Kawasaki KX125, KX125 1999, KX125 2002, KX250 Service Manual

Kawasaki
KX125
KX250
Motorcycle
Service Manual
Quick Reference Guide
Brakes
••
••
••
••
110.•
Suspension
11 •
Steering
12.
Electrical System
13.
Appendix
141
General Information
Fuel System
Cooling System
Engine Top End
Engine Right Side
Engine Removal/Installation
Engine Bottom EndlTransmission
WheelslTires
Final Drive
This quick reference guide will assist you in
locating a desired topic or procedure.
• Bend the pages back to match the black tab
of the desired chapter number w ith the black
tab on the edge at each lable 01 contents
page.
• Refer to the sectional table of contents for
the exact pages to locate the specific topic
required.
1
2
3
4
5
6
7
8
9
KX125
KX250
Motorcycle
Service Manual
1
1
LIST OF ABBREVIATIONS
A
ampere(s)
Ib
pound(s)
ABDC
after bottom dead center
alternating current
after top dead center
before bottom dead center
bottom dead center
before lop dead center
m
maler(s)
min
minule(s)
newton(s)
pascal(s)
horsepower
pound{s) per square inch
AC
AlOe
BBDC
BDC
BTDC
·C
DC
F
'F
N
Pa
PS
p~
degree(s) Celsius
revolution
direct current
'pm
larad(s)
TOC
ft
degree(s) Fahrenheit
foot, feel
9
gram{s)
TlA
V
W
h
hour(s)
liter(s)
L
n
revolution{s) perminute
lop dead center
10lal indicator reading
voll(S)
watt(s)
,
\
ohm(s)
1
1
1
Read OWNER'S MANUAL before operating
Foreword
This manual is designed primarily for use by trained
mechanics in a property equipped shop. However, it
contains enough detail and basic information to make
it useful to the owner who desires to perform his own
basic maintenance and repair work. A basic knowledge
at mechanics, the proper use of tools, and workshop
procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the
owner has insufficient experience or doubts as to his
ability to do the work, all adjustments, maintenance, and
repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and to avoid
costly mistakes, read the text, thoroughly familiarize
yourself with the procedures before starting work, and
then do the work carefully in a clean area. Whenever
special tools or equipment are specified, do not use
makeshift tools or equipment. Precision measurements
can only be made if the proper instruments are used,
and the use of substitute tools may adversely affect safe
operation.
To get the longest life out of your motorcycle:
• Follow the Periodic Maintenance Chart in the Service
Manual.
• Be alert for problems and non-scheduled maintenance.
• Use proper tools and genuine Kawasaki motorcycle
parts. Special tools, gauges, and testers that are
necessary when servicing Kawasaki Motorcycles are
introduced by the Special Tool Manual. Genuine parts
provided as spare parts are listed in the Parts Catalog.
• Follow the procedures in this manual carefully. Don't
take shortcuts.
• Remember to keep complete records of maintenance
and repair wi th dates and any new parts installed.
How to Use this Manual
In preparing this manual, we divided the product into
its major systems. These systems became the manual's
chapters. All information lor a particular system from
adjustment through disassembly and inspection is located
in a single chapter.
The Quick Reference Guide shows you all of the
product's system and assists in locating their chapters.
Each chapter in turn has its own comprehensive Table of
Contents.
The Periodic Maintenance Chart is located in the
General Information chapter. The chart gives a time
schedule for required maintenance operations.
If you want spark plug information, for example, go to
the Periodic Maintenance Chart first. The chart tells you
how frequenlly to clean and gap the plug. Next, use the
Quick Reference Guide to locate the Electrical System
chapter. Then, use the Table of Contents on the first page
of the chapter to find the Spark Plug section.
Whenever you see these WARNI NG and CAUTION
symbols. heed their instructions! Always follow safe
operating and maintenance practices.
AWARNING
This warning symbol identi fies specia l instructions or procedures which, if nat correctly followed, could result in personal inj ury, or loss of
life.
CAUTION
This caution symbol identifies specia l instructions or procedures which, if not strictly observed, could resu lt in damage ta or destruction
of eq ui pment.
This manual contains four more symbols (in addition to
WARNING and CAUTION) which will help you distinguish
different types of information.
NOTE
o This note symbol indicates points of particular interest for more efficient and convenient operation.
• Indicates a procedural step or work to be done.
o Indicates a procedural sub-step or how to do the work
of the procedural step it follows. It also precedes the
text of a NOTE.
Indicates a conditional step or what action to take based
on the results of the test or inspection in the procedural
step or sub-step it follows.
*
In most chapters an exploded view illustration of the
system components follows the Table 01 Contents. In
these illustrations you will lind the instructions indicating
which parts require specilied tightening torque, oil, grease
or a locking agent during assembly.
GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing .. ... .... .... ........................................ ................... ...... .. .... ...... ......... .. ....................................... .. ... ............ .. 1-2
Model Identification .. ...
.................. .. ... ........... ..... .... ....... ......................................... .. ..... .. .. .... .... .. .. ..... ..... ... ...... ..... .. .. . 1·4
General Specifications .. ................... ........ .... ... .. ... ............................................... .................. .. .... .... .. .. .. ....... .. .. ... ... ......... 1·8
Periodic Maintenance Chart ... ... ... ... . .... .. .... .. ........ ..................... .... .... ........................ .. .... ...... ... ...... .... .... .. ....... .............. 1-15
Torque and Locking Agent .... ..... .................................. ..
.... ......... .. ............... ....... .. ...... ................................. .... ... .. .. 1-16
Special Tools .................... .............. ....
.. .. ... .. ... . ......................................................
........................... 1·19
Cable, Wire and Hose Routing ... ........ .... .... ..... .. .. .. .... .... ................................................. .... .. .. .. ........... .. .......... .. ...... ...... 1·23
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection seMce or carry out a disassembly and reassembly operation on a motorcycle,
read the precautions given below. To facilitate actual operations. noles, illustrations, photographs, cautions, and detailed
descriptions have been included in each chapter wherever necessary. This section explains the items thai require particular
attention during the removal and reinstallation or disassembly and reassembly 01 general parts.
Especially note the following :
(1 ) Dirt
Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will shorten the life of the
motorcycle. For the same reason, before installing a new part, clean off any dust or metal filings.
(2) Battery Ground
Disconnect the ground (-) wire from the battery before perlorming any disassembly operations on the motorcycle.
This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated
wtlile disconnecting the wires from electrical parts, as well as damage to Ihe electrical parts themselves. For
reinstallation, first connect the positive wire to the positive (+) terminal of the battery
(3) Installation, Assembly
Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly
sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during
removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record
the locations and routing whenever possible.
(4) Tightening Sequence
When installing botts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure
to lollow the sequence. When installing a part with several botts, nuts, or screws, start them all in their holes and
tighten them to a snug fil, thus ensuring that the part has been installed in its proper location. Then, lighten them
to the specified torque in the tightening sequence and method indicated. If lightening sequence instructions are not
given, lighten them evenly in a cross pattern. Conversely, to remove a part, first loosen all the botts, nuts, or screws
thai are retaining the part a 1/4-lurn before removing them.
(5) Torque
When torque values are given in this Service Manual, use them. Either too little or 100 much torque may lead to
serious damage. Use a good quality, reliable torque wrench.
(6) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially
difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap
lightly using a wooden or plastic·faced mallet. Use an impact driver for screws (particularly for the removing screws
held by non·permanent locking agent) in order to avoid damaging the screw heads.
(7) Edges
Walch for sharp edges, as they could cause injury through careless handling , especially during maiO( engine
disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over.
(8) High·Flash Point Solvenl
A high·fla sh point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North
America is standard solvent (generic name) . Always follow manufacturer and container directions regarding the use
01 any solvent.
(9) Gasket, O-Ring
Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter Irom the mating
surlace of the gasket or O·ring to ensure a perlectly smooth surface to prevent oil or compression leaks.
(10) Uquid Gasket, locking Agent
Clean and prepare surlaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly.
Excessive amount may block engine oil passages and cause serious damage.
(11 ) Press
When using a press or driver to inslall a part such as a wheel bearing, apply a small amount 01 oil to the area
where the two parts come in conlact to ensure a smooth lit.
(12) Ball Bearing and Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle
bearings that were removed with new ones. Install bearings with the manulacturer and size marks lacing out. applying
pressure evenly with a suitable driver. Apply force only to the end of the race that contacts the press fit portion, and
press it evenly over the base component.
(13) Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. Oil or
grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until
the face of the seal is even with the end of the hole, unless instructed otherwise. When presSing in an oil or grease
seal wtlich has manufacturer's marks, press it in with the marks facing out.
•
1
GENERAL INFORMATION 1-3
Before Servicing
(14) Circtip, Retaining Ring, and Cotter Pin
When installing circlips and retaining rings, lake care to compress or expand Ihem only enough to inslalilhem and
no more. Install the circlip with its chamfered side lacing load side as well.
Replace any circtips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and
deforms them. If old ones are reused, they could become detached while the motorcycle is driven, leading to a major
problem.
(15) Lubrication
Engine wear is generally at its maximum while the engine is warming up and before ailihe sliding surfaces have
an adequate lubricative film. During assembly, make sure to apply oil to any sliding surface or bearing that has been
cleaned. Old grease or dirty oil could have losl ils lubricative quality and may contain foreign particles Ihat act as
abrasives; therefore, make sure 10 wipe it off and apply fresh grease or oil. Some oils and greases in particular should
be used only in certain applications and may be harmful if used in an application for which they are not intended .
(16) Direction of Engine Rotation
To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Positive rotation is
counterclockwise as viewed from the left side of the engine. To carry out proper adjustment. it is furthermore necessary
to rotate the engine in the direction of positive rolation as well.
(17) Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are removed.
Replacement parts will be damaged or lose their original function once they are removed. Therefore. always
replace these parts with new ones every time they are removed. Although the previously mentioned gasket, O·ring,
ball bearing, needle bearing, grease seal, oil seal , circiip. and cotter pin have not been so deSignated in their respective
text, they are replacement parts.
(tS) Electrical Wires
All the electrical wires are either one-color or two·color. A two-color wire is identified first by the primary color and
then the stripe color. For example. a yellow wire with thin red stripes is referred to as a "yellow/red" wire; it would
be a ·redlyellow~ wire if the colors were reversed. Unless instructed otherwise. electrical wires must be connected to
wires of the same color.
Two-Color Electrical
Wire(cross-section)
i~e
Co lo . I nd i Cl t od o n t h o I i ..
Cot • • t" ' ; . .... 00 'ho . 1" "' " .....
Ye I low / Red
---Y ! RI---
Strand s
Ye I low
U OfO.O U '
C
(19) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If
there is any doubt as to the condition of them , replace them with new ones.
Abrasion
Bent
Color change
Crack
Dent
Deterioration
Hardening
Scratch
Seizure
Warp
Wear
(20) Specifications
Specification terms are defined as follows:
' Standards' show dimensions or performances which brand-new parts or systems have.
' Service limits' indicate the usable limits. If the measurement shows excessive wear or deteriorated performance,
replace the damaged parts.
1-4 GENERAL INFORMATION
Model Identification
KX125-L1 Left Side View
KX125-Ll Right Side View
GENERAL INFORMATION 1·5
Model Identification
KX25~L 1 Left Side View
KX250-L 1 Right Side View
1-6 GENERAL INFORMATION
Model Identification
KX125-L2 Left Side View
KX125-L2 Right Side View
GENERAL INFORMATION 1-7
Model Identification
KX250-L2 Left Side View
KX250-L2 Right Side View
1·8 GENERAL INFORMATION
General Specifications
KX125·l1
Items
KX12S-L2
Dimensions:
Overall length
Overall height
Wheelbase
Road clearance
390 mm
Seat height
Dry mass
Curb mass:
945 mm
Front
46 kg
Rear
49 kg
2-slroke, single cylinder, crankcase reed
valve
Cooling system
Bore and stroke
Displacement
Compression ratio
liquid-cooled
54.0 x 54.5 mm
Maximum horsepower
124 mL
Low speed: 9.8: 1 (EU) (FA) 9.4 : 1
High speed: 8.2: 1 (EU) (FR) 7.8: 1
29.1 kW (39.5 PS) @11,500 rl min (rpm)
Maximum torque
24.9 N·m (2.54 kgf·m, 18.4 in·lb)
@1 1,OOQr/min{rpm)
Carburetion system
Starting system
Ignition system
Ignition timing
Spark plug
Port timing
Inlet:
Carburetor, KEIHIN PWK36S
10.3° BTDC @11 000 rl min (rpm)
-
Low speed: 9.4 : 1 (EU) 9.0 , 1
High speed: 7.9: 1 (EU) 7.5 : 1
---
G
12.3 BTOC @11 000 rl min (rpm)
-
NGK BA9EVX
Open
Full open
Close
-
Open
64.1 GBBOC
63.5° BBDC
Close
64 .1° ABDC
63.5° BBDC
Open
82.1 · BBOC (low speed),
81.4° BBDC (lOW speed),
95.8° BBOC (high speed)
95.3° BBOC (high speed).
82., ° ABDC (low speed),
81.4 ABDC (low speed),
95.3° ABDC (high speed)
95.8° ABOC (high speed)
Lubrication system (Gasoline : oil)
Petrol mix (32:1)
Drive Tra in:
Primary reduction system:
Type
Gear
Reduction ratio
3.200 (64120)
Wet, multi disc
Transmission:
Type
-
Primary kick
COl
Close
Clutch type
1430 mm
8.5 L
Type
Exhaust;
-
87 kg
Fuel tank capacity
Engine:
Scavenging
-
2130 mm
815 mm
1 210 mm
1435 mm
Overall width
6-speed, constant mesh. return shift
0
-
--
1
1
1
I
I
GENERAL INFORMATION 1-9
General Specifications
KX12S-L1
Items
Final drive system:
Type
Chain drive
4.000 (48/12)
Reduction ratio
12.800 @Top gear
Overall drive ratio
Transmission oil:
Grade
Viscosity
SE, SF or SG class
Capacity
0.7 L
SAE 10W20 or 10W40
Frame:
Type
Tubular, semi-double cradle
Steering angle
45~ to either side
Caster (rake angle)
26·
109 mm
Trail
Size
Makerrype
80/100-21 51M
Rear lire:
Size
MakeIType
t 00/90-1 9 57M
DUNLOP, Tube type
Front suspension:
Type
Telescopic fork (up side down)
Wheel travel
310 mm
Type
Swingarm (Uni-Irak)
Wheel travel
330mm
Single disc
Front lire:
Rear suspension:
Brake type:
Front and
Effective disc diameteBear
Front
Rear
DUNLOP, Tube type
220mm
190 mm
Specifications are subject to change without notice, and may not apply to every country.
(EU): Europe Model
(FA): France Model
KX125-l2
--
--
-
305mm
-
1-10 GENERAL INFORMATION
General Specifications
Items
KX250-Ll
Dimensions:
Overall length
Overall width
Overan height
Wheelbase
Road clearance
Seat height
Dry mass
Curn mass:
Front
Aear
2 175 mm (AS) (EU) (FA) 2170 mm
815 mm
1 210 mm
1 480 mm (AS) (EU) (FA) 1 475 mm
380mm
950mm
97 kg
51 kg
52 kg
8.S l
Fuel tank capacity
Engine
Type
2-stroke, single cylinder, piston reed valve
Cooling system
Uquid-cooled
Sore and stroke
66.4 )( 72.0 mm
Displacement
249 mL
Compression ratio
10.8 : 1 (low speed), 9.0 : 1 (high speed)
(AS)(EU)(FR) 10.4:1 (low speed),
MaxilTllJrn horsepower
8n (h;gh speed)
40. 1 kW (54.6 PSI @8 500 rl min (rpm)
Maximum torque
49.0 N·m (5.0 kgf-m, 36 ft·lb)
Carburetion system
Starting system
Calibrator, KEIHIN PWK38S
Ignition system
CDI
@ 7500 rl min (rpm)
Primary kick
Ignition timing
II " BTDC @7 000 r/min (rpm)
Spark plug
NGK BR8EVX
Port timing
Inlet
Open
Close
Scavenging
Exhaust
Open
Full open
59.1° BBoC
Close
59.1 ° ABDC
Open
76.9° BBOC (low speed),
b
91.4 BBOC (high speed)
Close
76.9° ABOC (low speed),
91.4 ABDC (high speed)
Lubrication system (Gasoline: oil)
Petrol mix (32:1)
Drive Train
Primary reduction system:
Type
Gear
2.750 (55120)
Reduction ratio
Clutch type
Transmission:
Type
Gear ratios
l sI
2nd
3,d
4th
5th
KX2S()"L2
2 175 mm (AS) (EU) 2 170 mm
-
-
1 480 mm (AS) (EU) 1 475 mm
--
-
13° BTOC 07000 rl min (rpm)
-
-
-
Wet, multi disc
-
5 speed, constant mesh, return shift
1.800 (27/15 )
1.625 (26116)
-
1.333 (24118)
1.136 (25122)
1.000 (24124)
-
-
1
GENERAL INFORMATION 1-11
General Specifications
KX25o-L2
KX2SD-Ll
Items
Final drive system
Type
Chain drive
Reduct ion ratio
3.692 (48/13)
-
3.692 (48113)
(AS) (EU ) 3.500 (49/ 14)
(AS) (EU) (FR) 3.500 (49/ 14)
(AS) (EU) (FR) 9.625 @Top gear
Transmission oil:
10.153
10.153
Overall drive ratio
Grade
SE, SF, or SG class
Viscosity
SAE 10W30 or 10W40
Capacity
O.8SL
(AS) (EU) 9.625 @Top gear
-
Frame:
Type
Tubular, semi-double cradle
Steering angle
Casler (rake angle)
45° to either side
26'
Trail
109 mm
Front lire:
Rear tire:
Front suspension:
Rear suspension
Brake type:
-
--
Size
80/ 1oo·21S1M
MakefType
BRIDGESTONE, Tube type
BAIDGESTONE, Tube type
(EU) (FA) DUNLOP, Tube type
(EU) DUNLOp, Tube type
-
Size
110/90-1962M
MakelType
BRIDGESTONE, Tube type
BAIDGESTONE, Tube type
(EU)(FA) DUNLOP, Tube type
(EU) DUNLOP, Tube type
Type
Telescopic fork (up side down)
Wheel travel
310 mm
Type
Swingarm (UnHrak)
Wheel travel
330 mm
Front and Rear
Single disc
Effective disc diameter
Front
220 mm
Rear
190 mm
Specifications are subject to change without notice, and may not apply to every country.
