERING 13 1 Steering Table of Contents Exploded VIEW E 13 2 MPOCIAl TOONS EA EAEE E E TT 13 4 Tus 13 5 SIBSrria MNS PSCU OM E dues at E ALLEM EL 13 5 Steering Adjustment MEE 13 5 POTOSI DR 13 6 Steering Stem Removals 13 6 Steering Stem Installation 13 7 Steering Stem 13 8 Steeung 3temBedlng uas ptite ec 13 9 Steering Stem Bearing Removal pp 13 9 Steering Stem Bearing Installation titan 13 9 Steering Stem Bearing Wear Damage pp 13 9 Steering Stem Bearing Lubrication
170. gn the groove of the lever with the punch mark of the shift shaft e Remove Bolts A Front Left Footpeg B Shift Pedal C e Remove Nut A Shift Pedal B External Shift Mechanism Removal e Drain the engine oil see Engine Lubrication System chapter e Remove Clutch see Clutch chapter Engine Sprocket Cover see Final Drive chapter e Unscrew the shift lever clamp bolt and remove the shift lever from the shift shaft http mototh com 8 18 CRANKSHAFT TRANSMISSION External Shift Mechanism e Turn the shift drum and position the neutral groove A as shown e Remove the shift shaft D while pushing C the shift mechanism arm B toward the shaft External Shift Mechanism Inspection e Examine the shift shaft A for any damage x lf the shaft is bent straighten or replace it xIf the splines B are damaged replace the shaft xIf the springs C D are damaged any way replace them xIf the shift pawl E is damaged in any way replace the shift shaft assembly e Check the return spring pin A is not loose x If it is loose unscrew it to apply a non permanent locking agent to the threads and tighten it Torque Shift Shaft Return Spring Pin 29 N m 3 0 kgf m 21 ft lb e Check the gear positioning lever B and their spring C for breaks or distortion x lf the lever or springs are damaged in any way replace them e Visually inspect the shift drum cam D x lf the cam is
171. h com Starter Motor Removal 15 48 Starter Motor Installation 15 48 Starter Motor Disassembly 15 48 Starter Motor Assembly 15 49 Brush Inspection 15 50 Commutator Cleaning and NAS DOCU ON MPO 15 50 Armature 1 lt 15 50 Brush Lead Inspection 15 51 Brush Plate and Terminal Bolt Inspection ette 15 51 Starter Relay Inspection 15 51 Starter Circuit Relay Inspection 15 52 Lighting System 15 55 Headlight Beam Horizontal Verti cal Adjustment 15 55 Headlight Bulb Replacement 15 55 AC Lighting Voltage Inspection 15 56 Tail Brake Light Bulb Replacement 15 58 Turn Signal Relay Inspection 15 59 Meter Gauge Indicator Unit Speedometer Removal Speedometer Disassembly Indicator Unit Removal Installa tion Bulb Replacement Switches and Sensors Front Brake Light Switch Inspection 15 64 Rear Brake Light Timing INSpection 15 64 Rear Brake Light Timing Adjustment 15 64 Switch Inspection 15 64 Fuse 15 65 Main Fuse 15 A Removal 15 65 Main Fuse 15 A Inspection 15 65 Fuse 10 A Removal 15 65 Fuse 10 A Installation 15 65 Fuse 10 A Inspection 15 66 15 2 ELECTRICAL SYSTEM Parts Location
172. hat the grommet C face to out side as shown CAUTION If the filter is installed reversely it can cause the engine seizure http mototh com 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures the with new e Apply grease to the O ring and the grommet e Install the cover C and tighten the cover bolts Torque Oil Filter Cover Bolts BN125 A1 A3 9 8 N m 1 0 kgf m 87 in Ib 125 4 8 8 0 90 kgf m 78 in Ib e Pour in the specified type and amount of oil see Engine Oil Change Oil Screen Cleaning e Remove the oil screen cover A e Remove the gasket e Remove the oil screen B from the clutch cover e Clean the oil screen A thoroughly whenever it is removed for any reason e Clean the oil screen with a high flash point solvent and remove any particles stuck to it A WARNING Clean the screen in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvents NOTE OWhile cleaning the screen check for any metal particles that might indicate internal engine damage e Check the screen carefully for any damage holes broken wires gasket pulling off x lf the screen is damaged replace it e Install the oil screen A Olnsert the oil screen with UP mark B facing up and the
173. he caliper holder shafts If the body does not slide smoothly only one pad will wear more than the other pad wear will increase and constant drag on the disc will raise the brake and brake fluid temperature e Visually inspect the caliper holder shafts for excessive wear or warp and rubber friction boots for damage x If the rubber friction boot is damaged replace the rubber friction boot x lf the caliper holder shaft is damage replace the caliper holder http mototh com 11 12 BRAKES Front Brake Pads Brake Pad Removal 125 1 2 Remove the caliper with the hose attached e Remove Caliper Pad Bolts A Outer Pad B e Remove the inner pad piston side pad C Brake Pad Removal BN125 A3 e Loosen the caliper pad bolts A e Remove the caliper with the hose attached Remove Caliper Pad Bolts Pads Brake Pad Installation BN125 A1 A2 e Before installation clean the pads with a high flash point solvent e Push the caliper piston in by hand as far as they will go OThe inner pad has a wear protect plate A Do not mix up the outer pad and the inner pad Tighten Torque Caliper Pad Bolts 18 N m 1 8 kgf m 13 ft Ib Brake Pad Installation BN125 A3 e Before installation clan the pads with a high flash point solvent e Push the caliper pistons in by hand A as far as they will go e Install the pads and caliper pad bolts e Tighten Torque Caliper Pad Bolts 18 N m 1 8 kg
174. he throttle may become stuck possibly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur Carburetor Installation e When installing the carburetor into the carburetor holder fit the ridge B of the carburetor into the recess A of the carburetor holder Tighten the clamp screws A so that face the screw posi tion and screw head direction e Check fuel leakage from the carburetor WARNING Fuel spilled from the carburetor is hazardous e Adjust the following items if necessary Throttle Cable Idle Speed 8006096851 Carburetor Disassembly e Remove the carburetor see Carburetor Removal A 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 this includes any appliance with a pilot light http mototh com 3 16 FUEL SYSTEM Carburetor e 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 e Remove the spring seat screws D e Remove the jet needle A from the vacuum piston B along with the spring seat C e The pilot screw is set at the factory and should not be removed But
175. hicle pollution contains what is commonly referred to as the Act s tampering provisions Sec 203 a The following acts and the causing thereof are prohibited 3 A for any person to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title prior to its sale and delivery to the ultimate purchaser or for any manufacturer or dealer knowingly to remove or render inoperative any such device or element of design after such sale and delivery to the ultimate purchaser 3 B for any person engaged in the business of repairing servicing selling leasing or trading motor vehicles or motor vehicle engines or who operates a fleet of motor vehicles know ingly to remove or render inoperative any device or element of design installed on or in a motor vehicle or motor vehicle engine in compliance with regulations under this title follow ing its sale and delivery to the ultimate purchaser NOTE OThe phrase remove or render inoperative any device or element of design has been generally interpreted as follows 1 Tampering does not include the temporary removal or rendering inoperative of de vices or elements of design in order to perform maintenance 2 Tampering could include a Maladjustment of vehicle components such that the emission standards are ex ceeded b Use of replacement parts or accessories which adversely affect the perf
176. high Front fork bent Too soft Tire air pressure too low Front fork oil insufficient and or leaking Front fork oil viscosity too low Rear shock adjustment too soft Front fork rear shock absorber spring weak Rear shock absorber oil leaking Brake Doesn t Hold Disc brake Air in the brake line Pad or disc worn Brake fluid leakage 16 36 APPENDIX Troubleshooting Guide Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in mas ter cylinder Brake master cylinder scratched inside Drum brake Brake maladjusted Brake linings or drum worn Overheated Water in brake drum Brake cam camshaft worn Oil on brake linings Battery Trouble Battery discharged Battery faulty e g plates sulphated shorted through sedimentation elec trolyte insufficient Battery leads making poor contact Load excessive e g bulb of excessive wattage Ignition switch trouble Alternator trouble Wiring faulty Regulator rectifier trouble Battery overcharged Regulator rectifier trouble Battery faulty http mototh com MODEL APPLICATION Year Model Beginning Frame SENE JKABN125AAAQD0001 we 2000 BN125 A3 JKABN125AADA00001 2001 BN125 A4 JKABNRA1011DA00574 ams enaA ane ENARA T 2006 BN125A6F or LENTUM S o This digit in the frame number changes from one machine to ano
177. ht stays on 23 21 or 140 250 2 42 or 46 75 95 Cycle s per minute Correspond to one light burned out http mototh com 8 12040251 C 15 60 ELECTRICAL SYSTEM Lighting System Turn Signal Light Circuit 125 1 2 O AY p 4 6 Et BK Y BK Y GY BS e BK Y E KS 8kK Y d 6 6 BK Y BK Y E S BK Y 6 BRE 6 BK Y gt 4 _BK Y d 9 6 12121 3 Turn signal indicator light Turn signal relay lgnition fuse 10 A Front right turn signal light Front left turn signal light Rear right turn signal light Rear left turn signal light Turn signal switch lgnition switch Starter relay Main fuse 15 A Battery http mototh com Lighting System ELECTRICAL SYSTEM 15 61 Turn Signal Light Circuit BN125 A3 A5 ey BIS 6 ES 6 amp 9 GP12122BW3 Turn signal indicator light Turn signal relay Ignition fuse 15 Front right turn signal light Front left turn signal light Rear right turn signal light Rear left turn signal light Turn signal switch Ignition switch Starter relay Main fuse 30 A Battery http mototh com 15 62 ELECTRICA
178. ial Tool Bearing Driver Set 57001 1129 e Tighten the bearing retaining screws securely in the right crankcase half Torque Bearing Retaining Screws 4 9 N m 0 50 kgf m 43 in Ib e Put the output shaft oil seal D in being careful of the proper direction as shown http mototh com 6104010251 6104090851 CRANKSHAFT TRANSMISSION 8 11 Crankcase e Using compressed air A blow out the oil passage in the right crankshaft B e Positioning the connecting rod A big end at BDC put in the crankshaft jig B between the crankshaft flywheels e Press the crankshaft C in the right crankcase half D Special Tool Crankshaft Jig 57001 1174 e Apply engine oil to the transmission gears bearings shift forks shift drum and crankshaft bearing P oO gt 5 4 DO A 2 lt m M V E e Install Shift Drum A Transmission Shafts B Shift Forks C Balancer Shaft D Be careful of its direction e Check that the shift drum is in neutral position e Check that two dowel pins A are in place of the right crankcase half e Apply liquid gasket to the mating surface B of the left crankcase half Sealant Kawasaki Bond Liquid Gasket Silver 92104 002 e Using a suitable tool on the left crankcase to press around the hole for the crankshaft fit the crankcase halves to s gether with a press on the tool 8104137881 e
179. iew D gos 2 e http mototh com ENGINE END 4 3 Exploded View No Fastener TOTUS Remarks N m kgf m ft Ib 1 Valve Adjusting Cap Bolts BN125 A1 9 8 1 0 87 in lb Valve Adjusting Cap Bolts BN125 A4 8 8 0 90 78 in lb 2 Camshaft Chain Cover Bolts BN125 A1 A3 9 8 1 0 87 in lb Camshaft Chain Cover Bolts BN125 A4 8 8 0 90 78 in lb Cylinder Head Bolts M9 26 2 7 19 5 4 Cylinder Head Bolts M6 12 1 2 104 in lb 5 5 Spark Plug 13 1 3 9 5 6 2 Chain Damper Bolts 125 1 98 10 87 inb Chain Cover Damper Bolts BN125 A4 88 0 90 78 in lb Air Suction Valve Cover Bolts 125 1 9 8 1 0 87 in lb T Cylinder Head Blank Bolts 125 4 8 8 0 90 78 in lb 10 Switch Valve Pipe Mounting Bolts Vacuum Hose Fitting Oil Pipe Banjo Bolt M10 13 Oil Pipe Banjo Bolts M8 9 8 1 0 87 in lb 14 Oil Pipe Mounting Bolts BN125 A1 9 8 1 0 87 in lb Oil Pipe Mounting Bolts BN125 A4 8 8 0 90 78 in lb 15 R marked side faces up 16 RN marked side faces up 17 Air suction valve For AT CH DE of BN125 A1 A2 and other than the CAL of BN125A3 18 Other than AT CH DE of among the BN125 A1 A2 19 California Model EO Apply engine oil G Apply grease L Apply a non permanent locking agent M Apply molybdenum disulfide greas
180. if ference between the highest and lowest dial readings is the amount of runout x If rim runout exceeds the service limit check the hub bear ings first Replace them if they are damaged If the prob lem is not to the bearings correct the rim warp runout A certain amount of rim warp can be corrected by recen tering the rim Loosen some spokes and tighten others within the standard torque to change the position of dif ferent parts of the rim If the rim is badly bent however it must be replaced Rim Runout with tire Installed Standard Axial TIR 0 8 mm 0 03 in or less Radial TIR 1 0 mm 0 04 in or less Service Limit Axial TIR 2 0 mm 0 08 in Radial TIR 2 0 mm 0 08 in http mototh com 6J04061081 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Pressure Inspection Adjustment Remove the air valve cap e 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 Adjust the tire air pressure according to the specifications if necessary Air Pressure when cold Front BN125 A1 A2 Up to 185 kg 408 Ib 150 kPa 1 5 kgf cme BN125 A3 Up to 155 kg 21 psi 342 Ib Rear BN125 A1 A2 Up to 185 kg 408 Ib 175 kPa 1 75 BN125 A3 Up to 155 kg kgf cm 25 psi 342 Ib e Install the air valve cap certainly after air pre
181. il in use possibly causing an accident If the frame is bent dented cracked or warped replace it http mototh com 6009010281 http mototh com ELECTRICAL SYSTEM 15 1 Electrical System Table of Contents Parts Locatiom pp Exploded View Specifications pp Special Tools and Sealant Wiring Diagram Electrical Wiring Wiring Inspection attery 2 Battery Removal Installation Electrolyte Specific Gravity Inspection Initial Charging Ordinary Charging Charging System Alternator Cover Removal Alternator Cover Installation Alternator Rotor Removal Alternator Rotor Installation Stator Coil Removal Stator Coil Installation Alternator Inspection Regulator Rectifier Inspection Charging Voltage Inspection Ignition System Crankshaft Sensor Removal Installation Crankshaft Sensor Inspection Crankshaft Sensor Peak Voltage INSpection catus Ignition Timing Inspection Ignition Coil Removal Ignition Coil Installation Ignition Coil Inspection Ignition Coil Primary Peak Voltage Spark Plug Removal Spark Plug Cleaning Inspection Spark Plug Gap Inspection CDI Unit Removal CDI Unit Inspection Electric Starter System http motot
