Mitsubishi Eliminator 125 (2005) manual

ELIMINA T OR 125 Motorcycle Service Manual[...]

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This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend 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. Quick Reference G[...]

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ELIMINA T OR 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 & Machinery Company/Kawas[...]

LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) AT D C 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 °C degree(s) Celsius r revolution DC direct c[...]

EMISSION CONTROL INFORMA TION T o protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi- tionally , Kawasaki has incorporated an e[...]

WE RECOMMEND THA T ALL DE ALERS OBSER VE THESE PROVISIONS OF FEDERAL LA W , THE VIOLA TION OF WHICH IS PUNISHABLE BY CIVIL PENAL TIES NOT EXCEEDING $10,000 PER VIOLA TION. T AMPERING 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[...]

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[...]

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GENERAL INFORMA TION 1-1 1 General Information T able of Contents Before Servicing ................................................................................................................ ..... 1-2 Model Identification............................................................................................................ ..... 1-7 Gener[...]

1-2 GENERAL INFORMA TION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the preca utions given below . T o facilitate ac tual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever [...]

GENERAL INFORMA TION 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 pr ior to assembly . Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts[...]

1-4 GENERAL INFORMA TION 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 th[...]

GENERAL INFORMA TION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely nec[...]

1-6 GENERAL INFORMA TION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as s pecified. Direction of Engine Rota tion When rotating the crankshaft by hand, the fr[...]

GENERAL INFORMA TION 1-7 Model Identification BN125-A1 (Europe) Left Side View BN125-A1 (Europe) Right Side View[...]

1-8 GENERAL INFORMA TION Model Identification BN125-A1 (Singapore) Left Side View BN125-A1 (Singapore) Right Side View[...]

GENERAL INFORMA TION 1-9 General Specifications Items BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ Dimensions Overall length 2 150 mm (84.6 in.) Overall width 780 mm (30.7 in.) Overall height 1 020 mm (40.2 in.) 1 035 mm (40.8 in.) ← 1 050 mm (41.3 in.) (US, CA) 1 045 mm (41.1 in.) BN125-A7 ∼ (N, NU) Wheelbase 1 470 mm (57.9 in.) Road clearance[...]

1-10 GENERAL INFORMA TION General Specifications Items BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ Maximum torque 9.7 N·m (0.99 kgf·m, 7.2 ft·lb) @8 000 r/min (rpm) (US)– ← 9.8 N·m (1.00 kgf·m, 7.2 ft·lb) @8 000 r/min (rpm) (BN125-A7 ∼ , N, NU) Carburetion system Carburetor , MIKUNI BS28 Starting system Electric starter Ignition system[...]

GENERAL INFORMA TION 1- 1 1 General Specifications Items BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ Gear ratios: 1st 2.700 (27/10) 2nd 1.705 (29/17) 3rd 1.300 (26/20) 4th 1.090 (24/22) 5th 0.952 (20/21) Final drive system: Ty p e Chain drive Reduction ratio 3.066 (46/15) ← 2.800 (42/15) (BN125-A7 ∼ ,N , NU) Overall drive ratio 10.708 @T op ge[...]

1-12 GENERAL INFORMA TION General Specifications Items BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ T rail/brake light 12 V 5/21 W Alternator: Ty p e Single-phase AC Rated output 8.75 A/12 V @4 000 r/min (rpm): BN125-A1 15 A/14 V @8 000 r/min (rpm): BN125-A2 ∼ Specifications subject to change without notice, and may not apply to every country . ([...]

GENERAL INFORMA TION 1-13 T echnical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) Description ○ Unlike the conventional CDI, the DC-CDI uses a battery instead of a magneto as a power source. ○ The DC-CDI powered by a battery generates strong ignition spark even at l ow engine speeds. The conventional CDI, which uses[...]

1-14 GENERAL INFORMA TION T echnical Information-DC-CDI (Direct Cu rrent-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 igni tion coil, a spark plug, an ignition switch, and an engine stop sw[...]

GENERAL INFORMA TION 1-15 T echnical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) This sudden change in the primary current induces a primary voltage (counterelectromotive force) which is equal to the capacitor voltage (about 225 V) but against the discharging current . The primary voltage induces a high secondary volta[...]

1-16 GENERAL INFORMA TION T echnical Information-DC-CDI (Direct Cu rrent-Capacitor Discharge Ignition Sys- tem) Diode A diode functions as an electrical check valve. It conducts current easily from its cathode to its anode, but it will not permit current flow in the opposite direction. Since electric- ity attempts to flow from negative (–) to pos[...]

GENERAL INFORMA TION 1-17 T echnical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) Every time either end of the timing plate on the rotor passes by the crankshaft sensor , a pulse is generated and sent to the CDI unit, that is, two pulses are generated per one revolution of the rotor . One is a positive pulse [A] and the[...]

1-18 GENERAL INFORMA TION T echnical Information-DC-CDI (Direct Cu rrent-Capacitor Discharge Ignition Sys- tem) The crankshaft sensor generates a crankshaft sensor sig- nal and sends it to the signal generator . The signal genera- tor generates A and B signals synchronized with the crank- shaft sensor signal. These signals are shown in the figure. [...]

GENERAL INFORMA TION 1-19 T echnical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) (Ignition T iming 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 [...]

1-20 GENERAL INFORMA TION T echnical Information-Coasting Enricher The coasting enricher [A] prevents backfiring during en- gine braking by supplying a rich fuel mixture to the engine. When the motorcycle is cruising or accelerating, the engine vacuum is low , and the return spring [3] pushes the valve in its opened position [5]. The passage [6] is[...]

GENERAL INFORMA TION 1-21 T echnical Information-Coasting Enricher Fuel and Air Supply of Enricher System[...]

1-22 GENERAL INFORMA TION Unit Conversion T able Prefixes for Units Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units of Mass kg × 2.205 = lb g × 0.03527 = oz Units of V olume L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L× 1 . 0 5 7 = qt (US) L × 0.8799 = qt (imp) L × 2.1 1[...]

PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T able of Contents Periodic Maintenance Chart .............. 2-2 T orque and Locking Agent ................. 2-4 Specifications .................................... 2-9 Special T ools ..................................... 2-1 1 Periodic Maintenance Procedures..... 2-12 Fuel System ..... ..............[...]

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. FREQUENCY Whichever comes first *O D O M E T E R READING × 1 000 km ( × 1 000 mile) 1 6 12 18 24 30 36 OP[...]

PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever comes first *O D O M E T E R READING × 1 000 km ( × 1 000 mile) 1 6 12 18 24 30 36 OPERA TION Every (0.6) (4) (7.5) (12) (15) (20) (24) Spark plug-clean and gap † • • • • • • General lubrication-perform • • • Nuts, bolts, and fasteners tightness-inspect ?[...]

2-4 PERIODIC MAINTENANCE T orque 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 [...]

PERIODIC MAINTENANCE 2-5 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Oil Pipe Banjo Bolts M8 9.8 1.0 87 in·lb Oil Pipe Banjo Bolts M10 25 2.5 18 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 in·lb Camshaft Bearing Holder Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 [...]

2-6 PERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb 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 T erminal Bolt 9.8 1.0 87 in·lb Crankshaft/transmission Primary Gear Nut 69 7.0[...]

PERIODIC MAINTENANCE 2-7 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Brake Pedal Bolt 9.8 1.0 87 in·lb Suspension Front Fork T op Plugs 23 2.3 17 Front Fork Bottom Allen Bolts 20 2.0 15 L Front Fork Clamp Bolts (Upper) 20 2.0 15 Front Fork Clamp Bolts (Lower) 34 3.5 25 Rear Shock Absorber Nuts (Upper) 34 3.5 25 Rear Shock[...]

2-8 PERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks T urn Signal Light Holder Nuts 5.9 0.60 52 in·lb Neutral Switch 15 1.5 11 Sidestand Switch Screws 3.9 0.40 35 in·lb L The table below , relating tightening torque to thread diameter , lists the basic torque for the bolts and nuts. Use this table for onl[...]

PERIODIC MAINTENANCE 2-9 Specifications Item 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 ––– Vis co si t y SAE 30 ––– Engine T op End V alve Clearance: Inlet 0.08 ∼ 0.12 (0.0031 ∼ 0.0[...]

2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit (BN125-A6 ∼ ) 4.1 mm (0.161 in.) 1 mm (0.04 in.) Rear 7.3 mm (0.29 in.) 2 mm (0.08 in.) Final Drive D r i v eC h a i nS l a c k 25 ∼ 40 mm (0.98 ∼ 1.57 in.) ––– 20 Link Length 254.0 ∼ 254.6 mm (10.00 ∼ 10.02 in.) 259 mm (10.2 in.) Brakes Brake Lever Free Play Non-a[...]

PERIODIC MAINTENANCE 2-1 1 Special T ools Steering Stem Nu t Wrench: 57001-1 100 Jack: 57001-1238 Fork Oil Level Gauge: 57001-1290[...]

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

PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Throttle Grip Free Play Adjustment • Loosen the locknut [A]. • T urn the adjuster [B] until the proper amount of free play can be obtained. • T ighten the locknut against the adjuster . If the throttle grip free play cannot be adjusted with the adjuster , use the cable adjusters at the[...]

2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment • Start the engine and warm it up thoroughly . • T urn the idle adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary . Front [B] Air Cle[...]

PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Remove the canister mounting bracket bolts [A] and re- move the brackets [B] and canister [C] together . • Disconnect the hoses from the canister . • Visually inspect the canister for cracks and other damage. If the canister has any cracks or bad damage, replace it with a new one. NO[...]

2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cylinder Head Bolt Tightness Inspection • Check that 6 mm [A] and 9 mm [B] cylinder head bolts are tightened evenly . Standard head bolts tightening torque are shown below . Tighte ning T orque 6 mm Cylin der Head Bo lts: 12 N·m (1.2 k gf·m, 104 in ·lb) 9 mm Cyl inder Head Bolts: 2 6 N?[...]

PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures V alve Clearance Adjustment If the valve clearance is not within the specified range, adjust the clearance by loosening the locknut and turning the adjusting screw . • T ighten the nuts to the specified torque and check the valve clearance again. T orque - V alve Adjustin g Screw Locknut: [...]

2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pull the clutch cable [A] tight and tighten the adjusting nuts [B] against the clutch cable bracket. • T urn the adjuster at the clutch lever until the free play is correct. • T ighten the knurled locknut at the clutch lever . WA R N I N G Be sure that the outer cable end at the clut[...]

PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Recommended Engine Oil Grade: (BN125- A1 ∼ A3): API SE, SF or SG (BN125- A4 ∼ ): API SE, SF or SG API SH, SJ or SL with JASO MA Vis co si ty : SAE 10W- 40 Capacity: 1.1 L (1.16 US qt) (When filter is not removed) 1 . 2L( 1 . 2 7U Sq t ) (when f ilter is remove d) 1 . 4L( 1 . 4 8U Sq t ) [...]

2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the O-ring [A] with new one. • Apply grease to the O-ring and the grommet [B]. • Install the cover [C] and tighten the cover bolts. T o rque - Oil Filter Cover B olts (BN125-A1 ∼ A3): 9.8 N·m (1.0 kgf·m, 87 i n·lb) (BN125-A4 ∼ ): 8.8 N ·m (0.90 kgf·m , 78 in·lb) •[...]

PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Wheels/Tires Spoke Tightness Inspection • Check that all the spokes are tightened evenly . If spoke tightness is uneven or loose, tighten the spoke nipples evenly . T orque - Spoke Nipples: 2 .0 ∼ 3.9 N ·m (0.20 ∼ 0.40 kgf·m, 17 ∼ 35 in·lb) • Check the rim runout. WA R N I N G I[...]