(AS): Australia Model
(EU): Europe Mode!
(FR): France Model
-
305mm
1-12 GENERAL INFORMATION
General Specifications
KX125-L3
Items
KX2SD-L3
Engine
Type
2-slroke, single cylinder. crankcase
2-stroke, single cylinder, piston reed
Cooling system
Bore and stroke
reed valve
liquid-cooled
54.0 x 54.5 mm
valve
liquid-cooled
66.4 x 72.0 mm
Displacement
Compression ratio
124 mL
249 mL
Low speed: 9.7 : 1 (EU) 9.3: 1
High speed: 8.0: 1 (EU) 7.7 : 1
Maximum horsepower
Maximum torque
29. 1 kW (39.5 PSI @11 500 rl min (rpm)
Low speed: 10.8: 1 (EU) 10.4 : 1
High speed: 9.0 : 1 (EU) 8.7 : 1
40.8 kW (55.6 PSI @8 500 rl min (rpm)
50.0 N'm (5.1 kgf·m, 36 h·lb)
@ 7 500 rl min (rpm)
Carburelion system
Starting system
Ignition system
Ignition timing
Spark plug
Port timing
Inlel
Scavenging
Exhaust
Opeo
24.9 N-m (2.54 kgf·m, 18.4 in·Jb)
@ 11 000 rl min (rpm)
Carburetor, MIKUNI TMX36
Primary kick
CDI
10.3' BTDC @1 1 000 rl min (rpm)
Carburetor, KEIHIN PWK38S
Primary kick
NGK BA9EVX
NGK BA8EVX
Full open
CDI
13' BTDC @7 000 rl min (rpm)
Full open
Close
-
-
Opeo
65.3° BBDC
59.1° BBDC
Close
65.3° ABDC
59.1° ABDC
Opeo
82.9" BBDC (low speed),
76.9' BBDC (low speed),
Close
lubrication syslem (Gasoline: oil)
96.7" BBDC (high speed)
91.4' BBDC (high speed)
82.9" ABDC (low speed) ,
76.9' ABDC (low speed),
96.7 ABDC (high speed)
Petrol mix (32: 1)
91.4 ABDC (high speed)
Petrol mix (32:1)
Specifications are subject to change without notice, and may not apply to every country.
(EU): Europe Model
GENERAL INFORMATION 1-13
General Specifications
Items
KX12S-L4
KX2S0-L4
Dimensions:
2130 mm
815 mm
1 210 mm
Overall length
Overall width
Overall height
Wheelbase
Road clearance
Seat height
Dry mass
Curb mass:
Front
Rear
Fuel tank capacity
8.5 L
2 170 mm
815 mm
1 210 mm
1 475 mm
380mm
950mm
97 kg
51 kg
52 kg
8.5 L
2-stroke, single cylinder, crankcase
2·stroke, single cylinder, piston
reed valve
1430 mm
390 mm
945 mm
87 kg
46 kg
49 kg
Engine
Type
Cooling system
Liquid-cooled
Bore and stroke
54.0 x 54.5 rnm
124 mL
low speed 11 .0: 1 (EU) 10.4: 1
High speed 9.0: 1 (EU) 8.6 : 1
29.2 kW (39.7 PS)
@11 250 rl min (rpm)
25.7 N·m (2.62 kgf·m. 19,0 fHb)
@105OOr/min(rpm)
reed valve
Liquid·cooled
66.4 x 72.0 mm
249 mL
Low speed 10.5; 1 (EU) 10.1 : 1
High speed 8.9: 1 (EU ) 8.6: 1
40.S kW (55.6 PSI
@8 500 rlmin (rpm)
50 N·m (5.1 kgf·m, 37 fl·lb)
@ 7500 rl min (rpm)
Carburetor, MIKUNI TMX3S
Primary kick
CDI
10.3° BTDC @10900 r/min(rpm)
NGK BR9EIX
Carburetor, KEIHIN PWK38S
Primary kick
CDI
13° BTDC @7000r/min (rpm)
NGK BR8EIX
Full open
Full open
64.9° BBoC
64.9° ABDC
79.So BBDC (low speed),
94.So BBDC (high speed)
79.8° ABDC (low speed),
94.8 ABoC (high speed)
Petrol mix (32: 1)
57.6° BBoC
57.6° ABDC
78.1 ° BBoC (low speed),
9 1.40 BBoC (high speed)
78.1 0 ABDC (low speed),
91.4 ABoC (high speed)
Petrol mix (32 : 1)
Gear
Wet, multi disc
Gear
3.000 (63/2 1)
Wet, multi disc
6-speed. constant mesh, return shift
5-speed, constant mesh, return shift
Displacement
Compression ratio
Maximum horsepower
Maximum torque
Carburetion system
Starting system
Ignilion system
Ignition liming
Spark plug
Port timing
Inlel
Scavenging
Exhaust
Open
Close
Open
Close
Open
Close
Lubrication system (Gasoline: oil)
Drive Train
Primary reduction system:
Type
Reduction ratio
Clutch type
Transmission;
Type
3.200 (64120)
1·14 GENERAL INFORMATION
General Specifications
Item s
KX2SD-L4
KX125-L4
1St
2nd
2.384 (31/13)
1.857 (26114)
3,d
1.529 (26117)
1.210 (23119)
4th
5th
6th
1.294 (22M)
1.125 (27/24)
1.000 (25125)
1.000 (2 1121)
0.869 (20/23)
Type
Chain drive
Chain drive
Reduction ratio
4.083 (49/12)
13.067 @Topgear
9.832
API SE. SF or SG
API SE, SF or SG
API SH or SJ with JASO MA
API SH or SJ with JASO MA
SAE lQW40
0.7 L
SAE tOW40
Type
Tubular, semi-double cradle
Tubular, semi-double cradle
Steering angle
Casler (rake angle)
45 to either side
26"
Trait
109 mm
Gear ratios:
1.800 (27/ 15)
1.470 (25117)
Final drive system:
Overall drive ratio
Transmission oil;
Type
Viscosity
Capacity
3.769 (49113)
O.85l
Frame:
Front tire:
0
45
0
to either side
Size
801100.21 51M
26"
109 mm
80/100-21 51M
Makeflype
DUNLOP, Tube type
BAIDGESTONE, Tube type
(EU) DUNLOp, lube type
Size
lOO190-1957M
110190-1982M
Make/Type
DUNLOP, Tube type
BRIDGESTONE, Tube type
Front suspenston:
Type
Telescopic fork (up side down)
Telescopic fo rk (up side down)
Wheel travel
300mm
300mm
Rear suspension:
Type
Swingarm (Uni-trak)
Swingarm (Uni-trak)
Wheel travel
330mm
330mm
Brake type:
Front and
Rear
Single disc
Single disc
Effective disc diameter:
Front
220 mm
220mm
Rear
190 mm
190 mm
Rear tire:
(EU) DUNLOP, tube type
Specifications are subject to change without notice, and may not apply to every country.
(EU): Europe Model
GENERAL INFORMATION 1-15
Periodic Maintenance Chart
The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.
FREQUENCY
OPERATION
Clutch - adjust
Clutch plates· check t
Throttle cable - adjust
Spark plug - clean. gap t
Air cleaner element clean
Air cleaner element replace
Carburetor - inspect ladjusl
Transmission oil - change
Piston and piston ring - clean/check t
Cylinder head, cylinder - inspect
Exhaust valve· clean/check
Silencer - clean/check t
Silencer packing - change
Small end bearing check t
Kick pedal and shift pedal clean
Exhaust pipe O-ring replace
Engine sprocket - check t
Coolant - check t
Radiator hoses, connections - check t
Reed valve - check t
Brake adjustment - check t
Brake pad wear check t
Brake fluid level check t
Brake fluid - change
Brake master cylinder cup and dust seal - replace
Brake caliper piston seal and dust seal replace
Brake hose - replace
Spoke tightness and rim runout check t
Drive chain - adjust
Drive chain - lubricate
Drive chain wear check t
Chain slipper and guide replace
Front fork inspect/clean
Front fork oil change
Nuts, bolts, fasteners - check t
Fuel system - clean
Fuel hose - replace
Steering play - check t
Steering stem bearing - grease
Rear sprocket - check t
General lubrication - lubricate
Wheel bearing check t
Swing arm and Uni-Trak linkage pivots grease
Swing arm and Uni· Trak linkage pivots check t
Rear shock oil - replace
t : Replace, add, adJUSt. clean or torque 11 necessary.
A : Replace
Each
race
Every 3
races
Every 5
Every 10
races
races
•
A
As required
•
•
•
•
A
II damaged
•
•
•
A
•
•
•
·•
A
•
•
•
•
•
•
•
A
•
•
Every 2 years
Every 2 years
Every 2 years
Every 4 years
•
•
•
•
11 damaged
•
I
1sttime after 2 races, then every 5 races
•
•
•
I
I
I
I
I
I
I
Every 4 years
·•
•
.
•
•
1sl time after 2 races. then every 5 races
1·16 GENERAL INFORMATION
Torque and Locking Agent
Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nul
may become damaged, strip an internal thread, or break and then fallout. The following lable lists the tightening toque
for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.
When checking the lightening tOQue 01 the bolts and nuls, first loosen the bolt or nut by hall a turn and then tighten to
specified torque.
Letters used in the ' Remarks" column mean:
L : Apply a non-permanenllocking agent to the threads.
LG : Apply liquid gasket to the threads.
S : Tighten the fasteners following the specified sequence.
Fuel System:
Carburetor Top Cover Allen Bolts
(other than KX125-L3j
Carburetor Top Cover Screw (KX I 25·L3)
Throttle Sensor Bolts
Rear Frame Mounting Botts
Carburetor Holding Clamp Screws
Carburetor Holder Mounting Bolts
Reed Valve Screws
Cooling System :
Water Hose Fitting Botts (Cvlinder)(KX250)
Water Pump Cover Bolls
Water Pump Impeller Bolt
Water Hose Clamp Screws
Coolant Drain Plug
(Water Pump Cover)
(Cvlinder)
(KX125)
Waler Pump Cover Fitting Bolts
(KX250)
Engine Top End:
(KX 125)
Cvlinder KIPS Cover Bolts
(KX250)
Cvlinder Head Nuts
Cylinder Head Cover Siud
Spark Plug
Coolant Drain Plug
Cylinder Nuts
Remarks
Torque
Fastener
(KX250)(CVlinder)
(KXI25)
N·m
kgl·m
tUb
3.9
0.4
35 in·lb
2.0
2.0
0.2
0.2
17 in·lb
17 in·lb
34
3.5
25
1.4
8.8
9.8
0.14
0.9
1.0
12 in·lb
78 in·lb
87 hlb
8.8
8.8
0.9
0.9
78 in·lb
78 in·lb
0.7
61 in·lb
13 in·lb
78 in·lb
78 in·lb
78 in·lb
6.9
1.5
8.8
8.8
8.8
4.9
0. 15
0.9
0.9
0.9
0.5
8.8
2.5
25
0.25
-
-
-
25
8.8
25
2.5
0.9
2.5
3.5
78 in·lb
18.0
(KX250)
34
Main Valve Cover Bolts
Main Valve Cover Bolt (KX I125125Q.-L3 ..... L4)
Engine Bracket Nuts:
Engine Side 10 mm
Frame Side 8 mm
(KX250)
Main Valve Retaining Screws
(KX250)
Operating Rod Retaining Screw
(10(250)
Operating Rod Left Side Plug
(KX250)
Valve Rod Cover Screw
(KX250)
Operating Rod Nut
0.6
8.8
Main Lever Mounting Allen Boh
Idle Gear Lever Boh
(KX I 25)
Silencer Inner Pipe Bolls
(KXI251250·L3)
Silencer Pipe Botts
(KXI251250· L3)
3.9
6.9
5.9
8.8
5.9
8.8
44
29
5.4
5.9
22
5.4
8.8
0.9
43 ;n·lb
2.5
781n·lb
22 in·lb
18.0
L (Planted
Side)
•
18
I
25
52 in·lb
0.9
4.5
3.0
78 in·lb
0.55
0.9
48 in-Ib
52 in·lb
16.0
48 in·lb
78 in·lb
0.4
0.7
0.6
0.9
0.6
0.9
35 in·lb
6 1 in·lb
52 in·lb
78 in·lb
52 in·lb
78 in·lb
0.6
2.2
0.55
33
22
Left-hand
Threads
L
L
L
L
L
j
GENERAL INFORMATION 1-17
Torque and Locking Agent
Engine Right Side:
Oil Filler Cap
External Shift Mechanism Return Spring Pin
Clutch Spring BoHs
Clutch Hub Nut
Exhaust Valve Advancer
lever Mounting Allen BoHs
Exhaust Valve Advancer lever
PoSitioning Screw
Remarks
Torque
Fastener
(KX 125)
(KX250)
Gear Positioning lever Nut
Gear Positioning l ever Pivot Stud
N·m
kQI·m
tt-lb
1.5
42
8.8
98
0.15
13 in·lb
4.3
0.9
10
31.0
78 in·lb
3.9
0.4
35 in·lb
D••
0.06
1.3
8.8
0.13
L
72
0.9
5 in·lb
11 in·lb
78 in·lb
-
-
-
• .9
8.8
8.8
25
59
8.8
8.8
0.7
0.9
0.9
2.5
• .0
0.9
0.9
61 in·lb
44
4.5
33
44
29
OR
4.5
3.0
1n.n
33
22
-
-
-
8.8
11
20
5.4
8.8
5.4
5.4
8.8
22
24
22
78
0.9
1.1
2.0
7B in·lb
0.55
0.9
48 in·lb
78 in·lb
0 .55
0.55
48 in·lb
48 in·lb
0.9
2.2
2.4
2.2
R.n
78 in·lb
L
l (planted
Side)
Water Pump Impeller Bolt
Kick Ratchet Guide Bolt
Kick Pedal BoH
(KX125)
(KX250)
Primary Gear Nut (KX125)
Clutch Cover Bolts
Engine Right Cover Bolts
7B in·lb
78 in·lb
IB.O
43
78 in·lb
78 in·lb
Engine Removal/lnstaltatlon:
Engme Mounting Nuts
Engine Bracket Nuts:
Engine Side 10 mm
Frame Side 8 mm
Swing Arm Pivot Shaft Nut
Eng ine Bottom EndfTransmission:
Cylinder Stud
7?
l (Planted
Side)
Crankcase Bolts
Crankshaft Web Cover Bolls
Transmission Oil Drain Plug
Output Shaft Bearing Retaining Screws
Drive Shaft Bearing Retaining 80lts
Drive Shaft Bearing Retaining Screw
(KX250)
Shift Drum Bearing Retaining Bolls
(KXI25)
(KX250)
Shift Drum Operating Plate Bolt
(On and after KX250-l2)
Flywheel Bolt (KXI25)
Flywheel Nut (KX250)
WheelslTires :
Front Axle
Front Axle Clamp Bolts
Rear Axle Nut
Spoke Nipple
Final Drive:
Rear Axle Nut
Rear Sprocket Nuts
Brakes:
Caliper Mounting Bolts (Front)
Brake Hose Banjo Bolts
Front Master Cylinder Clamp Bolts
79
20
110
8.0
2.0
8.0
1.
17
'8
58
14.5
80
11 .0
Not less
than 1.5
than " .1"
Nolless
'h I~ in·lb
110
11
3.-
80
25
2.5
2.5
0.9
18.0
18.0
78 in·lb
25
25
8.8
L
L
16.0
Not less
""
L
14.5
S
1·18 GENERAL INFORMATION
Torque and Locking Agent
Remarks
Torque
Fastener
Rear Master Cylinder M ounting Screws
Rear Master Cylinder Mounting Botts
(On and after KX 1251250-L2)
Rear Master Cylinder Push Rod Locknut
Brake Disc Mounting Bolls (Front. Rear)
Caliper Bleed Valves (Front, Rear)
Brake Pedal Mounting Boh
Caliper Holder Bolt
Brake Pad Bolt
Rear Brake Pad Bolt Pin
N·m
kqf·m
7.6
9.6
0.6
1.0
'6
9.6
7.8
25
27.5
16
2.5
1.6
1.0
0.6
2.5
2.6
1.6
0.25
20
54
29
26
96
39
34
63
63
2.0
5.5
3.0
2.85
76
4.9
25
20
6.0
0.5
2.5
2.0
22
76
65
5.4
4.4
25
6.6
2.2
6.0
6.6
0.55
0.45
2.5
0.9
fHb
69 in·lb
87 in·lb
13.0
87 in·lb
69 in·lb
'6
21.5
13.0
22 in·lb
Suspension:
Front Fork Clamp Botts (Upper. Lower)
Fron t Fork Cylinder Valve Assembly
Front Fork Top Plug
Push Rod Nut
Swing arm Pivot Shaft Nut
Rear Shock Absorber M ounting Nuts:
(Upper)
(Lower)
ne-Rod Mounting Nut (Front, Rear)
Rocker Arm Pivot Nut
10.0
4.0
3.5
6.5
6.5
14.5
40
22
20.6
72
29
25
6'
61
Steering:
Steering Slem Head Nut
Steering Slem Locknut
Handlebar Clamp Bolts
Front Fork Clamp Bolls (Upper, lower)
Elect rIca l System :
(KX125)
(KX250)
(On and af1er KX250-l2)
(KXI25)
Stator Plale Mounting Screws
(KX250)
Flywheel Boll
Flywheel Nul
Spark Plug
Magneto Cover Bolts
56
43 in·lb
18.0
14.5
16.0
56
48
48 in·lb
39 in·lb
18
78 in·lb
Basic Torque for General Fasteners
Torque
Threads dia.