182. ing the brush holder assembly and or terminal bolt assembly have a short Replace the brush holder assembly and the terminal bolt assembly Starter Relay Inspection e Remove Right Side Cover see Frame chapter Starter Circuit Relay Connect the hand tester A and 12 V battery to the starter relay C as shown Special Tool Hand Tester 57001 1394 x If the relay does not work as specified the relay is defec tive Replace the relay Testing Relay Tester Range x 1 range Criteria When battery is connected 0 Q When battery is disconnected http mototh com 6112196 P 8 11010751 C 15 52 ELECTRICAL SYSTEM Electric Starter System Starter Circuit Relay Inspection e Remove Right Side Cover see Frame chapter Starter Circuit Relay Connect the hand tester A 12 V battery as shown Relay Coil Terminal 1 and 2 Relay Switch Terminal 3 and 4 xIf the relay C does not work as specified the relay is defective Replace the relay Special Tool Hand Tester 57001 1394 Testing Relay Tester Range 1 range Criteria When battery is connected 0 When battery is disconnected Starter Circuit Relay A Starter Relay B Interlock Diodes C http mototh com ELECTRICAL SYSTEM 15 53 Electric Starter System Electric Starter Circuit 125 1 2 6P 2 6 Mox n X quee
183. ing Stem Nut Wrench Fork Oil Level Gauge 57001 1100 57001 1290 L2 M 875711005 C 875712905 C Jack 57001 1238 7571238ST C http mototh com 2 12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose Connection Inspection OThe 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 Remove the fuel tank see Fuel System chapter and check the fuel hose Replace the fuel hose if any fraying cracks B or bulges C are noticed Check that the hose is securely connected and clamps are tightened correctly e When installing route the hose according to Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hose avoids sharp bending kink ing flattening or twisting and route the fuel hose with a minimum of bending so that the fuel flow will not be ob structed Replace the hose if it has been sharply bent or kinked Throttle Grip Free Play Inspection If the throttle grip has excessive free play due to cable stretch or misadjustment there will be a delay in throttle re sponse Also the throttle valve may not open fully at full throttle On the other hand if the throttle grip has no play the throttle will be hard to control and the idle speed will be erra
184. ing onto the brake pedal e Push B the brake pedal A across the brake shaft and insert the pedal onto the shaft e Lightly tighten the brake pedal bolt A e Pry the brake return spring B onto the brake shaft with a screwdriver Tighten the brake pedal bolt Torque Brake Pedal Bolt 9 8 N m 1 0 kgf m 87 ft lb e Hook the rear brake light switch spring and brake return spring lower end e Insert a new cotter pin through the joint pin and spread its ends e Check Brake Pedal Position see Brake Pedal Position Inspec tion Adjustment Brake Pedal Free Play see Periodic Maintenance chap ter Rear Brake Light Switch Timing see Periodic Mainte nance chapter e Install the parts removed Brake Cable Removal e Remove Bands A Cover B Front Footpeg Mounting Bolts C http mototh com aima 11 20 BRAKES Rear Brake Pedal Brake Cable e Remove Cotter Pin and Joint Pin Brake Cable Nut A e Remove the silencer see Engine Top End chapter e 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 e Remove the cable dust boot A e Pull the outer cable housing B forward and take out the inner cable C from the groove of the stay e Pull the brake cable out of the frame Brake Cable Installation e Lubricate the cable before installation e Adjust the brake pedal position and free play Brake Cable Lub
185. is warped over the service limit replace it with a new one Friction and Steel Plate Warp Standard 0 2 mm 0 008 in or less Service Limit 0 3 mm 0 012 in http mototh com GF06035BS1 C GF06060281 GF13010781 CLUTCH 5 11 Clutch Clutch Spring Free Length Measurement e 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 e Visually inspect the clutch housing fingers A where the friction plate tangs hit them x If they are badly worn or if there are groove cuts whre the tangs hit replace the hosing Also replace the friction plates if their tangs are damaged Clutch Hub Spline Damage e Visually inspect where the teeth on the steel plates wear against the clutch hub splines x If there are notches worn into the clutch hub splines A replace the clutch hub Also replace the steel pates if their teeth are damaged http mototh com 5 12 CLUTCH Primary Gear Removal e Remove the clutch cover see Clutch Cover Removal e Using the gear holder A hold the primary gear and loosen the primary gear nut B Special Tool Gear Holder m1 75 57001 1015 e Remove Clutch see Clutch Removal C Primary Gear Nut B Spring Washer Primary Gear D
186. isconnect the breather hose from the separator and in ject about 20 mL 0 68 US oz of gasoline A into the sep arator B through the hose fitting e Disconnect the fuel return hose C from the fuel tank D e Place the open end of the return hose into the container and hold it with the same level of the tank top E e Start the engine and let it idle If the gasoline the separator comes out of the hose the separator works well If it does not replace the separator with a new one Canister Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter http mototh com http mototh com ENGINE END 4 1 Engine Table of Contents Exploded Specifications Special Tools Clean Air System For AT CH DE of BN125 A1 A2 and other than the Air Suction Valve Installation Air Suction Valve Inspection Vacuum Switch Valve Removal Vacuum Switch Valve Installation Vacuum Switch Valve Unit Test Clean Air System Hose Inspection uoces te tre tite Clean Air System California Model Vacuum Switch Valve Test Camshaft Chain Tensioner Camshaft Chain Tensioner REMOVAL eee Camshaft Chain Tensioner Installation Camshaft Camshaft Removal Camshaft Installation Camshaft Chain Removal Camshaft Chain Installati
187. juster Locknut Engine Mounting Bolts and Nuts Shift Pedal Bolt Muffler Mounting Bolts and Nuts Clutch Cable Adjuster Locknut Clutch Lever Pivot Nut Others Sidestand Bolt and Nut Front Footpeg Mounting Bolts Rear Footpeg Mounting Bolts http mototh com http mototh com FUEL SYSTEM 3 1 Fuel System Table of Contents Exploded VIEW 3 2 js cun f EET 3 8 3 10 Throttle Grip and Gables esent doeet 3 11 Free Play InSpectiom uere eee iei se eres edes deren Hp a pu cera 3 11 Free Play Adjustment nui dte Au osa cti ut t 3 11 Throttle Gable a iR etta Ra dde 3 11 Throttle Cable Lubrication and Inspection iu one Sette redd optet n nb iat prag cx 3 11 Erelio BAEO eec 3 12 Idle Speed Inspection 3 12 Idle Speed Adjustment 3 12 Service Fuel Level Inspection 3 12 Service Fuel Level Adjustment 3 13 Fuel System Cleanliness Inspection 3 14 Carburetor Removal 3 14 Carburetor Installation 3 15 Carburetor Disassembly 3 15 Carburetor Assembly 3 17 Carburetor Cleaning 3 18 Carburetor Inspection 3 19 Air Cleaner 3 21 Air Cleaner Element Removal 3 21 Element Cleaning and Inspection 3 21 Air Cleaner Draining 3 21 Air Cleaner Housing Removal 3 22 Air Cleaner Housing Installation 3 22 Fuel Tank 3 23 Fuel Tank Removal 3 23 Fuel Tank Installation 3 2
188. ket B Direction of Rotation CAUTION If a sprocket requires replacement the drive chain is probably worn also Upon replacing the rear sprocket inspect the chain and engine sprocket Sprocket Warp Inspection e Raise the rear wheel off the ground with a jack Special Tool Jack 57001 1238 e Set a dial gauge A against the rear sprocket B near the teeth as shown e Turn C the rear wheel The difference between the high est and lowest dial gauge readings is the amount of runout warp x lf the runout exceeds the service limit replace the rear ekosooons1 sprocket Rear Sprocket Warp Standard TIR 0 4 mm 0 016 in or less Service Limit 0 5 mm 0 020 Coupling Removal e Remove the rear wheel see Wheels Tires chapter e Remove the rear sprocket see this chapter http mototh com Sprocket Coupling FINAL DRIVE 10 9 Coupling Installation e Grease A the following and install the coupling Coupling Grease Seal Lips Coupling Internal Surface e Install the rear sprocket and the coupling see this chap ter e Install the rear wheel see Wheels Tires chapter Coupling Bearing Removal e Remove the coupling e Pry the grease seal out e Remove the bearing A by tapping from the wheel side Special Tool Bearing Driver Set 57001 1129 B Coupling Bearing Installation e Replace the bearing A with a new one e Press in the bearing with the
189. l System chapter Brake Master Cylinder B see Brakes chapter Left Handlebar Switch Housing C Clutch Cable Upper End D Speedometer Unit E with Cable e Remove the handlebar nuts A and take off the handle bar Handlebar Removal BN125 A3 e Remove Brake Master Cylinder A see Brakes chapter Right Handlebar Switch Housing B with Throttle Cables C Clutch Cable Upper End D Left Handlebar Switch E Starter Lockout Switch Lead F e Remove the caps A and handlebar holder clamp bolts B Handlebar Installation BN125 A1 A2 e Tighten the handlebar nuts Torque Handlebar Nuts 34 N m 3 5 kgf m 25 ft lb e Install the removed parts Brake Master Cylinder see Brakes chapter http mototh com Handlebar STEERING 13 11 e 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 e Install the handlebar switch housing Tighten Torque Handlebar Switch Housing Screws 3 4 N m 0 35 kgf m 30 in Ib Handlebar Installation BN125 A3 e There is a gap A between the upper handle holder and lower handle holder so that the handlebar should be in stalled securely When the upper holder shall be installed tighten the front handlebar clamp bolts first and then rear bolt with specified torque Tighten Torque Handlebar Holder Clamp Bolts 20 N m 2 0 kgf m 15 ft lb e Install the remo
190. l 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 e Situate the motorcycle so that it is vertical e Check that the engine oil level is between the upper A and lower B levels in the gauge NOTE OSituate the motorcycle so that it is perpendicular to the ground Olf the motorcycle has just been used wait several utes for all the oil to drain down 8605010881 Olf the oil has just been changed start the engine and run it for several minutes at idle speed This fills the oil filter with oil Stop the engine then wait several minutes until the oil settles CAUTION Racing the engine before the oil reaches every part can cause engine seizure x lf the oil level is too high remove the excess oil through the filler opening using a syringe or some other suitable device xIf the oil level is too low add the correct amount of oil through the oil filler opening Use the same type and make of oil that is already in the engine NOTE Olf the engine oil type and make are unknown use any brand of the specified oil to top off the level rather than running the engine with the oil level low Then at your earliest convenience change the oil completely Engine Oil Change e Refer to the Engine Oil Change in the Periodic
191. lator rectifier http mototh com 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 e Remove Oil Pipe see Engine Lubrication System chapter e Slide back the rubber cap e Remove the starter motor terminal nut A e Remove the starter motor mounting bolts B e Pull out the starter motor C Starter Motor Installation CAUTION Do not tap the starter motor shaft or body Tapping the shaft or body could damage the motor e When installing the starter motor clean the starter mo tor legs A and crankcase B where the starter motor is grounded e Replace the O ring A with a new one e Apply a small amount of engine oil to the O ring e Install the starter motor e Tighten Torque Starter Motor Mounting Bolts 8 8 N m 0 90 kgf m 78 Starter Motor Terminal Nut 4 9 0 50 kgf m 43 Starter Motor Disassembly e Remove the starter motor see this section e Take off the starter motor assembly bolts A and remove both end covers B and pull the armature out of the yoke http mototh com Electric Starter System ELECTRICAL SYSTEM 15 49 e Remove the terminal locknut A and terminal bolt B and then remove the brush with the brush plate from the yoke Starter Motor Assembly e Replace the O ri
192. less Service Limit 0 3 mm 0 012 in http mototh com 6108015851 C 11 16 BRAKES Brake Fluid Brake Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in Periodic Main tenance chapter Brake Fluid Change e Refer to the Brake Fluid Change in Periodic Maintenance chapter Brake Line Bleeding e Refer to the Brake Line Bleeding in Periodic Maintenance chapter http mototh com Hose BRAKES 11 17 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 e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hose A temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e There are washers B on each side of the brake hose fitting Replace them with new ones when installing e When installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses according to Cable Wire and Hose Routing section in Appendix chap ter e Tighten Torque Brake Hose Banjo Bolts C 25 N m 2 5 kgf m 18 ft lb e Bleed the brake line after installing the brake hose see Brake Line Bleeding Brake Hose Inspection e Refer to the Brake Hose Check in the Periodic Mainte nance chapter http mototh com 11 18 B
193. ll cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually de teriorate the rubber used in the disc brake e Apply brake fluid to the removed parts and to the inner wall of the cylinder e Take care not to scratch the piston or the inner wall of the cylinder e Apply silicone grease ex PBC grease to the following points Brake Lever Pivot Bolt Brake Lever Pivot Contact Dust Cover Tighten Torque Brake Reservoir Cap Screws 1 5 N m 0 15 kgf m 13 in Ib Brake Lever Pivot Bolt 5 9 N m 0 60 kgf m 52 in Ib Brake Lever Pivot Locknut 5 9 N m 0 60 kgf m 52 in Ib Master Cylinder Inspection Visual Inspection e Disassemble the master cylinder e Check that there are no scratches rust or pitting on the inner wall A of the master cylinder and on the outside of the piston B If a master cylinder or piston shows any damage replace them e Inspect the primary cup C and secondary cup D If a cup is worn damaged softened rotted or swollen the piston assembly should be replaced to renew the cups x lf fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cups e Check the dust cover E for damage x If the dust cover is damaged replace it e Check the relief F and supply ports are not plugged x If the relief port becomes plugged the brake pads will drag on the disc Blow the
194. lt and nut C e With a twisting motion work the fork leg A down and out Fork Installation e Install the fork so that the top end A of the inner tube is flush with the upper surface of the steering stem head B e Run the cables wires and hoses as shown in the Cable Wire and Hose Routing section of the Appendix chapter e Tighten Torque Front Fork Clamp Bolts Upper 20 2 0 kgf m 15 ft lb Front Fork Clamp Bolts Lower 34 3 4 kgf m 25 ft lb Fork Top Plugs 23 N m 2 3 kgf m 17 ft lb Turn Signal Light Holder Nut 5 9 N m 0 60 kgf m 52 in Ib e Install the front wheel see Wheels Tires chapter http mototh com 8 04013451 C Front Fork SUSPENSION 12 9 Check the front brake effectiveness after installation WARNING Do not attempt to ride the motorcycle until full brake lever is obtained by pumping the brake lever until the pads are against the disc brake will not function to the first application of the lever if this is not done Fork Disassembly Remove the front fork see Front Fork Removal e Drain the fork oil see Periodic Maintenance chapter OThe following parts are removed during draining the fork oil Top Plug Spacer Fork Spring Seat Fork Spring e Hold the front fork horizontally in a vise A e Stop the cylinder unit B from turning by using the special tools and Allen wrench e Unscrew the Allen bolt
