Kawasaki KX500 (2004) manual

KX125 KX250 KX500 Motorcycle Service Manual[...]

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This quick reference gu i de will Issist you in locating e desired topic or procedure . • Bend the pages back to match the black tab of th e desired chap t er nu mbe r wi th 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 specif i c top ic req u i red . Quic[...]

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Kawasaki KX125 KX250 KX500 Motorcycle Service Manual[...]

A ABDC AC ATDC BBDC BDC BTDC 'C DC F ' F It 9 h L LIST OF ABB REV I ATI O NS ampere(s) Ib Pound(s) after bottom dead center m meter(s) alternating current min minute(s) after top dead center N newton(s) before bottom dead center Pa PascaHs) bottom dead center before top dead center degree(s) Celsius direct current farad(s) degree(s) Fahre[...]

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 desires to perform his own basic main- tenance and repair work. A basic knowledge of mechanics , the proper use of tools , and workshop procedures must be [...]

NOTE o This note symbol indicates points of partic - ular interest for more eff i cient and con- venient operation . -Indicate a procedural step or work to be done . o lndicates a procedural sub - step or how to do the work of the procedural step it follows . It also precedes the text of a WARNING , CAUTION , or NOTE . * Indicates a conditional ste[...]

GENERAL INFORMATION , - , D General Information Table of Contents Before Servicing ... . ......... _ , _ .. . ..... . .•. . ... . ... . • ... .... _ ,_... ... . . .. ... . .. . .. .. . 1- 2 Mode l I dentification ...... . ...... . ................ .. . . ........................... . .... '-4 General Specificat i ons ....... . .. . .......[...]

1·2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle. carefu l reading of the applicable section is recommended to eliminate unnecessary work . Photographs , diagrams , notes, cautions , wa rn ings, and detailed des- criptions have been included wherever necessary . Nevertheless , even a detailed account has limitations[...]

GENERAL INFORMATION 1 -3 (11) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal gene r ally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out. Seals should be pressed into place us ing a surtable driver . which contacts evenly with the[...]

1 - 4 GENERAL INFORMATION Model Identification KX 125 · F1 Left Side View KX125 - Fl Right Side VIew[...]

GENERAL INFORMATION 1- 5 KX250 · F 1 left Side View KX250 - F 1 Right Side View[...]

1-6 GENERAL INFORMATION KX500 - Dl Left Side View KX500 - 01 Right Side View[...]

General Specification s Items Dimens i on s: Overall length Overall width Overall height Wheelbase Road clearance Seat height Dry weight Curb weight : Front Rear Fuel tank capacity Engine : Type Cooling system Bore and st roke Displacement Comp r ession ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Ignit[...]

1 · 8 GENERAL INFORMATION Item Frame : Type Steering angle Caster trake angle) Trail Fr ont tire: Make/Type Size Rear tire: Make/Type Size Front suspension: Type Wheel travel Rear suspension : Type Wheel travel Brake type: Front and Rear Effect ive d isc diameter: Front Rear KX125 · Fl Tubular, si ngle do wn tube 45° to Bither side 27' 122 [...]

Items Dim en s ion s : Overall length Overall w i dth Overall height Wheelbase Road clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity Eng i ne : Type Cooling system Bore and s troke Displacement Compression rat i o Maximum horsepower Maximum torque Carburetion system Starting system Ig ni tion system Ignition ti m i ng Spa[...]

' - '0 GENERAL INFORMATION Item Frame : Type Steering angle Caster (rake angle) Trail Front tire : MakelType Size Rear tire : Make / Type Size Front suspension: Type Wheel travel Rear suspension: Type Wheel travel Brake type : Front and Rear Effective disc d iameter: Front Rear KX250-F' Tubular, single down tube 45 0 to either side 2[...]

Item s Dimensions : Overall length Overall width Overall height Wheelbase Road clearance Seat hei g ht Dry weight Curb weight: Front Rear Fuel tank capacity Eng i ne : Type Coo ling system Bore and stroke D is placement Compression ratio Ma ximum horsepower Maximum torque Carbure t ion system S tart ing system Ign it ion system Ignition timing Spar[...]

1 - 12 GENERAL INFORMATION Item Frame : Type Stee r ing angle Caster (rake angle) Trail Front type : T ype Rear t ype : Size Type Size Front suspension : Type Wheel tra vel Rear suspension : Type Wheel travel Brake type : Front and Rear Effective disc diameter : Front KX500 - 01 Tubular. single down tube 45° to either s i de 28 · 129 rnm 8RIDGEST[...]

GENERAL INFORMATION 1-1 3 P e ri od ic M ai nt e na n ce Ch a rt FREQUENCY Each Every Every E very A, OPERATION race 3 races 5 ra c es 10 races required Clutch·-adjust • Clutch and friction plates-<:heck t • R Throttle cable-adjust • Spark plug - -clean, gap t • R Air cleaner element-clean • Air cleaner element - replace Damaged Carb [...]

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GENERAL INFORMATION 1 - 15 Torqu e Fa stene r N -m kg-m It - Ib Remarks Eng in e Right Side : External Sift Mechanism Return Sp ring Pin (KX 125 , 250) 22 2 , 2 1 6,0 L IKX500) 20 2 , 0 14 ,5 L Clutch Spring Bolt s 9 , 3 0 , 95 82 in -Ib Neutral Set Le ver Bolt 9 ,8 1 ,0 87 in-Ib Clutch Hub Nut IKX 125) 78 8 58 L IKX250, 500) 98 10 72 Primary Gear [...]

1 - 16 GENERAL INFORMATION Torque Fastener N -m kg-m It-Ib Remarks Brakes : Caliper Mounting Bolts(Front . Rear) 25 2 . 5 18 .0 Brake Hose Banjo Bolts 25 2.5 18 . 0 Front Master Cylinder Clamp Bolts 8 . 8 0.9 78 in - Ib Brake Lever Pivot Locknut 5 . 9 0 . 6 52 in - tb Brake Disc Mounting Screws (Front , Rear) 9 . 8 1 . 0 87 in - tb Caliper Bleed Va[...]

GENERAL INFORMA T ION 1- 17 The table below , re l ating tig h ten in g torque to t hr ea d d i amete r , lists t h e basic torq ue f o r t h e bo l ts a n d n ut s . Use this tab l e for o n ly t h e bo l ts and nuts w hi c h do not r equire a speci fi c to r que va l ue . A ll of t he val u es are for use w i th dry solve nt ·cJeaned t hr eads .[...]

1- 18 GENERAL INFORMATION Cable Routing KX 125 : KX250 : 1 . Throttle Cable 2. Brake Hose 3 . Clutc h Cable 4 . Ignit io n Coil 5 . Stator lead 1. Throttle Cable 2. Clutch Cable 3, Brake Hose 4. Stator Lead 5. Radiator Breather H ose[...]

GENERAL INFORMATION 1 - 19 KX500: 1 . Ignition Coil 2 . Thrott le Cable 3 . Radiato r Beather Hose 4 . Stator Lead[...]

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FUEL SYSTEM 2-1 Fuel System Table of Contents E x ploded V ie w ................. ... ..... , .. ". _._ ...... . ... . . ... .. . . _ . _ . .. . . . . . ... 2 -2 Specifications ..................... . .................... _,_ . .. " ... •. •....... ,..... 2 -4 Special Tools ....................................................... .. ..[...]

2 - 2 FUEL SYSTEM ....... ExPIOd ·· . ·· d · · · V ··:······ .. •· .. •··•··· lew ······ · ·· · ·· ·· · · ··· · · .... . ... ... . ..... . .. .. . .. . . . .. . .. . . . . .... . .... ....... ..... .. - , I I I I I I I I I I I I I I _____ J r- --- I -I !Al'f~ i j : ~ I I' ~ KX1 2 5 I ' [...]

r- I I I I I I I I I I I I I I I I I I I I I I I I I I I I I ________ 1 __ _ l.... - KX 2 5 0 , 5 00 T 2 --- --, I I I I I I I I I I I I I I FUEL SYSTEM 2 - 3 r I I j~ I I I I I I I I I I I I : ~ ifi! I ' L~~ : ------ --T- - - - ~ - KX12 5 • - ----, I I I I I I I I I I I I I I I I I I I I I I _-.--J 87 i n- lb) n - 9 . 8 N -m ( 1. 0 :g , : ,[...]

2-4 FUEL SYSTEM Specifications KX125 ' Item Standard Service Limit Thronle Grip Free Play 2 - 3 mm - - - Carburetor Specifications : Make / type KEIHIN PWK35 - - - Main jet 148 - - - Throttle valve cutaway 6 - - - Jet needle R2071J - 3 - - - Jet needle clip position 3rd groove from the top - - - Slow jet 62 - - - Air screw 11 h (turns out) Ser[...]

FUEL SYSTEM 2-5 KX500 ' . Item Standard Service Limit Throttle Grip Free Play 2- 3mm - -- Carburetor Specifications : Make / type KEIHIN PWK39 - - - Main jet 175 - - - Throttle valve cutaway 7 - - - Jet needle R1369N-3 - - - Jet needle clip position 3rd groove from the top - - - Slow jet 62 - - - Air Screw 1 112 (turns out) Service fuel le ve [...]

2 · 6 FUEL SYSTEM ......... . .. . .. . ..... . ...... . .. ... . .. . .. .................... Special Tools ............ . .. ... ... . ......... . . . . . .. .. . .. . . ............... Along with common hand tools , the following more specialized tools are required for complete fuel system servicing . Fuel Level Gauge : 57001 · 122 Pressure Ca[...]

Throttle Grip and C a bl e If the throttle grip h as excessive free play due to cab l e s tr etch or m i sadjustment, t he r e will be a de l ay in throttle response . Also, the thrott l e va l ve may not open fu l ly at full throttle . O n the other han d , if the throttle g rip has no p l ay , t he th r ottle wil l be h ard to co n tro l, a nd th[...]

2 -8 FUEL SYSTEM Throttle Cable In s tallat ion Notes - Install the throttle cable in accordan ce with the Cable Routing sect i on in the General Information c hapt e r. - After the in s tallation , adjust the cable properly . I WARNING' o()peration with an Inconectty routed or improperly adju s ted cable could result in an unsafe riding condi[...]

Carburetor ..................... . ........................................ Since the ca r buretor re gulates and mixes the fuel and air going to the engine, there are two gene ra l types of carburetor trouble : too rich a mixture (too much fuel), and too lean a mix ture (too l ittle fuel) , Such troub l e can be caused by dirt. wear , maladjust- m[...]

2·10 FUEL SYSTEM Service Fuel level (below the bottom edge of the carbo body) KX125 : 1. 0 ± , mm KX250: 1 .0 ± 1 mm KX500: 1 .0 ± , mm 1 . Fuel level Gauge: 5700 1 -122 2. Service Fuel level Service Fuel Level Adjustment I WARNING' oGasoline Is extremely flammable and can be ex - plosive under certain conditions. Always stop the engine an[...]

Fue l System Clean I WARNING' o Gasoline Is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke . Make sure the area Is well ventilated and free from any source of flame or sparks; this Includes any appliance with 8 pilot light. ePl ace a su i table containe r beneat h the carburetor . e T[...]

2 · 12 FUEL SYSTEM Carburetor Installation Notes -In stallation is the reverse o f removal . - Being careful not to bend or otherwise damage the jet need l e . Check to see that the t hr ottle valve goes all the way down i nto the carbureto r body , and slides smoothly . • When in sta lling the ca rbur eto r i nto the ca rburetor holde r . align[...]

Carburetor Disassembly . Remove the carburetor. - Remove the throttle va l ve assembly and carburetor cap from the carbu retor cable lower end . · Oisassemble t he throttle valve assembly ; spring , retainer , connector.clip . jet needle . circlip and throttle valve . A. Spring O . Clip B . Retainer E . J et Needle C. Connector F . Throttle Valve [...]

2- 14 FUEL SYSTEM Ca r bu r etor Assembly No t es - Assembly is the reverse of disassembly . - Clean the disassemb l ed parts before assembling . - Replace the f l oat bowl O-ring with a new one if it i s deteriorated or damaged. - Turn in the air screw fully but not t i ghtly , and then back it out 1 1f2 turns . A . Ai r Screw Carbure t or Clea n [...]

- Remove the float valve needle . - Check the float valve need le for wear . * If the needle is worn as shown below, replace the valve needle . - Push the rod in the valve needle , then release it . * If the rod does not came out fully by spring tension , replace the va l ve n eedle . Float Valve We. Push and releue 1 . Rod 3 . Valve Needle Wear 2 [...]

2 - 16 FUEL SYSTEM Ai, Cleaner Element Installation Notes -I nstallation is the reverse of removal. - W hen installing the element , coat the lip of the e l em en t with a t hi c k l ayer of all purpose grease to assu r e a co mp lete seal against the air c leaner e l e- ment base . Also , coat the base whe re the lip of the e lem e nt fits . A . C[...]

Fuel Tank Fuel Tank R emoval - Remo v e the seat. -T u rn the fue l tap to the OFF po s ition . -P ul l the f uel ho se o ff the fuel tap . I WARNING' oG8501lne Is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke. Make sure the area ls well ventilated and free from any source of flame[...]

2 - 18 FUEL SYSTEM Fuel Tap 1. D-ring 2 . Filter Sc r een '* If the fuel tap screen has any breaks or is deterio- rated . it may allow dirt to r each the carburetor, causing poor runni ng _ Replace the fue l tap . * I f the fuel tap l eaks. or allows fue l to f low w h en i t is at OFF position , replace the damaged D-ri ng. Fuel Tank Cap - In[...]

Reed Valve Reed Valve Remov al - Rem ove the ca rburet o r from the carbu r etor holder and air cleaner duct . -R emove the ca rburetor holder mounting bolts , and move the holder rearward . - Take the reed va l ve out of th e cy lind e r. -F or KX125 model ; remo ve the reed valve out of the c rankcase . RefJd Valve Installation - In s tallation i[...]

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COOLING SYSTEM 3-1 Cooling System Table of Contents Exploded View ........... . .. . ..• . ... . .... . .•••... ... ....... ".................... . ..... 3·2 Specif i cations ........ .. . . .. . .... . •. .. . ...... . .•. . ...... . ,' ", ... . .. . . ••• •. ...... .... . .. 3 - 5 Special Tool . .. ....... . . [...]

3 - 2 COOLING SYSTEM ... . . .. . . . . Exploded ~i~~ """""""""""""""""""" KX125 :[...]

KX250 : TEM 3-3 COOLING SYS[...]

3-4 COOLING SYSTEM KX500: T1: T2: T3: 87 I.-Ibl 9 8 N-m 11,0 k g -m'll a ft-Ibl . (I 5 kg-m , . I 1 5 N- m. 78 in-Ib (0 9 kg-m. 9 N-m .[...]