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

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 occu r during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are bald. ?[...]

2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Set the motorcycle up on its center stand. ○ Rotate the rear wheel to find the position where the chain is tightest. ○ Measure the vertical movement (chain slack) [A] midway between the sprockets. If the chain slack exceeds the standard, adjust it. Chain Slack Standard: 25 ∼ 40 mm [...]

PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Bend the cotter pin [A] over the nut [B]. • Check the rear brake ef fectiveness. WA R N I N G 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. • T ighten the chain adjuster locknuts. [...]

2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Lubrication • The chain should be lubricated with a lubricant which will both prevent the exterior from rusting and also absorb shock and reduce friction in the interior of the chain. If the chain is especially dirty , it should be washed in diesel oil or kerosene, and afterwar[...]

PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Check that the front brake cam lever [A] comes to an 80° ∼ 90° angle [C] with the rear brake rod [B] when the rear brake is fully applied. If it does not, remove the adjusting nut [D] and lever , then adjust the rear brake cam lever angle. • Check the brake pedal free play . WA R N[...]

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

PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Remove the clear plastic hose. • Install the reservoir cap. • T ighten the bleed valve, and install the rubber cap. T orque - Cal iper Bleed V alve: 7.8 N·m (0.80 kgf· m, 69 in·lb) Front Brake Reservoir Cap Screws: 2.5 N·m (0.25 kgf·m, 22 in·lb) • After changing the fluid, ch[...]

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 ha[...]

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

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

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

2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection • Check the steering. ○ Lift the front wheel off the ground using the jack [A]. Special T ool - Jack: 57001-1238 ○ With the front wheel pointing straight ahead, alternately tap each end of the handlebar . The front wheel should swing fully left and right fr[...]

PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Steering Stem Bearing Lubrication • Remove the steering stem (see Steering chapter). • Using a high-flash point solvent, wash the upper and lower steel balls. • Wipe all the old grease off the upper and lower outer races. • Visually check the races and balls. Replace the bearing asse[...]

2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe of f any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○ Whenever the vehicle has been operated under wet or rainy cond[...]

PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Nut, Bolt, and F astener Tightness Inspection Tightness Inspection • Check the tightness of the bolts and n u ts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (a[...]

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FUEL SYSTEM 3-1 3 Fuel System T able of Contents Exploded View .... .................................................................................................................... 3-2 Specifications ................................................................................................................. ........ 3-8 Special T ools ....[...]

3-2 FUEL SYST EM Exploded View[...]

FUEL SYSTEM 3-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Upper Chamber Cover Mounting Screws 3.5 0.36 31 in·lb 2 Spring Seat Screws 0.8 0.080 7i n · l b 3 Choke Lever Set Screw 0.8 0.080 7i n · l b 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[...]

3-4 FUEL SYST EM Exploded View Except the California Model[...]

FUEL SYSTEM 3-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Fuel T ap Plate Screws 0.8 0.080 7i n · l b 2 Fuel T ap Diaphragm Cover Screws 1.0 0.10 9i n · l b 2.5 0.25 22 in·lb with White W asher 3 Fuel T ap Mounting Bolts 4.9 0.50 43 in·lb with Black W asher 4. Catch tank 5. V acuum switch valve (For the A T , CH, DE of BN1[...]

3-6 FUEL SYST EM Exploded View California Model[...]

FUEL SYSTEM 3-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Fuel T ap Plate Screws 0.8 0.080 7i n · l b 2 Fuel T ap Diaphragm Cover Screws 1.0 0.10 9i n · l b 2.5 0.25 22 in·lb with White W asher 3 Fuel T ap Mounting Bolts 4.9 0.50 43 in·lb with Black Wash er 4. Catch tank 5. V acuum switch valve 6. Canister 7. Separator 8. [...]

3-8 FUEL SYST EM Specifications Item Standard Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.1 2 in.) Carburetor Make, T ype MIKUNI BS28 Idle Speed 1 300 ±50 r/min (rpm) Pilot Screw (T urns Out) 15 / 8 3.0 (BN125-A7 ∼ ,N ,N U ) (US, CA, CH) – Service Fuel Level 1 ∼ 3 mm (0.04 ∼ 0.12 in.) below from the bottom edge of the of the carburetor [...]

FUEL SYSTEM 3-9 Specifications Pilot screw [A] P l u g[ B ]( U S ,C A ,C H ) Pilot air jet [ C] Jet needle [D] Throttle valve [E] Pilot jet [F] Needle jet [G] Main jet [H] Float [I] V alve seat [J] V alve needle [K][...]

3-10 FUEL SYSTEM Special T ools Fuel Level Gauge: 57001-101 7 Carburetor Drain Plug W rench, Hex 3: 57001-1269[...]

FUEL SYSTEM 3-1 1 Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Grip Free Play Inspection in the Pe- riodic Maintenance chapter . Free Play Adjustm ent • Refer to the Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter . Throttle Cable Installation • Install the throttle cable in accordance with the [...]

3-12 FUEL SYSTEM Carburetor Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance chapter . Idle Speed Adjustment • Refer to the Idle Speed Adjustment in the Periodic Main- tenance chapter . Service Fuel Level Inspection WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditio[...]

FUEL SYSTEM 3-13 Carburetor Service Fuel Level Adjustment WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn 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 carbur[...]

3-14 FUEL SYSTEM Carburetor Fuel System Cleanliness Inspection WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn 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 su[...]

FUEL SYSTEM 3-15 Carburetor • Loosen the carburetor holder clamp [A] and air cleaner duct clamp. • Pull the carburetor out of the a ir cleaner duct end [B], and then pull it out of the carburetor holder [C] from the vehicle’s right side . • T ake out the carburetor . • Stuff pieces of lint-free, clean cloth into the carburetor holder and [...]

3-16 FUEL SYSTEM Carburetor • Remove: Upper Chamber Cover [A] V acuum Piston and Diaphragm CAUTION During carburetor disassembly , the careful not to damage the diaphragm. Never use a sharp edge to remove the diaphragm. • Remove the spring seat screws [D]. • Remove the jet needle [A] from the vacuum piston [B] along with the spring seat [C]. [...]

FUEL SYSTEM 3-17 Carburetor • Remove the coasting enricher cover . • Remove the diaphragm [A]. Carburetor Assembly • T urn in the pilot screw [A] fully but not tightly , and then back it out the same number of turn counted during dis- assembly . • For the Swiss, United States. and Canada models, drive in a new plug [B] in the pilot screw ho[...]

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

FUEL SYSTEM 3-19 Carburetor Carburetor Inspection WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn 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 . ?[...]

3-20 FUEL SYSTEM Carburetor • Check the tapered portion [A] of the pilot screw [B] for wear or damage. If the pilot screw is worn or damaged on the tapered por- tion, it will prevent the engine from idling smoothly . Re- place it. • Check that the vacuum piston [A] moves smoothly in the carburetor body . The surface of the piston must not be ex[...]

FUEL SYSTEM 3-21 Air Cleaner Air Cleaner Element Re moval • Remove the left side cover . • Remove the element cover [A]. Front [B] • Pull out the air cleaner element [A]. • Push a clean, lint-free towel into the air cleaner housing to keep dirt or other foreign material from entering. WA R N I N G If dirt or dust is allowed to pass through [...]

3-22 FUEL SYSTEM Air Cleaner Air Cleaner Housin g Removal • Remove: Side Covers and Seat (see Frame chapter) Fuel T ank (see Fuel T ank 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] • Remove the elemen[...]

FUEL SYSTEM 3-23 Fuel T ank Fuel T an k Removal WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn 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 seat and side co[...]

3-24 FUEL SYSTEM Fuel T ank Fuel T ank Cleaning WA R N I N G Clean the tank in a well-ventllated area, and take care that there are no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank. • Remove the fuel tank and drain it. • Pour s[...]

FUEL SYSTEM 3-25 Fuel T ank Fuel T ap In spection • Remove the fuel tap. • Check the fuel tap filter screen [A] for any breaks or dete- rioration. If the fuel tap screens have any breaks or are deterio- rated, they may allow dirt to reach the carburetor , causing poor running. Replace the fuel tap. If the fuel tap leaks, or allows fuel to flow [...]

3-26 FUEL SYSTEM Evaporative Emission Control Sy stem ( California Model Only) The Evaporative Emission Cont rol System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are re quired, a thorough visual in- spection must be made at the intervals[...]

FUEL SYSTEM 3-27 Evaporative Emission Control System ( Calif ornia Model Only) Separator Operation T est WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn 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 appl[...]

[...]

ENGINE TOP END 4-1 4 Engine T op End T able of Contents Exploded View .... ............................... 4-2 Specifications .................................... 4-6 Special T ools ..................................... 4-9 Clean Air System (For A T , CH, DE of BN125-A1 ∼ A2 and other than the CAL)................................................ [...]

4-2 ENGINE TOP END Exploded View[...]

ENGINE TOP END 4-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 V alve Adjusting Cap Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb V alve 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 3 Cylinder Head[...]

4-4 ENGINE TOP END Exploded View[...]

ENGINE TOP END 4-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Camshaft Bearing Holder Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 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?[...]

4-6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air Sytem V acuum Switch V alve Closing Pressure: Open → Close ––– (A T , CH, DE, of the BN125-A1 ∼ A2 and othe r than the CAL) 45 ∼ 53 kPa (340 ∼ 400 mmHg, 6.5 ∼ 7.7 psi) ––– (CAL) 41 ∼ 52 kPa (310 ∼ 390 mmHg, 6.0 ∼ 7.5 psi) ––– Camshaft Cam Heigh[...]

ENGINE TOP END 4-7 Specifications 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.) ––– V alve 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.) Cylinder , Piston Cylinder Inside Diameter 55.000 ∼ 55[...]

4-8 ENGINE TOP END Specifications Cam Height Cam Height [A] V alve Head Thickn ess V alve Stem Diameter [A] V alv e Head Thic kness [B] 45° [C] Camshaft Runout Va l v e S t e m B e n d Dial Gauge [A][...]

ENGINE TOP END 4-9 Special T ools Compression Gauge, 20 kgf/c m ²: 57001-221 V alve Spring Compressor Assembly: 57001-241 Piston Pin Pull er Assembly: 57001-910 V alve Seat Cutter , 45°- 27.5: 57001-1 1 14 V alve Seat Cutter , 45° - 32: 57001-1 1 15 V alve Seat Cu tter , 32°- 30: 57001-1 120 V alve Sea t Cutter , 32° - 35: 57001-1 121 V alve S[...]

4-10 ENGINE TOP END Special T ools Fork Oil Level Ga uge: 57001-129 0 Compression Gauge Adapter , M10 × 1.0: 57001-131 7 V alve Seat Cutter Hold er , 4.5: 57001-133 0 V alve Guide Arbor , 4.5: 57001-1331 V alve Guid e Reamer , 4.5: 57001-1333 Va l v e S e a t C u t t e r, 6 0 ° - 33: 57001-1334 ○ V alve Seat Cutter , 32°- 33: 57001-1 199 can a[...]

ENGINE TOP END 4-1 1 Clean Air System (For A T , CH, DE of BN125-A1 ∼ A2 and oth er than the CAL) AT : A u s t r i a CAL: California CH: Switzerland DE: Germany Air Suction V alve I nstallation • Install the air suction valve so that its number [A] of the read faces outside and downward. • T ighten: T orque - Air Sucti on V alve Cover Bolts: [...]