195. m Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts his ability to do the work all adjust ments maintenance and repair should be car ried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation For the duration of the warranty period we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your vehicle Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and no
196. m 0 006 0 007 in 0 38 mm 0 015 in Inlet 0 03 0 13 mm 0 001 0 005 in 0 33 mm 0 013 in Valve Seat Cutting Angle 45 32 60 Valve Seat Surface Outside Diameter Exhaust 25 5 25 7 mm 1 00 1 01 in Inlet 29 5 29 7 mm 1 16 1 17 in http mototh com Specifications ENGINE TOP END 4 7 Cylinder Piston Cylinder Inside Diameter Piston Diameter Piston cylinder Clearance Oversize Piston and Rings Piston Ring groove Item Standard Service Limit Width Exhaust 0 8 1 2 mm 0 03 0 05 in Inlet 0 8 1 2 mm 0 03 0 05 in Valve Spring Free Length Exhaust 43 51 mm 1 713 in 42 1 mm 1 66 in Inlet 43 51 mm 1 713 in 42 1 mm 1 66 in 55 000 55 012 mm 2 1654 2 1658 in 55 10 mm 2 169 in 54 960 54 975 mm 2 1638 2 1644 in 54 81 mm 2 158 in 54 968 54 982 mm 2 1641 2 1646 in 54 82 mm 2 158 in BN125 A7 NU 0 025 0 052 mm 0 0010 0 0020 in 0 0241 0 0385 mm 0 0009 0 0015 BN125 A7 NU 0 5 mm 0 02 in 1 0 mm 0 04 in Clearance Top 0 03 0 07 0 0012 0 0028 0 17 mm 0 0067 in Second 0 02 0 06 0 0008 0 0024 0 16 mm 0 0063 in Piston Ring Groove Width Top 0 82 0 84 mm 0 0323 0 0331 in 0 92 mm 0 0362 in Second 0 81 0 83 mm 0 0319 0 0327 0 91 mm 0 0358 in Piston Ring Thickness
197. m pushing out A replacement chain ten sioner spare parts has a holder plate e The holder plate can be made of 1 mm 0 04 in thick aluminum plate as shown http mototh com 8 10010351 C ENGINE END 4 15 Camshaft Chain Tensioner e Install the O ring in the tensioner body e Install the tensioner so that the arrow mark B faces up ward and tighten the mounting bolts Torque Chain Tensioner Mounting Bolts 125 1 9 8 1 0 kgf m 87in Ib BN125 A4 8 8 N m 0 90 kgf m 87in Ib e Remove the screwdriver or the holder plate A and tighten the cap Torque Chain Tensioner Cap 4 9 N m 0 50 kgf m 43 in Ib http mototh com 4 16 ENGINE END Camshaft Camshaft Removal e 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 e Turn the camshaft center bolt A clockwise so that the mark B on the sprocket aligns with the timing mark C on the cylinder head Be sure to position the piston TDC at the end of the compression stroke by turning the camshaft Align the mark when the inlet valve again comes up after it went down once e Remove Camshaft Chain Tensioner see this chapter Camshaft Sprocket A NOTE OHold the camshaft chain with some tool so that the chain does not fall into the engin
198. m the fuel tank e When installing the indicator unit tighten the front bolt first Bulb Replacement e To remove the wedge base type bulb A pull the bulb out of the socket B CAUTION Do not turn the bulb Pull the bulb out to prevent damage to the bulb Do not use bulb rated for other than voltage or wattage specified in the wiring dia gram http mototh com 15 64 ELECTRICAL SYSTEM Switches and Sensors Front Brake Light Switch Inspection e Refer to the Front Brake Light Switch Inspection in the Periodic Maintenance chapter Rear Brake Light Timing Inspection e Refer to the Rear Brake Light Timing Inspection in the Periodic Maintenance chapter Rear Brake Light Timing Adjustment e Refer to the Rear Brake Light Timing Adjustment in the Periodic Maintenance chapter Switch Inspection e Using the hand tester check to see that only the connec tions shown in the table have continuity about 0 OFor the handlebar switches and the ignition switch refer to the tables in the Wiring Diagram x If the switch has an open or short repair it or replace it with a new one Special Tool Hand Tester 57001 1394 Rear Brake Light Switch Connections Color BR BL W When brake pedal is pushed down O o When brake pedal is released Sidestand Switch Connections Color BK G When sidestand is down ae ee When sidestand is up O O Neutral Switch Connections Color SW
199. meter Incorrect values may lead to improper adjustments GB02082BS1 http mototh com GENERAL INFORMATION 1 7 Model Identification BN125 A1 Europe Left Side View 69038177 125 1 Right Side View 60730123 http mototh com 1 8 GENERAL INFORMATION Model Identification BN125 A1 Singapore Left Side View ni 9038170 125 1 Right Side View 6038121 http mototh com GENERAL INFORMATION 1 9 General Specifications tems BNIBAi A2 2 3 4 125 45 Dimensions Overall length 2 150 mm 84 6 in Overall width 780 mm 30 7 in Overall height 1020 mm 40 2 in 1 035 mm 40 8 in 1 050 mm 41 3 in US CA 1 045 mm 41 1 in BN125 A7 N NU Wheelbase 1 470 mm 57 9 in Road clearance 145 mm 5 7 in 160 mm 6 3 in 155 mm 6 1 in US CA Seat height 680 mm 26 8 in Dry mass 128 kg 1 255 282 135 kg 1 323 298 Ib Ib 132 kg 1 294 N 291 Ib US BN125 A4 Curb mass Front 64 kg 628 N 141 Ib lt 66 kg 647 146 Ib 65 kg 637 143 Ib 125 7 NU 80 kg 785 N 17616 84 kg 824 N 185 Ib 81 kg 794 179 lt Ib BN125 A4 US CA 82 kg 804 181 Ib CAL 83 kg 814 N 183 Ib BN125 A7 N NU Fuel tank capacity 13 L 3 43 US gal Performance
200. minated replace it with a new one e To prevent the gasoline from flowing into or out of the canister hold the separator perpendicular to the ground Connect the hoses according to the diagram of the sys tem Make sure they do not get pinched or kinked e Route hoses with a minimum of bending so that the air or vapor will not be obstructed e Be sure to plug the return hose to prevent fuel spilling before fuel tank removal A WARNING When removing the fuel tank be careful not to spill the gasoline through the return hose Spilled fuel is hazardous x If liquid gasoline flows into the breather hose remove the hose and blow it clean with compressed air Hose Inspection e Check that the hoses are securely connected Replace any kinked deteriorated or damaged hoses Separator Inspection e Refer to the Evaporative Emission Control System In spection in the Periodic Maintenance chapter http mototh com FUEL SYSTEM 3 27 Evaporative Emission Control System California Model Only Separator Operation Test A 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 this includes any appliance with a pilot light Connect the hoses to the separator and install the sepa rator on the motorcycle 6613010152 C e D
201. mit the drum must be replaced 6113010851 Gear Dog and Gear Dog Hole Damage e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes 6113010951 C http mototh com 8 22 CRANKSHAFT TRANSMISSION Ball Bearing Oil Seal Ball Bearing Replacement CAUTION Do not remove the ball bearings unless it is neces sary Removal may damaged them e Using a press or puller remove the ball bearing NOTE the absence of the above mentioned tools satisfac tory results may be obtained by heating the case to ap proximately 93 200 max and tapping the bearing in or out CAUTION Do not heat the case with a torch This will warp the case Soak the case in oil and heat the oil e Using a press and the bearing driver set A install the new bearing until it stops at the bottom of its housing Special Tool Bearing Driver Set 57001 1129 Ball Bearing Wear CAUTION Do not remove the bearings for inspection Re moval may damage them e Check the ball bearings OSince the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with engine oil OSpin A the bearing by hand to check its condition x If the be
202. n a well ventilated 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 e Remove the fuel tank and drain it e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Pour the solvent out of the tank e Remove the fuel tap from the tank see Fuel Tap Re moval Clean the fuel tap filter screens in high flash point sol vent Pour high flash point solvent through the tap in all lever positions e Dry the tank and the fuel tap with compressed air e Install the tap in the tank e Install the fuel tank Fuel Tap Removal e Remove the fuel tank and drain it e Remove the tap bolts A with nylon flat washers and take out the fuel tap Fuel Tap Installation e Replace the O rings A with a new one e Be sure to clamp the fuel hose to the tap to prevent leaks e Be sure the flat washers B are in good condition to pre vent leaks ODo not use steel washers in place of the flat washers because they will not seal the bolts properly and fuel will leak e Tighten Torque Fuel Tap Mounting Bolts 2 5 N m 0 25 kgf m 22 in Ib White Washer 4 9 N m 0 50 kgf m 43 in Ib Black Washer http mototh com 00200147 P GCO9089BS1 C FUEL SYSTEM 3 25 Fuel Tank Fuel Inspection
203. n scheduled maintenance e Use proper tools and genuine Kawasaki Mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki motorcycles are introduced by the Service Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use This Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference http mototh com Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices A WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could res
204. nd dimmer switch to e Run the engine at 4 000 r min rpm and measure the voltage AC Lighting Voltage Range Tester to Tester to 94 000 rpm 25 V AC R BK lead BK Y lead 11 16V e Stop the engine x If the voltage is kept between the values given in the table the lighting system is considered to be working normally x lf the voltage is much higher than the values specified in the table the regulator rectifier is defective or the regula tor rectifier leads are loose or open x f the voltage is much lower than the values specified in the table the regulator rectifier is defective or alternator output is insufficient Check the regulator rectifier and al ternator to determine which part is defective http mototh com ELECTRICAL SYSTEM 15 57 Lighting System Headlight Circuit BN125 A1 A2 1 BK Y BK Y R BK R BK 6P R BK BK Y 254 GP12118BW2 1 High beam indicator light 4 Alternator 2 Headlight 5 Regulator rectifier 3 Dimmer switch 6 Headlight switch Headlight Circuit BN125 A3 A5 or R BK 2 BK Y R Y R Y BL Y R BK BL Y Y W Y Y Y elm oG R Y BL Y 9 1 o GPi2119BN2 C 1 High beam indicator light 5 Alternator 2 Headlight 6 Regulator rectifier 3 Dimmer switch 7 Ignition switch 4 Headlight switch 8 He
205. ng Brake Line Bleeding The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever is transmit ted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever movement will be partially used in compressing the air This will make the lever feel spongy and it will be a loss in braking power A WARNING Be sure to bleed the air from the brake line when ever brake lever action feels soft or spongy after the brake fluid is changed or whenever a brake line fitting has been loosened for any reason e Remove the reservoir cap and fill the reservoir with fresh brake fluid to the upper level line in the reservoir e With the reservoir cap off slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reser voir OBleed the air completely from the master cylinder by this operation e Install the reservoir cap e Remove the rubber cap from the bleed valve on the caliper e Attach a clear plastic hose to the bleed valve and run the other end of the hose into a container e Bleed the brake line and the caliper as follows ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close B the bleed val
206. ngs with new ones e Apply a thin coat of grease to the oil seal A and needle bearing B e Fit the toothed washer C into the end cover e Install the brush plate A and tighten the terminal locknut B Torque Starter Motor Terminal Locknut 6 9 0 70 kgf m 61 in Ib e Fit the tongue C on the brush plate into the end cover groove e Insert the armature A between the brushes e Align the marks C on the yoke B and end covers A e Tighten the starter motor assembly bolts Torque Starter Motor Assembly Bolts 3 4 0 35 kgf m 30 in Ib http mototh com 15 50 ELECTRICAL SYSTEM Electric Starter System Brush Inspection e 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 Standard 9 5 10 5 mm 0 37 0 41 in Service Limit 8 mm 0 31 in Commutator Cleaning and Inspection e Smooth the commutator surface A if necessary with fine emery cloth B and clean out the grooves e Measure the diameter A of the commutator B x lf the commutator diameter is less than the service limit replace the starter motor with a new one Commutator Diameter Standard 27 95 28 05 mm 1 10 1 11 in Service Limit 27 mm 1 06 in Armature Inspection e Using the x 1 hand tester range measure the resis tance between any two commutator segments A Special Tool Hand Test
207. o prevent the caliper piston from jumping out CAUTION Do not lay the wheel down on the disc This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground Front Wheel Installation e Apply grease to the seal lip A of the speedometer gear e Install the speedometer gear housing so that the projec tions C fit in the drive notches B e Fit the collar A on the right side of the hub http mototh com Wheels Rims WHEELS TIRES 9 7 e Fit the fork leg stop A between the speedometer gear housing stop B and install the front wheel e 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 e Insert a new cotter pin A NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle tighten the nut clockwise B up to next alignment Olt should be within 30 degree OLoosen once and tighten again when the slot goes past the nearest hole e Bend the cotter pin A over the nut B e Check the front brake effectiveness A WARNING Do not attempt to drive 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 on the first application of the lever if this is not done Rear Wheel Removal e Raise the rear wheel B off the ground using the jack A
208. o high Clutch housing frozen on drive shaft Clutch release mechanism trouble Clutch hub nut loose Clutch hub spline damaged Gear Shifting Faulty Doesn t go into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear set lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift pawl broken Jumps out of gear Shift fork ear worn bent Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear set lever spring weak or broken Shift fork guide pin worn Drive shaft output shaft and or gear splines worn Overshifts Gear set lever spring weak or broken Shift mechanism arm spring broken Abnormal Engine Noise Knocking CDI unit trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Valve noise Valve clearance incorrect Valve spring broken or weak Camshaft bearing worn Rocker arm worn Rocker shaft worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure damage Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mount