COOLING SYSTEM 3 -5 Spe ci fication s Item Standard Coolant : Type Pe r manent type of antifreeze for a l uminum engines and radiators Color G r een Mixed ratio Soft wate r 50%, Coolant 50% Total amo u nt : KX125 O.SS l KX250 1 . 1 l KX 5 00 1.3 l Radiator : Cap r elief p r essu re 95 - 125 k P a 10.95 - 1 . 25 kg / cm 2 , 1S psil ......... . .. . [...]

3 - 6 COOLING SYSTEM Coolant Check the coo lant l evel each day before riding the motorcycle . and replenish coolant if the level is low . Change the coo lant in accordance with the Periodic Maintenance Cha rt (see the General Information chapte r ). I WARNING' a To avoid burns , do not remove the radiator cap or try to Inspect the coolant lev[...]

e place a can t amer under the coolant drain pl ug. and d r ain the coolant from the r a diator a n d engine by re moving the drain plug at the bottom of the wate r pu m p cover. Immed iate ly w ipe o r was h out any coo lant t hat spills on the frame , engine , o r wheel. A. Wa t er Pump Cove r B . Drain Plug A . Wate r Pump Cover B . Drain Plu g [...]

3 - S COOLING SYSTEM ,:r If hard water I. used in the system, It causes scale accumulation In the water passages , and considerably reduces the efficiency of the cool - Ing system . The coolant provided when shipping Type Permanent type antlf'.8ze Color Mixed ratio Fr •• zlng point Total amount for aluminum engln •• and radiators Green[...]

- Remo ve the pre ssu re teste r , repleni s h the coolant, and install the radiator cap * If the pressure drops and no external sou r ce is found, check for internal leaks. Check the cylinder head gasket for leaks. Cooling Sys t em Flushing Over a period of t i me, the coo li ng system accu- mu l ates rust , sc ale , and lime in t he water jacket [...]

3 - 10 COOLING SYSTEM KX500 : A . Wa t er Pump Cove r B. B olts Water P ump Cover Ins t alla t io n No t es 'I nstallat i on is the reverse of removal. - Replace the pump cover gasket with a new one. - Fill the cooling system (see Coolan t Fi ll ing) . Impe ll er Removal e Orain the coo l a nt (see Coolant D r ai n ing) , . Remove the cove r b[...]

Water Pump Shaft In sta llation KX125 , 250 : 1 1 . Oil Seal 3. Marked Side 2. Wate r Pump Shaft 4 . Right En gine Cover KX500 , 1 2 3 1 . Oil Seal 3. Marked Side 2 . Wate r Pump Shaft 4 . Right Engine Cover o Be sure to apply a molybednum disulf i de grease to the water pump s haft when installing . If it is in - stalled dry . the seals may wear e[...]

3 - 12 COOLING SYST E M · Press the ball bearing into the hole with a bearing driver set (specia l too l: 57001-1 1 29) untif the bear - ing is bottomed against the step . Radiato r Radia t or Removal - Remove the radiator cover(s). - Drain the coolant ( see Coolant Draining) . - loosen the hose clamps , and pull off the cooling and breather hoses[...]

a Keep t he air nozzl e over 0 . 5 m 120 in . 1 away from the radiator . a Blow air perpendicularly to the rad i ator core. a Navar blow air at an angle against the fins but straight through them in the direction of natural air flow . a N a var s hake the air nozzle at a right angle against the fins . be s ure to move it at a level with the fins . [...]

3 - 14 COOLING SYSTEM Cooling Hoses, Breather Hose Installation Notes - In sta ll the coo ling noses or breather hose being careful to follow the preformed bends (see Exploded View , H ose Rout ing in the Cenerallnformation cha~ ter1 Avoid sharp bending. kinking,. flattening. o r twisting . - Tighten the hose clamps secu rel y . A . Cooling Hoses B[...]

ENGINE TOP END 4- 1 Engine Top End Table of Conten t s E x ploded View ......................................... _ ......... .. ............ . ...... . Specifications .....................• _ . . . .... . .•••.. . .. .. .... . . ... .... .•• ................ Special Tools . .. . ... . ........ . ....... . .. . ... . ........ . .... . . [...]

4-2 ENGINE TOP END Exploded View T1 : 25 N - m 12 . 5 kg - m . 18 .0 ft - Ib) T2 : 26N -m 12 . 6 kg - m . 19 .0 ft - Ibl T3 : 6 . 9 N - m (0 . 7 kg - m. 81 In - Ibl T4 : 9 . 8 N - m 11 . 0 kg -m . 87 In - fbI T5 : 25 N -m 12 . 5 kg - m . 18 . 0 ft - Ibl T6 : 8 .9 N -m 10 . 7 kg -m . 61 In - fbI T7 : 8 . 3 N-m (0 . 86 kg -m , 74 in - Ib) T2[...]

KX250 : 18 . 0 ft - Ibl 25 N-m 12 . 5 kg -m . 19 . 0 ft - Ibl T1 : 25 N-m (2 .6 kg -m . 61 I n -Ib) T2 : 6 9 N -m 10 . 7 kg - m , 87 in - Ib) T3 : 9 ' S N -m (1 . 0 k g - m ' 26 ft - Ibl T4 : 34 N -m 13 . 5 k9 : ~ : 11 fHb) T5 . 15 N - m 11 . 5 kg 87 in - Ibl T6 : 8 N-m '1 . 0 kg -m . 87 in -Ib) T7 : 9 . m 11.0 kg -m . T8 : 9 .8 N ·[...]

4-4 ENGINE TOP END KX500 : n : T2: T3: T4 : T5 : T6: T7 : 26 N - m (2 6 k 25 N-m (2'S k g - m • 18 ft-Ib) 6.9 N-m (0 7 :-m . 19 ft - Ib ) 34 N-m (3 6 k g-m , 61 in - Ibl 20 N -m (2 ' O k g-m . 25 ft -Ib) 9 . 8 N -m 11 0 :-m. 14 . 5 fHb) 9 . 8 N - m (1 ' 0 k g - m . 87 in -Ib) . g-m , 87 In - Ib)[...]

ENGINE TOP END 4-5 Specifications KX125: Item Standard Service Limit Cylinder Head: Cylinder compression ( usable range) --- 770 - 1200 kPa (7.7 - 12 kg / cm 2 • 109-171 psil Cylinder head warp --- 0 . 03 mm Cylinder. Piston: Cylinder inside diameter 56 . 015-56 . 030 mm 56 . 10 mm Piston diameter 55 . 940 - 55 . 955 mm 55.79 mm Piston / cylinder[...]

4-6 ENGINE TOP ENO KX250 : Item Cylinder Head : Cylinder comp ression Cylinder head warp Cylinder . Piston : Cylinder inside diameter: Piston diameter : Piston / cylinder clearance Piston ring / groove cl ea ranc e Pi ston ring groove width Piston ring thickness Piston ring end gap Piston Pin diameter P iston pin hole diameter Small End in side dia[...]

ENGINE TOP ENO 4-7 KX500 : Item Standard Service Limit Cylinder Head: Cylinder compression (usable range) --- 735- 1150 kPa 17.35- 11.5 kg / em', 105 - 1 64 psi! Cylinder head warp --- 0 . 03 mm Cylinder. Piston: Cylinder inside diameter 86 . 020-86.035 mm 86.10 mm Piston diameter 85 . 910-85.925 mm 85.80 mm Piston / cylinder clearance 0.105-0[...]

4 - 8 ENGINE TOP END .. .. . .. . . . . . . .. .. .. . . . .... .... ................. . ...... . . .. .. . Special Tool Compres s ion Gauge : 57001 · 221 Adapter : 57001 · 1159 Piston Pin Puller Assembly : 57001 - 910 Pi s ton Ring Plie,s : 6700' - 115 o o o[...]

.. . ....... .............................. . ... . . .. .. . ........... Cylinder Head Cylinder Compression Measurement - Start the engi ne - T hor oughly wa rm up the engine so that the engine oil between the piston and cylinder wa ll wi ll he l p seal comp r ession as it does during normal running . - Stop the engine . - Remove the spark plug. a[...]

4-10 ENGINE TOP END - Tighten the cylinder head bolts o r nuts to t he spe- cified to r que. Tighten i ng T o rqu e: 25 N-m (2 .5 kg · m. 18 ft - Ibl - Tighten the spark plug to the specified torq ue . Ti gh t ening Torque : 27 N-m 12 _ 8 kg-m_ 20 ft - Ibl C yli nd er H ead Wa rp In sp e cti on • Lay a straightedge ac r oss t he lower surface of[...]

ENGINE TOP ENO 4 - " KX500: - Remove the idle gear. - Lift up the right and left exhaust va l ves until the gear surfaces a re flush with cylinder surface . p A. Shaft Lever C. Retaining Sc rew . B. Shaft lever Mounting Nut 0 KX'25 : - Remove the main exhaust valve cover bolts, and remove the cover and gasket. A. Cover B . Gasket - Pull o[...]

4 - 12 ENGINE TOP END - Remove the cylinder. and remove the main exhaust va l ve . A. Main Exhaust Va l ve KX250 : - Up side dow n the cylinder . ' Remove the plug and gasket. A. Plug B . Gasket ' Push in the operati n g rod as far as it will go . This cause to align the punch ma rks on the exhaust va l ve with the notch on the operating [...]

KX50 0 : - Up si de down the c y lind er . - Remove the plug and gasket. - Remove the pin on the cylinder . - Remove the va l ve guide from the exhaust va lve . A. Exhaust Valve C. Pin B. Valve Gui d e - Unbolt the left plug . - Pull up the exhaust valves , and then pull out the va l ve operating rod to t he right side . A . Valve Ope r ating Rod 8[...]

4-14 ENG.lNE TOP END KX1 2 5 Model E x hau s t V a lv e Op eratin g R od In s tall at io n 3 @) 00 I D~D I' D ) 1 . Ex h a u st Va lve s 2. Idle Ge ar 3 . Pu nc h Ma rk 4 . Gu id e 5 . M ai n Ex h a u s t V al ve[...]

aFo r KX2S0 model ; tighten the main exhau st valve b r acket mounting bolts secu rely . Check that there is no gap between the bracket and cyli nder. 00 1. No Cap 2. Bracket 3. Main Exhaust Va l ve ENGINE TOP END 4 - 15 o Engage the valve pinions with the rod rack so that the paint marks on the pinions are positioned to- ward the front af the engi[...]

4 - 16 ENGINE TOP END T ig htening Torque 20 N- m 12 . 0 kg-m. 14 .5 ft - Ibl A . Valve Opera t ing Rod D. Exhaust Va l ves B . Oil Seal E . Va l ve Guides C. O - Ring O Put the exhaust va l ves into the holes in the cyl- i nd er. o AppJya 2 -s troke eng i ne oi l to the teeth of the valve operating rod . o Pull up the exhaust va l ves , inse rt th[...]

Cylinde r Installation Notes - Installation is (he reverse of removaL - Scrape any carbon out of the exhaust port . - Check for a crust of minerals and rust in the cy linder water jacket, and r emove them if necessary . - Replace the cy lind er base gaske t with a new one . - Apply engine oil to the piston s urface , piston rings and cylinder bore [...]

4-18 ENGINE TOP END - When installing the piston rings on the piston , note the following ; o lf installing the piston rin gs by hand . first fit one end of the piston ring against the pin in the ring groove , spread the ring opening with the other hand and then s lip the ring into the groove . aFar the KX250 model ; both the top and the seco nd ri[...]

KX125 : Standard : SelVice Umit: KX250 : Standanl : 56 . 015 - 56 . 030mm , and less than O . 01mm difference between any two measurements . 66 . 10mm. or more than O.05mm difference between any two measurements . 67 . 400 - 67 . 415mm . and leas than O . Olmm difference between any two measurements . Service Umit: 67 . 48mm . Of more than 0 . 06mm[...]

4-20 ENGINE TOP END Piston Ring . Piston R ing Groove Inspection • Visuallv inspect the piston rings and the piston ring grooves . * If the rings are worn uneven ly or damaged , they must be replaced . * If the piston ring grooves are worn unevenly or damaged , the piston must be rep l aced and fitted with new rings . • Check fOl' uneven g[...]

Pi s ton Pin Diameter KX1 2 S, Standard : Service lim i t : KX2S0 , Standard : Servi c e L i m i t : KXSOO , Standard : Service Lim i t : 15 . 995 - 16 . 000 mm 15 . 96 mm 17 . 995 - 18 . 000 mm 18 . 96 mm 18 . 995 - 19 . 000 mm 18 . 96 mm Pi s ton Pin Hole D i amete r KX12S , Standard : Service L i m i t : KX2S0 , Standard : Service L i mit : KXSO[...]

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ENGINE RIGHT SIDE 5 - ' Engine Right Side Table of Contents E xpl oded View .......... . •. .. .. .......••............ ,..... . . .••• .. ........ . .... .. ...... 5 -2 Specifications ........... " ........... , .. . .. . ........... , ..........•.............. ,. ,... 5 - 5 Special Tool s .. . .. .... . ............. .. ..[...]

~ : 2 ENGINE RIGHT SIDE ... "" . Exploded ~·i. · · · ·· · "· · ·· .. . .... . ... ... . .. . ............ . . . . . . . ... . . . . . w . .. . KX . . . . 125 : . . . . . . . . . . . .. .. . .. ... . ..... .. .......... o ~ ? ",,~(i)'~ o ®~i/~' ~ . ~i ' '''-" .. T3 : 9 .3 N ' m[...]

KX250 T1, 9 .3 N·m 10 . 95 kg - m . 82 In·lbl T2: 9 .8 N -m 11 .0 kg -m , 87 In - Ib) T3: 98 N -m (10 kg -m , 60 ft -Ib) T4 : 9 . 8 N- m (1.0 kg -m . 87 in - Ibl T5 : 3 .9 N- m (0 . 4 kg -m . 35 in - Ibl T6 : 2 . 0 N-m (0 . 2 kg -m . 17 in - Ibl T7 : 9 .8 N- m 11 . 0 kg -m . 87 in - Ibl T8 : 9 .8 N-m (1 . 0 kg -m . 81 in - Ibl T9 : 22 N-m (2 . 2 [...]

5 · 4 ENGINE RIGHT SIDE KX500 : ~(8 ~ T1: 9 . 8 N-m 11 .0 kg - m . 87 In - Ibl T2 : 3 .9 N -m 10.4 kg-m. 36 In - Ibl T3 : 2 .0 N -m (0 . 2 kg-m . 17 In-Ibl T4 : 9 .8 N -m 11 .0 kg-m. 87 in - Ib) T5 : 9 . 3 N-m 10 . 96 kg -m , 82 In-Ibl T6 : 98 N-m (10 kg - m . 72 ft-Ibl T7 : 9.8 N-m 11 .0 kg-m . 87 In-Ib' T8 : 20 N · m 12 .0 kg · m . 14.6 f[...]