(mm)
N·m
kgf·m
5
3.4 ..... 4.9
0.35 ,..,. 0.50
6
5.9 "" 7.8
14 "" 19
0.60 "" 0.80
1.4 ..... 1.9
52 ,..,. 69 in·lb
6
10
2.6 .... 3.5
19.0 ..... 25
4.5 ..... 6.2
7.4 ..... 10.0
33 ..... 45
25 "" 34
44 ", 61
fHb
30 ..... 43 in·lb
,0.0 ..... , 3.5
12
14
73 "" 98
16
18
11 5 - 155
165 ..... 225
11.5 _ 16.0
83 ..... 115
17.0 ..... 23.0
125 ..... 165
20
225 "" 325
23 "" 33
165 ..... 240
54 ..... 72
L
GENERAL INFORMATION 1-19
Special Tools
Fuel Level Gauge, M18. 1.0 : 57001-122
Bearing Puller : 57001-158
Bearing Puller Adapter: 57001-136
Compression Gauge : 57001-221
Steering Stem Bearing Driver : 57001-137
Flpheel Puller : 57001-252
Inside Circlip Pliers : 5700'-'43
Piston Pin Puller Assembly : 57001-910
e
o
o
Outside eirelip Pliers : 57001-144
Hand Tesler : 57001-1394
1-20 GENERAL INFORMATION
Special Tools
Rim Protector: 57001-1063
Head Pipe Outer Race Driver : 57001-10n
Bead Breaker Assembly : 57001- 1072
Crankcase Splitting Tool Assembly : 57001-1098
Steeting stem Bearing Driver Adapter : 57001-1074
Steering Stem Nut Wrench : 57001-1100
Head Pipe Outer Race Press Shah : 5700'- 1075
Hook Wrench : 57001-1101
Head Pipe Outer Race OrivfI( : 57001- 1076
Bearing Driver Set : 57001-1129
GENERAL INFORMATION 1-21
Specia l Too ls
Compression Gauge AdaptllH". M14 II 1.25 : 57001-1159
Fork Oil L.evel Gauge : 57001-1290
Crankshaft Jig : 57001 - 1174
Fork Piston Rod Puller. M12 x 1.25: 57001-1289
•
Jack : 57001-1238
Flywheel & Pulley Holder : 57001-1343
Clutch Holder : 57001- 1243
Throttle Sensor Adapter : 57001-1414
Fork Cylinder Holder : 57001 - 1413
Fork Oil Seal Driver, 6'16 : 57001-1395
•
1-22 GENERAL INFORMATION
Special Tools
Fork 011 Sea' Driver, ~8 : 57001-1509
Head Pipe Outer Race Remover : 57001-1107
Kawasaki Bond (Liquid Gasket - Sliver) : 92104-002
Holder· Front Fork Cylinder: 57001-1442
ITII " . nl C
Fuel Leve' Gauge: 57001- 1468
I
I l I " " . II •
Flywheel Holder: 57001-1313
GENERAL INFORMATION 1-23
Cable, Wire and Hose Routing
KX125-L1/L2
6
:.
1-_=
10
'0
11
I
----
• .0. . . . . . .
~
A : KX125-L1 only
1. Throttle Cable
2. Clutch Cable
3. Engine Stop Switch Lead
4. Run the clutch cable forward
of the headpjpe.
5. Radiator Overflow Tube
6. Righi Screen
7. Run the overflow lube backward
01 the down lube.
8. Run the tube outside of the engine
mount bracket.
9. Run the tube forward of the
radiator connection pipe
10. l eft Screen
11 . Frame
12. Regulator/Recti fier
13. Do not clamp the throttle cable
14. Bands
15. Main Harness
16. To throttle sensor
17. Connect position of the
throttle sensor.
18. Frame
19. Capacitor
20. C.O.1. Unit
21. Fuel Cui Valve Connector
22. Magneto Connector
23. Band
24. Magneto
25. Ignition Coil
26. Bands
1-24 GENERAL INFORMATION
Cable, Wire and Hose Routing
KX125-L3 ..... L4:
5
6
9
.;
IO.,n
I
I
I
.;
7
.~.
I ~
"
1>'
I"
I'
I
®----( I
11
nOlo"," C
, . Throttle Cable
2. Clutch Cable
3. Engine SlOp Switch lead
4. Aun the clutch cable forward
allhe head pipe.
5. Radiator Overflow Tube
6. Right Screen
7. Aun the overflow lube backward
allhe down tUbe.
8. Aun the tube outside of the engine
mount bracket.
9 . Aun the lube forward of the
radiator connection pipe .
17. Frame
18. C.O.I. Unit
10. left Screen
19. Magneto Connector
11 . Frame
12. Regulator/Rectifier
13. Do not clamp the throlile cable
14. Bands
20. Band
21. Magneto
22. Ignition Coil
23. Air vent tube
(KX125-l4 Model)
24. Band (KX I25-l4 Model)
15. Main Harness
16. Band
GENERAL INFORMATION 1-25
Cable, Wire and Hose Routing
KX250:
5
,
A: KX25O-Ll onlv
B: KX250-l3 ,.., L4
1. Throttle Cable
2. Engine SlOp Switch Lead
3. Clutch Cable
4. Aun the clutch cable forward
of the head pipe
5. Radiator Overflow Tube
6. Right Screen
7. Run the tube backward of
the down tube
8. Run the lube outside of the
Engine mount bracket
9. Run the tube forward of the
radiator connection pipe.
10. l eft Screen
11. Frame
12. Regulator/Rectifier
13. Do not clamp the throttle cable.
14. Bands
15. Main Harness
16. To the throttle sensor
17. Connect position of the throttle sensor
18. Frame
19. Capacitor
20. C.D.I. Unit
21 . Fuel Cui Valve Connector
22. Magnet Connector
23. Band
24 . MagnetD
25. Ignition Coil
26. Clamps
27 . Radiator Hose
28. Bands
1-26 GENERAL INFORMATION
Cable, Wire and Hose Routing
View A
KX250 :
","'U'" ~
1. Clamps
2. Left Radiator
3. Right Radiator
4. To the steering stem hole.
5. Air Vent Hose
6. To the fuel lank cap
7. Band
8. Run the tube forward oltha engine bracket
and backward of the radiator mount bracket.
9. Run the tube outside 01 the engine
mount bracket
10. Cleaner side clamp mounting angle.
11 . Carburetor
12. Clamp the air vent hoses wi th clamps
which are installed together with chain cover
and run them along with the chain cover.
13. Clamps
14. Air Vent Hoses
15. Run the vent hoses between
the lower pipe and other pipes.
GENERAL INFORMATION 1-27
Cable, Wire and Hose Routing
Fron t Br ake :
Vi ew X- X
View P
Rea r Brak e:
11 010,0, . . (
1. Front Brake Reservoir
2. Banjo Bolts
3. Clamp
4. Clamp Brackets
5. Hose Guard
6. Bleed Valves
7. Front Brake Caliper
8. Rear Brake Caliper
9. Caliper Guard
10. Clamps
11. Rear Brake Reservoir
12. Rear Brake Disc
13. Rear Brake Master Cylinder
14. Bend the cotter pin end by
along the jOint pin.
FUEL SYSTEM 2-1
Fuel System
Table of Contents
Exploded View ... ..... .. ... ....... ... ... .... ...... ..... ..... .. .. .. ..... ... .. ... ........ .... ....... . ....... ................. .. .................................................. 2·2
Specifications ............... ... ..... ... .. .. .... ..
.................. ... .. ... .......... ..... .......................................................... ................ 2-5
Throttle Grip and Cable..................................................................
...............
. .............................................. 2-7
Free Play Inspection...... .... .... .... ......
... ... ... ... .. .. ....... .... ... ..... .... ... .... ....... ...... ... . ... .. .. .. .... ............... ... ...... 2·7
Free Play Adjustment ......... .. .... .. ... .. ........ ........ .... . ... ... .... .. ..... ...... .... .......................................................................... 2-7
Throttle Cable Installation............
............................................................................... .... ......... ... .. .. 2·7
Cable lubrication .....
............... ................................
.............................................................................. 2-8
............. ............. 2·8
Cable Inspection... ... ...... ... .... .. ........ .. ............. .. ... ....... ... .... ..... .. ..... .. .... .. .... .. ... ..... .. .. ... ...........
Carburetor ................
....................................... ....................................................... ..................
. ........ 2·9
Idle Speed Inspection ........................................................................................
... ..... ... .. .... ...... .... ... .
.... ... ..2-9
Idle Speed Adjustment........ ...... ....... ..... ... ......... ... ....
.... ......... ........ .... .... ... ....... ....... .. .... .. ....
..... .... 2·9
Service Fuel level Inspection .................................................................................................................................2·9
Service Fuel level Adjustment.. .......... ................. ......................................... .............
............... 2· 10
Carburetor Removal ........................................ ........................ .. .. ........ ... .... ........ ... ... ...... .... ..
...... .... ....... .... .. 2- t 1
... .. ...... .. ......... .... 2·12
Carburetor Installation .. . ........... .......................... ............................................ .... ...... ...... .... ..
Fuel Inspection..... .... .. .... ..... .... ... .. ... .... ..... ... ... ..... .... ...........................................................
.......................... 2·13
Carburetor Disassembly... .... .... ... ...... . .. .. .... .. ...... .. ..
...................................................................................... 2-13
Carburetor Assembly ......................................................................... ............................
. ........... .. ... ..... ... ... ... .2· t 5
Carburetor Cleaning ............................ ........................ ................... ......................
.... .... ... .. .. .. ........ .. ..... ... ... ... 2·16
Carburetor Inspection ....... ...... ......... ...... .. . ... ......... ....... ...
................................................................................... 2·16
Air Cleaner .....................................................................................................................................................................2· ' 8
Housing Removal ........ .................................................................................... .
......................... 2·18
Air Cleaner Housing Installation ....................................................................... ........... ... ... ... .. ... ... .. ..
..... .... .. ... .2·18
Element Removal .............................................. ........... .... .... ..... .... ... .... ... .. ... .... ...
... 2· 18
Element Installation.. ........... .. .... .. ......... .. .. ..... .... ... ... ........... .... .... ..
.................................................................. 2·18
Element Cleaning and Inspection .... .. .. ........ ..... ............ ...... ... ...... ..................................................... .... ...... ... ... .. .. 2·19
Fuel Tank ............................................................................................................. .... .. .... .. .... ... ... ...... .. ..... .... ... ... ...... .... ... 2·20
Fuel Tank Removal ........................................................
...................................................
... ..... 2·20
Fuel Tank Installation .............................................................................................................................................2·20
Fuel Tap Removal .. .. .... ... ... .... ... .. ... .. .. .. ... ................................. ...............................................
...... ........ ...... .. 2·20
Fuel Tap Installation ............................................. .............. ........ .. .... ..... ... ..
. .. ........ .... .. .. ..... .... ... ... ... .. .. ..... 2·21
Fuel Tap Inspection .............................................
.... .. ... ... ... .... ........ . .... ... ... ... .. .............................. 2·21
Fuel Tank and Tap Cleaning ... .. .... .. .. ... .. .. .. ...
........... .. . ... ..... .... ... .................................................................... 2-21
.... ... .. .... ... 2·22
Reed Valve .. .............. . .... .. ......... ............ .. ... .... .... ... .. ....... ....... ...... ... ........................ .. .. ..... ....... ....... .. .. ...
Reed Valve Removal ...............•................................................................................................................................ 2-22
Reed Valve Installation.....................................
........ ........ ... .... ... .. ... ... ..... ... ......... ... .. .. ................... 2·22
Reed Valve Inspection ............................................................................................................................................2-23
2-2 FUEL SYSTEM
Exploded View
18
ICOIOIO , . . C
1. Throttle Cable
2. Throttle Grip
3. Carburetor Holder
4. Spring
5. Retainer
6. Connector
7. Jet Needle Clip
8. Jet Needle
9. Throttle Valve
10. Choke Knob
11 . Idle Adjusting Screw
12. Spring
13. Air Screw
14. Slow Jet
15. Float Valve Needle
16. Main Jet
17. Float
, 8. Reed Valve
19. Throttle Sensor
20. Fuel Cut Valve
21 . Power Jet
0 : Apply oil.
G: Apply grease.
T1: 8.8 N'm (0.9 kgf·m , 78 in·lb)
T2 : 1.4 N·m (0.14 kgf·m , 12 in·lb)
T3 : 2.0 N·m (0.2 kgf·m , 17 in·lb)
T4 : 9.8 N·m (1 .0 kgf·m , 18 in·lb)
T5 : 3.9 N·m (0.4 kgf·m, 35 in·lb)
FUEL SYSTEM 2-3
Exploded View
KX125-l3
'i
~/
G
~
e
~
~~
~r
""
,
It0101O) .. C
1. Throttle Cable
2. Throttle Grip
1, . Idle Adjusting Screw
12. Air Screw
3. Carburetor Holder
4. Spring
13. Slow Jet
0: Apply oil.
G: Apply grease.
T1 : 8.8 N·m (0.9 kgf·m , 78 in-Ib)
14. Float Valve Needle
15. Main Jet
16. Needle Jet
T2: 1.4 N-m (0.14 kgf·m , 12 in-Ib)
T3: 9 .8 N·m (1 .0 kgf·m , 18 in-I b)
T4: 2.0 N-m (0.2 kgf·m , 17 In-Ib)
5. Retainer
6. Connector
7. Jet Needle Clip
8. Jet Needle
9. Throttle Valve
1O. Choke Knob
17. Float
18. Reed Valve
2-4 FUEL SYSTEM
Exploded View
'~U01U " C
1. Fuel Tank Cap
2. Fuel Tank
3. Fuel Tap
4. Air Cleaner Housing
5. Element
6. Frame
7. Holder
8. Air Cleaner Duct
9. Rear Frame
G: Apply grease.
0 : High-quality foam-air filter all
T1: 34 N·m (3.S kgf·m, 25 ft·lb)
T2 : 1.4 N·m (O.14 kgf·m, 12 in ·lb)
FUEL SYSTEM 2-5
Specifications
KX125-L 1/L2'.
Standard
Item
Throttle grip free play and Cable
Carburetor:
MakeIType
Main jet:
I
KX125-Ll
--
KEIHIN PWK36S
158
'6
Jet needle
Jet needle clip position
N7NW
3rd groove from the top
Slow jet
Air Screw
#40
1 1/2 (turns out)
10.5 ± 1 mm
- --
· ..
---
· -.
2nd groove from the top
(AS)(EU) 3rd groove from
the top
#40 (AS)(EU) #45
-
body)
6 .S± lmm
Float height
Service Limit
-.-
2 _ 3mm
Throttle valve cutaway
Service fuel level
(above the bottom edge of the earb.
KX12S·12
...
---
·-· ..
·.-
see Electrical System chapter
see Electrical System chapter
Fuel cut valve
Throttle sensor
Air Cleaner:
Element oil
Reed Val ve:
Reed warp
---
High-quality foam-air filter oil
---
0.5 mm
.
KX2SG-L 1/L2'
Standard
Item
Throttle grip free play and Cable
Carbureto r:
Makerrype
Main jet:
Throttle valve cutaway
KX 2S0-L,
I
Service Limit
KX2 50· L2
---
2 - 3mm
KEIHIN PWK38S
# 158(AS){EU)(FA)# 160
-# 158(AS)(EU)(FA)#160
· ..
---- ---
.7
'8
Jet needle
Jet needle clip position
N3YK
4th groove from the top
N3WE(AS){EU) N3YF
3rd groove from the top
(AS)(EU) 4th groove
from the top
#52 (AS)(EU) #45
·..
- -- --
_. -
Slow jet
.45
Air Screw
1 1/2 (turns out)
Service fuel level
(above the bottom edge of the carbo
10.5:t: 1 mm
-
Float height
6.5:t: lmm
-
Fuel cut valve
see Electrical System chapter
Throttle sensor
see Electrical System chapter
body)
· ..
Air Cleaner:
Element oil
Reed Valve:
Aeed warp
Hiah-aualitv foam-air filter oil
---
(AS) Australia Model
(EU) Europe Model
(FA) France Model
Special Tools - Fuel Level Gauge, M1S )( 1.0 : 57001 - 122
--0.5 mm
2·6 FUEL SYSTEM
Specifications
.
KX12S·
Standard
KX125-L3
Item
KX I 2S-L4
Service Limit
Carburetor:
MakeIType
MIKUNI TMX36
MIKUNI TMX38
· ..
Main jet:
.360
0350
· ..
Throttle valve cutaway
-
· ..
Jet needle
115.5
68EFI 6-69
6BEKI-69-3
· ..