209. o the inside of the needle bearings and grease seals e Loop the drive chain A onto the swingarm e Install the swingarm e Install the removed parts see appropriate chapters e Tighten the following Torque Swingarm Pivot Nut 98 N m 10 0 kgf m 72 ft lb Rear Shock Absorber Bolts 34 N m 3 5 kgf m 25 ft Ib Swingarm Bearing Removal e Remove Swingarm see this chapter Sleeve Grease Seals Remove the needle bearings A using the oil seal amp bear ing remover B Special Tool Oil Seal amp Bearing Remover 57001 1058 Swingarm Bearing Installation e Apply plenty of grease to the new needle bearings sleeve and grease seal lip e Position the bushings A as shown using a suitable bear ing driver in the bearing driver set OBe sure to install the needle bearing so that the manufac turer s marks are faced out This prevents bearing dam age Special Tool Bearing Driver Set 57001 1129 http mototh com 8 06010151 Swingarm SUSPENSION 12 15 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 However if excessive play is felt check the swingarm bushings for wear and replace them if necessary Swin
210. of the left side cover outward to clear the stopper e Pull C the cover rearward to clear the hook and remove it Left Side Cover Installation e Slip the stopper A of the left side cover onto the hook B e Push the stopper of the cover into the grommet e Tighten the screws Right Side Cover Hemoval e Insert the ignition switch key into the right side cover e Turn A the key clockwise and pull B the front part of the cover outward to clear the stopper e Pull C the cover rearward to clear the hook and remove it Right Side Cover Installation e Slip the stopper A of the right side cover onto the hook B e While turning the ignition switch key clockwise push the stopper of the cover into the grommet e Turn the key counterclockwise and pull out the key http mototh com 14 8 Seat Seat Removal e 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 e Remove the pad assembly C e For the Singapore and U S A models remove the bolts A cover B and collar C on both sides Front D e Remove the seat bolts A and take off the seat B Seat Installation e Slip the hook A of the seat under the bracket B on the fuel tank e Install the removed parts OFor the Singapore and U S A models install the collar noting its direction see above figure http mototh com
211. oller send a trigger signal to the gate through the cathode K G in the figure in the thyristor When this happens the current flows from the cathode to the anode K A in the thyristor Third step Surging current into the Primary Winding When the thyristor conducts the charge stored in the capacitor is released suddenly flowing through the primary winding back through the thyristor to the capacitor http mototh com GENERAL INFORMATION 1 15 Technical Information DC CDI Direct Current Capacitor Discharge Ignition Sys tem DC DC Converter Transformer 12V De gt 225 DC Capacitor Ignition Osci lt gt lator Ignition Timing Controller Secondary Winding Crankshaft Sensor 6806104BN2 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 The sec ondary voltage multiplied by winding ratio about 90 1 reaches about 20 000 V Final step Thyristor resets After the charge stored in the capacitor is completely released the cathode to anode voltage is removed in the thyristor and the thyristor stops conducting and automatically resets Then the DC DC converter charges the capacitor again and operation returns to first step The control of Igni
212. om 3 12 FUEL SYSTEM Carburetor Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Idle Speed Adjustment e Refer to the Idle Speed Adjustment in the Periodic Main tenance chapter Service Fuel Level Inspection WARNING Gasoline is extremely flammable and 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 this includes any appliance with a pilot light Remove the carburetor and hold it upright on a stand see Carburetor Removal e Prepare an auxiliary fuel tank and connect the fuel tap to the carburetor using a suitable hose e Prepare a suitable fuel hose e Connect the fuel level gauge A to the carburetor float bowl with the fuel hose Special Tool Fuel Level Gauge 57001 1017 e Hold the gauge vertically against the side of the carbure tor body so that the middle line B is several millimeters higher than the bottom edge C of the carburetor body e Turn the fuel tap to the ON position to feed fuel to the carburetor then turn out the carburetor drain plug D a few turns Special Tool Carburetor Drain Plug Wrench Hex 3 57001 1269 e Wait until the fuel level in the gauge settles e Keeping the gauge vertical slowly lower the gauge until the middle line is even with the bottom edge E of the carburetor body
213. on Cylinder Head Cylinder Compression Measurement Cylinder Head Removal Cylinder Head Installation Cylinder Head Assembly 4 11 4 11 4 11 4 11 4 11 4 12 4 12 4 13 4 13 4 14 4 14 4 16 4 16 4 17 4 18 4 19 4 21 4 21 4 22 4 23 4 24 http mototh com Cylinder Head Cleaning Cylinder Head Warp Valve Clearance Inspection Valve Clearance Adjustment Valve Valve Installation Valve Guide Removal Valve Guide Installation Valve to Guide Clearance Measurement Wobble Method Valve Seat Inspection Valve Seat Repair Cylinder Piston Cylinder Removal Piston Remowval Cylinder Piston Installation Cylinder Piston Piston Cylinder Clearance Piston Ring Piston Ring Groove Wear Piston Ring Groove Width Piston Ring Thickness Piston Ring End Carburetor Holder Carburetor Holder Installation Muffler Muffler Removal Muffler Installation 4 24 4 25 4 26 4 26 4 26 4 26 4 26 4 26 4 27 4 27 4 28 4 28 4 33 4 33 4 33 4 33 4 35 4 35 4 36 4 2 ENGINE END Exploded V
214. on e Install the clutch lever so that the mating surface of the lever holder is aligned with the punch mark A on the handlebar Clutch Cable Removal e Loosen the locknut A at the clutch lever and screw the adjuster B e Line up the slots C in the clutch lever locknut and ad juster and then free the cable from the lever e Free the clutch inner cable tip from the clutch release lever e Push the release lever toward the front of the motorcycle and tape the release lever to the clutch cover to prevent the release shaft from falling out e Pull the clutch cable out of the frame Clutch Cable Installation e Run the clutch cable correctly see Appendix chapter e Adjust the clutch lever free play see Periodic Mainte nance chapter Clutch Cable Lubrication e Refer to the General Lubrication in the Periodic Mainte nance chapter http mototh com Clutch Cover CLUTCH 5 7 Clutch Cover Removal e Drain the engine oil see Periodic Maintenance chapter e Remove Front Footpeg Oil Pipe Banjo Bolt A e Screw the clutch lever adjuster in completely so as to give the clutch cable plenty of play e Remove the clutch cable holder B of clutch release lever e Free the clutch inner cable tip from the clutch release lever C e Remove the clutch cover bolts and remove the clutch cover A OTurn the release lever toward the rear to free the release shaft B from the clutch spring plate pusher and rem
215. or pin and regrease them OApply grease to the center of shaft and very lightly on the cam surfaces Do not over grease e Push the camshaft into the panel so that the triangular mark A on the cam surface points toward the center of the panel A WARNING Improper Installation will cause ineffective braking e Visually inspect the brake shoe springs for breaks or dis tortion x If the springs are damaged in way replace them e Fit the large spring A and small spring B onto the brake shoes as shown e Wrap a clean cloth around the linings to prevent grease or oil from getting on them and install the shoes on the brake panel http mototh com 11 22 BRAKES Rear Brake Panel Drum e 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 Install the cam lever in its original position on the camshaft and tighten its bolt Brake Panel Inspection e Remove the brake panel see Brake Panel Removal e Check the brake camshaft diameter and the brake camshaft hole diameter of brake panels Brake Camshaft Diameter Standard BN125 A1 A6 11 957 11 984 mm 0 471 0 472 in BN125 A7 and 8 United 14 95 14 99 mm States Models 0 589 0 590 in Service Limit BN125 A1 A6 11 88 mm 0 47 in BN125 A7 and A8 United 14 88 mm 0 59 in States Models Brak
216. ormance or durability of the motorcycle c Addition of components or accessories that result in the vehicle exceeding the stan daras d Permanently removing disconnecting or rendering inoperative any component or element of design of the emission control systems http mototh com 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 vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below e Replacement of the original exhaust system or muffler with a component not in compliance with Federal regulations e Removal of the muffler s or any internal portion of the muffler s e Removal of the air box or air box cover e Modifications to the muffler s or air inlet system by cutting drilling or other means if such modifications result in increased noise levels http mototh co
217. orque No Fastener Nm kgf m Remarks 1 Brake Disc Bolts 27 2 8 20 L 2 Caliper Mounting Bolts 2 5 18 3 Caliper Holder Shaft Bolts 1 8 13 4 Caliper Pad Bolts 1 8 13 5 Caliper Bleed Valve 0 80 69 in lb 6 Hose Banjo Bolts 2 5 18 7 Brake Lever Pivot Bolt 0 60 52 in lb 9 050 S2ini 8 090 78inb S 10 Brake Reservoir Cap Screws E 0 15 13 in Ib 11 Front Brake Light Switch Screws 1 0 0 10 9 in lb 12 Diaphragm plate BN125 A1 A2 13 BN125 A1 A2 B Apply brake fluid R Replacement Parts S Follow the specific tightening sequence Si Apply silicone grease or PBC grease http mototh com 11 4 BRAKES Exploded View 6L02258885 C BRAKES 11 5 Exploded View Torque No Fastener Remarks Nm ftlb 1 Brake Pedal Bolt 9 8 1 0 87 in lb 2 Torque Link Bolt and Nut 34 3 5 25 Apply grease R Replacement Parts http mototh com 11 6 5 Specifications Item Standard Service Limit Front Brake Pad Lining Thickness 4 5 mm 0 177 in BN125 A1 A2 6 0 mm 0 236 in BN125 A3 1 m 0 04 in 1 m 0 04 in Disk Thickness 3 8 4 2 mm 0 150 0 165 in 3 5 mm 0 138 in 4 3 4 7 mm 0 169 0 185 in 4 0 mm 0 157 in 125 NO ES BN125 A4 Disc Runout Less than 0 2 mm 0 008 in 0 3 mm 0 012 in Brake Fluid Grade DOT 4 Rear Brake Shoe Spring Free Leng
218. ot properly Exhaust Smokes Excessively White smoke Piston oil ring worn Cylinder worn Valve oil seal damaged Valve guide worn Engine oil level too high Black smoke Air cleaner clogged Main jet too large or fallen off Starter plunger stuck open Fuel level in carburetor float bowl too high Brown smoke Main jet too small http mototh com Fuel level in carburetor float bowl too low Air cleaner duct loose Air cleaner O ring damaged Air cleaner poorly sealed or missing Handling and or Stability Unsatisfactory Handlebar hard to turn Cable routing incorrect Hose routing incorrect Wiring routing incorrect Steering stem nut too tight Steering stem bearing damaged Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm pivot bearings worn Handlebar nut loose Rim warped or not balanced Wheel bearing worn Spokes loose Steering stem head bolt loose Front rear axle runout excessive Handlebar pulls to one side Frame bent Wheel misalignment Right wheel bearings are not bottomed out Swingarm bent or twisted Swingarm pivot shaft bent Steering maladjusted Front fork bent Right and left front fork oil level uneven Right and left shock absorber adjustment uneven Shock absorption unsatisfactory Too hard Front fork oil excessive Front fork oil viscosity too high Rear shock absorber adjustment too hard Tire air pressure too
219. ove the clutch cover CAUTION Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary If re moved the oil seal replacement may be required Apply high temperature grease to the oil seal lips Clutch Cover Installation e Install the dowel pins A and replace the cover gasket with a new one e Install the O ring B e Install the clutch cover with the clutch release lever toward the rear e Engine the clutch release shaft with the clutch spring plate pusher by turning the clutch release lever A toward the front http mototh com 5 8 CLUTCH Clutch Cover e With the shaft pulled a little out of the cover turn the lever until it becomes hard to turn OThe release lever should have about 11 mm 0 43 in A clearance between the lever and the washer Tighten the cover bolts and clutch cable holder bolts OWhile pushing B the clutch cable holder A rearward until the holder touches the clutch cover tighten the clutch cable holder bolt Torque Clutch Cover Bolts BN125 A1 A3 9 8 N m 1 0 kgf m 87 in Ib 125 4 8 8 0 90 kgf m 78 in Ib Replace the banjo bolt washers with new ones Tighten the oil pipe banjo bolt Torque Oil Pipe Banjo Bolt 25 N m 2 5 kgf m 18 in Ib e Pour in the specified type and amount of oil see Periodic Maintenance chapter e Install the front footpeg e Adjust and inspect the following Clutch Le
220. p Switch Starter Button Color Brake Lever Pulled In Released 98051 17830 WIRI783CN5 6 http mototh com 15 18 ELECTRICAL SYSTEM Wiring Diagram BN125 A2 A5 Europe Right Handlebar Switches 1 Front Brake Light Switch 2 Engine Stop Switch 3 Starter Button 4 Headlight Switch L3 BR BR ATERY gato NW M Ignition Switch IGNITION Oa GY GY T BL BL TAIL2 iej R R rans jo lt R W Meter Light 12V 1 7 Speedometer R BL R W BK Y High Beam Indicator BK Y Light 12V 3 4W R BK R BK Neutral Indicator ih BL W Light 12V 3 40 Le LG Turn Signal Indicator ey Light 12V 3 44 6 6 xt gt gt 0 gt LE Ss Es BK Headlight eta 12V 60 558 R Y Xo Ss City Light a 12V 4 BK Y O BK Y jA PUSH FREE rr e ON Side Stand Front Right Turn pld cy Switch Signal Light gt 12 21 Left Handlebar Switches 12V 3 04 1 Button 2 Turn Signal Switch 3 Dimmer Switch 4 Starter Lockout Switch Front Left Turn pla 6 Signal Light BK Y BK Y 12V 21 Pad LEFT HANDLEBAR SWITCH CONNECTIONS Sidestand Switch Horn Button Turn ren mE Dimmer Switch Lockout Switch Color BK R BK Y Color W1L1784CW5 C http mototh com
221. pecific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners 30 43 in lb 52 69 in lb 10 0 13 5 19 0 25 33 45 54 72 83 115 125 165 165 240 PERIODIC MAINTENANCE 2 9 Specifications Hem Standard Service Limit Fuel System Throttle Grip Free Play 2 3 mm 0 08 0 12 in Idle Speed 1 300 50 r min rpm Air Cleaner Element Oil Grade SE SF or SG class Viscosity SAE 30 Engine Top End Valve Clearance Inlet 0 08 0 12 0 0031 0 0047 in Exhaust 0 15 0 19 0 0059 0 0075 in Clutch Clutch Lever Free Play 2 3 mm 0 08 0 12 in Engine Lubrication System Engine Oil Grade BN125 A1 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 2L 1 27 US qt when filter is removed 1 4 L 1 48 US qt when engine is completely dry Between upper and lower level lines Wait 2 3 minutes after idling or running Tires Rim Runout With Tire Installed Axial TIR 0 8 mm 0 03 in or less TIR 2 0 mm 0 08 in Radial TIR 1 0 mm 0 04 in or less TIR 2 0 mm 0 08 in Air Pressure When Cold Front BN125 A1 A2 Up to 185 kg 408 Ib load 150 kPa 1 5 kgf cm 21 psi BN125 A3 Up to 155 kg 342 Ib load 150 kPa 1 5 kgf cm 21 psi Rear BN125 A1 A2 Up to 185 kg 408 Ib load 175 kPa 1