. .......... . .............. . .... . ............... . . • •. • •..• ••• • Specifications Item Clutch : Clutch lever free play Clutch Spring free length KX125 KX250 KX500 Friction plate thickness KX125 KX250 . 500 Friction plate / clutch housing clear- ance Friction and steel plate warp . . ... . . .... . .. . , ..........•. ?[...]

5 · 6 ENGINE RIGHT SIDE Right Engine Cover Right Eng i ne Cover Remo va l - Drain the t ran smission oil (see Transmission Oi l Change in the Engine Bottom End{Transmission chapter) . - Drain the coo l ant (see Coolant Change in the Coot- ing System chapter) , e Remove the fo ll owing parts . Kick Pedal C lu tc h Cable lower End Brake P eda l Impe[...]

- For K X 12 5 model ; turn the cl utch release lever to- ward the r ear . - Install the right engine cove r using the kick s haft oil se al guide (sp eci al t oo l ) to protect the cove r oi l sea l. A . Kick Shaft Oi l Sea l Guide : 5700 1- 263 - Fit t he s haft le ve r bo ss in the groove of the va lve ope r ating (a d col la r. and in s tall th[...]

5 · 8 ENGINE RIGHT SIDE KX500 : A. lever S haft C. Allen Bolts B . Exhaust Advance r Assemb l y - Remove the p lu g sc r ew and take out the pos iti on· i n g pin . - Pull the lever shaft out of the right e ng i n e cove r. ! 8 A. Plug Screw C. l eve r S haft B . Positioning Pin -P ull off the wate r pump shaft (see Water Pump S h aft Removal in [...]

Exhaust Advancer Assembly Disassembly /Assem bly Notes - The exhaust advancer assembly consists of the fo ll owing parts . E x haust Advancer A ss embly A . Exhaust Advance r Assembly 1 . P ins 2 . Rod 3 . Guide 4 . O-ring 5. Steel Balls 6 . Ho l der 7. Needle Bearing B . Space r 9 . Collar 10 . Collar 11 . Spring 12 . Gear - Check the exhaust adva[...]

5 · '0 ENGINE RIGHT SIDE Clut c h Proper clut c h le ve r play between the clut c h lever and the clutch lever holder is 2-3 mm . Play in - c r ease with cab le st ret c h and friction plate wear , necessitating adjustment. When there is too much lever play, first try adjusting the cab le at the clutch le ver . I W AR NI NG' o To a v o i[...]

KX125 : - Remove the fta t washe r and cl u tch p u sher in the clutch hub . A. C lut c h Pusher B . flat Washer - Remove the mag n eto cove r . - Use the r oto r ho lder and a d apter " A U (s pe cia l tools) to prevent the clutch from rotating, loosen the clutch hub nut (see E l ectrical System chapte r). - Remove the clutch s prin gs and sp[...]

5 - 12 ENGINE RIGHT SIDE Clutch Installation Note s -I nstallation i s th e reverse of r e mo v al. - Apply mo l ybdenum disulfide grease to the outside of the s l eeve . - Apply transmission oil to the in side of the cl u tch housing gear and kick starter driven gear . - In sta ll the friction plates a nd stee l plates , sta rtin g with a friction[...]

Friction Plate Thicknes s Measurement 1 . Friction Plate F ric t ion an d St e el Pl a t e W arp In sp ection • Pl ace each friction p l ate o r steel plate on a surface plate , and measure the gap between the surface plate and each f r iction plate or steel plate . The gap is the amount of friction or stee l plate warp . * If any plate is warped[...]

5 - 14 ENGINE RIGHT SIDE External Shift Mechani s m External Shift Mechanism Removal - Remove the following parts . Shift Pedal Magneto Cover Right Engine Cover Clutch Housing . Pull out the shift shaft with the shift mechanism arm and arm sp ring . and remo ve the return spring . A . External Shift Mechanism B. Neutral Set Lever C. Spring - Remo v[...]

Prim a ry Gear Primary Gear Removal - Remove the righ t engine cove r (see Right Engine Cover Remo v al) . - Remove the clutc h (see C lutch Removal) . e For KX125 model; remo ve t h e primary gear nut, spring washer, woodruff key, primary gear, and D- r ing. A. Primary Gear Nut - Fo r KX250. 500 mode l ; remove the cirdip, and take off the primary[...]

5 - 16 ENGINE RIGHT SIDE A . Chamfe r ed Side eF o r KX250 , 500 ; replace the o ld ci rclip with a new one . Klckstarter Kickstarter Assembly Removal - Remove the following part s. Right Engine Co v er C lut c h Housing . Pull the end of the kick s pring out of the hole in the crank c ase . KX126 : A. Kick Spring B . Kickstarter Assembly KX260 : A[...]

KX500 : A . Kick Spring B. Kicks t arte r Assembly C. Ratchet Guide D . Bolts - Remove the ratchet guide and bolts . - Remove the kicksta r ter assembly _ Kickstarter A ssembly I nstall at io n No tes -In sta ll ation is the reve r se o f removal. - Apply a non-permanent locking agent to the threads of the ratchet guide bolu . Kickstarte r Assem bl[...]

, , , . - 1 ., - , . • • ,[...]

ENGIN E REMOVAL II NSTALLATION 6 -' Engine Removal/Installation Table of Content s Expl o ded View .... . ......... . .................. . .......... . ..... ......... .... ... . . 6 - 2 Eng i ne Removal / I nstallation ......... .. ... . . . ... . ..... .• ........... . .. ......... 6-3 Engine Removal ..................... . ............. _[...]

6 - 2 ENGINE REMOVAL/INSTALLA TION . . . .. . . .... ............ .. . .. . ... . . ............. . ... . ....... Exploded View ... .... . . ... . . ............... . . .... . . .... . . ...... ..... .. ... . . r------------------, I T1 I KX125 Model I I I I I I I I I I I I I I I I L ________ ---"" / / / T1 : 25 N -m (2 .6 kg-m. 19.0 ft-I[...]

Engine Removal / Installation Engine Removal - Drain the transmission oil (see Tran smission Oi l Cha n ge in t he Engine Bottom End{Transmission chap- ter). - Drain the coolant (see Coolant Change in the Cool- ing System chapter) . - Remove the fo ll owing parts . Right and Left S ide Cove r s Radiator Cover Seat fuel Tank Expansion Chamber Spark [...]

[...]

ENGINE BOTTOM END/TRANSMISSION 7 · ' Engine Bottom End/Transmission Table of Contents Exploded View .......................... . .............. . ... . ..... .. . ................. .. 7-2 Specificat i ons ................ . ... . .. ... .. . .. . ....... . .. . . . ..................... ........ 7 - 5 Special Too ls ... . . . ....... . .... .[...]

DITRANSMISSION 7 - 2 ENGINE . . . . . . . ... . .. . .... . . . . .. . .. . .. .. . BOTTOM EN . . .. .. .. .. ....... . .......... d View .. . .. . ... . . . . . . . . .. .. . .. ... ... . . Explode .... ..... . ................ KX125 : y! ~,,~ ~ b ~ / anent locking av-nt . l : Apply. no=m diautflde gr .... . M . Apply moly 62 In - Ib) ~ T 1: 6 .9 [...]

KX250 : l : Apply a non-permanent locking agent . f1 : 5 .9 N - m (0.6 kg-m . 52In - lb) T 2: 9 . 8 N-m 11.0 kg-m. 87 In - Ib) T 3 : 9 .8 N-m 11.0 kg-m . 87 i n - Ib} T4 : 20 N -m 12 . 0 kg-m , 14 .5 ft - Ib) T5 : 9 .8 N-m 11.0 kg -m. 87 In - Ib) T6 : 22 N -m (2 .2 kg-m . 16 . 0 ft - Ib) ENGINE BOTTOM ENOITRANSMISSION 7 - 3[...]

7 -4 ENGINE BOTTOM ENO/TRANSMISSION KX500 : l : Apply. non - J*menent locking egent . T 1 : 5. 9 N' m (0 . 6 kg - m , 62 In-lbl T 2 : 9 .8 N-m 11.0 kg - m , 87 In-lbl T3 : 20 N ' m {Z .O kg -m . 14 .6 ft·lbl T4 : 22 N ' m 12 . 2 kg -m. 18 .0 ft - Ibl •[...]

ENGINE BOTTOM ENOITRANSMISSION 7-5 Specifications Item Standard Service limit Transmission Oil : Grade SE class - -- Viscosity SAE 10W 30 o r 10W 40 --- Amount : KX 125 0 . 65 L -- - KX250, 500 0.8 L - -- Crankshaft . Connecting Rod : Connecting rod : Bend and twist not more than O.03mm l O.20mm / l00mm 100mrn Big end ra dial clearance : KX125 0 . [...]

7 - 6 ENGINE BOTTOM ENOITRANSMISSION Special Tools .. . .... ... .............. . ........ .. ..... . .................. . . Along with common hand tools and precision instruments . specia li zed tools are required for com- plete crankshaft/transmission servicing. Clrcllp P1l e r s: 57001-144 Crankshaft Jig: 57001 · 1174 • Bearing Drive, Set : 5[...]

Transmission Oil I n order for the transmission and clutch to function p r operly, always maintain the transmission oil at the proper level and change the oil periodica l ly. I WARNING' o Motorcycle operation w it h insufficient, deter i- orated, or c ontaminated transm iss ion oil will cause accelerated wear and may result in trans- mission s[...]

7 -8 ENGINE BOTTOM ENDITRANSMISSION KX250, KX500 , A. Tran s mission Oil Drain Plug • Check the gasket at the drain plug for damage . * Repla ce the gas k et with a new o n e if it is damaged . • After the oi l has co mpletely drained out, i n stall the drain p lu g with the gasket, and tighten it to the specified to r que . TIghten i ng Torque[...]

KX600 , A. Crankcase Bolts -I nstall the crankcase splitting tool and adapter (s pe cia l tools) i nto the left side of the crankcase . Be certain to screw the tool in all the way . A. Crankcase Splitting Tool Set: 57001-1 096 B . Adapter : 5700 1 -136 - Tighten the bolt o n the c r ankcase splitting tool to split the c rank case halves . - Once th[...]

7-10 ENGINE BOTTOM ENO/TRANSMISSION NOTE 0 00 nor remove the bearings unless it is necessary . Removal may damage them. o lnstall the bearings for the crankshaft in the right and left crankcase so that their sealed sides face toward the oil sea/ side. Olighten the output and drive shaft bearing re- taining bolts to the specified torque . TIghtening[...]

Crankshaft . Connecting Rod Crankshaft Removal - Split the crankcase (see Crankcase Splitting) . - Remove the transmission shafts (see Transmission Shaft Removal) . - Using a press remove the c rank s haft from the right crankcase . *If the bearings stay on the crankshaft when sp l itting the crankcase or removing the c rankshaft from the right cra[...]

7 - 12 ENGINE BOTTOM ENO/TRANSMISSION Cra n ks h aft A sse mbl y No t es Since the assembly of the cra nk shaft dema n ds ex - acting tolerances . the disassembly and reassembly of the crankshaft can on ly be done by a shop having the necessary too l s and equip m ent. - Reassem ble the c r a n ks h aft accordi ng to the sta n dard tolerances in Sp[...]

Crankshaft Runout 7.5 mm Turn the crankshaf t slowly. Crankshaft Alignmen t 7.5 mm * If the run ou t at eithe r point exceeds the serv i ce limit, a l ign the flywheels 50 that the runout falls w i thin the service limit • In the case of horizontal misal i gnment, which is the mo st com m on, st rike t h e projecting rim of the f l y- wheel wit h[...]

'-'4 ENGINE BOTTOM END/TRANSMISSION Transmission Transmission Shaft Remo val - Split the c r ankcase (see Crankcase Splitting) . -Pull off the shift rod. and disengage the shift fo rk guide pins from t h e shift drum grooves . - Remove t h e s h ift drum . - Remove the shift forks from the transmission gears . - Take out the drive shaft a[...]

_The drive s haft gears ca n be identified b y size ; the s mallest diameter gear is 1st gear, a nd the l argest is 5th (KX250, 500) or 6th (KX125). Be sure that all pa r ts are put back in the co rre ct sequence, facing the proper di r ect i on, and that a ll c irciip s a nd the washer are properly in place . Drive Shaft Gears KX125 : 1 . 1 st gea[...]

7 - 16 ENGINE BOTTOM ENOITRANSMISSION KX500, 1. 2nd gear (29 T; dog re cesses face right ) 2 . 4th gear (2 1T ; fork groove goes to the rig ht side of the gea r teeth) 3. 3rd gear (26T ; dog recesses face left ) 4. 5th gear (19T; fork groove goes to the left side of the gear teeth ) 5. 1st gear (32T; dog recesses face left) - Check that each gear s[...]

® A . Drive Shaft 3rd Gear Shift Fork B . Output S haft 4th Gear Shift Fork C. Output Shaft 5th Gear Shift Fork Drive shaft ', d gea r fingers a re s horter than shift fork t ho se of the other two shift forks Outp u t shaft 4th gear guide pin goes to cen- s h ift fork te, Output shaft 5th gear guide pin goes to left shift fork si de of the f[...]

7 - 1B ENGINE BOTTOM ENDITRANSMISSION A. S h ift Fo rk F i nge r * If a gear shift fo rk groove is worn over t he serv - ice limit , the gear must be rep l aced . Gear Shift Fork Gr oov e Width Standard : IKX1 25 1 4.06 - 4 . 16 mm IKX 2 50 . 5001 4 . 55 - 4 . 85 mm Servi c e Limit : IKX1261 4.25 mm (KX2 5 0 . 6 001 4.7 6 mm A. Gear Shift Fo rk Gro[...]

A . Dog Hole B . Dog Ball Bearing Wear • C h eck the ball bearing o n both sides of t h e s hift dr um , drive shaft an d o u tput shaft . o Si nc e the ball bearings are m a d e to extreme l y close tolerances. t he wea r must be judged by feel rather tha n measurement. C lean each bearing in a high flash-point solvent , dry it (do not sp in the[...]

[...]

WHEELSfTlRES 8 - 1 Wheels/Tires Table of Contents Exploded View .... . . .. ............. . ...... . _ ...... . .. . .............. . ................. . Specifications Specia l Tool s ...... . ............ .... .... . .. .. ........ . .• •• .. ................ .... ...• .. .. Wheels . .. ..... ..... ... . .. . . . ..... ... . .. . . ... . [...]