Jet needle clip position
4th groove from the top
3rd groove from the top
· ..
Slow jet (Pilot jel)
#50
1145
·.
Air Screw (turns out)
2.0
1'
Service fuel level
3% 1 mm
-
- ..
-- -
15 ± 1 mm
-
---
,
(above the bottom edge of the
carbo body)
Float height
-
Special Tools - Fuel Level Gauge: 57001-1468
•
.
KX2S0·
Standard
KX250-L3
Item
Carburetor:
MakefType
KEIH IN PWK38S
Main jet:
"60
Power jet
'48
.8
Throttle valve cutaway
Jet needle
Jet needle clip position
NAFF
KX250·l4
-
Service Limit
"65
-- .
-- -
-
-. -. -
-
(EU) 3rd groove from the l op
-
-. -
Slow jet (Pilot jet)
*52
#55
---
Air Screw (turns oul)
1 112
1 1/4
Service fuel level
10.5% 1 mm
2nd groove from the top
---. -
(above the bottom edge 01 the
cart>. body)
Float height
6.5::1: 1 mm
Fuel cut valve
see Electrical System chapter
Throttle sensor
see Electrical System chapter
(EU) Europe Model
---
1
1
i
FUEL SYSTEM 2·7
Throttle Grip and Cable
If the throHIe grip has excessive Iree play due 10 cable stretch or
misadjustment, there will be a delay in throHle response. Also, the
throllie valve may nol open fully at full throHIe. On the other hand, if
the throllie grip has no play, the throHle will be hard to conlrol , and the
idle speed will be erra tic. Check the throttle grip play periodically in
accordance with the Periodic Maintenance Chart, and adjust the play if
necessary.
The throHle cable routing is shown in Cable, Harness, Hose Routing
in the General Information chapter.
Free Play Inspection
• Check throHle grip free play [B) by lighlly turning the throHIe grip (AJ
back and forth.
If the free play is improper, adjust the throHIe cable.
*
Tnrattle Grip Free Play
Standard;
2_ 3mm
• Check that the throWe grip moves smoothly from full open to close,
and the throHIe closes Quickly and completely in all steering positions
by the rel um spring.
II the throHle grip does not return properly, check the thraHIe cable
routing, grip free play, and cable damage. Then lubricate the IhroHIe
cable.
• Run the engine at the idle speed, and lurn the handlebar all the way
to the right and left to ensure that the idle speed does not change.
II the idle speed increase, check the throWe cable free play and the
cable routing.
*
*
Free Play A djustment
• loosen the locknut [AJ at the upper end of Ihe IhraHIe cable.
• Tum the adjuster [BI until the proper amount 01 throttle grip free play
is obtained.
• Tighten the locknut.
B
...
A
,g>/
/~ (
.o~
* II the throHle grip free play cannot be adjusted with the adjuster al
the upper end of Ihe throttle cable. use the cable adjuster [AI at the
carburetor.
• Free Ihe fuel cut valve connector from Ihe frame.
• Pull Ihe boot off of the carburetor top. Make the necessary free play
adjustment at the lower cable adjuster, lighten the locknut (Bl. and
installihe boot.
• Turn the handlebar from side 10 side while idling the engine. II idle
speed varies, the throttle cable may be poorly routed or it may be
damaged.
Operation with an improperly adjusted, incorrectly routed, or
damaged cable could result in an unsafe i
condition .
Throttle Cable Installation
• Inslall the throHle cable in accordance wi th Ihe Cable. Harness. Hose
Rouling section in the General Informa tion chapler.
• After the installation, adjust each cable properly.
Operation with an incorrectly routed or improperly adju sted
cable could result in an unsafe riding condition.
••• OIl' e
2-8 FUEL SYSTEM
Throttle Grip and Cable
Cable Lubrication
Whenever the cable is removed, and in accordance with the Periodic
Maintenance Chart (see Generallnlormalion chapter), do the following .
• Apply a thin coating of grease [AJ to the cable upper end.
• lubricate the cable with a penetrating rust inhibitor.
lu. a"u, c
Cable Inspection
• With the throttle cable disconnected at both ends, the cable should
move freety (AI within the cable housing.
If cable movement is not free after lubricating, if the cable is frayed,
or if the housing is kinked, replace the cable.
*
"Goo ' UI, C
FUEL SYSTEM 2-9
Carburetor
Since the carburetor regulates and mixes the fuel and air going to
the engine, there are two general types of carburetor trouble: too rich
a mixture (too much fuel), and too lean a mixture (too little fuel). Such
trouble can be caused by dirt, wear, maladjustment, or improper fuel
level in the fl oat chamber. A dirty or damaged air cleaner can also alter
the luelto air ratio.
Idle Speed Inspection
• Start the engine and warm it up thoroughly.
• With the engine idling, turn the handlebar to both sides.
If handlebar movement changes the idle speed, the throttle cable may
be improperly adjusted or incorrectly routed, or it may be damaged.
Be sure to correct any 01 these conditions before riding (see Cable,
Harness, Hose Routing in the General Information chapter).
*
Operation with an improperly adjusted, incorrectly routed, or
cable could result in an unsafe ri ding condition.
• Check idle speed.
Adjust it as needed.
*
Idle Speed Adjustment
• First lurn in the air screw (AI until it seats lightly, and back it out the
specified number of turns. (see specifications of this chapler)
• Start the engine and warm it up thoroughly.
• Turn the idle adjusting screw (81 to obtain desired idle speed. If no
idle is preferred, turn out the screw until the engine stops.
• Open and close the throttle a few times to make sure that the idle
speed is as desired. Readjust if necessary.
Service Fuel Level Inspection
AWARNING
Gasoline is extremely flammable and can be explosive under
certain conditions. Always stop the engine and do n ot smoke.
Make sure the area Is well ventilated and free from any source
of flame or sparks ; this Includes any appliance with a pilot
light.
• Turn the fuel tap 10 the OFF position.
• Remove the luel lank.
• Remove the carburetor, and hold it in true vertical position on a stand.
The fu el hose and carburetor cable do not have to be removed to
inspect the fuel level (AI.
• Put the lueltank on a bench, and connect the fuel tap to the carburetor
using a suitable hose.
• Remove the drain plug Irom the bottom of the float bowl, and screw
a fuel level gauge (81 into Ihe plug hole.
Special Tools· Fuel level Gauge , Mt8 II 1.0: 57001-122
For KX125-L3 .... L4 :
B
Special Tools · Fuel l evel Gauge: 57001-1468
CCOfOlllH C
2-10 FUEL SYSTEM
Carburetor
• Hold the gauge vertically against the side of the carbure tor body so
thai the ' zero' line [C] is several millimeters higher than the bottom
edge (OJ of the carburetor body.
• Turn the fuel lap to the ON position to feed fuel to the carburetor.
• Wait until the fuel level in the gauge settles.
• Keeping the gauge vertical, slowly lower the gauge until the "zero'
line is even with the bottom edge of the carburetor body.
NOTE
o Do not lower the 'zero' line below the bottom edge of the carburetor
body. If the gauge is lowered and then raised again, the fuel level
measure shows somewhat higher than the actual fuel level. If the
gauge is lowered too far, dump the fuel out of it into a suitable
container and start the procedure over again.
• Read the fuel level in the gauge and compare it to the specification.
Service Fuel Level (above 1he bottom edge of the carbo body)
Standard:
10.5:1: 1 mm
3.0:1: 1 mm (KX125-13 .... L4)
*
II the fuel level is incorrect. adjust it.
• Turn the fuel tap to the OFF position and remove the fuel level gauge.
• Install the drain plug on the bottom of the float bowl.
Service Fuel Level Adjustment
AWAANING
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 a pilot
light.
• Remove the carburetor, and drain the fuel into a suitable container.
• Remove the float bowl.
• Drive out the pivot pin [AJ and remove the float [BJ.
• KX125-l3 ..... L4, unscrew the pivot pin screw [AJ and remove the float
[8[.
• Bend the tang [AI on the floa t arm very slighlly to change the float
height. Increasing the float height lowers the fuel level and decreasing
the float height raises the fuel level.
Float Height
Standard:
6.5:1:1 mm
15 :1: 1 mm (I(XI25-L3 .... L4)
• •• 1011 • . ,
C
FUEL SYSTEM 2-11
Carburetor
NOTE
o Float height fA} is the distance from the float bowl mating surface
fa] of the carburetor body (with the gasket removed) to the top of
the float fe]. Measure the height with the carburetor upside down.
o Do not push the needle rod {DJ in during the float height measure-
A
ment.
o
• Assemble the carburetor, and recheck the tuel level.
If the tuel level cannot be adjusted by this method. the float or the
float valve is damaged.
*
Carburetor Removal
AWARNING
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 a pilot
light.
• Turn the fuel tap to the OFF position and pull the fu el hose off the
tap.
• For KX125 L1 '"" L2, and KX250. disconnect the throttle sensor and
fuel cut valve connectors.
• loosen the clamps [AJ. and remove the carburetor from the end of
the air cleaner duct. and then pull it out of the carburetor holder.
• Drain the fuel from Ihe floal bowl by remove the drain plug . After
draining, instailihe drain plug securely.
• Unscrew the carburetor cap bolts [AJ.
For KX125-l3 '" L4. unscrew the carburetor cap screws [AJ.
2·12 FUEL SYSTEM
Carburetor
• Pull out the throttle valve assembly [AJ.
CAUTION
II the throttle valve is not removed from the cable, wrap it in a
clean cloth to avoid damage .
• After removing the carburetor, push a clean, lint-free lowel into the
carburetor holder and the air cleaner ducl to keep dirt o r other foreign
material from entering.
l eOl. , .. I ,
~
If dirt or dust is allowed to pass through into the carburetor,
the throttle may become stuck, possibly causing an accident.
CAUTION
If dirt gets through into the engine, excessive engine wear and
possibly engine damage will occur.
Carburetor Installation
• For KX125-lt ..... L2 and KX25O, lifting up the link shaft end [A] of the
throttle sensor inslailihe throttle valve assembly.
• Being careful nollo bend or otherwise damage Ihe jet needle. Check
to see that the throttle valve [8] goes all the way down into the
carburetor body, and slides smoothly.
• When installing the carburetor into the carburetor holder, align the
center ]A] of the carburetor with the groove IB) on the holder.
• Tighten the clamps securely.
Torque ·
Carburetor Holding Clamp Screw: 1.4 N·m (0.14 kg'·m, 12
In-Ib)
leo.. .. .. , c
• Aoute the air vent and overflow hoses properly (see General Information chapter).
CAUTION
Always keep the hoses free of obstruction, and make sure they
do not get pinched by the chain or shock absorber.
• For KX 125-L1 '" L2, and KX250, connect the throttle sensor and fuel
cUi valve connectors.
• After installing the carburetor, do the following.
o Turn the fuel tap to the ON position, and check for fuel leakage from
the carburetor.
o Adjust the following items if necessary:
Throttle Cable
Idle Speed
FUEL SYSTEM 2-13
Carburetor
Fuel Inspection
AWARNING
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-venlilated and free from any source
of flame or sparks; this includes any appliance wilh a pilot
light.
• Turn Ihe fuel tap to the OFF posrtion.
• Remove the carburetor.
• Place a suitable container beneath the carburetor.
• Remove the drain plug (A) from the bottom of the float bowl and check
for water or dirt in the fuel.
If any water or dirt comes out, ctean the carburetor, fuel tap and fuel
tank (see this chapter) .
• Instatl the drain plug on the float bowl, and tighten it securely.
• Install the carburetor.
*
Carburetor Disassembly
• Remove the carburetor.
• Unscrew the carburetor cap bolts (Ai.
For KXI25-l3 ...... l4, unscrew the carburetor cap screws [A).
• Pullout the throttte valve assembly
• Remove the throttle vatve assembly (A], spring (8], retainer (C] and
carburetor cap from the carbure tor cable lower end.
• Disassemble the throttle valve assembly; connector (A], jet needle
with circtip [8 J and throttle valve [C].
c
ICOIO ,,,ll
C
2-14 FUEL SYSTEM
Carburetor
• Remove the choke knob/starter plunger assembly (A] from the
carburetor.
(For 10( 125-l1 .... L2 and KX25O)
• Remove the fual cut valve [A] from the carburetor.
(For KX125-Ll ..... L2 and KX250)
• Remove the throttle sensor mounting screws (Al.
• Before removing the throttle sensor [BJ. mark [CJ the carburetor body
and sensor so that it can be installed later in the same position .
• Remove the throttle sensor link assembly screws [A).
• Remove the link assembly [8].
~
I
FUEL SYSTEM 2-15
Carburetor
• Remove the following parts f rom the carburetor body.
A. Idle Adjusting Screw
B. Spring
C. Air Screw
D. Spring
E. Slow Jet
F. Main Jet
G. Float Valve Needle
H. Float
~t
I. Pin
J. O'ring
K. Float Bowl
l. Power Jet
10
cb<
E
F
CCOIOlllU C
KXI25--l3 "" l4:
• Remove the following parts from the carburetor body.
A . Idle Adjusting Screw
B. Nut
C. Air Screw
D. Spring
E. Slow Jet
F. Main Jet
G. Float Valve Needle
H. Float
I. Pin Screw
J. O-ring
K. Float Bowl
L. Needle Jet
M . Float Plate
;cOIO" IS! C
Carburetor Assembly
• Clean the disassembly parts before assembling.
• Replace the O-rings with a new one if it is deteriorated or damaged.
• Turn in the air screw tAl fully but not tightly, and then back it out the
specified number of turns. (see Specifications of this chapter)
• For KX 12S-L 1 ,.... L2, and KX250, install the throttle sensor so that the
marks aligns and check it position (see Electrical System chapter).
Torque -
A
Throttle Sensor bo tts : 20 N·m (0.2 kg' .m , 17 in·lb)
.cOlO ... "
C
2·16 FUEL SYSTEM
Carburetor
Carburetor Cleaning
AWARNING
Clean the carburetor in a well-ventilated area, and take care
that there is no spark or flame anywhere near the working
area; Ihls includes any appliance with 8 pilot light. Because
of the danger of highly flammable liquids, do not use gasoline
or low flash. point solvent to clean the carburetor.
• Make sure the fuel tap is in the OFF position.
• Remove the carburetor.
• Drain the fuel in the carburetor.
• Disassemble the carburetor.
CAUTION
Do not use compressed air on an assembled carburetor, the
float may be deformed by the pressure.
Remove as many rubber or plastic parts from the carburetor
8S possible before cleaning the carburetor with a cleaning
solulion. This will prevent damage or deterioration of the
parts. Do not use a strong carburetor cleaning solution which
could attack the plastic parts; instead, use a mild high flashpoint cleaning solution safe for plastic parts.
Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged.
• Immerse all the metal pans in a carburetor cleaning solution .
• Rinse the parts in water.
• After the parts are cleaned, dry them with compressed air.
• Blow through the air and fuel passages with compressed air.
• Assemble the carburetor, and install it on the motorcycle.
Carburetor Inspection
AWARNING
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 a pilot
light.
• Remove the carburetor.
• Belore disassembling the carburetor, check the fuel tevel (see Fuel
Level Inspection) .
.. II the luel level is incorrect, inspect the rest of the carburetor before
correcting it.
• Pull the carburetor cable 10 check that the throttle valve {AI moves
smoothly and returns by spring pressure.
.. lithe throttle valve does not move smoothly. Replace the carburetor.
• Disassemble the carburetor.
• Clean the carburetor.
,
t c•• ou ", C
FUEL SYSTEM 2· 17
Carburetor
• Check the O-rings on the float bowl, pilot screw, and throttle sensor
are in good condition.
If any of the a-rings are nol in good condition, replace them.
• Check the tapered portion [A) of the pilot screw [B) for wear or
damage.
If the pilot screw is worn or damaged on the tapered portion, it will
prevent the engine from idling smoothly. Replace it.
*
*
teo.o"'"
• Remove the float valve needle.
• Check the plastic lip [AJ of the float valva needle [Bl lor wear.
* 11 the needle is worn as shown right Ie], replace the valve needle.
• Push the rod (01 in the valve needle, then release it.
the rod does not come out full y by spring tension, replace the valve
needle.
Push and release lEI
*"
CD
• Remove the slow jet.
• Check the slow jet for any damage.
If the slow jet is damaged, replace it with a new one.
• Remove the throttle valve and jet needle.
• Inspect the outside 01 the throttle valve for scratches and abnormal
wear.
II it is badly scratched or worn , replace the throttle valve.
• Inspect the inside 01 the carburetor body lor these same faults.
II it is badly scratched or worn, replace the entire carburetor.
• Check the jet needle lor wear.
A worn jet needle should be replaced.
• Clean the luel and air passages with a high flash-point solvent and
compressed air.
*
*
*
*
c
2-18 FUEL SYSTEM
Air Cleaner
Housing Removal
• Loosen the air cleaner duct clamp.
• Remove:
Radiator Shrouds
Side Covers
Seat
Silencer (see Engine Top End chapter)
Rear Fender fA)
•
Rear Aap IBI
• Disconnect the C.O.I Un~ and condenser connectors.
• Remove:
Band Ie)
Rear Frame Bolts [01
• Remove the air cleaner housing IE].
Air Cleaner Housing Installation
• Installation is the reverse of the removal.
• TIghten the rear frame mounting bolts [A] .
Torq~ ·
Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25 tHb)
Element Removal
• Remove the seat.
• Remove the wing bolt [A) and pull out the element [B].
• Sluff a clean, lint-free towel into the carburetor so no dirt is allowed
to enter the carbure tor.