222. peed Spark weak Battery voltage low Spark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect CDI unit trouble Crankshaft sensor trouble Ignition coil trouble Fuel air mixture incorrect Pilot screw maladjusted Pilot jet or air passage clogged Needle jet bleed holes or needle jet clogged Pilot passage clogged Air cleaner clogged poorly sealed or miss ing Starter plunger stuck open Troubleshooting Guide Fuel level in carburetor float bowl too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Fuel tap clogged Air cleaner O ring damaged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head warped Cylinder head gasket damaged Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Other CDI unit trouble Carburetor vacuum piston doesn t slide smoothly Carburetor vacuum piston diaphragm dam age Engine oil viscosity too high Drive train trouble Brake dragging Overheating Clutch slipping Air suction valve trouble AT DE SG CH Vacuum switch valve trouble AT DE SG CH Casting enriche
223. pp 13 9 Handlebar Em 13 10 Handlebar Removal BNT25 A 1 2 o sep 13 10 Handlebar Removal BN125 AS 1 cet cette Renan 13 10 Handlebar Installation 125 1 2 a esce 13 10 Handlebar Installation BN125 A3 4 13 11 Hear View Mirror Removal Europe 13 11 Rear View Mirrors Installation Europe pp 13 11 http mototh com 13 2 STEERING Exploded View BN125 A1 http mototh com STEERING 13 3 Exploded View No Fastener Torque Remarks kgf m ft Ib 1 Steering Stem Head Bolts 44 4 5 33 2 Steering Stem Nut Handa tight Hand tight Hand tight or 4 9 or 0 50 or 43 in lb Handlebar Nuts 34 3 5 25 4 Handlebar Weight Screws L 5 Handlebar Switch Housing Screws 3 4 0 35 30 in lb 6 Front Fork Clamp Bolts Lower 34 3 5 25 5 7 Front Fork Clamp Bolts Upper 20 2 0 15 5 8 Handlebar holder clamp bolts 20 2 0 15 5 9 125 adhesive Apply grease L Apply a non permanent locking agent S Follow the specific tightening sequence http mototh com 13 4 STEERING Special Tools Steering Stem Bearing Driver 57001 137 Steering Stem Bearing Driver Adapter 34 5 57001 1074 875701375 C 0 7571074ST Head Pipe Outer Race Press
224. procket with the timing mark D on the cylinder head NOTE OPull the tension side exhaust side of the chain up to remove slack Tighten Torque Camshaft Sprocket Bolts 12 N m 1 2 kgf m 104 in Ib e Install Camshaft Chain tensioner see Camshaft Chain Ten sioner Installation Alternator Rotor see Electrical System chapter Alternator Cover see Electrical System chapter Camshaft Chain Cover e Tighten Torque Camshaft Chain Cover Bolts BN125 A1 9 8 N m 1 0 kgf m 87 in Ib 125 4 8 8 N m 0 90 kgf m 78 in Ib http mototh com ES a 8 11010351 C ENGINE END 4 21 Cylinder Head Cylinder Compression Measurement NOTE OUse the battery which is fully charged e Warm up the engine thoroughly e Stop the engine e Remove Fuel Tank see Fuel System chapter Spark Plug Owner s Tool Spark Plug Wrench Hex 16 92110 1172 A e Attach the compression gauge A and adapter B firmly into the spark plug hole Special Tools Compression Gauge 20 kgf cm 57001 221 Compression Gauge Adapter M10 x 1 0 57001 1317 e Using the starter motor turn the engine over with the throt tle fully open until the compression gauge stops rising the compression is the highest reading obtainable Cylinder Compression Usable Range 960 1 470 kPa 9 8 15 0 kgf cm 139 213 psi 2500 r min rpm e Install the spark plug and tighten it Torque
225. r clamp bolt C first and then the lower clamp bolt D There will be a gap at the lower part of the clamp after tightening Torque Master Cylinder Clamp Bolts 8 8 N m 0 90 kgf m 78 in Ib e Replace the washers that are on each side of the hose fitting with new ones e Tighten Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 ft Ib e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage Master Cylinder Disassembly e Remove the master cylinder see Master Cylinder Re moval e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Unscrew the pivot nut and pivot bolt and remove the brake lever e Pull the dust cover out of place and remove the circlip Special Tool Inside Circlip Pliers 57001 143 e Pull out the piston assembly A return spring B CAUTION Do not remove the secondary cup C from the pis ton since removal will damage it http mototh com GL07082BS1 11 14 BRAKES Master Cylinder Master Cylinder Assembly e 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 Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate wi
226. r if it is very loose in the carburetor body replace the piston and or the carburetor e Disassemble the carburetor and clean the fuel air pas sages with a high flash point solvent and compressed air e Stuff the lint free clean cloths into the air cleaner housing to keep dirt or other foreign material from entering A WARNING If dirt or dust is allowed to pass through into the carburetor the throttle valve may stuck possibly causing an accident http mototh com GC06010281 66060106851 C Air Cleaner FUEL SYSTEM 3 21 Air Cleaner Element Removal Remove the left side cover e Remove the element cover A Front B Pull out the air cleaner element A e Push a clean lint free towel into the air cleaner housing to keep dirt or other foreign material from entering A WARNING If dirt or dust is allowed to pass through into the car buretor the throttle valve may become stuck pos sibly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur Element Cleaning and Inspection e Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter Air Cleaner Draining A catch tank is provided beneath the air cleaner housing and catches the water or oil from the bottom of the housing Usually water or oil does not collect at the bottom of the housing In the event th
227. r trouble APPENDIX 16 33 Fuel level in carburetor float bowl too high or too low Needle jet bleed holes or needle jet clogged Air cleaner clogged poorly sealed or miss ing Air cleaner duct loose Fuel to carburetor insufficient Water or foreign matter in fuel Carburetor holder loose Fuel tank air vent obstructed Fuel tap clogged Fuel line clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Valve spring broken or weak Valve not seating properly valve bent worn or carbon accumulation on the seating surface Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect CDI unit Miscellaneous Throttle valve won t fully open Carburetor vacuum piston doesn t slide smoothly Carburetor vacuum piston diaphragm dam aged Poor Running or No Power at High Brake dragging Speed Clutch slipping Firing incorrect Overheating Spark plug dirty broken or gap malad justed Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect CDI unit trouble Crankshaft sensor trouble Ignition coil trouble Fuel air mixture incorrect Starter plunger stuck open Main jet clogged or wron
228. r tube e Remove Spacer A Fork Spring Seat B Fork Spring C e Pour out the fork oil to the container C with the fork up side down B OPump the outer tube A up and down to expel the oil from the fork e Holding the fork tube upright press the inner tube all the way down NOTE OThe spring should not be installed e Fill the front fork with the specified oil Fork Oil Viscosity SHOWA 55 8 or equivalent Fork Oil Capacity when changing oil Approx 165 mL 5 58 US oz e Wait for about five minutes so that any suspended air bub bles can surface e Measure the oil level using the fork oil level gauge A Special Tool Fork Oil Level Gauge 57001 1290 OSet the gauge stopper B so that its lower side shows the oil level distance specified C Olnsert the gauge tube into the inner tube D and position the stopper across the top of the inner tube E OPull the handle slowly to draw out the excess oil until no more oil comes up the tube xlf no oil is drawn out there is not enough oil in the fork Pour in some more oil then draw out the excess Front Fork Oil Level Fully compressed without fork spring Standard 218 2mm 8 58 0 08 in http mototh com Q B 6M04030281 A LS CS c S 6 04040551 C 8 04013552 C PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures e Install the fork spring A with the small
229. rd 45 53 kPa 340 400mmHg 6 5 7 7 psi Clean Air System Hose Inspection e Be certain that all the hoses are routed without being flattened or kinked and are connected correctly to the right air cleaner housing vacuum switch valve carbure tor holder and air suction valve covers they are not correct them Replace them if they are damaged http mototh com GE04034BS1 C Secondary air cannot flow 8 04010381 6 Clean System California ENGINE TOP END 4 13 Vacuum Switch Valve Test Remove the vacuum switch valve Connect the vacuum gauge A and syringe or fork oil level gauge to the vacuum hoses as shown Special Tool Fork Oil Level Gauge 57001 1290 Air Flow C e Gradually raise the vacuum lower the pressure applied to the vacuum switch valve and check the valve opera tion When the vacuum is low the vacuum switch valve should permit air to flow When the vacuum raises to valve closing pressure it should stop air flow Spring A Diaphragm B Valve C Low Vacuum D Secondary Air Flow E High Vacuum F Secondary Air Flow Cannot Flow G x If the vacuum switch valve does not operate as described replace it with a new one NOTE O To check air flow through the vacuum switch valve just blow through the air cleaner hose Vacuum Switch Valve Closing Pressure Open Close Standard 41 52 kPa 310 390 mmHg http
230. ressure non adjustable Non adjustable SHOWA SS 8 or equivalent 191 2 5 mL 6 46 0 085 US oz completely dry approx 165 mL 5 58 US oz when changing oil 218 2 mm 8 58 0 08 in below from inner tube top with fully compressed without fork spring 398 5 mm 15 7 in Service limit 391 mm 15 4 in 1st step Adjustable range 1st 5th steps No gas http mototh com SUSPENSION 12 7 Special Tools Fork Cylinder Holder Handle Fork Outer Tube Weight 57001 183 57001 1218 875701835 875712185 Fork Cylinder Holder Adapter Front Fork Oil Seal Driver 57001 1011 57001 1219 ST571011ST 875712198 Oil Seal amp Bearing Remover Jack 57001 1058 57001 1238 7571058ST C 7571238ST C Bearing Driver Set Hook Wrench Owner s Tool 57001 1129 92110 1143 7571129ST C 7921143ST C http mototh com 12 8 SUSPENSION Front Fork Fork Oil Change e Refer to the Front Fork Oil Change in the Periodic Main tenance chapter Fork Removal x lf the fork leg is to be disassembled loosen the top plug beforehand To loosen the fork top plug loosen the fork upper clamp bolts e Remove Brake Caliper see Brakes chapter Front Wheel see Wheels Tire chapter x If the fork leg is to be disassembled loosen the fork bot tom Allen bolt A beforehand e Loosen the upper A and lower fork clamp bolts B e Loosen the turn signal light holder bo
231. rical System chapter Crankshaft Sensor Inspection e Remove the alternator lead connector A Set the hand tester to the x 100 range and measure the resistance between the G W and W Y lead terminals in the female connector Special Tool Hand Tester 57001 1394 there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced Crankshaft Sensor Resistance BN125 A1 A2 180 280 BN125 A3 190 2900 e Using the highest resistance range of the tester measure the resistance between the G W and W Y lead in the fe male connector and chassis ground Any tester reading less than infinity lt indicates a short necessitating replacement of the crankshaft sensor as sembly Crankshaft Sensor Peak Voltage Inspection NOTE OBe sure the battery is fully charged OUsing the peak voltage adapter is a more reliable way to determine the condition of the crankshaft sensor than crankshaft sensor internal resistance measurements e Remove Right Side Cover see Frame chapter e Disconnect the crankshaft sensor connector A http mototh com Ignition System ELECTRICAL SYSTEM 15 39 e Set the hand tester B to the x 25 V DC range and con nect it to the peak voltage adapter C as shown in the diagram e Connect the black lead of the adapter to W Y lead and red lead to G W lead in
232. rication e Whenever the cable is removed or in accordance with the Periodic Maintenance Chart lubricate the brake cable Refer to General Lubrication in the Periodic Maintenance chapter OApply a thin coating of grease to the cable upper end OUse a commercially available pressure cable lubricator to lubricate the cable OWith the cable disconnected at both ends the cable should move freely in the cable housing http mototh com 110075 Rear Brake Drum BRAKES 11 21 Brake Panel Removal Remove the rear wheel see Wheels Tires chapter Separate the brake panel from the wheel hub Brake Panel Installation e Fit the brake panel into the rear wheel and then install the rear wheel see Wheels Tires chapter Brake Panel Disassembly e Remove the brake panel see Brake Panel Removal e Before removing the brake cam lever mark A the posi tion of the cam lever so that it can be installed later in the same position e Before removing the brake lining wear indicator mark the position of the brake camshaft and lining wear indicator so that it can be installed later in the same position e Using a clean cloth B around the linings to prevent grease or oil from getting on them remove the brake shoes A by pulling up C on the center of the linings e Remove the springs D to separate the two shoes Brake Panel Assembly e Clean the old grease from the camshaft and brake shoe anch
233. rter Battery Crankshaft 4 Relay 12V Sensor Neutral Switeh Motor e park Green e areen Light Green IGNITION SWITCH CONNECTIONS RIGHT HANDLEBAR SWITCH CONNECTIONS 0 Orange Front Brake Light Switch Engine Stop Switch Starter Button Pink Color Bk eotov v n Pu Purpie DECEM OFF Push o rR Pulled in Released 7 White Released RUN a Y Yellow 98052 10844 W2R 084AW5 6 http mototh com 15 22 ELECTRICAL SYST Wiring Diagram 125 6 US NU US CA N NU United States Canada No Catalytic Conveter No Catalytic Conveter Right Handlebar Switches 1 Front Brake Light Switch LEFT HAND LEBAR SWITCH CONNECTIONS Sidestand Switch Horn Button Turn VT Sw itch Dimmer Switch Starter Lockout Switch Color BK R BK Y Color OFF Push Released Pulled 4 2 Engine Stop Switch United Kingdom model 3 Starter Button Ge bsc M rr on Tease Mama er BR haren Ot Ignition Switch snronl co ev ev BL BL pur c R Go j R w R W ee TEST 53 7 8 Meter Light PENN AAS aa E 1 1 Speedometer Here LEA BK Y BK Y r High Beam Indicator Light 12V 3 4W amp gd He l1 Neutral Indicator B