8 - 2 WHEELSITIRES Exploded View T1 : 5' N-rn (5.5 kg-rn, 40 fNb) T2 : 9.3 N-rn (0 . 96 kg"," , 82 In-4bl T3 : 26 N-rn (2:.5 kgom, 18 ft-tb) T4: 98 N-rn (10 kg-rn, 72 ft~bl 1'5 : 1.5 N-rn 10 . 15 kg",", 13 in-tb)[...]

WHEELS/TIRES 8 · 3 Specifications Item Standard Service Limit Whoels: Rim runout : Axial Under 0 . 5 mm 2mm Rad i al Under 0 . 8 mm 2mm Axle runou t/ l00 rnm Under 0 . 10 mm O . 2mm 10 . 7 mm : AL ) Tires: IKX125 , 250) Front: Size 80 / 1oo · 2151M --- Make, type DUNLDP K490 ® DUNLOP K990 --- Rear : S i ze : KX125 loo / loo · 1859M --- K X 250 [...]

8-4 WHEELSITIRES Special Tools Bearing Driver Set: 67001 · 1129 Bead Breaker A .. ' y : 57001-'072 Tire Iron : 67001 - 1073 Rim Protector: 57001·1063 ClrcUp Pliers : 67001·143 NOTE o The t i re i rons (P I N 5 7 001 · 10 7 3 ) are in c luded in the bead breaker assembly (P I N 57001 · 1072J .[...]

Whe e l s F ro n t Wheel Removal _ P l ace a stand or block under the motorcycle so that the front wheel is raised off the ground. - Rem ove the axle clamp nuts , a nd remove the wheel with t he axle. _ Remove the axle n ut, a n d remove the wh eel. 0 00 I1bt lay the wheel on the ground wrth the disc facing down . Thi s can damage or warp the dis c[...]

8 · 6 WHEELSITIRES Rear Whee/Installation Notes - Installatio n is the reverse of removal . - Fit the brake holder stop against the swi ng arm stop . A . Brake Holder C. Swing Arm B . Stop (B r ake Holder) O. Stop (Swina Arm) - Fit the caps to the irooves on the co ll ar . A . Cap B . Groove C. Co llar -In stall the drive c hain . Install the mast[...]

I WARNING. otf any spoke breaks, it should be replaced immedi- ately. A missing spoke pklces an additional load on the other spokes, which wi! eventualy cause other spokes to break. Rim Inspection • Inspect the rim for small crack s, dents. bending, or warping . * If there is any damage to the rim, it must be re- placed . • Set a dial gauge aga[...]

8·8 WHEELSITIRES Tires Tire Removal 0 00 not lav the wheelan the ground with the disc facing down , This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground . - Remove the whee l from the moto r cycle (see W h ee l s) . - To maintain wheel ba l ance, mark the va l ve stem pos it ion on the tire wit h c h[...]

- Position the tire on the rim so that the valve is at the ti re balance mark (the chal k mark made during removal or the yellow paint mark on a new tire) . A . Balance Mark - Tighten the bead protector nut securely , - C heck and adjust t he ai r pressure after in sta llin g . Tire Pressure Inspection / Adjustment - Us ing tire press ure gauge, me[...]

8-10 WHEELSITIRES Hub Bearing 000 not lily the wheelan the ground with the disc facing down . This can damage or wrap the disc. Place blocks under the wheel so the disc does n01 touch the ground . Hub Bearing Removal Notes -R emove the hub bearing by tapping evenly around the bearing inner race as shown . Bearing Removal 1 . Bar 2. Distance Co ll a[...]

Hub Bearing Inspection and Lubrication Since the wheel bearings are made to extremely dose tolerances, the clearance cannot normally be measured_ • For front hub bearing, turn each bearing back and forth while checking for roughness or bind ing . * If roughness or binding is found, rep l ace the bearing. • For rear hub bearing , wash the beari [...]

[...]

FINAL DRIVE 9 - 1 Final Drive Table of Contents E x ploded V i ew ......................................... . .................. . ..... . ..... . Spec i fication s Special Tools Drive Chain .. .. .... ..... ..... . ....................... .. . _ ._ ....... . .. ....... . ... .... . . . . . Drive Chain Slack Inspection ............. . .......... . [...]

9 · 2 FINAL DRIVE Exploded View /1 __ - - ~ KX250 . 500 _-- ~' -- I - --- ~. --- I . _ I Ii) I,) -- I ,...... ..... (" I I I I ......... ....- I L.-....... .... ...... .... I _- I ____ KX125 - I -- -- I ..J I _- 1 -- -- T1 : 29 N- m (3 .0 kg -m . 22 , 0 ft - Ibl T2 : 98 N- m (10 kg -m . 72 ft - Ibl[...]

FINAL DRIVE 9 - 3 Specifications Item Standard Service Limit Drive Chain: Make Daido - -- Type 0 . 1.0 520 OS - 5 --- Length : KX125 112link --- KX250 , KX500 114 link -- - Chain slack 50-60 mm less than 50mm, or more than 65mm 20 - link length 317 . 5 mm 323 mm Sprockets : Engine sprocket diameter KX125 50 . 98 - 51 . 18mm / 12T 50 . 7 mm KX250 , [...]

9 - 4 FINAL DRIVE . . . ..... ................... ... ... . . ... . . . . .. . .. . . ... .... .... . .. Drive Chain Drive Chain Slack Inspection - Support the motorcycle on its side stand . - Check the wheel alignment (see Whee l Alignment Jnspection l and adjust it if neces s ary ( see Wheel Alignment Adjustment) . NOTE o Clean the drive chain if[...]

Wheel Alignment Inspection - Check that the notch on the l eft cha in adjuster aligns with the same swing arm mark as the right chain adjuster. A. Marks B . Notches NOTE o Wheel alignment can also be checked using the st raightedge or string method. I WARNING' o Misaignment of the wheel wiN resutt in abnormal wear , and may resuft in an unsafe[...]

9 - 6 FINAL DRIVE Dr ive Ch a in Make Daido Type 0.1. 0 52005-5 links: KX125 112 KX250 114 KX500 114 Drive Chain LubriC8tion - If the cnain appears especially dirty , it should be cleaned before lubrication with high flash-point sol- vent - Apply oil to the si des of the rollers so that oil wi ll penetrate to the rollers and bushings . - Wipe off a[...]

Sprocket Engine Sprocket Removal - Remove the following parts . Engine Sp ro cket Cover Drive C hain(free of e n gine s procket ) - Remove the c irclip , and pull off the engine sprocket . Engine Sprocket Installation Notes -In sta ll ation is the reverse of removal. A . Engine Sp r ocket B. Circlip - For KX 1 25 ; instal l the sprocket so that the[...]

9 -8 FINAL DRIVE Sprocket Oiamete, (Engine) 10(125 Standard : Service lImtt : 10(250. 500 Standard: Service limit: IR •• r) Standard : Service limit : 50.98-61.18 mm 50 . 7 mm 60.99 - 61 . 19 mm 60.7 mm 227.43-227.93 mm 227.1 mm NOTE o lf IJ sprocket requires replacement , the chain is probably worn also. When rep/acing 8 sprocket , inspect the[...]

BRA KES 1 0 · 1 Brakes T a ble of Con t ent s Exp loded V ie w .............................. , ............... . ................... . ... . 10 -2 Spec i f ica ti ons . ......• •• ....................................... . ......••.. , ...... . ••.. 10 -4 Special T oo l .... . .................. . . ................................. [...]

' ~~~I~~~'~' ~ : I~~ . .. ...... . ... .. . . .. . . . .. . ............. . . ............ . . . 10 - 2 BRAKES ........ . ....... . . .. . .......... . ..... . . Front Di s c Brake @[...]

D isc Brake Rear j---@ " . ~ ~ I [!l . W fIJfIJ l..Jr I 'I 52 in - Ib ) 9 N-m (0 . 6 k g - m . 18 . 0 ft - Ib ) T1 : ~ 5 N -m 12 . 5 kg - rn. 78 In - Ibl T2 : 8 N - m 10 .9 kg - m . 18 .0 ft - Ib) T3 : ~ 5 N-m 12 . 5 kg -m . 69 in - Ibl T4 : 78 N-m (0 .8 kg -m . 87 in - Ibl T5 : 's N-m 11 .0 kg - m . 78 in - Ibl T6 : 9 . (0 . 9 kg -m[...]

10·4 BRAKES ...... ............. .. .... . . ...... . .. . ........... .. . .. . . . . .. . . Specifications D isc Brake Item Standard Service limit Brake Adjustment : Brake lever p l ay Adjustable (to suit rider) --- Brake pedal position Adjustable (to su i t rider) --- Brake pedal play Adjustable (to su i t rider) --- Brake Pads : Pad lining thi[...]

Disc Brakes [ WARNING' o When working with the disc brake. observe the precautions listed betow . 1 . Never reuse old brake fluid . 2. Do not use flu id from a conta in e r that ha s been left unsealed o r that has been ope n for a long time . 3, Do n ot mix two types and brands of fluid for use i n the brake . This lowe r s the brake fluid bo[...]

10 · 6 BRAKES R ea r B rake Ped a l Pl ay Ad j u s tment - Adjust t he rear brake peda l p l ay to suit you . - Loosen the adjuster locknu t and turn t he ad ju ste r o n t he rear master cy l inder . - After adj u stme n t, t i gh te n t he l ock nut sec ur e l y . A . Ad j uste r C. Br a ke P ed a l B . Rea r Master Cy lin der D. l ock n ut Cali[...]

A . App ly compressed air . B . Cloth NOT E o lf t h e caliper is to be disassembled after removal and compressed air is not available, remove the piston using the following three steps before disconnecting the brake hose from the caliper. o Prepare a suitable dished container for brake fluid, and perform the work above it. oRemove the pads, spring[...]

10 · B BRAKES Brak e Ped s: P ad Removal - Remove the caliper from the disc . and take out the piston side pad from the caliper holder . • Push the caliper holder toward the piston , and then remove the pad from the ca liper holder shaft. A. Pads C. Holder Shafts B . Caliper Ho l der P ad I ns ta llatio n • Push the ca l iper piston in by hand[...]

A. Banjo Bolt C. Rese r voi r B. Master Cylinder - When removing the brake hose , temporarily secu r e the end of the brake hose to some high p l ace to keep fluid loss to a minimum . - Unscrew the damp bolts, and take off the master cy linder as an assembly with the reservo i r and b r ake leve r . A. Clamp Bo l ts Front M aster Cylinder Insta/Jat[...]

10 - 10 BRAKES - When removing the brake hose , tempora r ily secure the end of the brake hose to some high place to keep fluid loss to a minimum . - Unscrew the master cylinder mounting bolts , and remove the master cylinde r with the reservoir . • Unscrew t he reservoi r cap (the diaphragm comes off with the reservoir cap ) and pour the brake f[...]

Master Cylinder A ss embly Notes - Assembly is the r everse of disassembl y. - Take care not to damage the i nn e r s urf ace of the cy lind er , or the pi sto n . - Clean all parts with brake fluid o r alcohol , and apply brake fluid to the inner surface of the cylinder before assembly . - Tighten the brake lever pivot bo lt l ocknut sec urely . M[...]

'0 - '2 BRAKES Brake Disc : Disc I ns p ection • Visually inspect the disc. * If it is scratched or damaged , repla ce the disc . • l1easure the thickness of each disc at the lX>int where it has worn the most * Rep l ace t he disc if it has worn past the serv i ce l imit . 1 . Disc 2 . Measuring Area DIoc l1-kI<nou Standard : F[...]

Brake Fluid Level Inspect i on In spect the brake fluid level in the f ron t and r ea r brak e fluid re se rvoir s per io d ica lly . - Check the brake fluid level in the reservoir . NOTE o Hold the reservoir horizontal when checking brake fluid level. * The front and rear res ervo irs must be kept more than half fu ll with brak e flu id . If the a[...]

10-14 BRAKES Filling up the Brake line , . Open the bleed valve . 2. App l y the brake and hold it . 3. Close the bleed valve with the brake held app lied . 4. Then quickly release the brake . Bleeding the BrBke Line The brake fluid has a very low compression coeffj.. cient so that almost all movement of the brake lever or pedal is transmitted dire[...]

Brake Hose : Brake Hose RemovaVlnstallation Notes - When r emovi ng the brake hose , take care not to spill the brake fluid on the frame or other painted parts . - When removing the brake hose , temporarily secure the end of the brake hose to some high place to keep fluid los s to a minimum . oBrake fluid quk:Idy ruins painted or p&ated surface[...]

[...]

SUSPENSION ,, - , Suspension Table of Contents Exploded View ............ . _ .............................................. . ...... .. . ... 11-2 Specifi ca tions ..............• _ .......... .. .............. ..... . •• • •. .........•........... 11-3 Special Tools .........................•................ , ..... . ..............[...]

11 - 2 SUSPENSION . .. . ...••••••••• • •. . . .. . . . . . . .••••••••••..... .. . . . .... . .•.. . . Ex~loded View .... .. . . . . ........ .. .. . . ... . . . . ..................... . . . . ... . . • T1: 20 N · m 12 . 0 kg · m. 14 . 5 ft - Ibl T2 : 54 N -m 15 . 5 kg-m . 40 h-Ibl T3: 78 N -m (8 .0[...]

SUSPENSION 11 -3 Specifications Item Standard Service limit Front Fork : Air pressure Atmospheric pressure (Maximum air pres sure) 40kPa (0 . 4 kg / cm 2 , Spsi) Oil viscosity: SAE 5W --- Oil capacity : KX 125 535 ± 4mL -- - 10(250 535 ± 4 mL --- 10(500 597 ± 4 mL --- (adjustable range) Oil le v el : K X 125 130 ± 2mm 100 - 160 mm ( full . Y co[...]

11 -4 SUSPENSION Spec i al Tools Front Fork Cylinder Holder : 5700' - '245 Front Fork Oil Seal Driver ; 57001 - 1219 Front Fork Outer Tube Weight : 5700, - '218[...]

Front Fork Front Fork Adjustment The front fork shou l d always be adjusted for the rider's weight and track co nditions by using one or more of the fo ll owing methods . Basically , there are five adjustment yo u can make to the front fork . oAi r pressure adjustment -Air pre ssu r e acts as a progressive spri ng and affects the entire range [...]

11-6 SUSPENSION Softer E o 2 i Standard ..,. Harder 4 6 8 10 1 2 14 16 Number of turns clockwise u sab l e r8nge · 16 clicks Seated position adjuster turned fully counterc lockwi se oThe left and right fork lega must have the same shock damping . -P ut the caps into the bottom of the outer tubes . Oil Level Adjustment - Use a jack under the engine[...]