• Wipe out the inside 01 the air cleaner housing with a clean damp
i
lowel.
CAUTION
Check Inside of the Inlet tract and carburetor for dirt. It dirt Is
present, clean the intake tract and carburetor thoroughly. You
may also need to replace the element and seal the hou sing
and inlet tract.
j
Element Installation
• When installing the element, coat the lip of the element with a thick
layer ot all purpose grease {AJ to assure a complete seal against the
air cleaner element base. Also. coat the base where the lip 01 the
element fits.
• Apply grease to all connections and screw holes in the air cleaner
housing and intake tract.
• Take out the towel from the carburetor securely.
IC.,.,oU, •
1
FUEL SYSTEM 2-19
Air Cleaner
• Install the element so that its tab [AI faces upward and fit the element
projections [BI to the holes of the housing [C!.
Element Cleaning and Inspection
NOTE
o In dusty areas, the element should be cleaned more frequentfy than
recommended interval.
o After riding through rain or on muddy roads, the element should be
cleaned immediately.
o Since repeated cleaning opens the pores of the element, replace
it with a new one in accordance with the Periodic Maintenance
Chart. Also. if there is a break in the element material or any other
damage to the element. replace the element with a new one.
AWARNING
Clean the element in a well-ventilated area, and take care that
there are no sparks or flame anywhere near the working area;
this includes any appliance with a pilot light. Because of the
danger of highly flammable liquids, do not use gasoline or a
low flash-point solvent to clean the element.
• Remove the air cleaner element, and separate the element [AI from
the frame [B).
• Clean the element in a bath of a high flash·point solvent using a soft
bristle brush. Squeeze it dry in a clean towel. Do not wring the
element or blow it dry; the element can be damaged.
• Check all the parts of the element for visible damage.
If any of the parts of the element are damaged, replace them .
• After cleaning, saturate the element with a high·quality foam-air-filler
oil. squeeze out the excess, then wrap it in a clean rag and squeeze
it as dry as possible. Be careful not to tear the sponge filter.
• Assemble the element.
• Remove the towel from the carburetor.
• Install the element.
*
2-20 FUEL SYSTEM
Fuel Tank
Fuel Tank Removal
AWARNING
Gasoline Is extremelv flammable and can be explosive under
certain conditions. Always stop the engine and do not smoke.
Make sure the area is well·ventiJated and free from any source
of flame or sparks; this includes any appliance with a pilot
light.
• Remove:
Radiator Shrouds
Seat
•
•
•
•
•
Turn the fuel tap to the OFF position .
Pull the luel hose oH the fuel tap.
Remove the fuel tank mounting bolt [A] and band (B).
Remove the fuel tank [C].
Drain the fuel tank.
Fuel Tank Installation
• Check the rubber dampers [AI on the frame and fuel tank.
If the dampers are damaged or deteriorated, replace them.
• Be sure the fuel hose is clamped to the luet lap to p revent leaks.
• Insert the fuel tank breather hose outlet end into the steering stem
hole (see General Information chapter).
*
Fuel Tap Removal
• Remove the fuel tank and drain it.
• Remove the mounting bolts [AJ and take out the fuel lap [8].
I
FUEL SYSTEM 2-21
Fuel Tank
Fuel Tap Installation
• Be sure the a-ring is in good condition to prevent leaks.
• Be sure to clamp the fuel hose to the tap to prevent leaks.
Fuel Tap Inspection
• Remove the fuel tap.
• Check the fuel lap fitter screen [A] for any breaks or deterioration.
II the tuellap screen have any breaks or is deteriorated , it may allow
dirt to reach the carburetor, causing poor running. Replace the fuel
*
B
tap.
* If the fuel tap leaks, or allows fuel to flow when it is at OFF position,
replace the damaged a ' ring [8].
.COtO,03U C
Fuel Tank and Tap Cleaning
AWARNING
Clean the tank in 8 well-ventilated area, and take care that
there is no sparks or flame anywhere near the working area.
Because of the danger o f highly flammable liquids, do not use
gasoline or low fla sh-point solvent to clean the tank.
• Remove the fuel tank and drain it.
• Pour some high flash-point solvent into the fuel tank and shake the
tank to remove dirt and fuel deposits.
• Pour the solvent out of the tank.
• Remove the fuel tap from the tank by taking out the bolts.
• Clean the fuel tap fitter screen in a high flash -point solvent.
• Pour high flash-point solvent through the tap in all lever positions.
• Dry the lank and tap with compressed air.
• Install the tap in the lank.
• Install the fuel tank.
2-22 FUEL SYSTEM
Reed Valve
Reed Valve Removal
• Remove the reed valve in accordance with the following procedure.
KX250:
o Drain the coolant.
o Remove the carburetor and coolant hose [Aj.
• Remove the holder mounting bolls [8J, and take 011 the carburetor
holder [C).
•
• Take the reed valve [A] out of the cylinder,
KX125 :
o Remove the carburetor, holder mounting bolts, and carburetor holder.
o Remove the reed valve rA] out althe crankcase.
Reed Valve Installation
• Install the reed valve [AJ so thai the ~up· marked {B] side fa ces
upward.
• Tighten the carburetor holder mounting bolts.
Torque·
Carburetor Holder Mounting Bolts: 8.8 N·m (0.9 kgf·m , 78
in·lb)
FUEL SYSTEM 2·23
Reed Valve
Reed Valve Inspection
• Inspect the reeds for c racks, folds, or other visible damage.
II there is any doubt as to the condition of a reed, replace the reed
valve part with a new one.
If a reed becomes wavy, replace the valve part with a new one even
if its warp is less than the service limit.
• Measure the clearance between the reed [AI and holder [BI. and
check the reed warp as shown.
If anyone of the clearance measurements exceeds the service limit,
replace the valve part with a new one.
*
*
*
Reed Wrap
Service limit:
O.5 mm
.."....., ,
COOLING SYSTEM 3· 1
Cooli ng System
Table of Contents
Exploded View .......................................................................... ... ...... ... .... ... .... ... ..... ... ........ .... ... .. ...... .... ..... ....... ............ 3·2
Specifications .. .. .. ....... .. ... .. .. .... .. ........ .. .. .... ...... ... .. .................. .... ...... .. .... .......... .. ....... ................................................. .... . 3-4
Coolant ... ........ .. .. .. .... ... ......... .. ...... .... ....... ................................................................................ ... .. ..... ..... ..................... .... 3·5
Coolant Level Inspection ...... ..... ..... ... ................................................................................... ............ .... .. .... ...... ...... 3·5
Coolant Deterioration Inspection .................... ........................................ ............................. ................................ 3-5
Coolant Draining. .. .... ..... ..... ... ..... ... ........ .... .. ....... ... .... ..... ..
.....................................
....... ... .. .. ..... .... .. ..3-5
Coolant Filling..... .. ........ ............. .. ................................... .... ...... ....
........... .. ...... ..... ..... . ................................. 3-6
... ... ..... .. .. ............... ......... ................................. 3-7
Air Bleeding ........... ......................................................
Cooling System Pressure Testing ................... _.. .. .... ....
... .... ....... ..... ... ...................................................... . 3-7
Cooling System Flushing .. ... ..... ...... ... ............. .......
.....................................
. ......... ...... ... .. ... ...... ............. 3-8
Disassembly and Assembly Precautions ................
.................................................................. 3-9
.................................................................................. 3-' 0
Water Pump ............................ .. .. .. .... .. .......... ... .... .. .... ..
Water Pump Cover Removal....... ... ...
... .. ... ..... .... ............ .... ............................ ...... ... .. .. .. .... ... .. 3-10
Water Pump Cover Installation .. .... ... .................
..............................................
... ... ........ .. .. .. ....... .... 3-10
....................................
................................... 3-10
Impeller Removal.... ... ..................................................
.... .. .... .. ... ... ........ .... .. ........
.............................. 3-10
Impeller Installation ............ .. ..... ... .. ....... ..... ... ...
.... ..... .......... ... ... 3-10
Impeller Inspection ............................ ................................................................................
Water Pump Shaft Removal.. .. ......... .............................................. ..... ..... ..... .... .. ...
..... .... ........ .. .. ......... 3-11
...... ..... .. .... ... .. ... ........ ... .. ... .. .... ... ............................................... 3-11
Water Pump Shaft Installation..........
Oil Seal Removal... . ... ...........
... .................. .............. .. ... ...... ....... ............. ......
... .... ..... ... .. 3-1 1
..... .. .. ........ 3- 11
Oil Seal Installation .. ............ .... ...... .. .. ....... ... ........ .......................................................... .
....... .......... 3-13
Radiator .. .. .. .. ... ... . ... ... .. .. .. .. ... .. .... . ....... .. ........................................................................ ......... ... .. .. ...
Radiator Removal .............................................................................. .......... .. ...................................................... 3- 13
..3-13
Radiator installation ......... .... ..... ... ........... .. ... .
Radiator Inspection .................................................................................................................................................. 3- 13
Cap Inspection ....................................................................................................................................................... 3-13
Filler Neck Inspection ........................................ .. .. ..... ... .. .. .. ......... ..... .... .. .... .. ... .. .. ..... ............................................. 3-14
Cooling Hoses, Breather Hose Inspection ... .. .... ... ...
..................................................................................... 3· 14
Cooling Hoses, Breather Hose Installation ................................................... ..... .. ..... .... .......................................... 3-14
3·2 COOLING SYSTEM
Exploded View
KX125 ,
12
1. Radialor
2. Radialor Cap
3. Water Pump Cover
6. Oil Seal (Short)
7 . Oil Seal (long)
8. Bearing
4. Drain Plug
9. Water Pump Gear
10. Right Engine Cover
5. Impeller
11. Cylinder Head
12. Cylinder
G: Apply grease
M: Apply molybdenum disulfide grease.
T1 : 8.8 N·m (0.9 kgf·m, 78 in·lb)
T2: 6.9 N·m (0.7 kgf.m , 61 in ·lb)
T3 : 1.5 N·m (0.15 kgf·m , 13 in·lb)
COOLING SYSTEM 3-3
Exploded View
KX250 :
(iJl=--
~
'~
~
1. Radiator
2. Radiator Cap
3. Water Pump Cover
4. Drain Plug
5. Impeller
6. Oil Seal (Short)
7. Oil Seal (Long)
8. Bearing
9. Water Pump Gear
10. Right Engine Cover
11 . Cylinder Head
12. Cylinder
13. Cylinder Drain Plug
14. Elbow Fitting
G: Apply grease
M: Apply molybdenum disulfide grease.
T1: B.8 N'm (0.9 kgf·m , 78 in .lb)
T2: 6.9 N·m (0.7 kg'·m , 61 in-Ib)
T3: 4 .9 N·m (0.5 kg'·m , 43 ft ·lb)
T4: 1.5 N·m (0.15 kgf·m, 13 in·lb)
3-4 COOLING SYSTEM
Specifications
Service Limit
Item
Coolant
Color
Permanent type antifreeze for aluminum engines and radia100;
Green
Mixed ratio
Soft water 50%, antifreeze 50%
Type
Total amount
KX125
a .97l
10(250
1.18 L
Radiator
Cap reliel pressure
95 .... 125 kPa
(0.95 - 1.25 koflcm' 14 _ 18osi'
Special Tools· Bearing Driver Set: 57001-1129
1,
COOLING SYSTEM 3·5
Coolant
Check the coolant level each day belore riding the motorcycle, and
replenish coolant il the level is low. Change the coolant in accordance
with the Periodic Maintenance Chart (see Generallnlormation chapter).
AWARNING
To avoid burns, do not remove the radiator cap or try to inspect
the coolant level or change the coolant when the engine is still
hot. Wait until it cools down.
Coolant Level Inspection
NOTE
Check the level when the engine is cold (room or ambient
temperature).
• Situate the motorcycle so that it is perpendicular to the ground.
• Remove the radiator cap rAJ.
NOTE
o Remove the radiator cap in two steps. First turn the cap counter·
clockwise to the first stop and wait there for a few seconds. Then
push down and turn it further in the same direction and remove the
cap.
• Check the coo[antlevel. The coolanl level (A] should be at the bottom
of the filler neck (8].
If the coolant level is low, add coolant through the filler opening to the
bottom of the filler neck. Install the cap.
*
Recommended coolant:
Permanent type of antifreeze (soft water and ethylene gtycot plu.
corrosion and ru st Inhlb ttor chemicals for a luminum engines and
radiators)
Water and coolant mixture ratio:
1:1 (water 50 %, CoolanlSO %)
Total amount:
KX 125: 0.97 l
KX250: 1.18 l
Coolant Deterioration Inspection
• Visually inspect the coolant.
II Whitish conon·like wafts are observed, aluminum parts in the cooling
system are corroded. IIIhe coolant is brown, iron or steel parts are
rusting. In either case, flush the cooling system.
If the coolant gives oH an abnormal smell, check for a cooling system
leak. It may be caused by exhaust gas leaking into the cooling
system.
*
*
Coolant Draining
The coolant should be changed periodically to ensure long engine
life.
AWARNING
To avoid burns, do not remove the radiator cap or try to change
the coolant when the engi ne is still hot. Wait until it cools
down.
Cootant on tires will make them slippery and can cause an
accident and injury. Immediately wipe up or wash away any
coolant that spills on the frame, engine or other painted parts.
Since coolant is harmful to the human body, do not use for
drinking.
.0.,.,.,1, C
3-6 COOLING SYSTEM
Coolant
• Remove the radiator cap.
NOTE
o Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop and wait there for a few seconds. Then
push down and turn it further in the same direction and remove the
cap.
• Place a container under the coolant drain plug (KX125) [AI or plugs
(KX250) [B]. and drain the coolant from the radiator and engine by
removing the drain plug on the waler pump cover and the cylinder
(KX250), Immediately wipe or wash out any coolant that spills on the
frame, engine, or wheel.
• Inspect the old coolanllor visual evidence of corrosion and abnormal
smell (see Coolant Deterioration Inspection).
Coolant Filfing
CAUTION
Use coolant containing corrosion Inhibitors made specifically
for aluminum engines and radiator. in accordance with the
instruction of the manufacture's. Soft or distilled water must
be used with the antifreeze (see below for antifreeze) In the
cooling system. If hard water Is used In the system, it causes
scale accumulation in the water passages, and considerably
reduces the efficiency of the cooling system.
Recommended Coot ant
Type:
Permanent type antifreeze (soft water and
ethylene glycol plus corrosion and rust Inhibitor
chemicals fOf aluminum engines and radiators)
Color:
Green
Mixed ratio:
Soft water 50 %, Coolant 50 %
Freezing point:
_35°C (-31 °F)
Total amount
KXI25: 0.97 L
KX250: 1.18 L
• InSlaUthe drain plug.
o Replace the gasket with a new one.
Torque·
Coolant Drain Plug on Water Pump Cover:
8.8 N·m (0.9 kgf·m, 78 In·lb)
Coolant Drain Plug on Cyllnoer (KX250):
8.8 N·m (0.9 kgf·m, 78 ft Ib)
,
COOLING SYSTEM 3-7
Coolant
• Fill the radiator up to the bottom of the radiator filler neck [B] with
coolant [A], and install the cap, turning it clockwise about 1/4 turn.
NOTE
B
o Pour in the coolant slowly so that it can expel the air from the engine
and radiator. The radiator cap must be installed in two steps. First
turn the cap clockwise to the first stop. Then push down on it and
turn it the rest of the way
• Check the cooling system for leaks.
Air Bleeding
Before putting the motorcycle into operation, any air trapped in the
cooling system must be removed as !ollows.
• Start the engine, warm up the engine thoroughly. and then stop the
engine. Wait until the engine cools down.
• Remove the radiator cap.
• Check the coolant leveL
If the coolant level is low, add coolant up to Ihe bottom 01 the filler
neck.
• Inslall the radiator cap.
• Check the cooling system lor leaks.
*
Cooling System Pressure Testing
CAUTION
During pressure testing, do not exceed Ihe pressure for which
the system is designed to work. The m aximum pressure is 125
kPa (1.25 kgl/cm 2 , 18 psi).
• Remove the radiator cap, and install a cooling system pressure tester
[A] and adapter [81 on the radiator filler neck [C].
c
NOTE
u ••••• os,
o Wet the adapter cap sealing surfaces with water or coolant to
prevent pressure leaks.
• Build up pressure in the system carefully until the pressure reaches
125 kPa (1.25 kgflcm2, 18 psi).
• Watch the gauge lor at least 6 seconds. If the pressure holds steady,
the cooling system is all right.
• Remove the pressure lesler. replenish the coolant, and install the
radiator cap.
II Ihe pressure drops and no external source is found, check for
internal leaks. Check the cylinder head gasket for leaks.
*
3·8 COOLING SYSTEM
Coolant
Cooling System Rushing
Over a period of time, the cooling system accumulates rust, scale,
and lime in the water jacket and radiator. When this accumulation is
suspected or observed, flush the cooling system. If this accumulation is
not removed, it will clog up the water passages and considerably reduce
the efficiency of the cooling system.
• Drain the cooling system.
• Fill the cooling system with fresh waler mixed with a flushing
compound.
CAUTION
Avoid the use of a flushing compound which is harmful
to the aluminu m engine and radlalor. Carefully follow the
instructions supplied by the manufacture of the clea ning
product.
• Warm up the engine, and run it al normal operating temperature lor
about len minutes.
• Slop the engine, and drain the cooling system after the coolant cools
down.
• Fill the system with fresh water.
• Warm up the engine and drain the system after the CocHant cools
down.
• Repeat the previous two steps once more.
• Flil the system with a permanenltype coolant, and bleed the air from
the system (see Air Bleeding).