234. rts are being removed x f the crankshaft is to be removed remove the following Camshaft Chain see Engine Top End chapter Cylinder Head see Engine Top End chapter Cylinder and Piston see Engine Top End chapter e Remove the external shift mechanism see External Shift Mechanism Removal e Remove the all crankcase bolts A from the left side of the crankcase e Remove the output shaft sleeve A and O ring B ODo not reuse the removed O ring e Screw the crankcase splitting tool A into the left side of the crankcase B Be certain to screw the adapters in all the way Special Tool Crankcase Splitting Tool Assembly 57001 1362 e Tighten the center bolt of the crankcase splitting tool to split the crankcase ORemove the left crankcase half http mototh com CRANKSHAFT TRANSMISSION 8 9 Crankcase eRemove the transmission shaft gears balancer shaft from the right crankcase half e Remove Shift Drum Cam Screw A Shift Drum Cam B Woodruff Key C Shift Drum D Gear Set Lever E 3 452 4 e Support the right crankcase half A with a suitable re tainer Remove the crankshaft from the right crankcase half using a press CAUTION Do not remove the ball bearings and the oil seals unless it is necessary If they are removed replace them with new ones Crankcase Assembly CAUTION Right and left crankcase halves are machined at the f
235. s A at the clutch cable bracket as far as they will go e Loosen the knurled locknut A at the clutch lever e Turn the adjuster B so that 5 6 mm 0 20 0 24 in C of threads are visible http mototh com GE15034BS1 C 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Pull the clutch cable A tight and tighten the adjusting nuts B against the clutch cable bracket e Turn the adjuster at the clutch lever until the free play is correct Tighten the knurled locknut at the clutch lever A WARNING Be sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever or it could slip into place later creating enough cable play to prevent clutch disengagement e Turn the release lever A clockwise until it becomes hard to turn then inspect the angle of the release lever is set within 80 90 range C x lf any angle is except 80 90 range inspect the parts of the clutch e After the adjustment is made start the engine and check that the clutch does no slip and that it releases properly Clutch Cable B Engine Lubrication System Engine Oil Change e Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily Then stop the engine e Place an oil pan beneath the engine e Remove the oil filler plug e Remove the engine oil drain plug A and let the oil drain completely Front B e If the oil
236. s 7 8 0 80 69 in Ib Brake Hose Banjo Bolts 25 2 5 18 Brake Lever Pivot Bolt 5 9 0 60 52 in lb Brake Lever Pivot Bolt Locknut 5 9 0 60 52 in lb Front Brake Reservoir Cap Screws 1 5 0 15 13 in lb Front Brake Light Switch Screws 1 0 0 10 9 in lb Front Master Cylinder Clamp Bolts 8 8 0 90 78 in lb S Torque Link Bolt and Nut 34 3 5 25 http mototh com Torque Locking Agent PERIODIC MAINTENANCE 2 7 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 Brake Pedal Bolt 87 in lb 23 20 20 34 34 34 98 2 3 2 0 2 0 3 5 3 5 3 5 10 0 17 15 15 25 25 25 72 Steering Steering Stem Head Bolt Steering Stem Nut Handlebar Nuts Handlebar Holder Clamp Bolts BN125 A3 Handlebar Weight Screws Handlebar Switch Housing Screws Front Fork Clamp Bolts Upper Front Fork Clamp Bolts Lower 44 Hand tight or 4 9 34 20 3 4 20 34 Frame Front Footpeg Bolts 23 Electrical System Spark Plug Crankshaft Sensor Screws Ignition Coil Bolt Igniter Mounting Screws Alternator Cover Bolts Alternator Cover Damper Bolts Alternator Rotor Nut BN125 A1 Alternator Rotor Nut BN125 A3 Alternator Rotor Nut BN125 A4 Starter Coil Bolts Alternator Lead Holder Bolts BN125 A1 A2 Alternator Lead Holder Bolts BN125 A3 Starter Motor Terminal
237. s loose Crankshaft bearings worn Primary gear worn or chipped Camshaft chain tensioner trouble Camshaft chain sprocket guide worn Air suction valve damaged AT DE SG CH Vacuum switch valve damaged AT DE SG CH Balancer gear worn or chipped Balancer shaft gear position maladjusted Balancer bearing worn Alternator rotor loose http mototh com APPENDIX 16 35 Troubleshooting Guide Abnormal Drive Train Noise Clutch noise Clutch rubber damper weak or damaged Clutch housing finger friction plate tang clearance excessive Clutch housing gear worn Metal chips jammed in clutch housing gear Transmission noise Bearings worn Transmission gears worn or chipped Metal chips jammed in gear teeth Engine oil insufficient Drive chain noise Drive chain adjusted improperly Drive chain worn Rear and or engine sprocket worn Chain lubrication insufficient Rear wheel misaligned Right wheel bear ings are not bottomed out Abnormal Frame Noise Front fork noise Oil insufficient or too thin Spring weak or broken Rear shock absorber noise Shock absorber damaged Spring weak or broken Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Master cylinder damaged Drum brake noise Brake linings overworn or worn unevenly Drum worn unevenly or scored Brake springs weak or broken Foreign matter in hub Brake not properly adjusted Other noise Bracket nut bolt etc mounted or tightened n
238. s or catches before the stop the steering is too tight OF eel for steering looseness by pushing and pulling A the forks x lf you feel looseness the steering is too loose NOTE OThe cables and wiring will have some effect on the mo tion of the fork which must be taken into account Be sure the wires and cables are properly routed OThe bearings must be in good condition and properly lubricated in order for any test to be valid Steering Adjustment e Loosen Front Fork Lower Clamp Bolts both sides A Steering Stem Head Bolt B e Lift the front wheel off the ground using the jack Special Tool Jack 57001 1238 e Adjust the steering Special Tool Steering Stem Nut Wrench 57001 1100 x lf the steering is too tight loosen the stem nut C a frac tion of a turn x lf the steering is too loose tighten the stem nut a fraction of a turn NOTE the stem nut 1 8 turn at a time maximum Torque Steering Stem Nut 4 9 N m 0 50 kgf m 43 in Ib e Tighten Torque Steering Stem Head Bolt 44 N m 4 5 kgf m 33 ft lb Front Fork Clamp Bolts Lower 34 3 5 kgf m 25 ft lb Check the steering again x lf the steering is still too tight or too loose inspect the steering parts http mototh com PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Steering Stem Bearing Lubrication e Remove the steering stem see Steering chapter e Using a high flash point solvent wash the upper an
239. sages for dirt or clogging Cil Pressure Standard 13 32 kPa 0 13 0 33 kgf cm 1 8 4 7 psi 94 000 r min rpm oil temperature 90 C 194 F Stop the engine and remove the oil pressure gauge and adapter A WARNING Take care against burns from hot engine oil that will drain through the oil passage when the oil pressure gauge adapter is removed e Install the new copper washers Tighten Torque Oil Pipe Banjo Bolt 25 2 5 kgf m 18 ft lb http mototh com 6012010552 C 6 12 ENGINE LUBRICATION SYSTEM Relief Valve Relief Valve Inspection e Remove the relief valve from the clutch cover e 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 NOTE Olnspect the valve in it assembled state Disassembly and assembly may change the valve performance xlf any rough sports are found during above inspection 0008000881 wash the valve clean with a high flash point solvent and blow out any foreign particles that may be in the valve with compressed air A WARNING Clean the relief valve in a well ventilated area and take care that there is no spark or flame anywhere near the working area Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent If cleaning does not solve the problem replace the relief valve as an as
240. se 2 2 e c 24 NON a e 2 e BK Y LL BK Y 6 11001 3 C Ignition switch Engine stop switch Starter button Starter circuit relay lgnition fuse 10 A Starter lockout switch Interlock diodes CDI unit Starter motor 10 Starter relay 11 Main fuse 15 A 12 Battery 13 Neutral switch http mototh com 15 54 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit BN125 A3 ele o 6 r BL W r RE n X amp e 2 2 e n 24 NOON a ere eer SS 2 c e LG G BK Z x gt lt 7 gt GP11052BW3 C Ignition switch Engine stop switch Starter button Starter circuit relay Ignition fuse 15 A Starter lockout switch Interlock Diodes CDI unit Starter motor Starter relay Main fuse 30 A Battery E http mototh com ELECTRICAL SYSTEM 15 55 Lighting System Headlight Beam Horizontal Vertical Adjustment e Turn the horizontal adjuster A on the headlight with a screwdriver in or out until the beam points straight ahead OTurn the horizontal adjuster clockwise to face the head light left e Turn the vertical adjus
241. sembly The relief valve is precision made with no allowance for replacement of individual parts http mototh com ENGINE LUBRICATION SYSTEM 6 13 Oil Pipe Oil Pipe Removal e 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 e Remove the oil pipe from the right side of the engine Oil Pipe Installation e Replace the washers on both sides of the oil pipe banjo bolt with new ones Tighten the following banjo bolts in the order listed to pre vent pipe warp Torque Oil Pipe Banjo Bolts Clutch Cover 25 N m 2 5 kgf m 18 ft lb Left Crankcase 9 8 N m 1 0 kgf m 87 in Ib Cylinder Head 9 8 1 0 kgf m 87 in Ib Tighten Torque Oil Pipe Mounting Bolt BN125 A1 A3 9 8 N m 1 0 kgf m 87 in Ib BN125 A4 8 8 0 90 kgf m 78 in Ib http mototh com http mototh com ENGINE REMOVAL INSTALLATION 7 1 Engine Removal Installation Table of Contents Exploded View 7 2 Special Tool 7 4 Engine Removal Installation 7 5 Engine Removal 7 5 Engine Installation 7 6 http mototh com 7 2 ENGINE REMOVAL INSTALLATION Exploded View http mototh com ENGINE REMOVAL INSTALLATION 7 3 Exploded View Torque No Fastener 9 Remarks Nm ftib Engine Mounting Bolts Nuts M10 4 5
242. ssed air to pre vent contamination of the bearings e Replace the bearings with new ones Olnstall the bearings so that the marked side faces out OPress in each right bearing A first until it bottoms out Special Tool Bearing Driver Set 57001 1129 B A WARNING Be sure to bottom out the right bearings on both front and rear wheels or misalignment of the wheel will result in abnormal drive chain wear and may result in an unsafe riding condition e Replace the grease seal in the front hub with a new one e Press in the grease seal A so that the seal surface flush B with the end of the hole OApply high temperature grease to the grease seal lips Special Tool Bearing Driver Set 57001 1129 C http mototh com 6J06027BS1 6J06028BS1 C 6J06004BS1 C 6J06008BS1 C WHEELS TIRES 9 13 Hub Bearings Wheel Bearings Inspection OSince the hub bearings are made to extremely close tol erances the clearance cannot normally be measured NOTE ODo not remove any bearings for inspection If any bear ings are removed they will need to be replaced with new ones Spin A the bearing by hand to check its condition x lf it is noisy does not spin smoothly or has any rough 0408002881 spots it must be replaced e Examine the rear hub bearing seal B for tears or leak age x If the seal is torn or is leaking replace the bearing Lubrication CAUTION
243. ssure inspec tion http mototh com 6J05010381 C 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 So it is false economy and unsafe to use the tires until they are bald e Remove any imbedded stones or other foreign particles from the tread e Visually inspect the tire for cracks and cuts replacing the tire in case of damage Swelling or high spots indicate internal damage requiring tire replacement e Measure the tread depth at the center of the tread with depth gauge A Since the tire may wear unevenly take measurement at several places If any measurement is less than the service limit replace the tire Tread Depth Standard Front BN125 A1 2 4 5 mm 0 18 BN125 A3 A5 4 0 mm 0 16 in BN125 A6 4 1 mm 0 16 in Rear 7 3 mm 0 29 in Service Limit Front 1 mm 0 04 in Rear 2 mm 0 08 in NOTE OMost countries may have their own regulations requiring a minimum tire tread depth be sure to follow them OCheck and balance the wheel when a tire is replaced with a new one A WARNING To ensure safe handling and stability use only the recommended standard tires for replacement in flated to the standard pressure Final Drive Drive Ch
244. ster mounting bracket bolts and re move the brackets B and canister C together e Disconnect the hoses from the canister e Visually inspect the canister for cracks and other damage xIf the canister has any cracks or bad damage replace it with a new one NOTE OThe canister is designed to work well through the motor cycle s life without any maintenance if it is used under normal conditions Separator Inspection e Remove the right side cover see Frame chapter e Disconnect the hoses from the liquid vapor separator A and remove the separator up from the bracket e Visually inspect the separator for cracks and other dam age xIf the separator has any cracks or is badly damaged re place it with a new one Engine Top Air Suction Valve Inspection e Remove the air suction valve see Engine Top End chap ter e Visually inspect the reeds A for cracks folds warps heat damage or other damage x If there is any doubt as to the condition of the reed replace the air suction valve as an assembly e Check the reed contact areas B of the valve holder for grooves scratches any signs of separation from the holder or heat damage x If there is any doubt as to the condition of the reed contact areas replace the air suction valve as an assembly any carbon or other foreign particles have accumulated between the reed and the reed contact area wash the valve assembly with a high flash point solvent CAUT
245. t Brake Panel rear Valve Core let out the air e To maintain wheel balance mark the air valve position on the tire with chalk so that the tire can be reinstalled in the same position Air Valve A Chalk Mark B e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with engine oil or petroleum distil lates because they will deteriorate the tire e Break the beads away from both sides of the rim with the bead breaker A Special Tool Bead Breaker Assembly 57001 1072 e Install the rim protectors A around the valve stem Lu bricate the tire irons B and rim protectors with soap and water solution or rubber lubricant e Step on the side of the tire opposite the valve stem and start prying the tire off the rim near the valve stem with tire irons special tools Special Tools Rim Protector 57001 1063 Bead Breaker Assembly 57001 1072 http mototh com 64005060451 64005060351 C 6005010151 WHEELS TIRES 9 11 Tires OFor 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 e Remove the protectors Tire Installation A WARNING To ensure safe handling and sta