Fork Spring Different fork springs are available to achieve ~itable front fork action in accordance wit h t h e rider's weig h t and track co ndition. e Harder s prings make the fork stiffer, and rebound action quicker. e Softer sp rings make the fork softer, and rebound aciton slower. Fork Clamp Position Steering qualities are greatly affecte[...]

" · 8 SUSPENSION A. Top Bolt B . O·Ring C. Sp r ing Se at D . Spacer E. S pring F. Push Rod C . Up pe r H ole H. Si d e Hole - Pour in the type and amount of fo rk oi l s pecif ied . Recommended oil KAYABA 01 or SAE 5W Front Fork Oil Capacity : KX125 : KX250 ; KX500 ; 535 ::t; 4 ml 635 :t: 4 mL 597 ::l:: 4 mL • Pump the fork slowly seve ra[...]

- Mount the axle clamp s, and tighten the clamp nuts , first tighten the upper clamp nuts and t h en the lower clamp nuts to the specified torque . The arrow mark on the axle clamp must point upwards . A. Arrow Mark B . Upper Clamp Nuts C. lower Clamp Nuts Tightening Torque 9 . 3 N-m (0 . 95 kg -m , 82 in-ib) -Tighten the c aliper mounting bolts to[...]

11 · 10 SUSPENSION ecJC i n the bottom of the outer tube . - Remove the caps on the bottom of the outer tubes . eHold the front fork with a vise. - Stop the cy linder from turning by u si ng the cylinder holder (specia l tool) . Unscrew the cyli nder va lve assembly , and take the cy lind e r va l ve a sse mbly and aasket out of the bottom of the [...]

A . Inner Tube D. Washer B . Outer Tube Seal E. Outer Tube Guide Bu sh C. Oil Seal F . Inn er Tube Guide Bush - Remove the cy lin der base from the bottom of the outer tube . A . Outer Tube B . Cylinde r Base Front Fork Assembly Notes - Assembly is the reverse of disassembly . - Check the O-ring at t h e top bolt. Replace it with a new one if damag[...]

11·12 SUSPENSION - After in s talling the wa s her , install the oi l se al by u s ing the fork oi l s eal driver (s pe c ial tool : 57(X)1· 1219, - Using the fork oil sea l dri ve r (s pecial tool : 57 001 · 1219), i n sta ll the du st sea l. .P our in the type and amount of fork oil s pecified , and adju st the oil lev e l (see Fork Oil C hang[...]

Fork Spring Free Length Standard : KX125 , 250 : 548 mm KX500 , 553 mm Service Limit : KX125 , 250 : 537 mm KX500 : 542 mm . .. " ...,.~-~ SUSPENSION 11 - 13 Rear Suspension IUni-Trak) Rear Shock Absorber : The rear suspension system of this motorcycle is Uni-trak . It consists of a rear shock absorber. swing arm , tie rod and r oc k er ar m .[...]

11 - 14 SUSPENSION A . Rebound Damp i ng A dju ste r B . Mark Gas Reservoir Compression Damp ing Adjustment To adjust compression damping. turn the co mpre s- sio n damping adjuster on the gas r eservoi r with the blad e of a sc rewdri ve r until you feel a click . If the damper setting fee l s too soft or too sti ff , adjust i t in a cco rdance wi[...]

I WARNING' O US8 onlv nitrogen ga s. 0 00 not incinerate the gas re se rvoir . Spring Prelo ad Adju stment - Remove the seat, right and left s id e covers . -l oosen the air clea ne r duct clamp screw. - Remove the silencer . - Remove the r ear frame a nd air cleaner case . A . Rear Frame B . Ai r Cleane r Case. • Pla ce a study block o r su[...]

11 - 16 SUSPENSION A. Rear S h ock Abso rb er B . Rea r S h ock Absorber Uppe r Mounting Bo lt o When pulling out the mounting bolts , lift the resr wheel slightly. Forcing or tapping on a bolt could damage the bolt. sleeve. and bearing . Rear Shock Absorber Installation Notes - Instal l ation is the reverse of remo va l. - Tighten the rea r shock [...]

Rear Shock Absorber Disassembly ( Oil Change) The oil s hould be changed in the rear shock ab- sorbe r at least once per racing season . The f requenc y for best performan c e must be based upon riding conditions and rider ability . - Remove the rear shock absorbe r from the frame (see Rear Shock Absorbe r Removal) . - Remove the shock abso r ber s[...]

11 -1 8 SUSPENSION - Adjust t he ga5 reservoir damp in g adjuste r to the softest position . -H o ld the upper end of the rear shock wit h the vise again . • Pry o r tap at the gap s in the stop with suitable tools to free t h e sto p from the rear s ho ck body. A ® A . Caps B . Tap - Slide the stop up to the top of the pu sh rod then lightly t [...]

- Check the circlip for weake nin g, deformity and flaws . If necessary , replace i t w ith a new one . I WARNING' o lf weakened . deformed or flawed clrclip is used , the gas reservoir cap may not hold when Injecting the nitrogen gas. This would allow oil and internal parts to explode out of the reservoir. - Mount the circli p in the g ro ove[...]

, , - 20 SUSPENSION [ CAUTlO~] o lf the circlip i s not 8 certain fit In the groove in the rear s hock body . the push rod .... mbly may come out of the shock absorber when in;actlng the nitrogen gas or riding the motorcycle . A. Circlip - Pull up the push rod assembly against the c!rcl1p, & Force the stop into the rear shock body by lightly ta[...]

- Separate the ch ain guides and chain s lip pe r s from the sw in g a rm . Swing Arm Installation Notes -I nsta ll ation is the reverse of removal. - Apply plenty of molybdenum disulfide grease to the inside o f the needle bearings and s l eeves . - Tighten the sw i ng a rm pivot shaft nut , and the tie- r od rear mounting nut to the specified tor[...]

, , - 22 SUSPENSION Rocker Arm In sta llation Nores . 'nstallation is the reverse of removal . - Apply plenty of mo l ybdenum disulfide grease to the inside of the rocker arm ho l e. outside of the s l eeve. and spherical bearings . -T ighten the following parts to the specified torque . nghtenlng Torque : Rocker Arm Nut: 81 N · m 18.3 kg-m .[...]

A . S l eeves Sleeve Outside Diameter Stand a rd : Service limit : Rocker Arm: Mounting B ol t Bend 21 . 987 - 22.000 mm 21.85 mm A bent bolt causes vib r ation. poor handling, and in s tabil ity . T o measure bo lt run out. remove the bolt , place i t in V blocks . and se t a dia l gauge to the bolt at a point half way between the blocks . Turn th[...]

[...]

STEERING 12 -1 Steering Table of Contents Exploded V iew ............ . ...... . ..... , ' , . ....... . " ...... ,' . • . ••• ........ . . • • •• ...... , 2 - 2 Special T o ol s .... . ... . .................. . . . ........• •. ..... . .. .•••. • .......... •.•. .. . ... 12 - 3 Steering Adju s tment [...]

12 - 2 STEERING Exploded View _1 , , KX250 . 500 ..... .., ... I --: ! iP~ KX250 , 500 , --------- -------7 I fl / / I / / I / / / .. / I I / I / I '- ______ ____ _ _ ...1 @ ,. Q Tl : 25 N · m {2.5 kg -m . 18 ft - Ibl T2: 44 N· m f4.6 kg - m, 33 ft · lbl T3 : 3 .9 N · m (0 . 4 kg -m . 36 In - Ib) T4 : 20 N· m (2 . 0 kg -m . 14 . 6 ft - Ib[...]

Special Tools Stem Nut Wrench: 5700' - 1100 Bearing Driver Set: 5700' - "29 Stem Bearing Driver : 57001-137 Stem Bearing Driver Adapter: 57001 · 1074 STEERING 12 - 3 Stem Bearing Remover : 51001-' 107 Driver Press Shaft : 6700' - '075 Driver : 67001-1106 57001-1076[...]

12 -4 STEERING Steering Adjustment Steering Inspection . Place a stand or b l ock under the m otorcycle so that the front wheel is raised off the ground . - With the front wheel pointing st raight ahead, alte r - nately nudge each end of the handlebar. The front wheel should swi ng fully left and right from the force of gravity until the fork hits [...]

Steering Removal / In sta llat i on ...... . ......................................... . .............. Steering Stem Remova/ - Remove the fo ll owing parts. F r ont Whee l Brake Hose Clamp Caliper Mounting Bo l ts Master Cylinder Clamp Front Fender Handlebar Front Fork - Remove the s teering stem head nut and washer . - Remove the steering stem he[...]

1 2- 6 STEERING - Remove the tower inner race (with its grease seat) which is pressed onto the steering stem . A . Roller Bearing Steering S t em Race I nstallation N otes ' Installation is the reverse of removal. ' App ly grease to the outer races, and then drive them into the head pipe using the drivers and the driver press shaft (speci[...]

. . .. . ............... . _ ....... . _ ............... ... . ....... _ .. . Steering Maintenance .... . .. . . .. .... . ...................... .... .... . . . ............ Steering Stem Bearing Lubrication • Remove the stee ring stem (see Stee rin g Stem Re- moval ). • Us i ng a high f l ash-point so l ve nt , wash the uppe r a nd lower tape[...]

[...]

ELECTRICAL SYSTEM 13-1 Electrical System Table of Contents Wiring Diagram . . .. . . .... . . . . .. .. .. . . . .... .. .... . ..... .. ... . . . . .. . . . .. ........... .. ... 13-2 Exploded View ............... . ....................................... ......... ........ 13 - 3 Specifications Special Tools 13 -5 , 3-6 Precautions ..............[...]

13 - 2 ELECTRICAL SYSTEM Wir i ng Diagram SPIn; Plug • __ .,. __ . ~".-.-. - ~-- 8 ''''' ~ B"'" ______ -(----') B.'" Engine :" .... SIOCI! ! B unon L ._ . .J 3PConnKtl)([...]

.. . ..... . .... ..... . E "~ " PI ' O' " d ... d .. · V .. i .. . w ·· · ··· ···· ·· · ·· · ·· · .... ··· · ~~ ; ~~ . ,' ........ . . . .... . .. . . ........... . . . .. . . . ... . ....... . KX250 , IUK ) ~ ~ . . ~ ELECTRICAL SYSTEM 13 · 3 T4[...]

13 -4 ELECTRICAL SYSTEM KX500 , T3 T1 : 5.9 N-m (0.6 kg-m . 62 in -Ib) T2 : 22 N - m 12 . 2 kg -m . 16 ft -Ib) T3 : 9 . 8 N-m '1 .0 kg -m . 87 in -Ib) T4 : 27 N - m (2 . 8 kg -m . 20 ft - Ibl T5 : 27 N - m 12 . 8 kg -m . 20 ft -Ib) T6 : 78 N - m 18 kg - m. 58 ft - Ibl Ia--@ (UK) : U .K . Model[...]

SPECIFICATIONS Item Ignition System : Ignition timing : KX125 KX250 KX500 Ignition coil: 3 needle arcing distance Primary wi nding resistance Secondary winding resistance COt unit internal resistance Spark plug : KX125 KX250 KX500 Spark plug gap ©: Canadian model @' U . K. model ELECTRICAL SYSTEM 13 - 5 Standard 13° BTDC @ 11000r / min (rpm)[...]

13·6 ELECTRICAL SYSTEM Special Tools Along with common hand tools , the followin g more s peciali ze d tools are required for co mplete electrical syste m servici ng . Rotor Holder: 57001-1248 Rotor Holder Adapter "A": 57001 - 1108 Flywheel Puller : 57001 - 252 Coil Tester : 57001 - 1242 Hand Tester : 57001 - 983 Spark Plug Wrench. Hex 2[...]

Pr eca ut io n s There are a number of important precaut ions that are musts when selVicing the electrical system . learn and obselVe all the rule s below . o The electrical parts shou ld never be struck sharp l y, as with a hammer , or allowed to fall 00 a hard surface . Such a shock to the parts can damage them . oT roubles may involve one or in [...]

13 - 8 ELECTRICAL SYSTEM .. ... . .. . . . . . ..... .. ... . .. .... . . . . . ............ .. ...... ....... Ignition Timing ... . . .. . . ... ......... . ............. .... ... . .... . .. . .... ..... . . Ignition Timing Adjustment • Remove the magneto cover . • C he ck to see if the mar k o n the magneto sta tor is a li gned with the mark[...]

Flywheel Magneto Fl ywheel M ag neto Rem oval 'R emove the magneto cover. 'H old the flywheel st eady with the rotor holder and adapter " A " (specia l toolsl. and remo ve the fly- wheel bolt or nut _ A. Fl yw h eel H o ld er : 57001-1248 B. Ada p te r " A "; 57001-1108 - Remove the rotor holder and adapter " A&qu[...]

13 - 10 ELECTRICAL SYSTEM A . Cl ean Off o Set the stator wiring grommet securely in the notch in the left crankshaft half , and route the wires according to the Wire Routing section in the Genera l Inf ormation chapter . A. Stator Lead B. Grommet oFit the wood ru ff key securely in the slot in the crankshaft before installing the flywheel . oHold [...]

... . ........ ....... ............. .......... .... .... .. .... ... . . Ignition System ................ ......... ............ ....... ....... .... .. .... Safet y In s tru c tion s I WARNING' o Tho Ignition system produces ex1nHneIy high _. Do not touch the spark plugs. high tension coils. or spark plug leads while the engine Is running, o[...]

13 - 12 ELECTRICAL SYSTEM Ignition Coil Winding Re s i s tance (J) 6 (5 -- ./ (j) 1 . Measure primary w in ding resistance . 2. Mea s ur e seco nd ar y win d i ng resista n ce . 3 . i gnition Coil * If the meter reads as specified , the ignition coi l windings are probably good . H owever , if the i gnition system still does not perform as it shoul[...]

ELECTRICAL SYSTEM 13·13 COl Unit T es t Us ing the Kawasaki Hand T es ter KX125 : T ester Posi ti ve (+) l ea d Con n ect i on 0 lead Co l or Black/W h ite White / R ed W h it e/ Gree n Bl ack . 2 (Excite r ) ( Pickup ) ( Picku p ) ( I g n . (o il ) U ~ • 500 KO' 500 k O' 500 k o- 0 BlackfWhite 0 1 1 1 0 ( E xciter) U ~ ~ ~ 'C ~ ?[...]

13-14 ELECTRICAL SYSTEM KX500 : Tester Positive (+) lead Connection c lead Co lor Black/White White / Red 0 (Exciter) (Pickup) . ~ u ~ • c Black/White < 0 (Excite r) = u " • White / Red • ~ (Pickup) = - I - White / Green • > (Pickup) = . ~ • ~ B l ack • z (lgn . Coi l) = • • - B l ackIYe li ow • • = >- (Ground) Sta[...]