4-12 ENGINE TOP END Clean Air System (For A T , CH, DE of BN125-A1 ∼ A2 and other th an the CAL) V acuum Switch Valve Unit T est • Remove the vacuum switch valve (see V acuum Switch V alve Removal). • Connect a commercially available vacuum gauge [A] and syringe [B] (or fork oil level gauge) to the vacuum hoses as shown. Special T ool - Fork [...]

ENGINE T OP END 4-13 Clean Air System (California M odel) Va c u u m S w i t c h Val ve T e s t • Remove the vacuum switch valve. • Connect the vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown. Special T ool - Fork Oil Level Gauge : 57001–1290 Air Flow [C] • Gradually raise the vacuum (l ower the pressur[...]

4-14 ENGINE TOP END Camshaft Chain T ensioner Camshaft Chain T ensioner 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 hal[...]

ENGINE T OP END 4-15 Camshaft Chain T ensioner • Install the O-ring in the tensioner body . • Install the tensioner so that the arrow mark [B] faces up- ward, and tighten the mounting bolts. T orque - Chain T ensioner Mounting Bolts (BN125-A1 ∼ A3): 9.8 N ·m (1.0 kgf·m 87in· lb) (BN125-A4 ∼ ): 8. 8 N·m (0.90 kgf ·m 87in·lb) • Remove[...]

4-16 ENGINE TOP END Camshaft Camshaft Removal • Remove: Fuel T ank [A] (see Fuel System chapter) Camshaft Chain Cover [B] V alve Adjusting Caps [C] • Holding the camshaft center bolt [A] with a wrench, loosen the camshaft sprocket bolts [B]. • T urn the camshaft center bolt [A] clockwise so that the mark [B] on the sprocket aligns with the ti[...]

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

4-18 ENGINE TOP END Camshaft • Install the camshaft bearing holder [A]. • Apply engine oil to the rocker shaft surface and cam por- tion of the rocker arm, and then install them at t he original position. ○ Install the rocker shafts [B] so that the screw threads face outward. • Replace the rocker shaft bolt washers with new ones. • Instal[...]

ENGINE T OP END 4-19 Camshaft • Remove the crank balancer gear [A]. Special T ool - O utside Circlip Pliers: 57001-144 ○ Stuff a clean cloth into the hole [B] so that the balancer damper springs will not fall into it. • Remove the camshaft chain holder [A], and pull the camshaft chain [B] upward. • Remove the cylinder head (see Cylinder Hea[...]

4-20 ENGINE TOP END Camshaft ○ Align the three punch marks [D] on the balancer shaft gear [A], crank balancer gear [B], and coupling [C]. • Install the alternator (see Electrical System chapter). • Align the punch mark [A] on the crankcase with the “T” mark [B] on the rotor . • Engage the camshaft sprocket [A] with the chain [B]. Then a[...]

ENGINE T OP END 4-21 Cylinder Head Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged • W arm up the engine thoroughly . • Stop the engine. • Remove: Fuel T ank (see Fuel System chapter) Spark Plug Owner ’ s T ool - Spark Plug Wrench, Hex 16: 921 10-1 172 [A] • Attach the compression gauge [A] and adapter [B][...]

4-22 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove: Fuel T ank (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) • Remove: Engine Upper Bracket [A] Camshaft Cha[...]

ENGINE T OP END 4-23 Cylinder Head Cylinder Head Installation • Install: Dowel Pins [A] New Cylinder Head Gasket [B] • Apply molybdenum disulfide grease to the threads of the 9 mm cylinder head bolts [1 ∼ 4], and engine oil to both sides of the washers. • T ighten the 9 mm bolts following the tightening sequence as shown. T ighten them firs[...]

4-24 ENGINE TOP END Cylinder Head Cylinder Head Assembly • Install the rubber dampers as shown. Dampers [A] Fins [B] Front [C] Cylinder Head Cleaning • Remove the cylinder head (see Cylinder Head Removal). • Remove the valves (see V alve Removal). • W ash the head with a high-flash point solvent. • Scrape the carbon out of the combustion [...]

ENGINE T OP END 4-25 Cylinder Head Cylinder Head Warp • Clean the cylinder head (see Cylinder Head Cleaning). • Lay a straightedge across the lower surface of the cylinder head at the positions as shown. • Use a thickness gauge [A] to m easure the space between the straightedge [B] and the cylinder head. Cylinder Head W arp Standard: ––?[...]

4-26 ENGINE TOP END Va l v e s V alve Clearance Inspection • Refer to the V alve Clearance Inspection in the Periodic Maintenance chapter . V alve Clearance Adjustment • Refer to the V alve Clearance Adjustment in the Periodic Maintenance chapter . V alve R emoval • Remove the cylinder head (see Cylinder Head Removal). • Remove the rocker s[...]

ENGINE T OP END 4-27 Va l v e s V alve Guid e Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). CAUTION Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head and heat the oil. • Dr[...]

4-28 ENGINE TOP END Va l v e s V alve Seat Inspection • Remove the valve (see V alve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat. If the outside diameter is too large or too small, repair the seat (see V alve Seat Repair).[...]

ENGINE T OP END 4-29 Va l v e s Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair . Therefore the cutter must not be used for other purposes than seat repair . 2. Do not drop or shock the valve seat cutter , or the dia- mond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cu[...]

4-30 ENGINE TOP END Va l v e s • Measure the outside diameter of the seating surface with a vernier caliper . If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Widened Width [A] of engagement by machining with 45° cutter Ground V olume [B] by 32° cutter 32° [C[...]

ENGINE T OP END 4-31 Va l v e s If the seat width is too wide, make the 60° grind [A] de- scribed below . If the seat width is within the specified range, lap the valve to the seat as described below . • Grind the seat at a 60° angle until the seat width is within the specified range. ○ T o make the 60° grind, fit 60° cutter into the holder[...]

4-32 ENGINE TOP END Va l v e s[...]

ENGINE T OP END 4-33 Cylinder , Piston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) • T ap lightly up the cylinder [A] with a plastic mallet to sep- arate from the crankcase. • Remove the cylinder base gasket. Piston Removal • Remove the cylinder (see Cylinder Removal). • Place a clean cloth under the piston and re[...]

4-34 ENGINE TOP END Cylinder , P iston ○ When installing the piston pin snap ring, compress it only enough to install it and no more. CAUTION Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall. NOTE ○ The oil ring rails have no "top" or "bottom". • Install the oil [...]

ENGINE T OP END 4-35 Cylinder , Piston • Apply engine oil to the cylinder bore. • Position the piston ring openings. • Install the cylinder [B] while compressing [A] the piston rings with your thumbs. • Install the removed parts. Cylinder Wear • Since there is a difference in cylinder wear in different di- rections, take a side-to-side an[...]

4-36 ENGINE TOP END Cylinder , P iston Piston/Cylinder Clearance • Subtract the piston diameter from the cylinder inside di- ameter to get the piston/cylinder clearance. Piston/Cylinder C learance Standard: 0.025 ∼ 0.052 mm (0.0010 ∼ 0.002 0 in.) If the piston/cylinder clearance is less than the specified range, use a smaller piston or i ncre[...]

ENGINE T OP END 4-37 Cylinder , Piston Piston Ring Thickness • Measure the piston ring thickness. ○ Use a micrometer to measure at several points around the ring. Piston Ring Thicknes s (T op, Second) Standard: 0.77 ∼ 0.79 mm (0.0303 ∼ 0.031 1 in.) Service Limit: 0.70 mm (0.028 i n.) If any of the measurements is less than the service limit[...]

4-38 ENGINE TOP END Carburetor Holder Carburetor Holder Installation • Apply grease to the O-ring [A], and install the carburetor holder . ○ T ake care not to pinch the O-ring. • T ighten: T orque - Carburetor Holder Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the insulator [B] so that its recess aligns with the boss [A] on the carbur[...]

ENGINE T OP END 4-39 Muffler WA R N I N G T o avoid a serlous burn, do not remove the muffler when the engine is still hot. W ait until the muffler cools down. Muffler Removal • loosen the muffler body clamp bolt [A]. • Remove the muf fler body mounting bolt and nut [B]. • Remove the muffler body [A] backward. • Remove the exhaust pipe moun[...]

[...]

CLUTCH 5-1 5 Clutch T able of Contents Exploded View ................................................................................................................... ..... 5-2 Specifications ................................................................................................................. ........ 5-4 Special T ools ..............[...]

5-2 CLUTCH Exploded View[...]

CLUTCH 5-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Clutch Hub Nut 98 10.0 72 2 Clutch Spring Bolt 8.8 0.90 78 in·lb Clutch Cover Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 3 Clutch Cover Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb Oil Seal Retaining Plate Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 4 Oil Seal Retaining Plate Bolt[...]

5-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 2 ∼ 3 m m (0.08 ∼ 0.12 in.) ––– Clutch Friction Plate Thickness 2.92 ∼ 3.08 mm (0.1 15 ∼ 0.121 in.) 2.8 mm (0.1 1 in.) Friction and Steel Plate Warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) Clutch Spring Free Length 35.0 mm (1.38 in.) 34.0 mm (1.34 in.)[...]

CLUTCH 5-5 Special T ools Gear Holder , m1.75: 57001-1015 Clutch Holder: 57001-1243[...]

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

CLUTCH 5-7 Clutch Cover Clutch Cover Removal • Drain the engine oil (see Periodic Maintenance chapter). • Remove: Front Footpeg Oil Pipe Banjo Bolt [A] • Screw the clutch lever adjuster in completely so as to give t h ec l u t c hc a b l ep l e n t yo fp l a y . • Remove the clutch cable holder [B] of clutch release lever . • Free the clu[...]

5-8 CLUTCH Clutch Cover • With the shaft pulled a little out of the cover , turn the lever until it becomes hard to turn. ○ The release lever should have about 1 1 mm (0.43 in.) [A] clearance between the lever and t he washer . • T ighten the cover bolts and clutch cable holder bolts. ○ While pushing [B] the clutch cable holder [A] rearward[...]

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

5-10 CLUTCH Clutch • Install the washer [A] as shown. Crankcase Side [B] • T ighten the clutch hub nut [C], while holding the clutch hub with the clutch holder . Special T ool - C lutch Holder: 57001-1243 T o rque - Clutch H ub Nut: 98 N·m (10.0 k gf·m, 72 ft·lb) • Install the spring seat [B], and then the spring [C] with the concave side [...]

CLUTCH 5- 1 1 Clutch Clutch Spring Free Le ngth Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 35.0 mm (1.38 in.) Service Limit: 34. 0 m m (1.34 in.) Clutch Housing Finge r Damage • Visually inspect the clutch housing fing[...]

5-12 CLUTCH Primary Gear Primary Gear Removal • Remove the clutch cover (see Clutch Cover Removal). • Using the gear holder [A], hold the primary gear and loosen the primary gear nut [B]. Special T ool - Gear Holder , m1.75: 57001-1015 • Remove: Clutch (see Clutch Removal) [C] Primary Gear Nut [B] Spring W asher Primary Gear [D] Woodruf f Key[...]

ENGINE LUBRICA TION SYSTEM 6-1 6 Engine Lubrication System T able of Contents Exploded View ................................................................................................................... ..... 6-2 Engine Oil Flow Chart............................................................................................................. 6[...]

6-2 ENGINE LUBRICA TION SYSTEM Exploded View[...]

ENGINE LUBRICA TION SYSTEM 6-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Oil Drain Plug 18 1.8 13 Oil Screen Cover Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 2 Oil Screen Cover Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb 3 Oil Pressure Relief V alve 15 1.5 11 L Oil Filter Cover Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 4 Oi[...]