246. t e Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter Wear Inspection e Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter Lubrication e Refer to the Drive Chain Lubrication in the Periodic Main tenance chapter Drive Chain Removal e Remove the engine sprocket cover A Remove the clip A from the master link using pliers and remove the chain from the rear sprocket Take the chain off the motorcycle Drive Chain Installation A WARNING For safety use only the standard chain e Fit the drive chain back onto the sprockets with the ends at the rear sprocket e Install the master link from the frame side e Install the clip A so that the closed end of the U B pointed in the direction of chain rotation C e Adjust the drive chain slack see Periodic Maintenance chapter Check the brake for good braking power and no brake drag see Brakes chapter A WARNING If a full brake pedal is not obtained disassemble and inspect the brake parts Worn parts cause lock of the brake or loss of braking http mototh com GK04076BS1 Sprocket Coupling FINAL DRIVE 10 7 Engine Sprocket Removal Remove the engine sprocket cover bolts A and sprocket cover B Remove the engine sprocket bolts A e Pull the engine sprocket A off the output shaft along with the chain Engine Sprocket Installation e Install th
247. t pin Since the chain may wear unevenly take measurements at several places If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced Chain 20 link Length Standard 254 0 254 6 mm 10 00 10 02 in Service Limit 259 mm 10 2 in A WARNING If the drive chain wear exceeds the service limit re place the chain or an unsafe riding condition may result A chain that brakes or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control For safety use only the standard chain Standard Chain BN125 A1 A2 Make ENUMA CHAIN Type Joint Endless EK428SH R Link 132 Links 125 except the NU of BN125 A7 Make DAIDO Type Joint Endless DID424HG Link 132 Links 130 Links BN125 A7 N NU N Catalytic Converter Model NU Catalytic Converter United Kingdom Model http mototh com HJ07008BS1 C 6 04060651 C 2 26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Lubrication e 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 x lf the chain is especially dirty it should be washed diesel oil or kerosene and afterward soaked in a heavy oil Shake
248. ter x If the tester does not read 0 the lead is defective Re place the lead or the wiring harness B if necessary http mototh com 8 07010151 ELECTRICAL SYSTEM 15 27 Battery Battery Removal Installation e Remove Right Side Cover see Frame chapter Battery Holder e Disconnect the battery negative cable A first and then the positive cable B Front C e When installing the battery connect the positive cable A first and then the negative cable B CAUTION If the battery cable is not correctly disconnected or connected sparks can arise at electrical connec tions causing damage to electrical parts Electrolyte Specific Gravity Inspection e Check battery condition by testing the specific gravity of the electrolyte in each cell with a hydrometer A ORead the level of the electrolyte B on the floating scale x f the specific gravity is below 1 200 the battery needs to be charged NOTE OThe specific gravity of the electrolyte varies with changes in temperature so the specific gravity reading must be corrected for the temperature of the electrolyte OCelsius Add 0 007 points to reading for each 10 C 50 above 20 68 F or subtract 0 007 points for each 10 below 20 68 F OFahrenheit Add 0 004 points to reading for each 12 C 10 above 10 C 68 F or subtract 0 004 points for each 12 10 F below 10 68 F x If the specific gravi
249. ter B on the headlight in or out to adjust the headlight vertically OTurn the vertical adjuster clockwise to face the headlight up NOTE OOn high beam the brightest points should be slightly below horizontal with the motorcycle on its wheels and the rider seated Adjust the headlight to the proper gle according to local regulations Headlight Bulb Replacement e Remove the headlight rim screws A e Pull the headlight unit B and drop it out e Remove Bulb Socket A Dust Cover B e Remove the hook A http mototh com 15 56 ELECTRICAL SYSTEM Lighting System Replace the headlight bulb 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 NOTE OClean off any contamination that inadvertently gets on the bulb with alcohol or soap and water solution e Fit the dust cover A with the TOP mark B upward onto the bulb firmly as shown e Install the headlight unit B with the TOP mark A up ward e After installation adjust the headlight aim see this chap ter AC Lighting Voltage Inspection e Remove the headlight unit see this chapter ODo not remove the bulb socket e Connect the hand tester A to the R BK and BK Y leads in the socket as shown in the table e Push the headlight switch to ON a
250. termining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the new replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor leads and bad connections will affect electrical system operation OMeasure coil and winding resistance when the part is cold at room temperature OColor Codes BK Black BL Blue BR Brown CH Chocolate DG Dark green G Green GY Gray LB Light blue LG Light green O Orange P Pink PU Purple R Red W White Y Yellow http mototh com ELECTRICAL SYSTEM 15 25 Precautions OElectrical Connectors Connectors A Connectors B 8 06010251 C http mototh com 15 26 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc x If any wiring is poor replace the damaged wiring Pull each connector A apart and inspect it for corrosion dirt looseness and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect the hand tester between the ends of the leads Special Tool Hand Tester 57001 1394 OSet the tester to the x 1 range and read the tes
251. th Long 44 5 45 5 mm 1 752 1 791 in 47 2 mm 1 86 in Short 32 5 mm 1 280 in 34 1 mm 1 34 in Cam Lever Angle Brake Pedal Free Play 80 90 20 30 mm 0 79 1 18 in Brake Maintenance Brake Drum Inside Diameter Brake Shoe Lining Thickness Brake Camshaft Diameter Brake Camshaft Hole Diameter ES Spain NO Norway US United States 130 00 130 16 mm 5 118 5 124 in 3 85 4 15 mm 0 152 0 163 in 11 957 11 984 m 0 471 0 472 in BN125 A1 A6 14 95 14 99 mm 0 589 0 590 in BN125 A7 and A8 US 12 000 12 027 mm 0 472 0 474 in BN125 A1 A6 15 000 15 027 mm 0 591 0 592 in BN125 A7 and A8 US http mototh com 130 75 mm 5 148 in 2 mm 0 08 in 11 88 mm 0 47 in 14 88 mm 0 59 in 12 15 mm 0 478 in 15 15 mm 0 596 in BRAKES 11 7 Special Tools Inside Circlip Pliers Jack 57001 143 57001 1238 7570143ST C d 7571238ST C http mototh com 11 8 BRAKES Caliper Caliper Removal e Loosen the banjo bolt A at the brake hose lower end and tighten it loosely e Unscrew the caliper mounting bolts 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 CAUTION Immediately wash away any brake fluid that spills NOTE Olf the caliper is to be disassembled after removal and if compressed air
252. the chain while it is in the oil so that oil will pen etrate to the inside of each roller e An effective good quality lubricant specially formulated for chains is best for regular chain lubrication If a special lubricant is not available a heavy oil such as SAE 90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings e Wipe off any excess oil Oil Applied Areas A Brakes Brake Pedal Free Play Inspection e Check the brake pedal free play A when the pedal is pushed down lightly by hand Brake Pedal Free Play Standard 20 30 mm 0 79 in 1 18 in x If the pedal has improper play adjust it OTurn the adjusting nut B at the brake cam lever so that the lever has proper play e Operate the pedal a few times to see that it returns to its rest position immediately upon release e Rotate the rear wheel to check for brake drag e Check braking effectiveness xIf there is any doubt as to the conditions of the brake check the brake parts for wear or damage e Check that the brake lining wear indicator A points within the USABLE RANGE B when the brake lever is fully ap plied x lf it does not the brake shoes must be replaced and other brake parts must be examined http mototh com GKO4036BS1 PERIODIC MAINTENANCE 2 27 Periodic Maintenance Proced
253. the crankshaft sensor connector A e Turn the ignition switch e Pushing the starter button turn the engine 4 5 sec onds with the transmission gear in neutral to measure the crankshaft sensor peak voltage e Repeat the measurement 5 or more times Crankshaft Sensor Peak Voltage Standard 3 6 V or more Special Tools Hand Tester 57001 1394 Peak Voltage Adapter 57001 1415 Type KEK 54 9 B x If the tester reading is not specified one check the crank shaft sensor 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 The negative side is grounded This is to prevent damage to the diodes and CDI unit A WARNING The ignition system produces extremely high volt age Do not touch the spark plug ignition coil or spark plug lead while the engine is running or you could receive a severe electrical shock Ignition Timing Inspection e Remove the camshaft chain cover see Engine Top End chapter e Attach the timing light A in the manner prescribed by the manufacturer Special Tool Timing Light 57001 1241 e Start the engine and aim the timing light at the ignition timing mark on the camshaft sprocket B e Run the engine at the speed specified and note the align ment of the ignition timing marks http mototh com 15 40 ELE
254. the hole B so that the balancer damper springs will not fall into it e Remove the camshaft chain holder A and pull the camshaft chain B upward e Remove the cylinder head see Cylinder Head Removal e Remove the rear camshaft chain guide bolt C and pull the rear camshaft chain guide D Camshaft Chain Installation e Install Rear Camshaft Chain Guide A Cylinder Head see Cylinder Head Installation Tighten Torque Camshaft Chain Guide Bolt 8 8 N m 0 90 kgf m 78 in Ib e Engage the camshaft chain B with the crank sprocket and install the camshaft chain holder C e Tighten Torque Camshaft Chain Holder screws 4 9 0 50 kgf m 43 in Ib OPull the camshaft chain and tie the upper end of the chain with a cord so that the chain is not kinking e Install the inner and outer springs B into the groove near the punch mark A on the crank balancer gear and install the five springs and pins C into the other grooves OThe inner and outer springs are a little longer than the five identical springs http mototh com 4 20 ENGINE END Camshaft OAlign the three punch marks D on the balancer shaft gear A crank balancer gear B and coupling C e Install the alternator see Electrical System chapter e Align the punch mark A on the crankcase with the T mark B on the rotor e Engage the camshaft sprocket A with the chain B Then align the T mark C on the s
255. the new guide bushing A with a used guide bush ing B on it by tapping the used guide bushing with the fork oil seal driver C until it stops OThe split D of the bushing should face toward the side of the vehicle Special Tool Front Fork Oil Seal Driver 57001 1219 ORemove the used guide bushing http mototh com GMO4190BS1 C 6 04191851 C 8 04010251 C 6 04041151 C Front Fork SUSPENSION 12 11 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 e Install the retaining ring and dust seal by hand e Put the new gasket on the bottom of the outer tube Apply a non permanent locking agent to the threads of the Allen bolt and screw the Allen bolt into the bottom of the outer tube e Hold the outer tube horizontally in a vise A e Hold the cylinder unit B with the special tools and Allen wrench tighten the Allen bolt C Torque Bottom Allen Bolt 20 N m 2 0 kgf m 15 ft lb Special Tools Fork Cylinder Holder Handle 57001 183 D Fork Cylinder Holder Adapter 57001 1011 E e Pour in the specified type of oil and install the parts re moved Fork Oil Viscosity SHOWA SS 8 or equivalent Fork Oil Capacity completely dry 191 2 5 mL 6 46 0 085 US oz Inner Tube Outer Tube Inspection e Visually inspect the inner tube A and repair
256. ther Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1332 04 http mototh com Printed in Japan
257. tic Check the throttle grip play periodically in accor dance with the Periodic Maintenance Chart and adjust the play if necessary The throttle cable routing is shown in Cable Harness Hose Routing section in the Appendix chapter e Check the throttle grip free play A x lf the free play is incorrect adjust the throttle cable Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in e Check that the throttle grip moves smoothly from full open to close an the throttle closes quickly and completely in all steering positions by the return spring x If the throttle grip does not return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change x If the idle speed increase check the throttle grip free play and the cable routing http mototh com 6603020251 PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures Throttle Grip Free Play Adjustment e Loosen the locknut A e Turn the adjuster B until the proper amount of free play can be obtained e Tighten the locknut against the adjuster xIf the throttle grip free play cannot be adjusted with the adjuster use the cable adjusters at the lower ends of the throttle cables e Loosen the locknut and screw the adjuster at the upper end of the a
258. time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 1997 Kawasaki Heavy Industries Ltd Ninth Edition 1 Aug 1 2006 K http mototh com LIST OF ABBREVIATIONS ampere S Ib pound s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch degree s Celsius r revolution DC direct current rpm revolution s per minute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s Q ohm s L liter s Read OWNER S MANUAL before operating http mototh com 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
259. tion Timing Since the ignition timing is electronically advanced or re tarded this system has no mechanical parts such as a cam or contact breakers and there are no parts to wear out and no periodic maintenance is required So there is never any need to adjust the timing once it has been installed correctly Generally the spark plug must be fired at a proper crank angle before top dead center BTDC At low and mid range engine speeds the faster the en gine runs the further the ignition timing advances This pre low middle speed vents knocking and preignition and provides better engine performance If the engine speed increases further no timing advance is required because the engine can breathe in and burn the fuel air mixture in a shorter time The ignition timing does not increase further and the timing advance stops This also provides better engine performance and prevents the engine from overrunning and overheating The operation of a diode and thyristor is explained here in order to describe how the ignition timing is controlled gt gt deg BTDC Ignition Timing idling high speed 6806010951 C http mototh com 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