APPENOIX 14 - 1 Appendix Table of Contents Tro ubl es h oo t ing Guide ...... ,' .... , .... , ..... "...... . .. ........ .... . . .. . ........ ... 14 -2 Genera l Lubricatio n ...... . . .. ..... " ................. " .. . ...... ,.................. ... 1 4-5 Unit Conversion Table ....... . . . . .... . ... ..... . . ... . . .[...]

'4- 2 APPENDIX .............. , . . . . .. . . . ........ . ... . .. .... ...... ' .......... . Trouble s hoot i ng Guid e .. . ........ ... . . . . .. . . ..... . ....... .. . . . . . ................... NOT E o Th is is not a n exhaustive list, g ivi ng every possible cause for 6sch probl9m list8d. It is meant Simply 8S 8 rough guide to[...]

Fuel / air mixture incorrect; Main jet clogged or wrong size Jet needle or need l e jet worn Jet needle clip in w r ong position Float level too high o r too l ow Air jet or air passage clogged Ai r cleaner clogged, p oorly sealed, or missing Starter plunger stuck open Fue l to ca rburetor insufficient Water or foreign matter in fuel Fuel tank air [...]

14-4 APPENDIX Jumps out of g8ar : Shift fork worn Gear groove worn Gear dogs and/Of dog holes worn Shift drum groove worn Gear positioning lever s pring weak Of broken Shift fork guide pin worn DriVf! shaft, output shaft. and/or gear splines worn 0. ......... , Gear positioning lever spring weak or broken Shift mechanism arm spring broke n Abnormal[...]

S hoc k absorption un sa tisf a ctory : (Too hard) Front fo rk o il excessive Front fo rk oi l v i scosity 100 high Front fork l eg be nt Tire air pressure 1 00 high Rear sh ock absorber maladjusted (Too soft) front fo rk oil insufficient andlo r leaking Front fork oi l v i scos ity too lo w Front fo rie , rear s hock absorber s pr i ng wea k Rear [...]

14 -6 APPENDIX Unit Conversion Table .. . ..... ... . .. . . . . . .. . . . . . . . ..... . . .. . . . ... ... . . . . .. . . . ... . . . Prefixes for Unit s; P r ef ix Sy mb ol Po we r mega ki lo centi mini micro Units of Mass : Kg g x x Unit s of Volume : L x L x L x L x L x L x ml x ml x ml x Un it s of Force : N x N x k g x k g x M k c m "[...]

[...]

[...]

KX125 KX250 KX500 Motorcycle Service Manual Supplement This supplement is designed to be used in conjunction with the '88 KX125 / KX250 / KX500 Motor - cycle Service Manual (P I N 99924-1101-01). Th e maintenance and repair procedures described in this supplement are only those that are unique to '89 KX 125 / KX250 / KX500 motorcycle . Mo[...]

[...]

Table of Contents General Information Before Serv i cing ... ... . . .. .• • . . ... . .. Model Identification .. ......• • . ....... General Specification ..........••• • •. . . Periodic Maintenance Chart ..... • ••.... .• Torque and lock ing Agent . .....• ..... .. Cable Routing . . .. . . ••... . .... • . .. , .[...]

2 Engine Top End Exploded View .. , .. •• ....... , • • • . . .. 23 Specifications, ...... , .. , ......••.... 24 Special Tools ...................... . • Cylinder Head ....•..........••...... 25 Cylinder Compression Measurement ... . • Cylinder Head Aemoval •..••. , .... . • Cvlinder Head Installation Notes ..... . [...]

Crankshaft. Connecting Rod ..... . ...... . Crankshaft Removal .............. . Crankshaft In stallation Notes ........ . Crankshaft D isassemblv Note ...... . Crankshaft Assemblv Notes ........ . Connecting Rod Big End Radia l Clearance .......... • •.. Big End Seizure . ............ • .... Connecting Rod Big End Side Clearance ..........•[...]

4 Brake Pads .......... . .......••... Pad Removal ............... • ... Pad Installation .....•......•• • ... Pad Inspection ..... , ........... . Master Cylinder. .................... . Front Master Cylinder Removal .. , ... . Front Master Cylinder Insta l lation Notes .. . .................. . Rear Mauer Cylinder RemOllal ....... .[...]

Electrical Wiring .... . . . ..•.....•.•... Wiring Inspection ........ ...•••.. Ignition Tim ing . .... . ...........• • ... Ignition Timing Adjustment ..... • •.. FI,vwheel Magneto ................... . Flywheel Magneto Removal. ...... . . . Flywheel Magneto Installation ..... , .. Flywheel Magneto In spection ....... . Ign iti[...]

6 WARNING CONTAINS AS8ESTOS 8,".I~'ng IlbIIIO. d~11 I . danlll'ou, 10 h.~th Follow Hft.ty inmuct ...... (U . K . model only) This warning ma y apply to any of the follow - ing components or any assemb l y co nta ining one or more of these co mponent s:- Brake Shoes or Pads Clutch Friction Material Gaskets In su l ators SAFETY INSTRUC[...]

Except for the following description, the maintenance work for the KX125-G 1 is the same as for the KX 125-F 1 , for the KX250-G 1 is the same as for the KX250-F 1 , for the KX500·El i s the same as for the KX500-D1. General Information ............................. . ........................................ . ..... Model Identification KX125-Gl ([...]

8 KX250-G 1 (US and Can ad ian Model) Right S i de View KX250-Gl (Other than US and Canadian Model) Right Side View[...]

9 KX500·E1 (US and Canadian Model) Right Side View KX500·E1 (Other than US and Canadian Model) Right Side View[...]

10 General Specifications Items Dimensions: Overall length Overall width Overall height Wheelbase Road clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity Engine: Type Cooling system Bore and stroke Displacement Compression ratio Ma x imum horsepower Maximum torque Carburetion system Starting system Ignition system Ignition [...]

Items Transmis sion: Type Gear ratios : Final drive system: Type 1st KX125 · G1 6 · speed, constant mesh, return shift 2.142 (30 / 14) 2nd 1.714(24 / 14) 3rd 4th 5th 6th Reduction ratio 1.400 (28 / 20) 1.181 (26 / 22) 1 .04 1 (25124) 0.920 (23125) Chain drive 3.916(47 / 12) 12 .6 11 @Top gear SE class Overall d rive ratio Transmi ss ion oil: Fram[...]

12 Items Dimensions: Overall l e ngth Overall wid th Overall height Wheelbase R oad clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity Engine: Typ e Co o ling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system Ignition timing Spark Plug [...]

Items Transmission: Type Gear ratio s: Final drive system: Type 1st 2nd KX250 · G1 5 - speed , constant mesh, return shift 2. 133132 / 15) 1.687127 / 16) 3rd 1.388 125 / 18) 4th 1.136 (25122) Reduction ratio 5th 1.000 (24124) Chain driv e 3.357147 / 14) 9.232 @ Top gear SE c lass Overall drive ratio Transmission oil : Frame: Type Steering angle Ca[...]

14 Items Dimen sions: Overall l ength Overall width Overall height Wheelbase Road clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity Engine: Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion system Starting system Ignition system I gnition timing Spark Plug Port[...]

Items KX500-El Final drive system : Type Chain drive Reduction ratio 3.357 (47 / 14) Overall drive ratio 6.746 @ Top g e ar Transmission oil : Grade SE class Viscosity SAE 101'130 or 10W40 Capacity 0 . 8 L Frame : Type Tubular , single down tube Steering angle 45 0 to either side Caster (rake angle) 27 ' Trail 112mm ©@ 119mm Front tire :[...]

16 Periodic Maintenance Chart FREQUENCY Each Every Every Every As OPERATION race 3 races 5 races 10 races required Clutch-adjust • ·Clutch and friction plates-check t • R Throttl e cable -a djust • Spark plug - -clean, gap t • R Air cleaner element -c lean • Air cleaner element replace Damaged Carburetor inspec t/ adju st • w Transmiss[...]

17 Torque and Locking Agent Tight en all bolts and nuts to the proper torque using a n accurate torque wrench. If i nsuffici e ntly tightened, a bolt o r nut may become damaged or fall out. possibly resulting in damage to the motor - cyc le and injury to the rider. A bolt o r nut w hich is overtightened may become damaged , strip an internal thread[...]

18 Fastener Torque Remarks N -m kg-m ft-lb Suspension Front Fork Top Bolts · 27 2. 8 20 Front Fork Top Bolts" 29 3.0 22 Front Fork Clamp Bolts * 21 2.1 15 . 0 Front Fork Clamp Bolts" (Upper) 21 2.1 15 . 0 (Lower) 20 2.0 14 .5 Front A x le Clamp Nuts B . B 0 . 90 78 in - Ib Push Rod Stopper" 26 2.7 19.5 Front Fork Protector Bolt s &q[...]

Cable Routing KX125: 1. Clutch Cable 2. Clamp 3. Strap 4. Radiator Breather H ose KX125,250: 1 1. CO l Unit 2. Throttle Cable 3. Engine Stop Switch l ead 4. Clamp 19[...]

20 Fuel System Exploded Vi ew Specifications KX125: Item Carburetor Specifications: Make / type Main jet Throttle valve cutaway Jet needle Jet needle clip position Slow jet Air screw Service fuel level (below the bottom edge of the carbo body) Bore center Float height T1 : 34 N-m (3.5 kg-m, 25 ft · lb) T2 : 25 N ' m (2 .6 kg-m. 19 .0 ft-Ib) S[...]

21 KX250: Item Standard Service Limit Carburetor Specifications: Make /type KEIHIN PWK38 -- - Main jet 172 --- Throttle valve cutaway 7 - -- Jet needle R 1368J --- Jet needle clip position 4th groove from the top --- S l ow jet 55 --- Air screw 1 % (turns out) --- Service fuel level 1.0 ± lmm - - - (below the bottom edge of the carbo body) Bore ce[...]

22 Reed Va lve Reed Valve In stalla ti on • Ins ta ll the reed valve holder as shown. Upward )D D a a aup a a a a a D a a a a D ownward KX12S KX250 a a a aD-a KX500 1 . Projection j Cooling System Exploded View KX 500 : T1 : 6 , 9 N-m (0 .70 kg .m, 61 in . lb)[...]

23 Engine Top End Exploded View ........... .... ........................ .... .......... ... .................... KX125: o KX25Q: ""- --[...]

24 KX500: • T1: 9,8 N.m (1.0 kg-m, 87 in-lb) Specifications KX125: Item Standard Service Limit Cylinder, Piston: Cylinder inside diameter 56 . 020 - 56 . 035 mm 56.10 mm Piston /cy linder clearance 0 . 071 - 0.081 mm --- Piston ring groove width: Top 0 . 830 - 0. 850 mm 0.93 mm Second 0.815 - 0.835 mm 0.92 mm KX250: Item Standard Service Limit Cy[...]

............................................................................. Cylinder Head ............................................................................. Cylinder Head Installation Notes _F o r KX500 ·E l model, install th e cy lind er head gasket as shown. o~ 0 1 ® 4 1 1 . Metal Section 2. Short 3. long 4 . Short s id e faces upw[...]

26 . ..... ...... . ... ... ... . . . .. .... ......... ...... . . ..... ...... ........ .. .. ... .. Cylinder, Piston ....................... . ... . ......... ... ..... . ... ... ....... ........ .. ... . ... . Piston Diamet er Measurement e Measure the outside diameter of the piston 16 mm (KX12S), 20.5 mrn (KX250) or 26.1 mm (KX500) up from the [...]

27 Engine Right Side Exploded View KX125 : T1 : 88 N-m (9 . 0 kg..,.. , 65 ft . lb) KX25Q : T1 : 98 N-m (10 kg..,.. , 60 ft-lb)[...]

28 KX500: Specifications Item Standard Service Limit Clutch: Steel plate thickness 1.41 - 1. 59mm 1.31 mm Friction plate tang width: KX125 11 . 8 - 12.0mm 11.3 mm KX250, KX500 13 . 6 - 13.8 mm 13 . 1 mm[...]

..... . . . .......... R' .......• Ight Engine Co ....... . ....................... . ... . .. ver ....... . ... ... . .... . ..... . ........ .. Exhaust Ad ............. ....... . ......... . ................ . A vancer A ...... ssembl N ssembly D' o Th y otes lSassembly/ e exhaust adva lowing parts. neef assembly K X 125 : KX250: KX50[...]

30 Engine Removal/Installation Exploded View KX125: Engine Bottom End / Transmission Exploded View KX125: KX250: KX250. KX500: T1 : 34 N-m (3.5 kg-m, 25 ft-Ib) T2: 26 N-m (2.7 kg-m, 19 .5 ft-Ibl[...]

Crankcase Splitting Crankcase A s s embl y eF or KX500·El mode l , install t he bearing for the drive shaft into the left crankcase ha l f so that stepped side faces inside. e Apply non.pe r manen t lod;ing agent to the threads of the drive shaft bearing holder screws. 1. St epped Side 2. H olders 3. Apply non-per m ane n t locking ag ent. Cranksh[...]

32 Wheels / Tires Exploded View ................ . ..... ....... . . ... ......... .... ... .. ... . .... .. ........ .. ..... Specifications Item Tires : ( KX125,250) Front : Size Make, type A ear: Size : KX125 KX250 Make, type (KX5OO) Fr p nt : Size Make , type Rear: Size Make, type ® Size ® Make , Type ©@ Size ©@ Make , Type © : Canadian mo[...]

Wheels Front Wheel Removal (other than US and Canadian models) e P l ace a stand.or block under the motorcycle so that the front wheel is raised off the groond. e Loo sen the axle clamp nuts on the right side of the wheel. e Loosen the a)::le. A. Axle Clamp Nuts B. Axle e Remove the axle clamp nuts and the axle clamp. e Unscrew the axle from LH fro[...]

34 A. Arr o w Mark e T i ghten the upper clamp nuts first , and tighten the low e r clamp nuts t o the specified torque. Tight e ning Torque 8.8 N -m (0.9 kg-m, 78 in·lb) Final Drive Specifications Item Drive Chain : Make Type: KX 1 25 KX25 0 Length: KX 1 25 KX250, KX500 20- lin k length _ Check the front brake for weak braking po wer and bra ke d[...]

Brakes Exploded View .... ..... ......................... .......... .. .................. ... ... . .. .... I I I T2 Specifications Disc Brake: Ite m Brake Pad s; Pad li ning th ick n ess: Front R ea r Brake Discs: Disc thickne ss: Fr o nt T1 : 5.9 N-m (0.6 kg-m. 52 in~b) T2 : 25 N-m (2 . 5 kg-m, 18 . 0 ft~b) T3 : 8 .8 N - m 10 . 9 kg-m, 78 in&quo[...]