6-4 ENGINE LUBRICA TION SYSTEM Engine Oil Flow Chart 1. Oil screen 2. Oil pump 3. Clutch Cover Oil Passage 4. Oil Pressure Relief V alve 5. Oil Filter 6. Crankshaft Oil seal 7. Oil Pipe Banjo Bolts 8. Camshaft 9. Drive S haft 10. Output Shaft 1 1. Camshaft Chain Tunnel 12. Engine Breather Hose 13. Air Cleaner Housing A. Oil Flow B. Blowby Gas[...]

ENGINE LUBRICA TION SYSTEM 6-5 Specifications Item Standard Engine Oil Grade: (BN125-A1 ∼ A3) API SE, SF or SG (BN125-A4 ∼ ) API SE, SF or SG API SH, SJ or SL with JASO MA Vis co s it y 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 dr[...]

6-6 ENGINE LUBRICA TION SYSTEM Special T ools Oil Pressure Gauge, 5 kgf/cm² : 57001-125 Oil Pressur e Gauge Adapter , M1 0 × 1.25: 57001-1 182[...]

ENGINE LUBRICA TION SYSTEM 6-7 Engine Oil and Oil Filter WA R N I N G Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury . Oil Level Inspection • Situate the motorcycle so that it is vertical. • Check that the eng[...]

6-8 ENGINE LUBRICA TION SYSTEM Oil Screen Oil Screen Remo val • Refer to the Oil Screen Cleaning in the Periodic Mainte- nance chapter . Oil Screen Installation • Refer to the Oil Screen Cleaning in the Periodic Mainte- nance chapter .[...]

ENGINE LUBRICA TION SYSTEM 6-9 Oil Pump Oil Pump Removal • Remove the clutch cover (see Clutch chapter). • Remove the mounting screws [A] and remove the oil pump assembly [B]. ○ T urn the pump gear so that the pump mounting screws can be removed through the pump gear holes. Oil Pump Installatio n • Replace the O-rings with new one s. • In[...]

6-10 ENGINE LUBRICA TION SYSTEM Oil Pump Oil Pump Assembly • Install the oil pump gear [A]. • Fill the rotors [B] with engine oil. • Install the cover and tighten the oil pump assembly screw . T orque - Oil Pump Assembly Screw: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the washer and circlip. • Replace the O-rings with new ones. • Chec[...]

ENGINE LUBRICA TION SYSTEM 6-1 1 Oil Pressure Oil Pressure Measurement • Remove the air suction valve [A] (see E ngine T op End chapter). • Replace the oil pipe banjo bolt of the clutch cover [B] with the oil pressure gauge adapter (special tool) [C]. If the oil pressure gauge adapter bottoms out, add washer(s) (P/N: 1 1009-1 105) [D] under the[...]

6-12 ENGINE LUBRICA TION SYSTEM Relief V alve Relief V alve Inspection • Remove the relief valve from the clutch cover . • Check to see if the valve [A] slides smoothly when push- ing in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure. NOTE ○ Inspect the valve in it assembled state. Disassembly and[...]

ENGINE LUBRICA T ION SYSTEM 6-13 Oil Pipe Oil Pipe Rem oval • 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] • Remove the oil pipe from the right side of the engine. Oil Pipe In[...]

[...]

ENGINE REMOV AL/INST ALLA TION 7-1 7 Engine Removal/Installation T able of Contents Exploded View ................................................................................................................... ..... 7-2 Special T ool .................................................................................................. .............[...]

7-2 ENGINE REMOV AL/INST ALLA TION Exploded View[...]

ENGINE REMOV AL/INST ALLA TION 7-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Mounting Bolts, Nuts (M10) 44 4.5 33 2 Engine Mounting Bolts, Nuts (M8) 25 2.5 18 3 Engine Mounting Bracket Bolts, Nuts 25 2.5 18 4 Engine Ground T erminal Bolt 9.8 1.0 87 in·lb[...]

7-4 ENGINE REMOV AL/INST ALLA TION Special T ool Jack: 57001-123 8[...]

ENGINE REMOV AL/INST ALLA TION 7-5 Engine Removal/Installation Engine Removal • Place the jack [A] under the frame to lift the rear wheel [B] off the ground. Special T ool - Jack: 57001-1238 • Squeeze the brake lever slowly and hold it with a band [A]. WA R N I N G Be sure to hold the front brake when removing the engine, or the motorcycle may [...]

7-6 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Remove: Engine Mounting Bolts [A] Engine Mounting Bracket Bolts [B] ○ Pull out the mounting bolts while liftin g the engine. • Lift up the engine and move it to the right side of the frame. • Remove the engine [A] from the vehicle right side. Engine Installation • Insert the[...]

ENGINE REMOV AL/INST ALLA TION 7-7 Engine Removal/Installation If the engine sprocket is hard to install, remove the master link and the clip from the drive chain, and then install the engine sprocket. ○ Install the clip [A] so that the open end [B] of the "U" points in the opposite direction of chain rotation [C]. • Install the engin[...]

[...]

CRANKSHAFT/TRANSMISSION 8-1 8 Crankshaft/T ransmission T able of Contents Exploded View ................................... 8-2 Specifications .................................... 8-6 Special T ools and Sealant ................. 8-7 Crankcase ......................................... 8-8 Crankcase Disassembly .............. 8-8 Crankcase Assembly .[...]

8-2 CRANKSHAFT/TRANSMISSION Exploded View[...]

CRANKSHAFT/TRANSMISSION 8-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Primary Gear Nut 69 7.0 51 2 Balancer Shaft Gear Nut 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. [...]

8-4 CRANKSHAFT/TRANSMISSION Exploded View[...]

CRANKSHAFT/TRANSMISSION 8-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 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 in·lb 4 Engine Sprocket Holder Bolts 12 1.2 104 in·lb 5 Shift Shaft Return Spring Pin 29 3.0 21 L 6 Shift Lever Clamp Bolt 12 1.2 104 in·lb 7 Shift Pedal N[...]

8-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rod Connecting Rod Big End Side Clearance 0.20 ∼ 0.35 mm (0.008 ∼ 0.014 in.) 0.5 mm (0.020 in.) Connecting Rod Big End Radial Clearance 0.005 ∼ 0.017 mm (0.0002 ∼ 0.0007 in.) 0.07 mm (0.003 in.) Crankshaft Runout TIR 0.03 mm (0.0012 in.) or less TI[...]

CRANKSHAFT/TRANSMISSION 8-7 Special T ools and Sealant Outside C irclip Pliers: 57001-144 Gear Holder , m1.75: 57001-1015 Bearing Driv er Set: 57001-1 129 Crankshaft Jig: 57001-1 174 Crankcase Splitti ng T ool Assembly: 57001-1362 Kawasaki Bond (Liquid Gasket -Silver): 92104-002[...]

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

CRANKSHAFT/TRANSMISSION 8-9 Crankcase • Remove the tra nsmission shaft [A], gears and balancer shaft from the right crankcase half [B]. • Remove: Shift Drum Cam Screw [A] Shift Drum Cam [B] Woodruf f Key [C] Shift Drum [D] Gear Set Lever [E] • Support the right crankcase half [A] with a suitable re- tainer . • Remove the crankshaft [B] from[...]

8-10 CRANKSHAFT/TRANSMISSION Crankcase • Press the damper [A] into the crankcase with the bearing drier set. Special T ool - B earing Driver Set: 57001-1 129 • Chip off the old gasket from the mating surfaces of the crankcase halves and clean them off with a high-flash point solvent. • Using compressed air , blow out the oil passages in the c[...]

CRANKSHAFT/TRANSMISSION 8-1 1 Crankcase • Using compressed air [A], blow out the oil passage in the right crankshaft [B]. • Positioning the connecting rod [A] big end at BDC, put in the crankshaft jig [B] between the crankshaft flywheels. • Press the crankshaft [C] in the right crankcase half [D]. Special T ool - C rankshaf t Jig: 57001-1 174[...]

8-12 CRANKSHAFT/TRANSMISSION Crankcase • Check to see that the crankshaft, drive shaft, and output shaft all turn freely (in the neutral position). If the crankshaft will not turn, probably the crankshaft is not centered; T ap the mount portion [A] of the crankcase with a plastic hammer to reposition it. • Put the end of the woodruff key [A] in[...]

CRANKSHAFT/TRANSMISSION 8-13 Crankshaft Crank Balancer Gear Removal/Insta llation • Refer to Camshaft Chain Removal/Installation in the En- gine T op End chapter . Crankshaft Removal • Refer to the Crankcase Disassembly in this chapter . Crankshaft Installation • Refer to the Crankcase Assembly in this chapter . Crankshaft Disassembly If the [...]

8-14 CRANKSHAFT/TRANSMISSION Crankshaft • First correct the horizontal misalignment by striking the projecting crank half [A] with a plastic, soft lead, or brass hammer as shown. • Recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit. • Next, correct the vertical misalignment by either dr[...]

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

8-16 CRANKSHAFT/TRANSMISSION Starter Motor Clutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal and Installation in the Electrical System chapter . Starter Motor Clutch Disassembly • Remove the alternator rotor [A] (see Electrical System chapter). • Hold the alternator rotor with the flywheel holder [B] and[...]

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

8-18 CRANKSHAFT/TRANSMISSION External Shift Mechanism • T urn the shift drum and position the neutral groove [A] as shown. • Remove the shift shaft [D] while pushing [C] the shift mechanism arm [B] toward the shaft. External Shift Mechanism Inspectio n • Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace i[...]

CRANKSHAFT/TRANSMISSION 8-19 T ransmission T ransmission Shaft Removal • Split the crankcase (see Crankcase Disassembly). • Pull out the shift rod [A] allowing the shift fork guide pins to free from the shift drum [B]. • Remove the shift forks [C]. • Remove the shift drum. • Pull out the drive shaft [D] and output shaft [E] together with [...]

8-20 CRANKSHAFT/TRANSMISSION T ransmission T ransmission Assembly • Replace any circlips removed with new ones. ○ Install the circlips [A] so that the opening [B] is aligned w i t has p l i n eg r o o v e[ C ] . ○ Install the toothed washer [D] so that the teeth [E] are not aligned with the opening of the circlip. • The drive shaft gears ca[...]

CRANKSHAFT/TRANSMISSION 8-21 T ransmission Shift Drum Remova l/Installation • Refer to the Crankcase Disassembly/Installation in the Crankshaft/T ransmission chapter . Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause difficulty in shifting, or allow the transmission to jump out of[...]

8-22 CRANKSHAFT/TRANSMISSION Ball Bearing, and Oil Seal Ball Bear ing Replacement CAUTION Do not remove the ball bearings unless it is neces- sary . Removal may damaged them. • Using a press or puller , remove the ball bearing. NOTE ○ In the absence of the above mentioned tools, satisfac- tory results may be obtained by heating the case to ap- [...]

WHEELS/TIRES 9-1 9 Wheels/T ires T able of Contents Exploded View ................................................................................................................... ..... 9-2 Specifications ................................................................................................................. ........ 9-4 Special T ools .[...]

9-2 WHEELS/TIRES Exploded View[...]

WHEELS/TIRES 9-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Ti r e A i r V a l v e N u t s 1.5 0.15 13 in·l b 2 Spoke Nipples 2.0 ∼ 3.9 0.20 ∼ 0.40 17 ∼ 35 in·lb 3 Front Axle Nut 78 8.0 58 4 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 Part[...]

9-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Size: Front 17 × 1.85 ––– Rear 15 × 2.75 ––– Rim Runout (with tire installed): Axial TIR 0.8 mm (0.03 in.) or less 2 mm (0.08 in.) Radial TIR 1.0 mm (0.04 in.) or less 2 mm (0.08 in.) Axle Rumout/100 mm (3.9 in.) TIR 0.1 mm (0.004 in.) or less 0.2 mm (0.008 [...]