1
COOLING SYSTEM 3-9
Disassembly and Assembly Precautions
• Prior 10 disassembly of cooling system parts (radiator, pump. etc).
wail until the coolant cools down, and then drain the coolant.
• After assembling and filling the system with coolant, bleed any air
from the system.
3-10 COOLING SYSTEM
Water Pump
Water Pump Cover Removal
• Drain the coolant (see Coolant Draining).
• Loosen the cooling hose clamps [Al. and disconnect the cooling hoses
on the water pump cover [8].
• Unscrew the cover bolts [C], and remove the waler pump cover.
Water Pump Cover Installation
• Replace the pump cover gasket with a new one.
• Tighten the waler pump cover bolts and clamps.
Torque.
Water Pump Cover Bolts: 8.8 N·m (O.g kg'.m, 78 in·lb)
• Filt the cooling system (see Coolant Filling).
• Bleed the air from the cooling system.
Impeller Removal
• Drain the coolant (see Coolant Draining).
• Remove the cover bolts and take oullhe waler pump cover from the
right engine cover with the water hoses attached.
• Remove the impeller bolt [A}, and lake out the impeller [BI and washer.
Impeller Installation
• Tighten the impeller bolt.
Torque·
Impeller Bolt; 6.9 N·m (0.7 kgt·m, 61 In·lb)
Impeller Inspection
B
• Visually check the impeller [AJ.
If the surface is corroded, or if the blades [BJ are damaged, replace
the impeller.
*
A
COOLING SYSTEM 3-11
Water Pump
Water Pump Shaft Removal
• Remove:
Right Engine Cover (see Engine Right Side chapter)
• Pull out the water pump shaft [A] toward inside of the right engine
cover.
Water Pump Shaft Installation
• To prevent the oil seal lips from peeling, apply a molybdenum disulfide
grease [AI 10 Ihe water pump shaft [8] and insert it into the oil seals
rC] from the inside of the right engine cover [D].
CAUTION
Be sure to apply a molybdenum d isulfide grease to the water
pump shaft when installing. If it is installed dry, the seals may
wear excessively.
• Instal the impeller and check to see that Ihe impeller turn freely.
B
..ou'on' c
Oil Seal Removal
• Remove:
Right Engine Cover (see Engine Right Side chapter)
Water Pump Shaft
• Insert a bar [AI inlo the water pump shaft hole from the outside of
the right engine cover, and remove the ball bearing [B] by tapping [C]
evenly around the bearing inner race.
...OIo,on, c
• Insert a bar [AJ into the water pump shaft hole from the inside 01 the
right engine cover, and remove the oil seal [BI by tapping [C] evenly
around the seal lips.
Oil Seal Installation
CAUTION
If the oil seal or ball bearing is removed , replace aU of them
w ith new ones at the sa me time
• Be sure to replace the oil seals.
3·12 COOLING SYSTEM
Water Pump
• Apply plenty of high temperature grease to the oil seal lips (AI.
• Press the oil seals [B] into the hole from the outside of the right engine
o
cover.
Special Tools· Bearing Driver Set: 57001- 1129(CI
• Sellhe oil seal (thick) so thai dual lips side face outward and set the
oil seal (thin) so that a lip faces outward as shown.
NOTE
o Use a bearing driver larger in diameter than the oil seal, and press
the oil seal into the hole until the edge of the oil sea/located O. 1 0.5 mm {OJ deep from the surface of the hole.
• Press the ball bearing into the hole unlil the bearing is bottomed
against the step IE].
Special Toots· Bearing Driver Set: 57001-1129
IHII'O'"
•
COOLING SYSTEM 3· 13
Radiator
Radiator Removal
• Drain the coolant (see Coolant Draining).
• Remove:
Radiator Shrouds
Fuel Tank (see Fuel System chapter)
Bolts (AJ
Radiator Screens [B]
Cooling Hose [C]
Bolts (0]
Radiator Brackets (El
Mounting Bolts (KX 12S: with clamp)
Upper Connecting Hose (F)
Lower Connecting Hose (G]
Cooling Hose [H]
Breather Hose [II
Radiator Instalfation
• Radiator installation is the reverse of removal.
• Route the cooling and breather hoses correctly.
Radiator Inspection
• Check the radiator core.
If there are obstructions to air flow, remove them.
II the corrugated fins are deformed. carefully straighten them with the
thin blade 01 a screwdriver [A].
*
*
CAUTION
Do not tear the radiator tubes while straightening the fins.
* If the air passages of the radiator core are blocked more than 20%
by unremovable obstructions or irreparably deformed fins. replace the
radiator with a new one.
CAUTION
When cleaning the radiator with steam cleaner, be carefu l of
the following to prevent radiator damage.
Keep Ihe sleam gun Ie] away more than 0.5 m [8] from the
radiator core. Hold the steam gun perpendicular to Ihe core
surface. Run the steam gun following the core fin direction
[AI.
Cap Inspection
• Check the condition of the valve spring [BJ, and the top and bottom
valve seals [A) of the radiator cap.
If anyone of them shows visible damage. replace Ihe cap.
*
3· 14 COOLING SYSTEM
Radiator
• Wet the lop and bottom valve seals with water or coolant to prevent
pressure leaks.
• Inslalilhe cap [AI on a cooling system pressure tester [BI.
B
• Watching the pressure gauge, slowly pump the pressure lester to
build up the pressure. The gauge hand must remain within the relief
pressure range in the table below at least 6 seconds. Continue
to pump the lester until the relief valve opens, indicated by the
gauge hand flicking downward. The relief valve must open within
the specified range.
Radiator Cap Rellel Pressure:
Standard:
95 ..... 125 kPa (0.95 '" 1.25 kgf/cm2, 14 ..... 18
psi)
* II the cap cannot hold the pressure, or jf the relief pressure is too
high or 100 low, replace the cap with a new one.
Filler Neck Inspection
• Check the radiator 'iller neck for signs 01 damage.
• Check the condition of the top and bottom sealing seats rA] in the
liller neck. They must be smooth and clean for the radiator cap to
function property.
Cooling Hoses, Breather Hose Inspection
• In accordance with the Periodic Maintenance Chart, visually inspect
the hoses rA] for signs of deterioration. Squeeze the hose. A hose
should not be hard and brittle, nor should it be soft or swollen.
• Replace any damaged hose.
Coofing Hoses, Breather Hose Installation
• Instalilhe cooling hoses or breather hose being careful to follow the
pertormed bends (see General Information chapter). Avoid sharp
bending. kinking, flattening, or twisting.
• Tighten the hose clamps securely.
IAOIGOII.,
~
ENGINE TOP END 4· 1
Engine Top End
Table of Contents
~~~:~~~~.:.:.:.:.:.:.:.:.:.:.: .:. :.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:~.:.:.:.:.:~.:.:.:.:.:.:.:.:. .:.:~.:.:.:.:.:. :.:.:.: .:~.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.: :.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:~.:.:.:.:.:.:.:.:. .:.:.:.:.:.:.:.:. :.:.:.:.:~ .:.:.:.:.:.:.:.:.:.: :~~ [II
Cylinder Compression Measurement .........................................................................................................................4-7
Cylinder Head RefTlOval ................................................................................................ ......................................... .... 4-7
Cylinder Head Inslallalion .............................. ...... ................................................................................ ...... ........... ..... 4-8
Cylinder Head Warp Inspection ....... ........... .. .......................................... ................................................................... 4-8
Cylinder .............................................................................................................................................................................4-9
Cylinder Remollat .............................. ........................................................................ ......................................... ....... . 4-9
Cylinder Installalion ........... .. ............................ ...... ........................................................... .... ...... .. ... ......................... 4-10
Piston Removal............. ... ... .. .......... .............
................................................................................................ 4-11
Piston Installation .................................................................................................................................................... 4-11
Cylinder Wear Inspeclian ............................................. ...... ............................................... .............
....... .. .. . 4-13
Piston Diameter Measurement ........................ ............................................ ............ .. ..................... .. .. ... ... ... .......... ... 4-13
Piston/Cylinder Clearance ................................ .... ............................................................................ .. ........... .. .. ....... 4-14
Pislon Ring, Pislon Ring Groove Inspection ............................................................................................................4-14
Piston Ring End Gap Inspeclion ..... .................................................................................................................... .... .4- 15
Piston, Pistoo Pin, Connecting Rod Wear Inspection ......................................................................................... ..... 4-15
Exhaust Valve (Ki PS) ............................................... ....................................... .... ... .. ... ...................................... ....... ....... 4-16
Exhaust Valve Removal (KX125 Model) ........... ................................. ... ........ ........................................................... 4-16
Exhaust Valve Removal (KX250 Model) .... .............................................................. ....................... .. ........... ........ .. 4-16
Exhaust Valve installation (KX125 Model) .............................................................................................................4-18
.... ........................................................... 4-20
Exhaust Vallie Installation (KX250 Model)............ .. ... ..............
Muffler (Expansion Chamber, Silencer) .............. .. ..........................................................................................................4-25
Muffler Removal ...................................................................................................................................................... 4-25
Muffler Inslallation ....................................... ....................................................... ...... ......................... ........... ... ....... 4-25
Silencer Packing Change ........................................................................... ..... ......................................................... 4-25
4-2 ENGINE TOP END
Exploded View
KX125:
,
j
;
~1\1)
a:
16
•
18
0
3
ENGINE TOP END 4-3
Exploded View
A: KX125-Ll only
B: KX125-L2 '" L4
1. Spark Plug
2. Engine Brackets
3. Cylinder Head
4. Cylinder
5. Idle Gear Lever
6. Main Valve Cover
7. Main Lever
8. Pin
9. Slide Valve
10. Butterfly Valve
11. Valve Holder
12. Pin
13. Main Shaft
14. Governor Shaft Lever
15. Piston Ring
16. Piston
17. MR" Mark
18. MIN" Mark
19. Piston Pin
20. Expansion Chamber
21 . Rubber Seals
22 . Gasket
23. Silencer
24. KIPS Cover
25. Spring
26. Exhaust Valve-assy
G: Apply grease.
L: Apply a non-permanent locking agent.
0 : Apply 2-stroke engine oil.
M: Apply molybdenum disulfide grease.
SS: Apply Silicone Sealant.
T1 : 25 N·m (2.5 kgf·m, 18 ft·lb)
T2 : 29 N·m (3.0 kgf·m, 22 ft·lb)
T3: 44 N·m (4.5 kgf·m, 33 ft-lb)
T4: 25 N·m (2.5 kgf·m, 18.0 ft·lb)
T5: 6.9 N'm (0.7 kgf·m, 61 in ·lb)
T6 : 8.8 N·m (0.9 kgf·m, 78 in·lb)
T7: 3.9 N·m (0.4 kgf·m, 35 in·lb)
T8: 5.9 N·m (0.6 kgf·m, 52 in·lb)
8.8 N·m (0.9 kgf·m, 78 in·lb)(KX125-L3 '"" L4)
4·4 ENGINE TOP END
Exploded View
KX250:
j
\
1
1
IlOUU'"
c
ENGINE TOP END 4-5
Exploded View
A: KX25O-L 1 only
B: KX250-L2 '" L4
1. Spark Plug
2. Engine Brackets
3. Cylinder Head
4. Cylinder
5. Operating Rod
6. Exhaust Valve (Left)
7. Exhaust Valve (Right)
8. Guide
9. O-Rings
10. Idle Gear
11 . Guide
12. Main Exhaust Valve Cover
13. Valve Holder
14. Pin
15. Slide Valve
16. Butterfly Valve
17. Valve Holder
18. Pin
19. Governor Shaft Lever
20. Piston Ring
21 . Piston
22. " IN" Mark
23. Piston Pin
24. Reed Valve
25. Carburetor Holder
26. Expansion Chamber
27. Rubber Seals
28. Gasket
29. Silencer
30. Main Valve Rod Cover
31. Main Valve Rod
32. Main Shaft
33. KIPS Cover
34. Cylinder Left Cover
35. Operating Rod Left Side plug
36. Main Lever
37. Spring
38. Exhaust Valve Assembly
G: Apply Grease.
L: Apply a non-permanent locking agent.
M : Apply molybdenum disulfide grease.
0: Apply 2-stroke engine oil.
SS: Apply Silicone Sealant.
T1 : 2.5 N·m (2.5 kgf·m, 18 ft·lb)
T2: 29 N'm (3.0 kgf·m, 22 ft·lb)
T3: 34 N'm (3.5 kgf·m, 25 ft·lb)
T4: 25 N·m (2.5 kgf·m. 18 ft·lb)
T5: 44 N·m (4.5 kgf·m, 33 ft·lb)
T6: 5.9 N·m (0.6 kgf·m, 52 in·lb)
8.8 N·m (0.9 kgf·m, 78 in·lb)
(KX250-l3 '" L4)
T7: 8.8 N·m (0.9 kgf·m, 78 in·lb)
T8 : 5.4 N' m (0.55 kgf·m, 48 in·lb)
T9: 22 N·m (2.2 kgf·m, 16 ft·lb)
TlO: 2.5 N' m (0.25 kgf·m. 22 in·lb)
Tll: 3.9 N·m (0.40 kgf·m. 35 in·lb)
4-6 ENGINE TOP END
Specifications
Item
Standard
Service Limit
Cylinder Head:
Cylinder compression
(Usable range)
· ..
890 ...... 1370 kPa
(9. 1 ..... 14.0 kgf/cm 2, 129 ..... 199 psi)
...
Cylinder head warp
0.03 mm
Cylinder, Piston:
Cylinder inside diameter
54.000 ..... 54.015 rnm
(15 mm below of the cylinder head)
L3 ..." L4 Model
Piston diameter
L3 ...... L4 Model
Piston/cylinder clear-
anca
L3 ...., L4 Model
54.000 .... 54.015 mm
54.08 mm
54.08 mm
54.010 ..." 54.025 mm
54.09 mm
53.945 ..... 53.960 mm
53.82 mm
53.955 -.. 53.970 mm
0.050 ,... 0.060 mm
53.83 mm
· ..
0.060 ..... 0.070 mm
· ..
Piston ring {groove clearance
0.015 ....., 0.050 mm
0.015 mm
Piston ring groove width
1.01 ...., 1.03 mm
1.10 mm
Piston ring thickness
0.980 _ 0.995 mm
0 .91 mm
Piston ring end gap
0.35 ..... 0.55 mm
0.90 mm
Pisl(l(l pin diameter
14.995 ..... 15.000 mm
14.96 mm
Piston pin hole diameter
15.001 ..... 15.0 11 mm
15.07 mm
Small end inside diameter
19.003 .... 19.0 14 mm
19.05 mm
.
KX250·
Item
Standard
Service Limit
Cylinder Head:
· ..
Cylinder compression
(Usable range)
Cylinder head warp
(8.1 ", 12.5 kgflcm2, 115 ...., 178 psi)
...
0.03 mm
795 "" 1230 kPa
Cylinder, Piston :
Cylinder inside diameter
66.400 '" 66.4 15 mm
66.48 mm
Piston diameter
66.336 ..... 66.351 mm
Piston/cylinder clearance
0.059 .... 0.069 mm
66.23 mm
· ..
Piston ring/groove clearance
0.025 .... 0.06 mm
0.18 mm
Piston ring groove width
1.01 "" 1.03 mm
1.13mm
Piston ring thickness
0.970 .... 0.985 mm
0.90 mm
Piston ring end gap
0.25 "" 0.45 mm
0.80 mm
Piston pin diameter
17.995 _ 18.000 mm
17.96 mm
Piston pin hole diameter
18.005 ...., 18.015 mm
18.07 mm
Small end inside diameter
22.003 _ 22.012 mm
22.05 mm
Special Tools· Compression Gauge: 57001-221
Piston Pin Putter Assembly: 57001-910
Compression Gauge Adapter, M14 JI; 1.25: 57001-1159
:
ENGINE TOP END 4-7
Cylinder Head
Cylinder Compression Measurement
• Start the engine.
• Thorough ty warm up the engine so that the engine oit between the
piston and cylinder wall will help seal compression as it does during
normal running.
• Stop the engine.
• Remove the fuet tank (see Fuel System chapter).
• Remove the spark plug, and screw a compression gauge firmly into
the spark plug hole.
Special Tools· Compression Gauge: 57001-221 (Al
Compression Gauge Adapter, M14 x 1.25: 5100 1-1159
[BJ
• With the throttle fully open, turn the engine over sharply with the
kickstarter several times until the compression gauge stops riding;
the compression is the highest reading obtainable.
Cylinder Compression
Usable Ra nge:
KX125: 890 - 1310 kPa (9. 1 - 14.0 kgt/cJTil, 129 - 199 psi)
KX250: 195 -1230 kPa (8.1 -12.5 kgf/c~, 115 -178 psi)
* if cylinder compression is higher than the usable range, check the
*
following:
1. Carbon build up on the piston head and cylinder head - clean off
any carbon on the piston head .
2. Cylinder head gasket. cylinder base gasket- use only the proper
gaskets for the cylinder head and base. The use of gasket of the
incorrect thickness will change the compression.
if cylinder compression is lower than the usable range, check the
following:
1. Piston/cylinder clearance, pistoo seizure.
2. Gas leakage around the cylinder head - replace the damaged
gasket and check the cylinder head for warping.
3. Piston ring, piston ring groove.
Cylinder Head Removal
• Drain the coolant (see Cooling System chapter).
• Remove:
Radiator Shrouds
Seat
Side Covers
Fuel Tank (see Fuel System chapter)
Muffler (see this chapter)
Radiators (see Cooling System chapter)
Cooling Hose
Spark Plug
Bolts & Nuts [AJ
Engine Mounting Brackets [BJ
• Remove the cylinder head nuts [A], and take off the cylinder head [BJ
and gasket.