36 Special Tool The following special too l is added for brake fluid change. Oil Syringe: 57001-1290 Disc Brakes Calipers : Caliper Removal - Loosen the brake pad bo l ts before the caliper remova l if the caliper is to be disassembled. aF or the front caliper of other than US and Canadian models, remove the brake hose clamp bolt and brake lever, a[...]

e For the front caliper, there are two pistons in the caliper. Holding the one piston in p lace, l ightly apply compressed air to where the brake l ine fits into the caliper. Another piston comes out by air pressure. Temporarily in sta ll the removed piston. Take care that not to push it so far. Remove the remaining piston by lightly applying compr[...]

38 Suspension . . . .... .......... . . . .... .. . . ... .... .. . ..... . . .. ............. . .... ........ ... . Exploded View . . ... .... .. ............ . ..... ... .......... .. .......... .. .... .. ........ ... .. . . , , , 0 • : cwJ 0 t© g j : , , L ____ _ _ _ ______ __ _ _ __ _ _ ___ ...J ...-----j n • r - - - - - - - - - - - - - [...]

39 Specifications Item Standard Service Limit Front Fork: Air pressure Atmospheric pressure --- Oil viscosity KAY ABA 01 - -- Oil capacity US and Canadian Models 605 ± 4mL - - - Other than US and Canadian Models 425 ±4 mL --- Oil level (fully compressed, spring removed) (adjustable range) US and Canadian Models 150 ± 2 mm 120-1BOmm Other than US[...]

40 ... . . .... . .. .. .. .... . ..... ... ... . ..... . ..... .. ...... ........... . ... ... ... ... . Special Tools ............... . ... ... .. .... ... ... ... ... ... .. .... .. .... ... .. ......... .. .. . ... Spring Hold er : 57001 · 1286 Oil Cylinge : 57001-1290 Front Fork Cylinder Holder : 57001 - 1287 Front Fork Oil Seal Drill'8r[...]

I WARNING I o Lift th e front wheel before unscrewing both top bolts, or·the front fork tubes compress all th e way and ha za rd can occ ur . _ Remove the following . Number Plate H andlebar Clamp Handlebar Front Fork Top Bolt A. Front Fork Top Bolt Front Fender Brake Hose Clamp (other than US and Canadian Models) Front Caliper A. Caliper C. Brake[...]

42 O At this ti m e, do no t hit th e front brak e pipe and other parts . • Pulling down the fork spring and insert th e s prin g holder (special tool) under the push rod nu t. A. Spri ng C. Spring Ho l der: 5700 1 · 1286 B. T op Bolt _ Unscrew the both right and l eft top bolts. • Remove the s prin g holder, an d r emove the spring. A. T o p [...]

e Adj u st the oil level as requi r ed within the adjustable r ange usi ng one o f the fo ll owing oils. Re commend ed Oil KAYABA 01 el nstall t h e spring guides and push rod nuts at the p u sh rods (other t h an US and Canadian Models). o l nsta ll the spring guide so that the hole comes l ower side. A. P ush Rod Nut C. Ho le B. Spring Guide e Pu[...]

44 Front Fork Disassembly (Oil Change) (US and Canadian Models) _ When f"cmoving the top bolt, insert the sp r ing holder (specia l tool) under the push rod nut. A. Top Bolt C. Spring Seat B. Spring Holder : 57001-1286 Front Fork Assembly (Oil Change) (US and Canadian Models) e After pouring in the fork oil specified, perform the following. o [...]

_ Remove the washer. ) A. Washer _ Remove the push rod nut, and remove the spring guide. A. Push Rod Nut B. Spring G u ide _ Pour the fork oil into a container. _ Clean the bottom of the inner tube. _ Remove the caps on the bottom of the inner tubes. - Hold the front fork with a vise. - Stop the cylinder from turning by using the front fork cylinde[...]

46 o Hording the inner tube by hand in a vertical position, stroke the outer tube up and down several.t imes and pull it down . This shock t o the fork l eg separates the outer tube from the inner tube . e Remove the guide bushes, washer, oil scal, retaining ring, dust seal from the inner tube. A. Guide Bushes B. Washer C, Oit Seal D . R etaining R[...]

_ Install the gu id e, rollar, stopper, circlip, O-ring on the push rod. A. St opper D. Guide B. Co ll ar E. O-ring C. Circlip - Install the rollar on the guide, and tighten the stopper to the specified torque. Tightening Torque 26 N-m (2.7 kg-m , 19_5 ft - Ib) -I nsert the pus h rod and cy l inder unit into the outer tube. _ App ly a liquid gasket[...]

48 A. Push Rod C. Hole B. Spring Guide e lnstall the push rod puller (special tool : 57001. 1 289). e lnstall the washer into the outer tube. e lnstall the spring. _ Pull up the push rod. e lnsert the spring holder (special tool) under the push rod nut. A. Push Rod C. Spring Holder : 57001·1286 B. Nut e Remove the push rod puller. -I nstall the to[...]

Steering Exploded View Electrical System .. ...... .... . . ..... ... . . . ........................................... ... ... . . Exploded View KX125: 11 : 5.9 N-m (0.6 k,'m. 52 in·lbl T2: 27 N-m 12.B kg·m, 20 ft · lbl 49 T1 : 25 N-m 12.5 kg-m, 18.0 ft-tb) KX250: T2[...]

50 . .. . ............ .... . ... ............ . ... . .. .. ... .. ........ .. .. . . .. . .... ..... Wir i ng Diagram .. ..... .... ... . ..... . ...... .... . . . . ..... . .. . . .... .... . .... . ..... . .. .. .. .. ... KX125/250 1. Spark Plug 2. I gn it ion Coil 3. COl Unit 4. P ickup Coil 5. Excitor Coil 6. Stator Coils 7. Magneto 8. Engine[...]

Spec ificati o ns It e m Ig nition Sy stem : Ignition t iming: KX 1 25 KX25 0 CO l unit interna l resistance Spark plug: Ignition Syst e m Spark Plug Gap Inspection Spa r k Plug Gap 0 .5 - 0 .6 mm COl Unit Inspection Spark p l ug gap 51 S ta nd a rd 1 3.8° BTDC@ll000r/m in Irpm) 1 4° B TD C @6000 rl min Irpm) refer to page 5 1 0.5 - 0 .6 mm NOTE [...]

MODEL APPLICATION Year Model Beginning Frame Number KX 1 2S.G l JKAKXRG 1 DKAOOOOOl or KX 1 25G'{)()()()()1 1989 KX250.Gl JKAKXMG10KAOOOOOlor KX25QG.{)()()()()1 KX500-El JKAKXVE10KAOOOOO l or KX500E.()()OO() l o : Th is digit in the frame number changes from one machine to another.[...]

Kawasaki KX500 Motorcycle Service Manual Supplement This supplement is designed t o b e used in conjunction with the ' 88 KX125IKX250 / KX500 Motoorcycle Service Manual (P I N 99924-1101-01) . The maintenance and repair procedures described in this supplement are only those that are unique to ' 90 and up KXSOO motorcycles. Most service op[...]

[...]

Table of Contents Ge n eral Information Befor . Servi cing ..... . .......•....... Mode l Identificat i on ... . ... . ...•...... Ge nera' Spec ifi cat i on s .........•...•. . . Per i od i c Ma i ntenance Chart .... , ••• " ••.. T or que and Lock i ng Agent , .. , ..•....... Cable Routing , .... . .........••.....[...]

2 Engine Top End E)(ploded V i ew •••.....•••••• . ..• . ..• SpeciflCltions .........••.... , ..• . ... Spec i. l Tools ...•....•...•...... . . . . Cylinder Held ... . .. . .. , ........ , ... . Cyl i nder ComprH. l on Measurement .. . . Cylinder Held Removal ... . ... , •... Cylinder Held Installation Notes . , [...]

Crankshaft , Connecting R od .. .. ........ . Crankshaft Rem ov a l. ............. . Crankshaft I nstallation Notes ....... , . Crankshaft D isassembly N o te ........ . Crankshaft Assembly Not es ........•. Connecting Rod B ig End Radial Clearance .... . ......... • Big End Seizure ................•• Connecting Rod B ig End Side Clearance [...]

4 R ea r Master Cylinder Remo val .. . . . .. . Rear Master Cy l inde r Installat i on N otes .. Front MISter Cy li nder Disassembly .... , Rear M.ster Cylinder Dl sassemblv . .. . . Ma s ter Cvllnder Assembly Not es ..... . Master Cylinder Inspection (Visual I nspecticn) . ..... , ..•.•• Brake D isc ....... , .. ... . . . . .• •• • ?[...]

A ABDC AC ATDC BBDC BDC BTDC ' c DC F ' F It 9 h L LIST OF ABBREVIATIONS ampere(s) Ib pound(s) after bottom dead center m meter(s) alternating current min minute!s) after top dead ce nter N newton!s) before bottom dead center Pa pascal Is) bottom dead cente r before top dead center degree!s) Celcius direct current fa,ad(,) degree!s) Fahre[...]

6 General Information ..... . . ..... .... . ... ..... .. ........ ... . .............. ... ... ..... ... .. .... ... Model Identification ............ .... . .. ... . .... . .... .................. .. . ....... .. ...... ....... . KX600-E2 KX51JO.E3[...]

General Specifications Item s Dimensions : Overall length Overall w i dth Overall height Wheelbase Road clearance Seat height Dry weight Curb weight: F ront Rear Fuel tank capacity Engine : Type Cooling system Bore and s t roke Displacement Compression ratio Maximum horsepower Maximum torque Carburetion sys t em Start in g sys t em I gnition sys te[...]

8 I tems Transmission : Type Gear rat ios: Final drive system : Type 1st 2nd 3,d 4th 5th Reduction ratio Overall drive ratio Tran smission oi l : Frame : Type Steering angle Caster (rake angle) Trail Front tire : Rear tire : Make/Type Size Make / T vpe Size Front suspension : Type Wheel travel Rear suspension : T ype Wheel travel Grade Viscosity Ca[...]

9 . . .. ... .. . ....... . .. ... ........ , .. ..... ..... . .... ................. , ......... . Periodic Maintenance Chart .. . . ...... .. , .... ..... ..... ... ....... " ... ..... ... . . . .... . .. .. . ...... .. ..... . FREQUENCY Each Every Every Every As OPERATION race 3 races 5 races 10 races required Clutch-adjust • Clutch and f[...]

10 Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench . I f insufficiently tightened, a bolt or nut may become damaged or falloff, possibly resulting in damage to the motor - cycle and injury to the rider. A bolt or nut which is overtightening may become damaged, strip an internal thread , or br[...]

Fuel System ................................................................. ... ........ Exploded View ..... . ................................................ .. .... .. .............. ... . ................. ..... . ... ....... .. .................. . .................. Specifications ..................... .. .... .. ...........................[...]

12 Reed Valve ........ . ...... .. .. . . ... .. .. . .. ... . .............. . .. ... .... . .. .. ... .. . ...... Reed Valve In stallat;on _ In sta ll the reed valve holder as shown. Upward D D Downward o 0 o oD-o Engine Top End o . . . . . ... . .... . ... .. .. .. ... . .... .. . . .. . .. . .. . ... . .... . ... .. .. . ..... ... .. . .. .. Ex[...]

Specifications Item Cylinder, Piston : Pi sto n d ia meter P isto n / cylinder c learance P iston p in hole diameter Cylinder Head Cylinder Head Insta/lation Notes -Ins tall t he cy l inder head gasket as shown. o o ~ o ® 4 1 1. Metal Section 2 . Short 3 . Long 4. Short side faces upward . 1 . . ... . .. ... ....... ... .. .... ... .... ........ .[...]

14 A : 26.S mm Piston / Cylinder Clearance Pilton/Cylinder Claaranet Stllnderd : 0, 100 - 0. 130 mm Engine Right Side Exploded Viow Specifications ...... . .................. .... ....................... . ....... .. .... .... ... .. .. Item Clutch : Steel plate th ickness Friction plate tang width P is ton , Piston Pin , Connecting Rod Wear Inspec[...]

... . ....... . .... . .. . .. . ......... . ..... . .............................. . .... .. . R ight Eng i ne Cover Exhaust Advancer Assembly Disassembly / Assembly Notes e The exhaus t advancer assembly consists of the fol- lowing parts. 1 . P ins 2. Rod 3. Guide 4 . ().ring S. Steel Ba ll s 6. Ho l der 7. Needle Bearing 8. Spacer 9. Collar 10 .[...]

16 Engine Bottom End / Transmission ..... ..... . .. .. .... .. .. .. . ............. . ... ... .. ... ........ . . ... . . ... .. .. . .. . Crankcase Splitting Crankcase Assembly _I nstall the bearing for the drive shaft Into the left crankcase half 50 that stepped side faces inside . • Apply a non·permanent locking agent to th e threads of the[...]

Wheels / Tires Exploded View Specifications ltom Tires: Front : Size Make , type Rear : Size Make , type IE) : European mode l IU): U.K. model Stondard 80 / 100-2151M T1 : 64 N-m (5,5 kg-m, 40 ft-Ib) T2: 29 N'm 13.0 kg-m, 22 ft·lb) T3 : 98 N'm (10 kg-m, 72 ft-Ib' Service Limit --- DUN LOP K490 IE, U) DUNLOP 0752 , Tube type --- 120 [...]

18 Wheels ............................................................................ Front Wheel Removal eR eplace a stand or block under the motorcycle SO that the front wheel is raised off the gr o und. - Loosen the right axle clamp nuts. -Un screw the axle . • Pull off the axle, and remove the wheel. A. Axle Clamp Nuts B . Axle CAUTION Do no[...]

_ Check the fr o nt brake fo r weak braking power and brake drag. AWARNING Do not attempt to drive the motorcycle until a full brake lever I, obtained by pumping th e brake levar until the PMis ere againtt the disc.. The brake will not function on tha fint application of tha levar jf thl' i, not done . Final Drive Exploded View 19 Rear Wheel R[...]

20 Drive Chain Drive Chain Slack Adjustment - Pull o ut th e cotte r pin, and l oose n the axle nut. A . Cotter Pin D. Locknut B . Axle Nut E . M arks C. Adjusting Bolt F. N o tch _ After adju s tment , insert a new cotter pin thr o u gh the axl e nut an d ax l e, and spread its ends. Wheel Alignment Inspe cti on WhHI Al ignme nt Inspection A. Mark[...]

Brakes Exploded View T2 Specifications Disc Brake : Item Brake Pads: Pad lini ng thickness: Brake Disc: Disc thic k ness : T1 ~ .. o f Front Rear Front Rear Standard 4.5mm 4 .7 mm T1 : 5 .9 N'm (0 .8 kg-m . 52 in-Ib) T2 : 26 Nom (2 .5 k9"m. 18.0 ft·lb) T3: B,8 N · m 10 .9 kg-m . 78 i n-Ib) T4 : 6. 4 N·m (0 . 65 kll"m, 48 in-Ib) T5[...]