WHEELS/TIRES 9-5 Special T ools Rim Protec tor: 57001-1063 Bead Breaker Assembly: 57001-1072 Bearing Driv er Set: 57001-1 129 Jack: 57001-1238 Bearing Rem over Shaft, 9: 57001-1265 Bearing Remover Head, 15 × 17: 57001-1267[...]

9-6 WHEELS/TIRES Wheels (Rims) Front Wheel R emoval • Remove the cotter pin and axle nut [ A]. • Remove the speedometer cable lower end [B]. • Raise the front wheel [B] off th e ground using the jack [A]. Special T ool - Jack: 57001-1238 • Pull out the axle and drop the front wheel [A] out of the forks. • Insert a wooden plate between the[...]

WHEELS/TIRES 9-7 Wheels (Rims) • Fit the fork leg stop [A] between the speedometer gear housing stop [B] and install the front wheel. • Install the axle from the right side and tighten the axle nut. T orque - Front Axle Nut: 78 N·m (8.0 kgf·m, 58 ft·lb) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in [...]

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

WHEELS/TIRES 9-9 Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. • Adjust the brake pedal f ree play (see Brakes chapter). • Check the rear brake ef fectiveness. WA R N I N G 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. Wheel Inspection • Rai[...]

9-10 WHEELS/TIRES Ti re s Air Pressure Inspection/Adjustment • Refer to the Air Pressure Inspection/Adjustment in the Pe- riodic Maintenance chapter . Tire Inspection • Refer to the T ire Wear Inspection in the Periodic Mainte- nance chapter . Tire R em ova l • Remove the following. Wheel (see this chapter) Brake Disc (front) Brake Panel (rea[...]

WHEELS/TIRES 9-1 1 Ti re s ○ For easier removal, always drop the tire bead opposite the valve stem into the rim well [A], and pry the tire bead a little at a time. • Do the same for the other side of the tire, then remove the rim from the tire. • Remove the protectors. Tire I nst all ati on WA R N I N G T o ensure safe handling and stability [...]

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

WHEELS/TIRES 9-13 Hub Bearings (Wheel Bearings) Inspection ○ Since the hub bearings are made to extremely close tol- erances, the clearance cannot normally be measured. NOTE ○ Do not remove any bearings for inspection. If any bear- ings are removed, they will need to be replaced with new ones. • Spin [A] the bearing by hand to check its condi[...]

[...]

FINAL DRIVE 10-1 10 Final Drive T able of Contents Exploded View ................................................................................................................... ..... 10-2 Specifications ................................................................................................................. ........ 10-4 Special T ools [...]

10-2 FINAL DRIVE Exploded View[...]

FINAL DRIVE 10-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks Engine Sprocket Cover Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 1 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 T orque Link Bolt and Nut 34 3.5 25 4 Rear Sprocket Nuts 26 2.7 19 5 Rear Axle Nut[...]

10-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Standard Chain: Make/type: ENUMA CHAIN (BN125-A1 ∼ A2) ––– Joint Endless EK428SH-R DAIDO (BN125-A3 ∼ ) Joint Endless DID424HG Link: 132 links ––– 130 links (BN125-A7 ∼ ,N ,N U ) ––– Chain Slack 25 ∼ 40 mm (0.98 ∼ 1.57 in.) ––– 20-link Length 25[...]

FINAL DRIVE 10-5 Special T ools Bearing Driv er Set: 57001-1 129 Jack: 57001-1238[...]

10-6 FINAL DRIVE Drive Chain Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter . Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter . Wear Inspection • Refer to the Drive Chain W ear Inspection in the Periodic Maintenance chapter . Lubrica[...]

FINAL DRIVE 10-7 Sprocket, Coupling Engine Sprocket Removal • Remove the engine sprocket cover bolts [A] and sprocket cover [B]. • Remove the engine sprocket bolts [A]. • Pull the engine sprocket [A] off the output shaft along with the chain. Engine Sprocket Installation • Install the engine sprocket so that the punch mark [A] face the outw[...]

10-8 FINAL DRIVE Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheels/T ires chapter). • Remove the drive chain (see Drive Chain Removal). • Remove the rear sprocket nuts [A] and separate the rear sprocket [B] from the coupling. Rear Sprocket Insta llation • Install the sprocket with the tooth number marking [A] out-[...]

FINAL DRIVE 10-9 Sprocket, Coupling Coupling Installation • Grease [A] the following and install the coupling. Coupling Grease Seal Lips. Coupling Internal Surface • Install the rear sprocket and the c oupling (see this chap- ter). • Install the rear wheel (see Wheels/T ires chapter). Coupling Bearing Removal • Remove the coupling. • Pry [...]

[...]

BRAKES 1 1-1 11 Brakes T able of Contents Exploded View ................................... 1 1-2 Specifications .................................... 1 1-6 Special T ools ..................................... 1 1-7 Caliper ............................................... 1 1-8 Caliper Removal .......................... 1 1-8 Caliper Installation ...[...]

1 1-2 BRAKES Exploded View[...]

BRAKES 1 1-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Brake Disc Bolts 27 2.8 20 L 2 Caliper Mounting Bolts 25 2.5 18 3 Caliper Holder Shaft Bolts 18 1.8 13 4 Caliper Pad Bolts 18 1.8 13 5 Caliper Bleed V alve 7.8 0.80 69 in·lb 6 Brake Hose Banjo Bolts 25 2.5 18 7 Brake Lever Pivot Bolt 5.9 0.60 52 in·lb 8 Brake Lever Pivot[...]

1 1-4 BRAKES Exploded View[...]

BRAKES 1 1-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Brake Pedal Bolt 9.8 1.0 87 in·lb 2 T orque Link Bolt and Nut 34 3.5 25 G: Apply grease. R: Replacement Parts[...]

1 1-6 BRAKES Specifications Item Standard Service Limit Front Brake Pad Lining Thickness: 4.5 mm (0.177 in.) (BN125-A1 ∼ A2) 1m( 0 . 0 4i n . ) 6.0 mm (0.236 in.) (BN125-A3 ∼ ) 1m( 0 . 0 4i n . ) 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.) (BN125-A3, NO, ES) (BN1[...]

BRAKES 1 1-7 Special T ools Inside Circlip Pl iers: 57001-143 Jack: 57001-1238[...]

1 1-8 BRAKES Caliper Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely . • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose Removal/Installation). CAUTION Immediately wash away [...]

BRAKES 1 1-9 Caliper ○ Insert a wooden board [A] 5 mm (0.2 in.) thick inside the caliper opening. ○ Apply compressed air [B] to the banjo bolt hole to allow the pistons [C] to protrude and stop at the woo den board. ○ Remove the wooden board and pull out the pistons by hand. If compressed air is not available, with the brake hose still attach[...]

1 1-10 BRAKES Caliper • Apply brake fluid to the inside of the cylinders and to the outside of the pistons and push the pistons [A] into the cylinders. • Check the friction boot [B] and dust boot [C] and replace them with new ones if they are damaged. • Apply a thin coat of silicon grease to the holder shafts [D] and the holder holes. • Ins[...]

BRAKES 1 1-1 1 Caliper Caliper Dust Seal/Friction Boo t Damage • Check that the dust seal and friction boot [C] are not cracked, worn, swollen, or otherwise damaged. • If they show any damage, replace it. Caliper Piston and Cylinder Damage • Visually inspect the piston [D] and cylinder surfaces for damage. Replace the caliper if the cylinder [...]

1 1-12 BRAKES Front Brake Pads Brake Pad Removal (BN125-A1 ∼ A2) • Remove the caliper with the hose attached. • Remove: Caliper Pad Bolts [A] Outer Pad [B] • Remove the inner pad (piston side pad) [C]. Brake Pad Removal (BN125-A3 ∼ ) • Loosen the caliper pad bolts [A]. • Remove the caliper with the hose attached. • Remove: Caliper P[...]

BRAKES 1 1-13 Master Cylinder Master Cylinder Removal • Remove the brake fluid from the reservoir with a syringe or other suitable device. • Disconnect the front brake light switch connectors [A]. • Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/In- stallation). ○ When removing the br[...]

1 1-14 BRAKES Master Cylinder Master Cylinder Assembly • Before assembly , clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts, G asoline, en[...]

BRAKES 1 1-15 Front Brake Disc Brake Disc Removal • Remove the wheel (see Wheels/T ires chapter). • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the marked side [A] faces out. • T ighten: T orque - Brake Disc Mounting Bolts [ B ]: 27 N·m (2.8 kg f·m, 20 ft·lb) Br[...]

1 1-16 BRAKES Brake Fluid Brake Fluid Level Inspection • Refer to the Brake Fluid Level Inspection in Periodic Main- tenance chapter . Brake Fluid Change • Refer to the Brake Fluid Change in Periodic Maintenance chapter . B r a k eL i n eB l e e d i n g • Refer to the Brake Line Bleeding in Periodic Maintenance chapter .[...]

BRAKES 1 1-17 Brake Hose Brake Hose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. • When removing the brake hose [A], temporar[...]

1 1-18 BRAKES Rear Brake Pedal and Brake Cable Brake Pedal Position Inspection/Adjustment • Check that the brake pedal [A] is in the correct position. Pedal Positio n [C] Standard: A bout 80 mm (3.1 5 in.) above footpeg top [B] If it is incorrect, adjust the brake pedal position. • Loosen the locknut [A], and turn the adjusting bolt [B] until t[...]

BRAKES 1 1-19 Rear Brake Pedal and Brake Cable • Remove the brake pedal [A] and return spring [B]. Brake Pedal Installation • Apply grease to the brake pedal pivot. • T emporarily install the brake return spring onto the brake shaft and hook the spring onto the brake pedal. • Push [B] the brake pedal [A] across the brake shaft and insert th[...]

1 1-20 BRAKES Rear Brake Pedal and Brake Cable • Remove: Cotter Pin and Joint Pin Brake Cable Nut [A] • Remove the silencer (see Engine T op End chapter). • Remove the adjusting nut on the end of the brake rod, and take off the joint pin and brake rod from the brake cam lever . • Remove the cable dust boot [A]. • Pull the outer cable hous[...]

BRAKES 1 1-21 Rear Brake Panel and Dru m Brake Panel Removal • Remove the rear wheel (see Wheels/T ires chapter). • Separate the brake panel from the wheel hub. Brake Panel Installation • Fit the brake panel into the rear wheel, and then install the rear wheel (see Wheels/T ires chapter). Brake Panel Disassembly • Remove the brake panel (se[...]

1 1-22 BRAKES Rear Brake Panel and Drum • Install the brake cam seal and fit the indicator [A] on the serration so that it points to the extre me right of the US- ABLE RANGE [B]. • Install the cam lever in its original position on the camshaft, and tighten its bolt. Brake Panel Inspection • Remove the brake panel (see Brake Panel Removal). ?[...]

BRAKES 1 1-23 Rear Brake Panel and Dru m Brake Shoe Springs Inspection • Visually inspect the brake shoe springs for breaks or dis- tortion. If the springs are damaged in any way , replace them. • Measure the free length of the brake shoe springs. If either is stretched beyond the service limit, replace both springs. Brake Shoe Springs Free Len[...]

[...]

SUSPENSION 12-1 12 Suspension T able of Contents Exploded View ................................................................................................................... ..... 12-2 Specifications ................................................................................................................. ........ 12-6 Special T ools ..[...]

12-2 SUSPENSION Exploded View[...]

SUSPENSION 12-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Fork T op Plugs 23 2.3 17 2 Front Fork Bottom Allen Bolts 20 2.0 15 3 Front Fork Clamp Bolt (Upper) 20 2.0 15 4 Front Fork Clamp Bolt (Lower) 34 3.5 25 5. Fork cover (BN125-A1 ∼ A5) 6. Brake hose clamp (BN125-A1 only) 7. Other than the US and CA Models 8. Speedm[...]