260. tons C to protrude and stop at the wooden board ORemove the wooden board and pull out the pistons by hand x If compressed air is not available with the brake hose still attached apply the brake lever to remove the pistons The remaining process is as described above e Remove Dust Seals A Fluid Seals piston seals B Caliper Holder C Friction Boot D Bleed Valve Rubber Cap CAUTION Immediately wash away brake fluid that spills Caliper Assembly e Clean all parts other than the outer and inner pads CAUTION For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Install the bleed valve A and the rubber cap B Tighten Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib e Replace the fluid seals A with new ones apply brake fluid to them and install them in the caliper body Either side of the fluid seal may face outboard e Check the dust seals B and replace them with new ones if they are damaged http mototh com GLO5083BS1 ae 8 9 6105015851 C 6105040251 11 10 BRAKES Caliper e Apply brake fluid to the inside of the cylinders and to the outside of the pistons and push the pistons A into the cylinders e Check the friction boot B and dust boot C and replace them with new ones if they are damaged e Apply a thin coat of silicon grease to the holder shafts D and the hol
261. tor Type Single phase AC Rated output 8 75 12 V 94 000 r min rpm BN125 A1 15 A 14 V 98 000 r min rpm BN125 A2 Specifications subject to change without notice and may not apply to every country CA Canada Model US United States Model N No Catalytic Converter NU No Catalytic Converter United Kingdom Model http mototh com GENERAL INFORMATION 1 13 Technical Information DC CDI Direct Current Capacitor Discharge Ignition Sys tem Description OUnlike the conventional CDI the DC CDI uses a battery instead of a magneto as a power source OThe 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 OThe DC CDI has a built in DC DC converter which changes battery voltage or battery changing volt age into high voltage AC Even if the battery loses its charge the DC CDI can use battery charging voltage OThe DC CDI doesn t have an exciter coil a power consumer therefore the battery is charged better Ignition System The DC CDI is connected as shown 125 1 Engine Stop Switch Voltage is detected Ignition Coil Reguletor Ignition Rectifier V Spark Plug 00900000090 000000 6806102 2 125 2 Engine Stop Switch Voltage is detected s P Alternator Ignition lt
262. ts rocker arms and valves locations so that they can be installed in their orig inal positions to keep the valve clearance unchanged e Using the valve spring compressor assembly remove the valves Special Tools Valve Spring Compressor Assembly 57001 241 A Valve Spring Compressor Adapter 22 57001 1202 B Valve Installation e Replace the oil seal C with a new one e Apply a thin coat of molybdenum disulfide grease to the valve stem A before valve installation e Check the following Valve moves smoothly up and down in the guide Valve seats properly in the valve seat e Install the spring D so that the closed coil end faces the spring seat B downwards e Put the spring retainer E on the springs and fit the split keepers F between the retainer and the stem while com pressing the valve spring Special Tools Valve Spring Compressor Assembly 57001 241 Valve Spring Compressor Adapter 422 57001 1202 Valve Guide Removal e Remove Valve see Valve Removal Oil Seal Spring Seat e Heat the area around the valve guide to 120 150 C 248 302 F and hammer lightly on the valve guide arbor A to remove the guide from the top of the head Special Tool Valve Guide Arbor 4 5 57001 1331 CAUTION Do not heat the cylinder head with a torch This will warp the cylinder head Soak the cylinder head and heat the oil http mototh com 8 15010152 C Valves ENGINE
263. ty of any of the cells is more than 0 050 away from any other reading the battery will probably not accept a charge It is generally best to replace the battery in this condition x lf the specific gravity of all the cells is 1 280 or more the battery is fully charged OWhen using the hydrometer read the electrolyte level at the bottom of the meniscus curved surface of the fluid GPOS000BS1 C http mototh com 15 28 ELECTRICAL SYSTEM Battery Initial Charging 28 224 Full Charge 1 28 20 d MATAN 16 EGE EBEN ATTI A 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 This proce dure prevents sparks at the battery terminals which JE CO tage could ignite any battery gases 8P08010181 0 STD pam 04 00 Specific Gravity e Remove the battery see this chapter e Fill each cell to the upper level line on the battery case with fresh electrolyte specific gravity 1 280 at a temperature of 30 86 F or less Let the battery stand for about 30 minutes before charging NOTE Olfthe electrolyte level drops add electrolyte to the upper level line before charging Set the charging rate at 1 10 the battery capacity and charge it for 10 hours The batt
264. ult in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly http mototh com GENERAL INFORMATION 1 1 General Information Table of Contents Before 1 2 Model Identification m 1 7 General Specification S esn CE 1 9 Technical Information DC CDI Direct Current Capacitor Discharge Ignition 1 13 Technical Information Coasting Enricher ccccsceeeesecceeeeeeeeeeseeceeeeeseeeeeesneaeesesaeeeeeeneneeees 1 20 Unit Conversion Table ern t pet nep dU ceni
265. unting Bolts BN125 A1 A3 Oil Pipe Mounting Bolts BN125 A4 Camshaft Bearing Holder Bolts BN125 A1 A3 Camshaft Bearing Holder Bolts BN125 A4 78 in lb Camshaft Sprocket Bolts 104 in Ib Camshaft Chain Holder Screw 43 in lb Camshaft Chain Guide Bolts 78 in lb Chain Tensioner Mounting Bolts BN125 A1 i 87 in lb A3 Chain Tensioner Mounting Bolts BN125 A4 78 in lb Chain Tensioner i 43 in lb Valve Adjusting Screw Locknuts 11 Rocker Shaft Bolts l 78 in lb Muffler Mounting Nut P 11 Clutch Clutch Hub Bolt Clutch Spring Bolts Clutch Cover Bolts BN125 A1 Clutch Cover Bolts BN125 A4 Oil Seal Retaining Plate Bolts BN125 A1 A3 Oil Seal Retaining Plate Bolts BN125 A4 Clutch Cover Damper Bolts Starter Locknut Switch Screws Primary Gear Nut Engine Lubrication System Engine Oil Drain Plug 18 1 8 13 Oil Screen Cover Bolts BN125 A1 A3 9 8 1 0 87 in lb Oil Screen Cover Bolts BN125 A4 8 8 0 90 78 in lb Oil Pressure Relief Valve 15 1 5 11 Filter Cover Bolts 125 1 9 8 1 0 87 in lb Oil Filter Cover Bolts BN125 A4 8 8 0 90 78 in lb Oil Pump Mounting Screws 4 9 0 50 43 in lb Oil Pump Assy Screw 9 8 1 0 87 in lb Oil Pipe Banjo Bolt 25 2 5 18 Clutch Cover S Oil Pipe Banjo Bolts 9 8 1 0 87 in lb Cylinder Head S Oil Pipe Mounting Bolts BN125 A1 A3 9 8 1 0 87 in lb Oil Pipe Mounting Bolts BN125 A4 8 8 0 90 78 Oil Filler Plug 2 5
266. ure and increase charg ing time proportionately e Turn the charger off or unplug it then disconnect it from the battery e Check battery condition If the battery condition indicates that it is not fully charged additional charging time is necessary http mototh com 15 30 ELECTRICAL SYSTEM Battery Battery Charging Rate Time Table 12 V 9 gt co gt e e lt gt at 1A charge rate at 2A charge rate 6 75 at 3A charge rate 6 7 8 9 10 141 12 1313 5 3 4 5 6 2 3 4 4 5 Hours of Gharging Time at Rates Shown http mototh com GP08017BN2 ELECTRICAL SYSTEM 15 31 Charging System Alternator Cover Removal e Drain the engine oil see Engine Lubrication System chapter e Remove Engine Sprocket Cover see Final Drive chapter Alternator Lead Connector A Remove Alternator Cover Bolts A Alternator Cover B Remove the torque limiter A Alternator Cover Installation e Install Dowel Pins A New Gasket B e Apply molybdenum disulfide grease to the starter pinion gear C and torque limiter shaft D e Route the leads correctly see Appendix chapter Tighten Torque Alternator Cover Bolts 8 8 N m 0 90 kgf m 78 in Ib e Pour the engine oil see Engine Lubrication System chap ter Alternator Rotor Removal e Remove the alternator cover see this chapter e
267. ures Check that the front brake cam lever A comes to 80 90 angle C with the rear brake rod B when the rear brake is fully applied x If it does not remove the adjusting nut D and lever then adjust the rear brake cam lever angle e Check the brake pedal free play WARNING Since a cam lever angle greater than 90 reduces braking effectiveness cam lever angle adjustment should not be neglected A change in cam lever an gle is caused by wear of internal brake parts When ever the cam lever angle is adjusted also check for drag and proper operation taking particular note of the brake lining wear indicator position In case of doubt as to braking effectiveness disassemble and inspect all internal brake parts Worn parts could cause the brake to lock or fall Brake Shoe Lining Wear Inspection e Remove the brake shoes see Brakes chapter Measure the lining thickness A at a few point OUse a calipers or scale and measure at several points Shoe Lining Thickness Standard 3 85 4 15 mm 0 152 0 163 in Service Limit 2 mm 0 08 in x If the lining thickness is greater than the service limit re place both shoes as a set e Install the brake shoes see Brakes chapter Brake Pad Wear Inspection e Remove the pads see Brakes chapter e Check the lining thickness A of the pads in the caliper If the lining thickness of either pad is less than the service limit B
268. urface OAfter grinding with 45 cutter apply thin coat of machin ist s dye to seating surface This makes seating surface distinct and 32 and 60 grinding operation easier OWhen the valve guide is replaced be sure to grind with 45 cutter for centering and good contact If the outside diameter A of the seating surface is too large make the 32 grind described below x If the outside diameter of the seating surface is within the specified range measure the seat width as described be low e Grind the seat at a 32 angle B until the seat outside diameter is within the specified range OTo make the 32 grind fit a 32 cutter into the holder and slide it into the valve guide OTurn the holder one turn at a time while pressing down very lightly Check the seat after each turn CAUTION The 32 cutter removes material very quickly Check the seat outside diameter frequently to pre vent overgrinding OAfter making the 32 grind return to the seat outside di ameter measurement step above e To measure the seat width use a vernier caliper to mea sure the width of the 45 angle portion of the seat at sev eral places around the seat x lf the seat width is too narrow repeat the 45 grind until the seat is slightly too wide and then return to the seat outside diameter measurement step above http mototh com 8 15011951 GE15012181 GE15012281
269. ve Engine Upper Bracket A Camshaft Chain Cover B e Remove the camshaft sprocket from the camshaft chain see Camshaft Removal e Remove 6 mm Cylinder Head Bolts A eur 9 mm Cylinder Head Bolts B Or TO Front C e Remove the 9 mm cylinder head bolt A at the rear right along with the cylinder head Front B NOTE Olf necessary tap lightly with a plastic hammer as shown Never tap on the fins e Clear the chain guides B and remove the cylinder head A http mototh com ENGINE 4 23 Cylinder Head Cylinder Head Installation e Install Dowel Pins A New Cylinder Head Gasket B e 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 e Tighten the 9 mm bolts following the tightening sequence as shown Tighten them first to the torque of 12 N m 1 2 kgf m 104 in Ib and then tighten them to the specified torque Torque 9 mm Cylinder Head Bolts 26 N m 2 7 kgf m 19 ft Ib e Tighten the 6 mm bolts 5 6 Torque 6 mm Cylinder Head Bolts 12 N m 1 2 kgf m 104 in Ib GE14041BS1 C e Install Camshaft Sprocket see Camshaft Installation Camshaft Chain Tensioner see Camshaft Chain Ten sioner Installation Valve Adjusting Caps e Apply grease to the O ring and install the camshaft chain cover Tighten Torque Camshaft Chain Cover Bolts BN125 A1 9 8 N m 1 0 kg
270. ve while hold ing the brake applied 3 Release the brake C 8813055 52 C http mototh com 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 OTap the brake hose lightly from the caliper to the reser voir for more complete bleeding e Remove the clear plastic hose e Tighten Torque Caliper Bleed Valve 7 8 N m 0 80 kgf m 69 in Ib Front Brake Reservoir Cap Screws 2 5 N m 0 25 kgf m 22 in Ib e Check the fluid level e After bleeding is done check the brake for good braking power no brake drag and no fluid leakage When working with the disc brake observe the pre cautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or
271. ved parts Rear View Mirror Removal Europe e Loosen the lower hexagonal area A for tightening to re move the rear view mirror from the holder CAUTION Do not force to tighten and or loosen the upper hexagonal area Adapter B with a pair of span ners Disassembly of this area is Not Available Non permanent locking agent D is already applied to the threads of this inner area Forcible loosen ing may damage the adapter and or the turning mechanism of the stay C Rear View Mirrors Installation Europe Screw the mounting area of the right rear view mirror into the holder all the way and tighten the lower hexagonal area for tightening securely A Lower Hexagonal Area for Tightening B Upper Hexagonal Area Adapter C Rear View Mirror Right http mototh com REISS GNO06022BS1 http mototh com 14 1 Frame Table of Contents Exploded 14 2 Special ee EE 14 6 SIME COVERS 14 7 Left Side Cover Removal 14 7 Left Side Cover Installation Ne 14 7 aus n geiles Cover Remi val D ta 14 7 Right Side Cover Installation Ecc Re as cit e ao fe diei 14 7 Itm 14
272. ver Free Play Rear Brake Rear Brake Light Switch If a full brake pedal is not obtained disassemble and inspect the rear brake parts Worn parts cause lock of the brake or loss of brak ing Clutch Cover Assembly e Install the oil seal retainer with the UP mark facing A upward x lf the oil seal is damaged replace it with a new one e Tighten Torque Oil Seal Retaining Plate Bolts BN125 A1 9 8 1 0 kgf m 87 in Ib 125 4 8 8 N m 0 90 kgf m 78 in Ib http mototh com 8 05010251 C CLUTCH 5 9 Clutch Clutch Removal e Remove the clutch cover see Clutch Cover Removal NOTE Olf the primary gear is to be removed remove the pri mary gear nut before clutch removal see Primary Gear Removal e Remove Clutch Spring Bolts A with Springs Clutch Spring Plate B Ball Bearing and Pusher C Friction Plates and Steel Plates e Using the clutch holder A hold the hub to remove the clutch hub nut Special Tool Clutch Holder 57001 1243 e Remove the spring washer e Remove Clutch Hub A Spacer B Clutch Housing C Clutch Installation e Apply molybdenum disulfide grease to the clutch housing bearing hole A e Install Clutch Housing B Spacer Clutch Hub http mototh com 5 10 Clutch e Install the washer A as shown Crankcase Side B e Tighten the clutch hub nut C while holding the clutch hub with the
273. when a strong wind is blowing 6 Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to wash off completely and will eventually dete riorate the rubber used in the disc brake 7 When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely washed away immediately 9 If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE http mototh com PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures Brake Master Cylinder and Dust Seal Replacement e 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 e Refer to the Calipers section in the Brakes chapter for Caliper Piston Dust Seals Replacement Brake Light Switch Inspection Front Brake

Kawasaki Boss 175 (Eliminator 125) service manual (eng

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