22 Disc Brakes Caliper" Caliper Removal eR emove the disc cover. A. Di sc Cover B . Mounting Bolts -L oose n the brake pad bo l ts before th e caliper remova l if t he caliper i s to be disassembled. A. Caliper Mounting Bolts B . Br.tke Pad Bolts Caliper Instal/at i on Note s eT ighten the brilke pad bolts to the specified torque if it was rem[...]

Brake Pads : Pad Removal • Loosen the brake pad bolts bef o re the calipe r rem oval. A. Brake Pad Bolts Pad Ins tallation eTi ghten the brake pad bolts to the specified torque. Spe ci fied Torque 18 N·m (1.8 kg-m. 13 . 0 ft · lbl Pad Inspect io n _ Check the lin ing thickness and condition of the pads in eac h ca l iper. *If ei ther pad is dam[...]

24 Suspension ... .. .. . ... . .. ..... ...... . ... . ... . ............ .......... .......... ..... ... . .. Exploded View L : Apply. noo-permanent locking agent to the threads . T1 : 21 Nom (2. 1 kg.m, 16 .0 ft · lb) T2: 20 N ' m (2 . 0 kg.m, 14 .5 ft·lb) T3 : 29 N ' m 13.0 kltm , 22 ft·lb) 1'4 : 27 N'm 12 .8 kg.m. 20 ft-[...]

25 Specifications It em Standard Service Limit Front Fork : Air pressure Atmospheric pressure - - - Rebound damping ad ju stment (Adjustable range) (turn the adjuster counterclockwise) : KX500 - E2 10 c lick s, (0) 8 clicks 16 clicks E 3 - E5 9 clicks, (0) 10 clicks 16 c li cks E6. E7 12 clicks 16 clicks E 8- El l 10 clicks 18 clicks Compression da[...]

Item Standard Service limit Rear Shock Absorbers : Gas pressure 1 000 k Pa (10 kg / cm 2 , 14 2 psi) - - - Spring preload (adjusting nut position from th e cen t er (ad ju s table range) of the upper mounting hole) : KX500 - E2 - E5 122 . 5 mm , (0) 123 . 5 mm 109 - 130 mm , (0) 109 - 132 mm E6 . E7 122 .5 mm 109 - 130 mm E8 - Ell 117 . 5mm 104-127[...]

Front Fori< ( KXSOO - E2 - E7 ) Rebound Damp in g Adjustment " , 16 o----@ Soher H,rd,r (COUIHerClock w i 5e ) (Ctoc kw in) Number of turns countercl o ckw i se usable range-16 clicks A. Seated position wit h adjuster turned fuJly c l ockwise . Front Fori< ( KXSOO - E8 - Ell) Rebound Damping Adju s tment " " .. " " $Q[...]

26 Special Tool s Fork SpJirti Holder : 67001-1286 Fork Push Rod Puller : 57001 · 1289 Oil Syringe : 57001 · 1290 Fork Oil Seal Driver : 57001-1340 Fork Cylinder Holder: 67001 · 1287 Jack : 57001-1238 /[...]

.... . ........ . ...... . ............ . .......... . .. . ....... . .... ... ..... . ...... . Front Fork ... ... ............ . ................................. . ........ .. ..... . ... .. .. Front Fork Adjustment The front fork should always be adjusted for the rider's weight and track conditions by u sing one or more of the following met[...]

28 Compre u ion Damp i ng Ad ju l tment _ Clean the bottom of the OlJter tubes. • Remove the caps on th e bottom of the outer tubes . e To adj u st compression damping. turn the adj u ster on the fro n t fork cylinder valve with the blade of a screw- driver until you feel a click. Adjust th e compression damping t o the specified setting. A. Adju[...]

A. Rebound Damping Adjuster Rod (short) B . Push Rod B Hoid the fork tube upside down over a clean containe r and pump it to drain the oil. Remove the r ebound damping adjuster rod (long) fr o m the push rod . A . Push Rod B. Rebound Damping Adjuster Rod (long) NOTE o To discharge the fork oil, pump the push rod up and down um tirmn. Filling with O[...]

30 - After purging the air from the assembly. let it sit for about five minutes so that any suspended air bubbles can surface. Adjusting Oil LweI e Set the oil syringe (special tool), stopper so that its lower side shows the oil level distance specified. A. Oil SyrinJ!i: 57001·1290 B. Stopper NOTE o ThtIIJIIU~ tube is grlKiulJted in 1 em division.[...]

Front Fork Removal (Each Fork Tube) Front Fork Remonl - Using the jack (spec ia l tool ) under the frame, stabilize the motorcycle. e Place a stand or block under the engine so that the front wheel is raised off t he ground. .. WARNING lift the front wheel before unscrewing both top plugs, or th e front f9rk tube , will full y compress causing inju[...]

32 _ Pull the fork spring away from the top plug a little and slip the fork spring holder (special tool) in on top of the spring seat and under the rod nut . A. Fork Spring B. P ush Rod Nut C. Fork Spring Holder : 57001·1286 - Use wrenches on the rod nut and the top plug to loosen the push rod nUL A. Top Plug C. Fork Spring B . Spring Seat e R emo[...]

3 1. Fork Cylinder Holder : 57001-1287 2. Cylinder Unit 3. Cylinder Valve Assembly A. l nnerTube C. O-ring B. Cylinder Valve Assembly D. Gasket NOTE 0 00 not remove the inner tube from the outer tube. A. Pu s h Rod C. Inn er Tube B. Inn er Cylinder _U nscrew the guide stay nu t from the piston holder, and remove the split ring keepers. eR emove the[...]

34 o Remove the retaining ring from the outer tube . A. Retaining Ring o Grasp the in ner tube and stroke the outer tube up and down several times. Th e sh ock to th e fork seal sep- arates the outer tube from th e in ner tube . e Rem ov e the guide bus h ings, washer, all se al , r etai n ing r in & dust seal from the inner tube . A . Guide Bu[...]

Inner Cylinder Auembly _ Install the oil lock piston on the piston holder so that the grooves face down. OFirst, insert the push rod into the cartridF, then, install the anti-bottoming piston . The hardened steel keepers that hold the anti-bottoming p isto n to the push rod can cause severe damage to the forlc if not in- stalled sec ur ely. 1. Push[...]

36 _ Screw on the push rod nut so that the chamfered side is down. o Position the push rod nut at 18.5 rnm or more from the top of the push rod. }@) n 1.18.5 mm 2. Push Rod Nut 3. CoUar (82 Mode l only) 4. Chamfered Side S. Spring Guide e lnsert the rebound damping adjuster rod (long) into the push rod. e lnsert the rebound damping adjuster rod (sh[...]

I n ner T ube I nspection e Visuall y inspect the inner tube, repair any damage. e Nicks or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. * If the damage is not repa i rable, replace the inner tube. Since damage to the inner lube damages the oil seal, replace the oil seal w[...]

38 ........ . ..... ... .. . ... . ................ .. .. " ...... . ... . .............. . ... . . .. Rsar Suspension (Un i· Trak) .... . ....... . ... . ... .. .. . ... . .... .. .. ... ........... .. .. .. .. .. ...... . .......... . Rsar Shock Ab s orber : Shock D am p i ng Adjus t me n t R ear Shoc k Absorber Rebound Da mping Adjustment [...]

Electrical System ...... . ..... .... ... ....... . . ...... . .. ... . .... ... ... ... .. ............. .... ... Exploded View ........... ..... . . . .. ... . .. . . ... .......... ... .... . . . .. . .. .. .. . .. . ... .. ...... .. ... ....... .. . .. .......... . ... .... ... . .. . . . . . ...... .... ... . ...... .. ... . .. .. Wiring Diagr[...]

40 ... ... . . ....... . ............................... . ........ . ................ . .. Specifications ............................. ..... .... ... ........................ . ....... ... Item Standard I SJlition System : Ignition timing : 19 ' BTDC @6 000 r / min (rpm) Ignition Coil : Primary winding resistance 0.311) ' 1 5% Secondary[...]

SUPPLEMENT - 2000 - 2004 MODELS 1·1 Supplement - 2000 - 2004 Models Table of Contents Foreword ............................................................ ..................................................................... 1-2 General I nformation ............................................ ....................................... . ...........[...]

1 -2 SUPPLEMENT - 2000 - 2004 MODELS Foreword How to Us e thi s Manual This " Supp l ement 2000 - 2004 Mode ls " designed to be used in conjunction with the front part of this manual (up to P.40) andior Base Manual ' SS KX12SIKX2S0IKXSOO Service Manual - Part No . 99924-1101-01 . The specifications and maintenance procedures describe[...]

General Information Model Identificat i on KX50o-E12 Left Si de V i ew : KX50o-E12 Right Side View : SUPPLEMENT - 2000 - 2004 MODELS 1-3[...]

1-4 SUPPLEMENT - 2000 - 2004 MODELS General Information General Specifications Items Dimens i ons : Overall l eng th Overall width Overall height Whee l base Road clearance Seat height Dry weight Curb weig ht Front R ear Fuel tank capacity Engine : T y pe Cooling sys t em Bore and s t roke Displacement Compress i on ra ti o Maximum h o r sepower Ma[...]

General Information Items Transmission : Type Gear ratios : Final dri ve system 1 sl 2nd 3rd 41h 51h SUPPLEMENT - 2000 - 2004 MODELS 1-5 KX500-E12 I KE500-E13 -E 16 S-speed , constant mesh , retum shift 2.000 (32116) 1.444 (26 / 18) 1 . 181 (26 /22) 0.954 (2 1 /22) 0.791 (19 / 24) Type Chain drive Reduclion ralio 3.357(47 1 14) Ov erall drive ratio[...]

1-6 SUPPLEMENT - 2000 - 2004 MODELS General Information Torque and Locking Agent Tighren all boits and nuts to the proper torque using an accurate wrench. If insufficiently tightened , a bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to th e rider . A bolt or nut which is overtightening may bec[...]

Fuel System Exploded View T1 : 34 N·m (3.5 kgf · m , 25 ft · lb) T2 : 34 N· m (3.5 kgf·m , 25 ft · lb) Specifications I te m Ca rbur e tor Specific a tion s: Make / type Main jet Throttle valve cutaway Jet needle Jet needle clip position Slow iet Air screw Service f uel l eve l SUPPLEMENT - 2000 - 2004 MODELS 1·7 • I COI .... " • St[...]

1-8 SUPPLEMENT - 2000 - 2004 MODELS Engine Removal/Installation T1 : 44 N ·m (4 . 5 kg f· m, 32.5 ft·lb) T2 : 29 N ·m (3 . 0 kg f ·m , 21.5 ft · lb ) IH~IO!II ' ! C[...]

SUPPLEMENT - 2000 - 2004 MODELS 1-9 Engine Bottom EndlTransmission Specifications Item Standard Transmission Oil : T ype AP I S E , S F or SG AP I SH or SJ with JASO MA Viscosity SAE 10W-40 Capacily 0 . 8 L Transmission Oil In order for the t ransmission and clutch to function prop· erly , a l ways maintain the transmission oil at the proper l ev [...]

1-10 SUPPLEMENT - 2000 - 2004 MODELS WheelslTires Exploded View T1: 79 N · m (8.0 kgf·m , 58 ft · l b) T2 : 34 N·m (3 .5 kgf·m , 25 ft · lb) T3 : 110 N·m (1 1 kgf·m , 81 ft · lb) Specifications Item Standard Tires : Fr o nt : Size 80/ 100 ·2 1 5 1M Make , type DUNLOP K490J (EU) DUNLOP D752FG , Tub e type R ear: S iz e 1 20/90- 1966M Make [...]

Final Drive Exploded View T1 : 34 N·m (3.5 kgf·m, 25 ft · l b) T 2: 110 N · m (1 1 kgf .m , 8 1 ft · lb ) T 3: 79 N·m (8 . 0 kgf ·m , 58 ft · l b) SUPPLEMENT - 2000 - 2004 MODELS 1·11 nOll l U " C[...]

1-12 SUPPLEMENT - 2000 - 2004 MODELS Brakes Exploded View A : KX500-E12 - E15 Models S: KX500-E16 Model - T1 : 5 .9 N·m (0.6 kgf·m , 52 in·lb) T2 : 25 N·m (2 . 5 kgf ·m . 18.0 ft · lb) T3 : 8.8 N ·m (0.9 kgf·m, 78 in·lb) T4 : 7 . 8 N ·m (0 . 8 kgf·m , 69 in · lb) T5 : 18 N·m (1 . 8 kgf · m. 13 . 0 ft · lb ) T6 : 28 N · m (2 . 8 kgf?[...]

Suspension Exploded View o o o ~ 8 T1 : 20 N·m (2 . 0 kgf · m , 14 .5 ft · lb) T2 : 30 N · m (3 . 0 kgf ·m , 22 ft·lb ) T3 : 28 N · m (2 . 9 kgf ·m , 21 ft ·l b) T4 : 8 .9 N · m (0 . 90 kgf · m , 78 in · lb) T5 : 54 N · m (5 . 5 kgf ·m , 40 ft · lb ) T6 : 83 N · m (8 . 5 kgf ·m, 61 ft · lb ) T7 : 39 N · m (4 . 0 kgf ·m , 29 ft ?[...]

1-14 SUPPLEMENT - 2000 - 2004 MODELS Suspension Rear Suspension (Uni-Trak) Rear Shock Absorber : The rear su s upension system of this motorcycle is Uni ~ t rak. It consists of a rear shock absorber , swing arm , tie-rod and rocker arm . To s uit to various riding conditions , the spring preload of the shock absorber ca n be adjusted or the spring [...]

Steering Exploded View T1 : 25 N ·m (2 . 5 kgf ·m , 1 8 ft · lb) T 2 : 44 N ·m (4 . 5 kgf·m , 33 ft · lb ) T 3 : 4 .9 N· m (0 .5 kg ·m , 43 in ·lb) T4 : 20 N·m (2. 0 kg ·m , 1 4.5 ft ·l b) SUPPLEMENT - 2000 - 2004 MODELS 1- 15 U O'~ll1 " e[...]

MOD EL APPLI C ATION Year M:>del Beginning Frame No . 1990 KX500-E2 JKAKXVE10LAOO2001 or KXSOOE-002001 1991 KX500-E3 JKAKXVE10MAD04001 or KX500E-004001 1992 KX500-E4 JKAKXVE10NAOO7001 or KXSOOE - 007001 1993 KX5OO-E5 JKAKXVE10PAOO8301 or KXSOOE-008301 1994 KX500-E6 JKAKXVE10RPD10001 Of KXSOOE-010001 1995 KX5OO-E7 JKAKXVE10SPD11001 or KX500E -0 1[...]