12-4 SUSPENSION Exploded View[...]

SUSPENSION 12-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear Shock Absorber Nuts and Bolts 34 3.5 25 2 Swingarm Pivot Nut 98 10.0 72 3. Chain guard (BN125-A1 ∼ A2 only) 4. Face the manufacture’s marks out.[...]

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

SUSPENSION 12-7 Special T ools Fork Cylinder Holder H andle: 57001-183 Fork Cylinder Holder Adapter: 57001-101 1 Oil Seal & Bearing Remover: 57001-1058 Bearing Driv er Set: 57001-1 129 Fork Outer T ube Weight: 57001-1218 Front Fork Oil Seal Driver: 57001-1219 Jack: 57001-1238 Hook Wrench (Owner’ s T ool): 921 10-1 143[...]

12-8 SUSPENSION Front Fork Fork Oil Change • Refer to the Front Fork Oil Change in the Periodic Main- tenance chapter . Fork Removal If the fork leg is to be disassembled, loosen the top plug beforehand. T o loosen the fork top plug, loosen the fork upper clamp bolts. • Remove: Brake Caliper (see Brakes chapter) Front Wheel (see Wheels/T ire ch[...]

SUSPENSION 12-9 Front Fork • Check the front brake effectiveness after installation. WA R N I N G Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brake will not function to the first application of the lever if this is not done. Fork Disassembly • Rem[...]

12-10 SUSPENSION Front Fork • Use the fork outer tube weight [A] to separate the outer tube [B] from the inner tube [C]. Holding the inner tube by hand, pull the outer tube several times to pull out the inner tube. Special T ool - Fork Outer T ube Weight : 57001-1218 • T ake out the cylinder base out of the outer tube. • Remove the guide bush[...]

SUSPENSION 12-1 1 Front Fork • Apply molybdenum disulfide grease to the oil seal lips and install the washer and oil seal [A] into the outer tube. Special T ool - Front Fork Oil Seal Driver: 57001-1219 [B] • Install the retaining ring and dust seal by hand. • Put the new gasket on the bottom of the outer tube. • Apply a non-permanent lockin[...]

12-12 SUSPENSION Front Fork Spring Inspection • Since the fork spring [A] becomes shorter as it weakens, check its free length [B] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of the replacement spring and that of the remaining spring vary greatly , the remainin[...]

SUSPENSION 12-13 Rear Shock Absorbers Spring Preload Adjustment • T o adjust the spring force, turn the adjuster on each shock absorber to the desired position. Owner ’ s T ool - Hook Wrench: 921 10-1 143 [A] Spring Prel oad Adjustment Adjuster Position 1 2 3 4 5 Spring T ension → Stronger WA R N I N G If a pair of adjusters are not adjusted [...]

12-14 SUSPENSION Swingarm Swingarm Removal • Remove: Chain Cover Rear Wheel (see Wheels/T ires chapter) Rear Shock Absorber Lower Mounting Bolts [A] (see this chapter) Silencer [B] (see Engine T op End chapter) Brake Cable [C] (see Brakes chapter) Pivot Nut [D] Front [E] • Pull out the swingarm pivot shaft, and remove the swingarm [A]. • Sepa[...]

SUSPENSION 12-15 Swingarm Swingarm Pivot Check • Remove: Rear Wheel (see Wheels/T ires 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 pl[...]

[...]

STEERING 13-1 13 Steering T able of Contents Exploded View ................................................................................................................... ..... 13-2 Special T ools ................................................................................................ .......................... 13-4 Steering ...........[...]

13-2 STEERI NG Exploded View BN125-A1 ∼[...]

STEERING 13-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Steering Stem Head Bolts 44 4.5 33 2 Steering Stem Nut Hand-tight or 4.9 Hand-tight or 0.50 Hand-tight or 43 in·lb 3 Handlebar Nuts 34 3.5 25 4 Handlebar We ight Screws – – – L 5 Handlebar Switch Housing Screws 3.4 0.35 30 in·lb 6 Front Fork Clamp Bolts (Lower) 34[...]

13-4 STEERI NG Special T ools Steering Stem Bearing Dr iver: 57001-137 Steering Stem Bearing Drive r Adapter , 34.5: 57001-107 4 Head Pipe Outer Race Press Shaft: 57001-107 5 Head Pipe Outer Race Driver , 51.5: 57001-107 6 Head Pipe Outer Race Driver , 46.5: 57001-1 106 Steering Stem Nut Wrenc h: 57001-1 100 Jack: 57001-1238[...]

STEERING 13-5 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter . Steering Adjustment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter .[...]

13-6 STEERI NG Steering Stem Steering Stem Removal • Loosen the steering stem head bolt [A]. • Open the headlight body and pull of f the connectors in the headlight body (see Electrical System chapter). • Remove the clutch cable upper end and lead connector . • Loosen the turn signal light holder bolts and nuts [B]. • Remove the nuts [A] [...]

STEERING 13-7 Steering Stem Steering Stem Installation • Apply grease to the upper and lower outer races in the head pipe so that the steel balls will stick in place during stem insertion. Install the upper steel balls (23) [A] and lower steel balls (23). All the steel balls are the same size. • Put on the upper inner race and steering stem cap[...]

13-8 STEERI NG Steering Stem • Install the front fork (see Suspension chapter). NOTE ○ Install the front fork at the correct position. Tighten the fork upper clamp bolts [A] first, next the stem head bolt [B], last the fork lower clamp bolts. T orque - Front Fork Clamp Bolts (Up per): 20 N·m (2. 0 kgf·m, 15 ft·lb) Steering Stem He ad Bolt: 4[...]

STEERING 13-9 Steering Stem Bearing Steering Stem Bearing Removal If the bearing is damaged , remove it. • T o remove the outer races [A] pressed in the head pipe, insert a bar [C] into the head pipe [B], and hammer evenly around the circumference of the opposite race to drive it out. • Hammer the bottom [A] of the lower inner race with a chise[...]

13-10 STEERING Handlebar Handlebar Removal (BN125-A1/A2) • Remove: Throttle Cables [A] (see Fuel System chapter) Brake Master Cylinder [B] (see Brakes chapter) Left Handlebar Switch Housing [C] Clutch Cable Upper End [D] Speedometer Unit [E] (with Cable) • Remove the handlebar nuts [A] and take off the handle- bar . Handlebar Removal (BN125-A3 [...]

STEERING 13-1 1 Handlebar • The front half of the right and left switch housings [A] has a small projection [B]. Fit the projection into the small hole [C] in the handlebar . • Install the handlebar switch housing. • T ighten: T o rque - Handlebar Sw itch Housing Scre ws: 3. 4 N·m (0.35 kgf·m, 30 in·lb) Handlebar Installation (BN125-A3 ∼[...]

[...]

FRAME 14-1 14 Frame T able of Contents Exploded View ................................................................................................................... ..... 14-2 Special T ool .................................................................................................. .......................... 14-6 Side Covers .............[...]

14-2 FRAME Exploded View[...]

FRAME 14-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Footpeg Bolts 23 2.3 17 O: Apply oil.[...]

14-4 FRAME Exploded View[...]

FRAME 14-5 Exploded View IT : Italy SG: Singapore US: United States (BN125-A4 ∼ )[...]

14-6 FRAME Special T ool Jack: 57001-123 8[...]

FRAME 14-7 Side Covers Left Side Cover Remo val • Remove the screws [A]. • Pull [B] the front part of the left side cover outward to clear the stopper . • Pull [C] the cover rearward to clear the ho ok, and remove it. Left Side Cover Installation • Slip the stopper [A] of the left side cover onto the hook [B]. • Push the stopper of the co[...]

14-8 FRAME Seat Seat Removal • For the models other than the Singapore and U.S.A. mod- els, remove the bolts [A] and loosen the bolts [B] on both sides. • Remove the pad assembly [C]. • For the Singapore and U.S.A. models remove the bolts [A], cover [B], and collar [C] on both sides. Front [D] • Remove the seat bolts [A] and take off the se[...]

FRAME 14-9 Fenders Front Fender Removal CAUTION Be careful not to scratch the pained surface during removal or installation. • Remove the mounting bolts [A] and take of f the front fender [B]. Front Fender Installation • Install the front fender so that the narrower side [A] faces forward [B]. Rear Fender Rear Removal • Remove the seat (see t[...]

14-10 FRAME Fenders Rear Fender Rear Disassembly • Remove the nuts [A] and take of f the rear turn signal light assembly [B]. • Remove the nuts [C] and take off the tail/brake light as- sembly [D]. Rear Fender Front Removal • Remove: Rear Fender Rear (see this chapter) D r i v eC h a i nC l i p Rear Brake Rod Rear End • Remove the rear axle[...]

FRAME 14-1 1 Frame Frame Inspection • Visually inspect the frame [A] for c racks, dents, bending, or warp. If there is any damage to the frame, replace it. WA R N I N G A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.[...]

[...]

ELECTRICAL SYSTEM 15-1 15 Electrical System T able of Contents Parts Location.................................... 15-2 Exploded View ................................... 15-4 Specifications .................................... 15-10 Special T ools and Sealant ................. 15-12 Wiring Diagram ................................. 15-13 Precautions.[...]

15-2 ELECTRICAL SYSTEM Parts Location[...]

ELECTRICAL SYSTEM 15-3 Parts Location 1. Speedometer 2. Starter lockout switch 3. Ignition coil 4. Starter motor 5. Ignition switch 6. Crankshaft sensor 7. Alternator 8. Neutral switch 9. Sidestand switch 10. Regulator/rectifier 1 1. Fuse unit 12. Starter circuit relay 13. Starter relay 14. T urn signal relay 15. Battery 16. CDI unit 17. Front brak[...]

15-4 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 15-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Alternator Cover Bolts 8.8 0.90 78 in· lb 2 Starter Motor Mounting Bolts 8.8 0.90 78 in·lb 3 Starter Motor T erminal Locknut 6.9 0.70 61 in·lb 4 Starter Motor Assembly Bolts 3.4 0.35 30 in·l b 5 Stator Coil Bolts 13 1.3 11 3 i n · l b 6 Alternator Lead Holde[...]

15-6 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 15-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Neutral Switch 15 1.5 11 2 Sidestand Switch Screws 3.9 0.40 35 in·lb L 3 Handlebar Switch Housing Screws 3.4 0.35 30 in·lb 4. Ignition switch 5. T urn signal relay 6. Starter circuit relay 7. Interlock diode 8. Fuse case (BN125-A1) 9. Rear brake light switch 10[...]

15-8 ELECTRICAL SYSTEM Exploded View[...]

ELECTRICAL SYSTEM 15-9 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Headlight Body Screws 2.9 0.30 26 in·lb 2 T urn Signal Light Holder Nuts 5.9 0.60 52 in·lb 3. Headlight unit 4. T urn signal lights 5. T ail/brake light 6. Canada and United Kingdom Models (BN125-A6 ∼ ) 7. Other than Canada and United Kingdom Models 8. United[...]

15-10 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Capacity 12 V 9 Ah ––– Electrolyte Level between level lines ––– Specific Gravity of Electrolyte 1.280 ±0.01 @20°C (68°F) ––– Charging System T ype: (BN125-A1/A2) Single-phase AC ––– (BN125-A3 ∼ ) Three-phase AC ––– Charging V oltage 14 ∼[...]

ELECTRICAL SYSTEM 15-1 1 Specifications Item Standard Service Limit Switches Rear Brake Light Switch T iming ON after about 10 mm (0.39 in.) pedal travel –––[...]