A
4-8 ENGINE TOP END
Cylinder Head
Cylinder Head Installation
• Replace the head gasket with a new one.
• Scrape out any carbon and clean the head with a high fl ash-point
solvent.
• Check for a crust of minerals and rust in the head waler jacket. and
remove them if necessary.
• For KX250: install a new cylinder head gasket with the EX marked
side fA] forward.
• Tighten the head nuts diagonally.
Torque -
Cylinder Head Nutl : 25 N·m (2.5 kgf·m , 18 h ·lb)
• Tighten the engine mounting bracket nuts.
Torque- Engine Mounting Bracket
Nut. :
10 mm: 44 N·m (4.5 kgl·m, 33 ft.lb)
8 mm: 29 N·m (3.0 kgl·m, 22 fHb)
• Tighten the spark plug.
Torque -
Spark plug: 25 N·m (2.5 kg',m, 18 ft·lb)
•
Cylinder Head Warp Inspection
• lay a straightedge [A) across the lower surface of the head al several
different points, and measure warp by inserting a thickness gauge [B)
between the straightedge and the head.
If warp exceeds the service limit, repair the mating surface. Replace
the cylinder head if the mating surface is badly damaged.
*
Cylinder Head Warp
StlfVlce Limit:
0.03 mm
1
ENGINE TOP END 4-9
Cylinder
Cylinder Removal
• Drain the coolant (see Cooling System chapter).
o For KX25O: be sure 10 remove Ihe cylinder drain plug.
• Remove the cylinder head (see this chapter).
• Remove the water hoses.
• Remove the KIPS cover at the cylinder.
• Remove the shaft lever in accordance with the following procedure .
1OC125:
o Remove the clip IAJ and pull out the governor shaft lever IBI from the
idle gear lever (C].
KX250:
o Loosen the clamps, and pull the carburetor out of the holder and the
air cleaner duct.
Remove the E-clip (AI, flat washer IB] and wave washer from the
operating rod.
For KX250-l2 '" L4, remove the E-clip [AI from the operating rod.
Put a 9 mm spanner wrench [Alan the shaft lever upper end.
Turn the shaft lever [B] counterclockwise with the wrench, and take
off the operating rod collar Ic} by pushing the operating rod into the
cylinder.
Before pulling the shah lever [AI free, turn the remaining E-ctip [BI to
a suitable position as shown in the tigure to prevent the shaft lever
boss [C] and the E-ctip from hiffing .
4· 10 ENGINE TOP END
Cylinder
• Remove the cylinder nuts [AJ.
• Lift oH the cylinder, and remove the cylinder base gasket.
II
necessary, tap lightly around the base 01 the cylinder with a plastic
mallei tAl, taking care not to damage the cylinder.
• Remove the exhaust valves from the cylinder (see Exhaust Valve
Removal).
Cylinder Installation
• Scrape any carbon out of the exhaust port.
• Check on a crust 01 minerals and rust in the cylinder wa ter jackel.
and remove them if necessary.
• Replace the cylinder base gasket with a new one.
• Apply engine oil to the piston surface, piston rings and cylinder bore.
• Check 10 see thai the pin [A] in each piston ring groove is between the
ends oltha piston ring, and lit the base oltha cylinder over each ring,
pressing in on opposite sides 01 the ring as necessary. Be certain
that the rings do not slip out of position.
• TIghten the cylinder nuts diagonally.
Torque·
CyUnder Nuts:
KX125: 25 N·m (2.5 kgf·m, 18 h.tb)
KX250: 34 N·m (3.5 kgf.m. 25 h'lb)
• For KX'25, using the 14 mm spanner wrench rAJ install Ihe shaft
lever 18]10 the idle gear lever.
A
A
ENGINE TOP END 4-11
Cylinder
• For KX250, inslall the shaft lever and operating rod collar in accordance with the following procedure.
o Put a 9 mm spanner [A) wrench on the shaft lever upper end.
o Turn the shaft lever counterclockwise with the wrench and fit the
groove of the operating rod coliar IB] to the boss of the shaft lever,
and instalilhe collar on the operating rod while holding the shaft lever
clockwise.
• After the collar installed, install the wave washer [BJ, flat washer [C] .
and E-clip [0] on the operating rod (A].
• For KX25O-l2 "" L4. after installing the collar, install the E-clip [D] on
the operating rod [AJ.
• InslaUthe KIPS cover.
Torque -
KIPS Cover Bo lts: 2.5 N·m (0.25 kgf·m , 22 in·lb)(KX250)
8.8 N·m (0.9 kgf·m, 78 In·lb)(KX125)
Piston Removal
• Remove the cylinder.
• Sluff a clean cloth into the crankcase opening around the connecting
rod so that no parts will fall into the crankcase.
• Remove one of the piston pin snap rings with needle nose pliers.
• Remove the piston by pushing the piston pin out the side from which
the snap ring was removed. Use a piston pin puller assembly [A), if
the pin is tight.
Special Tools - Piston Pin Puller A s sembly: 57001-91 0
• Remove the piston rlng(s).
o Carefully spread the ring [A) opening wi th your thumbs and then push
up on the opposite side of the ring to remove it.
.."OIOIS' 0
Piston Installation
• Stuff a clean cloth into the crankcase opening around the connecting
rod so that no parts will fall into the c rankcase.
• Scrape off any carbon of the piston, then lightl y polish the piston with
fine emery cloth.
• Clean carbon and dirt out of the piston ring groove using a suitable
1001.
CAUTION
Carbon particles can be very abrasive to piston ring . Don't
allow such particles to fall onto the cylinder walls.
4-12 ENGINE TOP END
Cylinder
• When installing the piston ring on the piston, nole the following:
o For KX25O, the top (AI and secood [BI rings are identical.
o First fil one end of the pisloo ring against the pin in the ring groove,
spread the ring opening with the other hand and then slip the ring
into the groove.
o For KX 125. the piston ring have a ~R" mark [AI on it upper surface.
o Install the ring so that the pin IAI in the piston ring groove is between
the ends of the piston ring.
KX25 0
KX 125
A
A
uno,on ,
UUO'O Il,
,
IEO'OUU'
C
• Apply 2-stroke engine oil to the connecting rod needle bearing and
the piston pin.
• Inslall the piston so that the ·IN~ marked side (AI faces the back side
altha engine.
• When installing a piston pin snap ring [AI, compress it only enough
to install it and no more.
CAUTION
00 not reu se snap ring s, as rem oval weakens and deforms
them. They could fall out and score the cylinder wall.
• Fit a new piston pin snap ring into the side of the piston so that the
ring opening [BI does not coincide with the notch [C] in the edge 01
the pistoo pin hole.
A
B
ENGINE TOP END 4·13
Cylinder
Cylinder Wear Inspection
NOTE
o Measure the cylinder inside diameter when the cylinder is cold
(room or ambient temperature).
• Visually Inspect the inside of the cylinder for scratches and abnormal
wear.
* If the cylinder is damaged or badly worn, replace it with a new one.
• Since there is a difference in cylinder wear in different directions, take
a side-Io-side and a front-Io back measurement shown in the figure.
If any 01 the cylinder inside diameter measurements exceeds the
*
q>
OPDC
~
[£~l6:
UUG,OU ,
c
service limit, the cylinder must be replaced with a new one since
the ELECTRO FUSION cylinder cannot be bored or honed.
Cylinder Inside Diameter
KX125:
Standard
L3 ..... L4 Model
Service Limit
La ..... L4 Model
KX250:
Standard
Service Limit
54.000 - 54.015 mm,
54.010 - 54.025 mm, and less tnan 0.01 mm
difference between any two measurements.
54.08 mm,
54.09 mm, or more tnan 0.05 mm difference
between any two measurements.
66.400 - 66.415 mm, and tes s than 0.01 mm
difference between any two measurements .
56.48 mm. or more tnan 0.05 mm difference
between any two meas urements.
KXI25 -15 mm
KX250 - 30 mm
Piston Diameter Measurement
• Measure the outside diameter of the piston 18.0 mm (KX125) or 20.5
mm (KX250) [AJ up from the bottom of the piston at a right angle to
Ihe direction of the piston pin.
If the measurement is under the service limit, replace the piston.
o\J
*
Piston Diameter
KX125:
Standard
L3 ..... L4 Model
Service Limit
L3 ..... L4 Model
53.945 - 53.960 mm
53.955 - 53.970 mm
53.82 mm
53.83 mm
KX250:
Standard
Service Limit
(A):
66.336 - 66.351 mm
66.23 mm
KX125 - 18.0 mm
KX250 - 20.5 mm
® f-- (
,L
Y
....o'c .. , t
4-14 ENGINE TOP END
Cylinder
Piston/Cylinder Clearance
The piston-to-cy1inder clearance is measured whenever a piston or
cylinder is replaced with a new one. The standard piston-la-cylinder
clearance must be adhered to whenever the cylinder is replaced.
11 only a piston is replaced, the clearance may exceed the standard
slightly. But it must nol be less than the minimum, in order to avoid
piston seizure.
The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measurements and then computing
the difference between the two values. Measure the piston diameter as
just described, and measure the cylinder diameter al the very bottom
01 the cylinder.
PI. tonICytinder Clearance
Standard:
KX125: 0.050 - 0.060 mm
L3 .... L4 Model: 0.060 - 0.070 mm
,
KX250: 0.059 - 0.069 mm
Piston Ring, Piston Ring Groove Inspection
• Visually inspect the piston rings and the piston ring grooves.
II the rings are worn unevenly or damaged, they must be replaced.
II the piston ring grooves are worn unevenly or damaged, the piston
must be replaced and 'illed with new rings.
• Check for uneven groove wear by inspecting the ring seating.
• The rings should fit perfectly parallel to the groove suriaces. If not,
the piston must be replaced.
• With the piston ring in its groove, make several measurements with
a thickness gauge (AI to determine piston ring/groove clearance.
If the clearance exceeds the service limit, measure the thickness of
the piston ring
If the ring has 'NOrn down to less than the service limit, replace the
ring; if the groove width exceeds the service limit, replace the piston.
*
*
*
*
•
Piston RlnglGroove Clearance
KX125:
Standard;
Service Umit;
KX2SO:
Standard:
Service Um!t;
0.030 .... 0.065 mm
0.165 mm
0.025 .... 0.060 mm
0.18 mm
Pis ton Ring Thickness
KX125:
Standard :
Service Umit
0.965 .... 0.980 mm
0.90 mm
KX2SO:
Standard:
Service Limit
0.970 .... 0.985 mm
0.90 mm
Piston Ring Groove Width
KX125:
Standard:
Service Umit
1.01 .... 1.03 mm
1.13 mm
KX250:
Standard:
Service Limit
1.01 .... 1.03 mm
1.13 mm
ENGINE TOP END 4· 15
Cyli nder
Piston Ring End Gap Inspection
• Place the piston ring (AJ inside the cylinder IB}, using the piston to
locate the ring squarely in place.
• Set it close to the bottom 01 the cylinder. where cylinder wear is low.
• Measure the gap between the ends althe ring with a thickness gauge
Ic]
* If the gap is wider than the service limit, the ring is averworn and
must be replaced.
Piston Ring End Gap
KX125:
Standard :
Service Limit:
KX250:
Stendard:
Service L.lmlt :
0.35 ..... 0.55 mm
0.90 mm
0.25 ..... 0.45 mm
0.80 mm
Piston, Piston Pin, Connecting Rod Wear Inspection
• Visually inspect the snap ring IA} still lilted in place.
II the ring shows weakness or delormation, replace the ring. Also il
the pin hole groove shows excessive wear, replace the piston.
• Measure the diameter 01 the piston pin (B] with a micrometer.
II the piston pin diameter is less than the service limit at any point,
replace the piston pin.
• Using a cylinder gauge, measure the diameter of both of piston pin
holes (C) in the piston and the inside diameter 01 the connecting rod
small end.
II either piston pin hole diameter exceeds the service limit, replace
the piston .
If the connecting rod smaU end inside diameter exceeds the service
limit, replace the crankshaft assembly.
• Check the needle beanng [OJ.
a The rollers in a needle bearing normally wear very little, and wear
is difficult to measure. Instead of measuring. inspect the bearing lor
abrasion , color change, other damage.
If there is any doubt as to the condition 01 a needle bearing, replace
the bearing and piston pin.
*
*
*
*
*
Piston Pin Diameter
KX125
Standard:
Service Limit:
KX250
Stend erd:
Service Limit:
Piston Pin Ho le Diameter
KX125
Standard:
Service Limit:
KX250
Standard:
Service Limit:
Small End Inside Diameter
KX I 25
Standard:
Service limit:
KX250
Standard:
Service Limit:
14.995 ..... 15.000 mm
14.96 mm
17.995 .... 18.000 mm
17.96 mm
15.001 ..... 15.011 mm
15.07 mm
18.005 ..... 18.015 mm
18.07 mm
19.003 .... 19.014 mm
19.05 mm
22.003", 22.012 mm
22.05 mm
4-16 ENGINE TOP END
Exhaust Valve (KIPS)
Exhaust Valve Removal (KX125 Model)
• Drain the coolant.
• Remove:
Radiator (see Cooling System chapter)
Muffler (see Muffler Removal)
KIPS Cover (see Engine Righi Side chapter)
Clip [AI
Governor Shaft lever IS}
Idle gear lever bolt Ie]
Idle gear lever 10]
• Remove:
Cylinder (see Cylinder Removal)
Main Valve Cover Bolts [AI
Main Valve Cover IBJ
•
• Pull out the main exhaust valve assembly [AJ .
• Unscrew the Allen bolt [8] .
1
• Pull out the main exhaust valve shaft [AI and remove the main lever
(BI with spring Ic]'
Exhaust Valve Removal (KX250 Model)
• Remove:
Carburetor (see Fuel System chapter)
Cylinder Head (see Cylinder Head Removal)
• Remove the KIPS cover altha cylinder
• Remove the E-clip [AI. flat washer IB) and wave washer from the
operating rod.
• Remove the cylinder (see Cylinder Removal).
• For KX25O-l2 .... l4, remove the E-clip (AJ from the operating rod.
ENGINE TOP END 4-17
Exhaust Valve (KIPS)
• Turn the cylinder up side down.
• Remove the plug [AJ and the gasket IBJ al the lett side of the cylinder.
• Pull out the operating rod [A] as far as it goes.
• Remove the operating rod retaining screw [8).
• Remove the idle gear [A].
• Lift up the exhaust valves IBJ. and remove the valve guides [C},
• lift up the exhaust valves, and pull out the operating rod [OJ. Then
take out the exhaust valves.
• Remove the main valve cover [Aj, main valve rod cover IB] and
cylinder left cover [C)lrom the cylinder.
• Remove the main shaft nut [A] from the main shafl [B]. and pull oul
the main valve gear [C].
CAUTION
Main shaft nut has leh-hand threads.
4-18 ENGINE TOP END
Exhaust Valve (KIPS)
• Unscrew the Allen bolt (AI from the main lever [B).
• Position the main exhaust valve lull open, and pull out the main shaft
lei
• Set the main exhaust valve lull closed position, and remove the main
lever.
• For KX250-L2 '" L4, remove the main lever [81 with spring IE].
• Pull oul the main exhaust valves and main valve rod [01 from the
cylinder.
• Pull out the main exhaust valves and main valve rod [OJ from the
cylinder.
KX250-L2 "" l4:
1
• Unscrew the two main exhaust valve retaining screws [AI.
• Take oul the pin ICJ from the main exhaust valves [8].
• For KX250-l.2 "" L4, unscrew the two main exhaust valve retaining
•
screw [AI and lake out the main exhaust valve assembly [OJ from the
cylinder.
1
KX25~_ L4:
Exhaust Valve Instal/ation (KX125 Model)
• Scrape out any carbon and clean the valves with a high flash·point
solvent.
• Check the fOllowing for sings of damage:
Exhaust Valve Assembly
Oil Sea]
Gaskets
If necessary, replace them with new ones.
• Apply a 2-stroke engine oil 10 the operation parts.
• APPly a high temperature grease to the oil seal lip.
*
ENGINE TOP END 4-19
Exhaust Valve (KIPS)
• Set up the exhaust valve assembly as shown.
Slide Valve [A)
Butterfly Valve [B]
Valve Holder (C]
Roller [0]
Pin lEI
Press in the roller direction [F]
• After inserting the rolier, slake the it ends.
• Check that when the slide valve is slided to front and rear, the butterfly
valve is move smoothl y up and down.
• Fit the spring [Al to the main lever [BJ.
• Insert the main shaft [A] in the hole of the cylinder and through the
holes in the main lever IBI with spring !C].
• Apply a non-permanenllocking agent to the Allen boH.
• Fix the main lever to the main shaft with the Allen boll (AJ.
Torque -
Main Lever Allen Bolt: 3.9 N·m (0.4 kgl·m, 35 in· 'b)
• Insert the exhaust valve assembly (AI into the hole in the cylinder,
then fit the pin [B]lo the main lever [C] and the spring [0) opening.
o When inserllhe exhaust valve assembly full opened position .
t
\
4-20 ENGINE TOP END
Exhaust Valve (KIPS)
• Install the idle gear lever [AI so thai the mark [8) on the main shaft
gear ICJ aligns with the groove [OJ on the idle gear lever.
• Check that the exhaust valve assembly slide smoothly.
• Tighten the bolt.
Torque·
Idle Gear Lever Bolt: 6.9 N·m (0.7 kgf ·m , 61 in.lb)
• Install the main cover.