15-12 ELECTRICAL SYSTEM Special T ools and Sealant Flywheel Pu ller , M30 × 1.5: 57001-1 191 Rotor Puller , M16/M18/M20/M22 × 1.5: 57001-121 6 Timi ng Light: 57001-124 1 S p a r kP l u gW r e n c h ,H e x1 6 : 57001-126 2 Flywheel Holder: 57001-1313 Hand T ester: 57001-1394 Peak V oltage Adapter: 57001-1415 Kawasaki Bond (Sili cone Sealant): 5601[...]

ELECTRICAL SYSTEM 15-13 Wiring Diagram Dummy Page[...]

15-14 ELECTRICAL SYSTEM Wiring Diagram BN125-A1[...]

ELECTRICAL SYSTEM 15-15 Wiring Diagram[...]

15-16 ELECTRICAL SYSTEM Wiring Diagram BN125-A2 ∼ (Singapore) and BN125-A4 (United States)[...]

ELECTRICAL SYSTEM 15-17 Wiring Diagram[...]

15-18 ELECTRICAL SYSTEM Wiring Diagram BN125-A2 ∼ A5 (Europe)[...]

ELECTRICAL SYSTEM 15-19 Wiring Diagram[...]

15-20 ELECTRICAL SYSTEM Wiring Diagram BN125-A5 (United States and Canada)[...]

ELECTRICAL SYSTEM 15-21 Wiring Diagram[...]

15-22 ELECTRICAL SYSTEM Wiring Diagram BN125-A6 ∼ (US, CA, N, NU)[...]

ELECTRICAL SYSTEM 15-23 Wiring Diagram[...]

15-24 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below . ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ Always check battery condition before condemning other parts of an el[...]

ELECTRICAL SYSTEM 15-25 Precautions ○ Electrical Connectors Connectors [A] Connectors [B][...]

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

ELECTRICAL SYSTEM 15-27 Battery Battery Removal/Installation • Remove: Right Side Cover (see Frame chapter) Battery Holder • Disconnect the battery negative (–) cable [A] first, and t h e nt h ep o s i t i v e( + )c a b l e[ B ] . Front [C] • When installing the battery , connect the positive (+) cable [A] first and then the negative cable [...]

15-28 ELECTRICAL SYSTEM Battery Initial Charging WA R N I N G 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 batt[...]

ELECTRICAL SYSTEM 15-29 Battery Ordinary Charging • Remove the battery (see Battery Removal). • If any of the cells are low , fill them to the LOWER level line with distilled water only . The electrolyte will expand during charging, and the level will rise. WA R N I N G Keep the battery away from sparks and open flames during charging, since th[...]

15-30 ELECTRICAL SYSTEM Battery Battery C harging Rate/T ime T able (12 V 9 Ah)[...]

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

15-32 ELECTRICAL SYSTEM Charging System • Using the flywheel puller [A] and rotor puller [B], remove the alternator rotor [C] from the crankshaft. Special T ools - Flywheel Puller , M30 × 1.5: 57001-1 191 Rotor Pulle r , M16/M18/M20/M22 × 1.5: 57001 -1216 ○ Holding the flywheel puller , screw in the rotor puller while tapping the head of the [...]

ELECTRICAL SYSTEM 15-33 Charging System Stator Coil Installation • T ighten: T orque - Stator Coil Bolts [A]: 1 3 N·m (1.3 kgf·m, 1 13 in·lb) Crankshaft Sensor Screws [B]: 3 .9 N·m (0.40 kgf·m, 35 in·lb) Alternator Lead Holde r Bolts (BN125-A3 ∼ ): 8.8 N·m (0 .90 kgf·m , 78 in·lb) (BN125-A1 ∼ A2): 13 N·m (1.3 kgf·m, 1 13 in·lb) ?[...]

15-34 ELECTRICAL SYSTEM Charging System • Check the stator coil resistance as follows. ○ Stop the engine. ○ Connect the hand tester as shown in the table. ○ Note the resistance readings. Stator Coil Resi stance (BN125-A1/A2) Connections Te s t e r Range Meter (+) to Meter ( − )t o Reading ×1 Ω Pink lead Engi ne ground 0.1 ∼ 0.8 Ω S[...]

ELECTRICAL SYSTEM 15-35 Charging System Regulator/Recti fier Internal Resistance (BN125-A3 ∼ ) Unit: k Ω T ester (+) Lead Connection Te r m i n a l W Y Y Y BK/Y W – ∞ ∞ ∞ ∞ Y 0.5 ∼ 10 – ∞ ∞ ∞ Y 0.5 ∼ 10 ∞ – ∞ ∞ Y 0.5 ∼ 10 ∞ ∞ – ∞ ( − )* BK/Y 0.5 ∼ 20 0.5 ∼ 10 0.5 ∼ 10 0.5 ∼ 10 – (–)*: T este[...]

15-36 ELECTRICAL SYSTEM Charging System Charging System Circuit (BN125-A1/A2) 1. Ignition switch 2. Alternator 3. Regulator/rectifier 4. Controller 5. Battery 6. Main f use 15 A 7. Starter relay 8. Light fuse 10 A 9. Load[...]

ELECTRICAL SYSTEM 15-37 Charging System Charging System Circuit (BN125-A3 ∼ ) 1. Ignition switch 2. Alternator 3. Regulator/rectifier 4. Battery 5. Main fuse 30 A 6. Starter relay 7. Light fuse 15 A 8. Load[...]

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 d[...]

ELECTRICAL SYSTEM 15-39 Ignition System • Set the hand tester [B] to the × 25 V DC range, and con- nect it to the peak voltage adapter [C] as shown in the diagram. • Connect the black lead of the adapter to W/Y lead and red lead to G/W lead in the crankshaft sensor connector [A]. • T urn the ignition switch. • Pushing the starter button, t[...]

15-40 ELECTRICAL SYSTEM Ignition System Ignition T iming Engine speed Head timing mark [ A ] ali gns with: 1 300 ±100 r/min (rpm) “T” mark [B] on camshaft sprocket If the ignition timing is incorrect, inspect the CDI unit and the crankshaft sensor . Ignition Coil Removal • Remove the fuel tank (see Fuel System chapter). • Disconnect the pr[...]

ELECTRICAL SYSTEM 15-41 Ignition System If the coil tester is not available, the coil can be checked for a broken or badly shorted winding with the hand tester . NOTE ○ The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. • Measure the primary winding resistance as follows. ○ Connect th[...]

15-42 ELECTRICAL SYSTEM Ignition System • T urn the ignition switch and engine stop switch on. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission gear in neutral to measure the igni- tion coil primary peak voltage. • Repeat the measurement 5 or more times. Ignition Coil Pri mary Peak V oltage Standard: 11 0 V [...]

ELECTRICAL SYSTEM 15-43 Ignition System 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 [...]

15-44 ELECTRICAL SYSTEM Ignition System CDI Unit Internal Resistance (BN125-A1/A2) Unit: k Ω T ester (+) Lead Connection T erminal 1 2 3 4 5 6 7 8 1 – 10 ∼ 41 10 ∼ 41 11 ∼ 44 35 ∼ 140 14 ∼ 56 18.5 ∼ 74 ∞ 2 8.5 ∼ 34 – 0 0.5 ∼ 2.2 18.5 ∼ 74 2.5 ∼ 10 3 ∼ 13 ∞ 3 8.5 ∼ 34 0 – 0.6 ∼ 2.4 18.5 ∼ 74 2.5 ∼ 10 3 ∼ 1[...]

ELECTRICAL SYSTEM 15-45 Ignition System Ignition System T roubleshooting[...]

15-46 ELECTRICAL SYSTEM Ignition System Ignition System Circuit (BN125-A1/A2) 1. Neutral switch 2. Interlock diodes 3. Sidestand switch 4. Starter lockout switch 5. Engine stop switch 6. Ignition fuse 10 A 7. Ignition switch 8. Regulator/rectifier 9. Crankshaft sensor 10. CDI unit 1 1. Ignition coil 12. Spark plug 13. Battery 14. Main fuse 15 A[...]

ELECTRICAL SYSTEM 15-47 Ignition System Ignition System Circuit (BN125-A3 ∼ ) 1. Ignition switch 2. Starter lockout switch 3. Crankshaft sensor 4. Interlock diodes 5. Sidestand switch 6. Ignition fuse 15 A 7. Engine stop switch 8. Neutral switch 9. CDI unit 10. Ignition coil 1 1. Spark plug 12. Main fuse 30 A 13. Battery 14. Regulator/rectifier[...]

15-48 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body . T apping the shaft or body could damage the motor . • Remove: Oil Pipe (see Engine Lubrication System chapter) • Slide back the rubber cap. • Remove the starter motor terminal nut [A]. • Remove the starter motor mountin[...]

ELECTRICAL SYSTEM 15-49 Electric Starter System • Remove the terminal locknut [A] and terminal bolt [B], and then remove the brush with the brush plate from the yoke. Starter Motor Assembly • Replace the O-rings with new one s. • Apply a thin coat of grease to the oil seal [A] and needle bearing [B]. • Fit the toothed washer [C] into the en[...]

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

ELECTRICAL SYSTEM 15-51 Electric Starter System Brush Lead Inspection • Using the × 1 Ω hand tester range, measure the resis- tance as shown. T erminal Bolt and Positive Brush [A] Brush Plate and Negative Brush [B] Special T ool - H and T ester: 57001-1394 If there is not close to 0 Ω , the brush has an open. Re- place the terminal bolt asse[...]

15-52 ELECTRICAL SYSTEM Electric Starter System Starter Circuit Relay Inspection • Remove: Right Side Cover (see Frame chapter) Starter Circuit Relay • Connect the hand tester [A] and 12 V battery [B] as shown. Relay Coil T erminal [1] and [2] Relay Switch T erminal [3] and [4] If the relay [C] does not work as specified, the relay is defective[...]

ELECTRICAL SYSTEM 15-53 Electric Starter System Electric Starter Circuit (BN125-A1/A2) 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Starter circuit relay 5. Ignition fuse 10 A 6. Starter lockout switch 7. Interlock diodes 8. CDI unit 9. Starter motor 10. Starter relay 1 1 . M a i nf u s e1 5A 12. Battery 13. Neutral switch[...]

15-54 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit (BN125-A3 ∼ ) 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Starter circuit relay 5. Ignition fuse 15 A 6. Starter lockout switch 7. Interlock Diodes 8. CDI unit 9. Starter m otor 10. Starter relay 1 1. Main fuse 30 A 12. Battery[...]

ELECTRICAL SYSTEM 15-55 Lighting System Headlight Beam Horizontal/V ertical Adjustment • T urn the horizontal adjuster [A] on the headlight with a screwdriver in or out until the beam points straight ahead. ○ T urn the horizontal adjuster clockwise to face the head- light left. • T urn the vertical adjuster [B] on the headlight in or out to a[...]

15-56 ELECTRICAL SYSTEM Lighting System • Replace the headlight bulb [A]. CAUTION When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode. NOTE ○ Clean off any contamination that inadvertently gets[...]

ELECTRICAL SYSTEM 15-57 Lighting System Headlight Circuit (BN125-A1/A2) 1. High beam indicator light 2. Headlight 3. Dimmer switch 4. Alternator 5. Regulator/rectifier 6. Headlight switch Headlight Circuit (BN125-A3 ∼ A5) 1. High beam indicator light 2. Headlight 3. Dimmer switch 4. Headlight switch 5. Alternator 6. Regulator/rectifier 7. Ignitio[...]

15-58 ELECTRICAL SYSTEM Lighting System Headlight Circuit (BN125-A6 ∼ ) 1. High beam indicator light 2. Headlight 3. Dimmer sw itch 4. Alternator 5. Regulator/rectifier 6. Ignition switch 7. Headlight fuse 15 A T ail/Brake Light Bu lb Replacement • Remove the tail/brake light lens [A]. • Push the bulb [A] in the socket, turn it counterclockwi[...]

ELECTRICAL SYSTEM 15-59 Lighting System • With the front pin [A] down, insert the new bulb by aligning the front pin with the groove [B] in the walls of the socket. • Push the bulb in, turn it clockw ise, and replace it. It should lock in position. • T ighten the lens screws. Be careful not to overtighten them. T urn Signal Relay Inspection ?[...]

15-60 ELECTRICAL SYSTEM Lighting System T urn Signal Light Circuit (BN125-A1 /A2) 1. T urn signal indicator light 2. T urn signal relay 3. Ignition fuse 10 A 4. Front right turn signal light 5. Front left turn signal light 6. Rear right turn signal light 7. Rear left turn signal light 8. T urn signal switch 9. Ignition switch 10. Starter relay 1 1.[...]

ELECTRICAL SYSTEM 15-61 Lighting System T urn Signal Light Circuit (BN125-A3 ∼ A5) 1. T urn signal indicator light 2. T urn signal relay 3. Ignition fuse 15 A 4. Front right turn signal light 5. Front left turn signal light 6. Rear right turn signal light 7. Rear left turn signal light 8. T urn signal switch 9. Ignition switch 10. Starter relay 1[...]

15-62 ELECTRICAL SYSTEM Lighting System T urn Signal Light Circuit (BN125-A6 ∼ ) 1. T urn signal indicator light 2. T urn signal relay 3. Ignition fuse 15 A 4. Front right turn signal light 5. Front left turn signal light 6. Rear right turn signal light 7. Rear left turn signal light 8. T urn signal switch 9. Ignition switch 10. Starter relay 1 1[...]

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

15-64 ELECTRICAL SYSTEM Switches and Sensors Front Brake Light Switch Inspection • Refer to the Front Brake Light Switch Inspection in the Periodic Maintenance chapter . Rear Brake Light Timing Inspe ction • Refer to the Rear Brake Light T iming Inspection in the Periodic Maintenance chapter . Rear Brake Light Timing Adjustment • Refer to the[...]

ELECTRICAL SYSTEM 15-65 Fuse Main Fuse 15 A Removal • Remove the right side cover (see Frame chapter). • Disconnect the starter relay connector . • Pull out the main fuse [B] from the starter relay [A] with needle nose pliers. Main Fuse 15 A Inspection • Remove the fuse (see Fuse Removal). • Inspect the fuse element. If it is blown out, r[...]

15-66 ELECTRICAL SYSTEM Fuse Fuse 10 A Inspection • Inspect the fuse element. If it is blown out, replace the fuse. Fuse Element [A] Blown Element [B][...]

APPENDIX 16-1 16 Appendix T able of Contents Cable, Wire, and Hose Routing .............................................................................................. 16-2 T roubleshooting Guide ........................................................................................................... 16-32[...]

16-2 APPENDIX Cable, Wire, and Hose Routing BN125-A1 ∼[...]

APPENDIX 16-3 Cable, Wire , and Hose Routing 1. Crankshaft Sensor 2. Oil Pipe 3. Clamp 4. Run the alternator lead under the oil pipe. 5. Alternator Lead 6. Run the neutral switch lead so that it shall not out of guide rib. 7. Guide Rib 8. Neutral Switch 9. T urn Signal Relay 10. Engine Ground Lead 1 1. Holder 12. Carburetor Drain Hose 13. Battery V[...]

16-4 APPENDIX Cable, Wire, and Hose Routing BN125-A1 ∼[...]

APPENDIX 16-5 Cable, Wire , and Hose Routing 1. CDI Unit 2. Ignition Coil Lead 3. Engine Breather Hose 4. T o Fuel T ap 5. Insulator 6. Run the ignition coil lead under the engine breather hose. 7. Clamp 8. Install the hose as shown. 9. Other than A T , DE, SG, CH Models AT : A u s t r i a CH: Switzerland DE: Germany SG: Singapore[...]

16-6 APPENDIX Cable, Wire, and Hose Routing Clean Air System[...]

APPENDIX 16-7 Cable, Wire , and Hose Routing 1. V acuum Hose 2. Three-way Joint 3. T o Fuel T ap 4. Air Hose 5. Air Pipe 6. Engine Breather Hose 7. Air Cleaner Duct 8. Air Cleaner Housing 9. V acuum Switch 10. Carburetor 1 1. Air Suction V alve 12. Insulator 13. Run the vacuum hose onto the left side of the duct (7), and then behind the hose (6) an[...]

16-8 APPENDIX Cable, Wire, and Hose Routing BN125-A1 ∼ A4[...]

APPENDIX 16-9 Cable, Wire , and Hose Routing 1. Ignition Switch 2. Run the ignition switch lead to the right. 3. Sidestand Switch Lead 4. Run the sidestand switch lead to the right. 5. Body Ground 6. Ignition Coil 7. Alternator Lead Connector 8. Sidestand Switch 9. Clamp 10. Band[...]

16-10 APPENDIX Cable, Wire, and Hose Routing BN125-A5 ∼[...]

APPENDIX 16-1 1 Cable, Wire , and Hose Routing 1. Indicator Light Connector (Move it to the right side after connected.) 2. Horn 3. Sidestand switch connector 4. Ignition coil 5. Regulator/Rectifier 6. Ground Lead 7. Alternator Lead 8. Put the connectors into the gusset after connecting them. 9. Sidestand Switch 10. Band 1 1. Left Handlebar Switch [...]

16-12 APPENDIX Cable, Wire, and Hose Routing BN125-A1 ∼[...]

APPENDIX 16-13 Cable, Wire , and Hose Routing 1. Rear Left T urn Signal Light 2. T ail/Brake Light 3. Rear Right T urn Signal Light 4. Rear Fender Rear 5. Rear Fender Front 6. Throttle Cables 7. Carburetor Air V ent Hose 8. Engine Breather Hose 9. Right Handlebar Switch 10. Brake Hose 1 1. Clutch Cable 12. Rear Brake Light Switch 13. Battery V ent [...]

16-14 APPENDIX Cable, Wire, and Hose Routing BN125-A1 ∼[...]

APPENDIX 16-15 Cable, Wire , and Hose Routing 1. Throttle Cables 2. Clutch Cable 3. Speedometer Cable 4. Left Handlebar Switch Harness 5. Right Handlebar Switch Harness 6. Sidestand Switch 7. Holder 8. Band 9. Clamp 10. BN125-A3 ∼[...]

16-16 APPENDIX Cable, Wire, and Hose Routing BN125-A1 ∼ A2[...]

APPENDIX 16-17 Cable, Wire , and Hose Routing 1. T ail/Brake Light Connector 2. Rear Left Turn Signal Light Connector 3. White T ape 4. Ignition Coil Connector 5. Body Ground 6. Front Left T urn Signal Light Connector 7. Front Right T urn Signal Light Connector 8. Join connectors in the headlight unit. 9. Speedometer Light Connector 10. Headlight C[...]

16-18 APPENDIX Cable, Wire, and Hose Routing BN125-A3 ∼ A4[...]

APPENDIX 16-19 Cable, Wire , and Hose Routing 1. Rear Left Turn Signal Light Connector 2. T ail/Brake Light Connector 3. Band 4. Ground Lead 5. Ignition Coil Lead 6. Regulator/Rectifier Connector 7. CDI Unit Connector 8. Left Handlebar Switch Connector 9. Horn Connector 10. Indicator Light Connector 1 1. Sidestand Switch Connector 12. Headlight Con[...]

16-20 APPENDIX Cable, Wire, and Hose Routing BN125-A5 ∼[...]

APPENDIX 16-21 Cable, Wire , and Hose Routing 1. Rear Left Turn Signal Light Connector 2. T ail/Brake Light Connector 3. Band 4. White T ape 5. Ground Lead 6. Regulator/Rectifier Connector 7. Ignition Coil Lead 8. Left Handlebar Switch Connector 9. Horn Connector 10. Indicator Light Connector 1 1. Sidestand Switch Connector 12. Front Left T urn Sig[...]

16-22 APPENDIX Cable, Wire, and Hose Routing BN125-A5 ∼[...]

APPENDIX 16-23 Cable, Wire , and Hose Routing 1. Diode Connector 2. Fuse Box Connector 3. Battery Positive Lead 4. Clamp 5. T urn Signal Relay 6. Alternator Connector 7. Battery Negative Lead 8. Band 9. CDI Unit Connector 10. Ignition Coil Lead 1 1. Run the indicator light lead from left side. 12. Connect them in the headlight housing. 13. City Lig[...]

16-24 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Contro l System (BN125-A5 ∼ : California Mo del)[...]

APPENDIX 16-25 Cable, Wire , and Hose Routing 1. Fuel T ank 2. Separator 3. Canister 4. V acuum Switch V alve 5. Air Cleaner Housing 6. Label (Blue) 7. Label (Red) 8. Hose (with blue stripe) 9. Hose (with blue stripe) 10. Hose (with red stripe) 1 1. Hose (with white stripe) 12. White Paint Mark 13. White Paint Mark[...]

16-26 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Contro l System (BN125-A5 ∼ : California Mo del)[...]

APPENDIX 16-27 Cable, Wire , and Hose Routing 1. V acuum Switch V alve 2. Go to the fuel tap 3. Carburetor Holder 4. Separator[...]

16-28 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Contro l System (BN125-A5 ∼ : California Mo del)[...]

APPENDIX 16-29 Cable, Wire , and Hose Routing 1. Run the ignition coil primary lead under the throttle cables, secondary air hose and breather hose. 2. Go T o Left Side 3. Separator 4. Go T o The Fuel T ank 5. Breather Hose 6. Secondary Air Hose 7. Air V ent Hose 8. Throttle Cables 9. V acuum Switch V alve 10. Carburetor Holder 1 1. Canister 12. Go[...]

16-30 APPENDIX Cable, Wire, and Hose Routing Evaporative Emission Contro l System (BN125-A5 ∼ : California Mo del)[...]

APPENDIX 16-31 Cable, Wire , and Hose Routing 1. Main Harness 2. Breather Hose 3. Secondary Air Hose 4. Air V ent Hose 5. Go to the fuel tank 6. Separator 7. Go to the canister 8. Clamp 9. Front[...]

16-32 APPENDIX T roubleshooting Guide NOTE ○ This 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 swi[...]

APPENDIX 16-33 T roubleshooting 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 b[...]

16-34 APPENDIX T roubleshooting 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: C[...]

APPENDIX 16-35 T roubleshooting Guide Abnormal Drive T rain 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 T ransmission noise: Bearings worn T ransmission gears worn or chipped Metal chips jammed in gear teeth[...]

16-36 APPENDIX T roubleshooting 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 W ater in brake drum Brake cam, camshaft worn Oil on brake linings Battery T rouble: Battery disc[...]

MODEL APPLICA TION Ye a r Model Beginning Frame No. 1998 BN125-A1 BN125A000001 or JKABN125AAA000001 1999 BN125-A2 BN125A016001 or JKABN125AAA016001 2000 BN125-A3 JKABN125AADA00001 2001 BN125-A4 JKABNRA1 □ 1DA00574 2002 BN125-A5 JKABNRA1 □ 2DA04626 or JKABN125AADA04626 2003 BN125-A6 JKABNRA1 □ 3DA08070 or JKABN125AADA08170 2004 BN125-A7 JKABNR[...]