Torque·
Main Valve Cover Bolts: 5.9 N·m (0.6 kgf·m, 52 In·lb)
8.8 N·m (0.9 kgt·m, 78 In.lb)(KX125125O-U ,... L4)
• Using the 14 mm spanner wrench [AI. install the governor shaft lever
[8] as shown.
• Install the clip and KIPS cover.
Torque·
KIPS Cover Boltl: 8.8 N·m (0.9 kgf·m, 78 in·lb)
,
Exhaust Valve Installation (KX250 ModeJ)
• Scrape oul any carbon and clean the valves with a high flash· point
solvent.
• Check the following for signs of damage:
Exhaust Valves and Valve Operating Rod
Oil Seal on Rod Seal Plug
O-rings
Gaskets
If necessary, replace them with new ones.
*
• Apply a 2-stroke engine oil to the following:
Exhaust Valve Upper and Lower Journals
Exhaust Valve Pinions
Valve Guides (inside)
Valve Operating Rod Journals
Valve Operating Rod Rack
Main Exhaust Valve Parts
• Apply a high temperature grease to the oil seal lip on Ihe operating
md.
• Set up the exhaust valve assembly as shown.
Slide Valve [A]
Butterfly Valve [B)
Valve Holder [C]
Roller [0]
Press in the Roller direction [E]
• Check that when the slide valve is slided to front and rear, the butterfly
valve is move smoothly up and down.
j
1
J
ENGINE TOP END 4-21
Exhaust Valve (KIPS)
KX250-l2 "" L4:
o
B
®I
HUl lO '"
KX2So-l2 "" L4:
• Fit the spring [AI to the main lever [BJ.
• Insert the main exhaust valve assembly [A] into the cylinder (BI.
• Install the retaining bolts Ie] securely.
• Check the main exhaust valves side smoothly.
• Put the pin [AI into the main exhaust valve holes.
• Instailihe main lever [B1 to the pin.
C
4-22 ENGINE TOP END
Exhaust Valve (KIPS)
KX250-L2 "'" l 4:
• Install the main lever (A) with spring to the slide valve pin (B).
• Insert the main shaft [AJ into the hole 01 the left upper end al the
cylinder and through the hole in the main lever (6). Then put the main
shaft into the cylinder hole.
KX250-L2 _ L4 :
• Insen the main shaft [AJ into the hole of the left upper end at the
cylinder and through the hole in the main lever [B) and spring [C}.
Then put the main shaft into the cylinder hole.
• Apply a non-permanent locking agent 10 the Allen bolt.
• Fix the main lever [8] to the main shaft [AJ with the Allen bolt Ie],
Torq ue·
•
Main Lever Mounti ng Allen Bolt: 3.9 N·m (0.4 kgf·m , 35 In .lb)
• Check thai the main exhaust valves slide smoothly.
KX25o-L2 "'" L4:
J
,
ENGINE TOP END 4-23
Exhaust Valve (KIPS)
• Inslall the main valve rod [AI in the cylinder so thallhe grooved side
181 faces outward.
• Turn the cylinder up side down.
• Push the main valve rod as far as it will go.
• Insert the exhaust valves in the cylinder. The right exhaust valve [A]
is smaller than the left exhaust valve.
• Engage the valve pinions with rod rack [AI so that the punch marks
(Red PanjabJ on the pinions are positioned toward the front of the
engine. The punch marks on the valve pinions should align with the
grooves [C] on the rod.
NOTE
o The marked tooth [AJ is iden tified by its shape also.
• Apply high temperature grease to the O-ring.
• Mount the valve guides [B, OJ on the exhaust valves [AI and idle gear
ICI.
4-24 ENGINE TOP END
Exhaust Valve (KIPS)
• Turn the cylinder upside down.
• Install the main valve rod cover (A] except gasket.
NOTE
o Install the main valYe rod cover to prevent the main valve rod
moving out when tightening the main shaft nut.
• Position the main exhaust valves lull open [B).
• Check the exhaust valves are in the lull open position.
• Install the main valve gear (A) and nul (B] on the main shaft reI. and
tighten the nul.
CAUTION
"
Main shaft nut has left·hand threads.
Torque·
Main Shaft Nul: 8.8 N·m (0.9 kgl·m, 78 In·lb)
• Remove the main valve rod cover.
• When the main exhaust valves lull open, check the end of the main
valve rod and cylinder are aligned with [Aj.
1
• Check the gasket on the left plug for signs of damage.
* If necessary, replace it with new one.
• Install the left plug on the cylinder.
Torque·
Operating Rod Left Side Plug: 22 N·m (2.2 kg'·m, 16.0 ft·lb)
• Install the retaining screw securely.
• Install the main valve cover, main valve rod cover and main shaft
cover on the cylinder.
Torque·
Main Valve Cover Bolts: 5.9 N·m (0.6 kg'.m, 52 in·lb)
Main Valve Cover Bolta: 8.8 N·m (0.9 kgf·m, 78 in·lb)
(KX 125125O-l.3 .... L4)
Main Valve Rod Cover Screw: 5.4 N·m (0.55 kgf·m, 48 in-Ib)
• Install the removed parts.
ENGINE TOP END 4· 25
Muffler (Expansion Chamber, Silencer)
Muffler Removal
• Remove:
Right Radiator Shroud
Right Side Cover
• Remove the mounting bolts [81 and pull the silencer {AJ off toward the
rear.
• Remove the exhaust pipe holding springs {AJ.
• Remove the muffler damper mounting bolts (A), and pull off the
expansion chamber to the front ward.
• Remove the exhaust gasket.
Muffler Installation
• Scrape any carbon out of the expansion chamber.
• Check the exhaust O-rings lor signs of damage.
If necessary, replace them with new ones.
*
Silencer Packing Change
Replace the silencer packing if exhaust noise becomes too loud or
the engine performance drops.
• Remove the silencer.
• Remove the inner pipe mounting bolts [Aj, and pull the inner pipe [8]
from the silencer body.
.f ....... '
c
4·26 ENGINE TOP END
Muffler (Expansion Chamber, Silencer)
• Unscrew the silencer pipe mounting bolts [A).
• Pull the silencer pipe IB} from the silencer body.
(o~
,\
A IlO'QO,n, c
1,
1
• Pull off the old silencer packing. and instal1lhe new silencer packing
[AJ into the silencer.
I,
• Apply silicone sealant to the circumference IB] of the silencer pipe
and inner pipe.
• Apply a non-permanent locking agent to the pipe mounting bolts.
• Install the silencer.
Torque -
,
I
1
Silencer Inner Pipe Bolts: 5.9 N·m (0.6 kgf.m, 52 In-Ib)
8.8 N·m (0.9 kgf-m, 78 In·lbXKX1251250-L3 "" L4)
Silencer Pipe Bolts: 5.9 N·m (0.6 kgf-m, 52 in·lb)
8.8 N·m (D.9 kg',m, 78 hlb)(KXI251250-L3 .... L4)
".n,.", c
I
ENGINE RIGHT SIDE 5-1
Engine Right Side
Table of Contents
Exploded View ...................................................................................................................................................................5·2
Specifications ... ... ............................................................................................... ............. ...... ... ............. .... .... .. .. ........ ..... .. . 5-4
Clutch Cable ....................................................................................................... ............................................................... 5·5
Clutch Lever Free Play Check ........... ..... ..... ....... .. ............................ ........... .. ............................................................. 5-5
Free Play Adjustment ................................................................................................................................................. 5·5
Clutch Cable Removal .......................................... .......................................... ............................................. ... ............ 5·5
Clutch Cable Installation .............................................................................................................................................5·6
Clutch Cable Lubrication and Inspectioo ... ... .......... ................................................................................................... 5·6
Clutch Cover.. ..................................... ... .. ........... .. ..................................................... .... ........ .................
... ......... ... ..5-7
Clutch Cover Removal ................................ ....... ........ .............. .............................................
........................... 5·7
Clutch Cover Installation ........................... ... .. .. .... ...................... .. ... ............... ................................................... ...... 5·7
Right Engine Cover .. .... .............. ......................................................... ......... ... ................................................. . ............. 5-8
RighI Engine Cover Removal .................................................................................................................................... 5-8
Cover Installation ......................................................................................... .. ......... ................................ ....... .. ..... .. .... 5.9
KX250: ..... .......... ........................................ .... .. ... ............................................. ......................................................... 5-10
Right Engine Cover Disassembly .. .. ... ............ .. .......................................................................................................5- 10
Exhaust Advancer Assembly Disassembly/Assembly ................................. .............................................................5-11
Right Engine Cover Assembly.............................................................................. .................................................... 5-11
Clutch .............. ............................................................................................. .......... ......................................................... 5-13
Clutch Removal..... .................................. .....
................................. ........................................................ .. .... 5-13
Clutch Installation .... ................ ... .............. ............ ..................... .... ... .. .... ................................................................ .. 5-14
Friction and Steel Plates Wear, Damage Inspection ................................................... ................................. .. ..... .. .. 5-15
Friction and Steel Plate Warp Inspection ........ ........................................ ..................... .. ... .. ..... ... .... ....................... 5-15
Spring Free Length Measurement .. ... ... .......... .... ........................ ..... .............. ............................................... ......... 5-16
Friction Plate/Clutch Housing Clearance ................................................................................................................ 5-16
Clutch Hub Spline tnspection ........ ......... ................................................................................................... ......... ...... 5-16
External Shift Mechanism ............................................................................................................................................... 5· 17
External Shift Mechanism RelnOVal ........... ................................................... ........................................................... 5-17
External Shift Mechanism Installation ......................................................................................................................5·17
External Shift Mechanism Inspection ... ... ........................................................ .. ............................................. .. ....... 5-17
Primary Gear .................................................. ......................................................... ........................................................ 5-19
Primary Gear Remova!. ........................... .......... ............................................. ..................................................... .. .5-19
...............
............. .. .. 5-19
Primary Gear Installation...................... ............. ................................. ...................
... ... .. .......... .......................... . 5·20
Kickslarter
.... .............................. .... .... ....................... ............ ... ..... ...
Kickshaft Removal ........................................................................................... .... ........................ .... ............. ......... 5-20
Kickstarter Assembly DisassembIy/Assembly ... .. ....................... ... .. ...... ......... ......................................................... 5-20
Idle Gear Removal ................................................................................................................................................... 5-21
Idle Gear Installation ................................... .... ......................................................... ................................. ... .... ...... 5·21
5-2 ENGINE RIGHT SIDE
Exploded View
KX1 25:
•
A: KX125-l3 .... L4
1. Clutch Lever
2. Clutch Cable
3. Release Lever Shaft
4. Clutch Cover
5. Push Rod
6. Push Rod Holder
7. Clutch Pressure Plale
8. Clutch Hub
9. Friction Plate
10. Steel Plate
11 . Governor Shaft lever
12. Clutch Housing
13. Sleeve
14. Exhaust Advancer Assembly
15. Primary Gear
16. Gear Set Lever
17. Shift Shaft
18. Kickslarler Idle Gear
19. Ratchet Gear
20. Kick Gear
21. Kick Shafl
l : Apply a nonpermanent locking
agenllo the threads.
M: Apply molybdenum disulfide grease
G: apply high temperature grease.
0 : Apply oil.
TO: Apply transmission oil
n : 98 N·m (10.0 kgf·m, 72 ft·lb)
T2: 1.5 N·m (0.15 kgf·m , 13 in·lb)
T3: 3.9 N·m (0.4 kgf·m, 35 in·fb)
T4: 59 N·m (6.0 kgf·m , 43 ft·fb)
TS: 0.6 N·m (0.06 kgf·m, 5 in·fb)
T6: 8.8 N·m (0.9 kgf·m, 78 in·fb)
T7: 42 N·m (4.3 kgf·m , 31 ft·lb)
T8: 25 N·m (2.5 kgf·m , 18 fHb)
ENGINE RIGHT SIDE 5-3
Exploded View
KX250 :
~~~G
~.
12
~18
o~
..0 ... . . ..
A : KX2So-L3 "" L4
I . Clutch Lever
2. Clutch Cable
3. Friction Plate
4. Sleel Plale
5. Clutch Hub
6. Clutch Housing
7. Sleeve
8. Clutch Cover
9. Clutch Pressure Plate
10. Push Rod
11 . Governor Shaft Lever
12. Exhaust Advancer Assembly
13. Release Lever Shaft
14. Push Rod Holder
15. Primary Gear
16. Waler Pump Drive Gear
17. Gear Sel Lever
18. Shift Shaft
19. Kickslarter Idle Gear
20. Ratchel Gear
21 . Kick Gear
22. Kick Shafl
L: Apply a nonpermanent locking
agent to the threads.
M: Apply molybdenum disulfide
grease.
G: apply high temperature grease.
0 : Apply oil.
TO: Apply transmission oil.
Tl : B.8 N·m (0.9 kgf·m, 78 in·lb)
T2: 98 N·m (10 kgf·m , 72 ft·lb)
T3: 42 N·m (4.3 kgf·m , 31 tUb)
T4: 3,9 N'm (0.4 kgf·m, 35 in·lb)
TS: 25 N·m (2.5 kgf·m, 18.0 tt·lb)
T6: 1.3 N·m (0.13 kgf·m, 11 in·lb)
T7: 1.5 N·m (0. 15 kgf·m, 13 in·lb)
~
5-4 ENGINE RIGHT SIDE
Specifications
.em
Standard
Service Limit
Clutch:
lever free play
2 - 3 mm
...
Friction plate thickness:
KX125
2.72 _ 2.88 mm
2.6mm
KX250
2.92 "" 3.08 mm
2.8mm
1.5 ..... 1.7 mm
1.4 mm
Sleel plate thickness:
KX125
1.46 .... 1.74 mm
1.36 mm
Friction plate warp
Not m ore than 0. 15 mm
O.3mm
Steel plate warp
Not more than 0.2 mm
0.3 mm
KX125
38.4 mm
36.9 mm
KX250
35.0 mm
33.6 mm
KX 125
0.04 "" 0.55 mm
0.15 .... 0.45 mm
O.9mm
KX250
Clutch spring free length:
Friction plateJclutch housing clear·
,nee
KX250
Special Tools· Flywheel Holder: 57001-1313
Clutch Holder: 57001 - 1243
Outside Circllp Pli.... : 57001-144
Flywheel & Pulley Ho lder : 57001-1343
a.amm
ENGINE RIGHT SIDE 5-5
Clutch Cable
Due to friction plate wear and clutch cable stretch over a long period
01 use, the clutch must be adjusted in accordance with the Periodic
Maintenance Chart.
Clutch Lever Free Play Check
• Slide the clutch lever dust cover [A) out of place.
• Check thai lhe clutch cable upper end is fully seated in the adjuster
lSI.
• Check that the clutch lever [C] has 2 "" 3 mm of play [OJ.
If it does not. adjust the lever play.
*
Free Play Adjustment
• Slide the clutch lever dust cover out of place.
• loosen the knurled locknut [AJ.
• Turn the adjuster IB] so thai the clutch lever will have 2 .... 3 mm of
play [C),
NOTE
o Be sure that the outer cable end at the clutch lever is fully seated
in the adjuster at the clutch lever: or it could slip into the place Ister,
creating enough cable play to prevent clutch disengagement.
• Tighten the locknut.
• If it cannot be done, loosen the locknut (AI at the lower of the clutch
cable, and turn the adjusting nut [B) so that clutch lever has 2 '"- 3
mm of play.
• After the adjustment is made, lighten the locknut. and start the engine
and check that the clutch does not slip and that it release properly.
Clutch Cable Removal
• Slide the dust cover out of place.
• Loosen the locknut at the upper of the cable, and turn the adjusting
nut to give the cable plenty of play.
• Loosen the knurled locknut [A) al the clutch lever, and screw in the
adjuster [8].
• Line up the slots [C] in the clutch lever, knurled locknut. and adjuster,
and then free the cable from the clutch lever.
5-6 ENGINE RIGHT SIDE
Clutch Cable
Free the clutch inner cable tip from Ihe clutch release lever.
CAUTION
Do not remove the clutch release shaft unless it Is absolutely
necessary. If removed, release shaft 011 seal must be replaced
with a new one.
• Pull the clutch cable out of the frame.
Clutch Cable Installation
• Run the clutch cable according to the Cable, Harness, Hose Routing
section 01 the General Information chapter.
• Adjust the clutch cable (see Free Play Adjustment).
Clutch Cable Lubrication and Inspection
• Lubricate Ihe clutch cable using the pressure cable luber in accordance with the Periodic Maintenance Chart.
• With the cable disconnected at both ends, Ihe cable should move
freely within the cable housing (see Appendix chapter).
•
I U_ G, .. . , C
j
ENGINE RIGHT SIDE 5-7
Clutch Cover
Clutch Cover Removal
• Drain the transmission oil (see Engine Bottom EndfTransmission
chapter).
• Remove the brake pedal (see Brake chapter).
• Unbolt the clutch cover bolts [A), and take off the clutch cover [BI.
UllOOOlll
Clutch Cover Installation
• There are two knock pins 01 the mating surfaces 01 right engine cover
and clutch cover.
• Replace the clutch cover gasket with a new one.
• Tighten the clutch cover bolls.
Torq ue - Clutch Cover Bolts: 8.8 N·m (0.9 kgf·m, 78 in·lb)
• Install the brake pedal (see Brake chapter)
~
5-8 ENGINE RIGHT SIDE
Right Engine Cover
Right Engine Cover Removal
• Removal:
Transmission Oil (drain) (see Engine Bottom End I Transmission
chapter)
Coolant (drain) (see Cooling System chapter)
Cooling Hose Lower end
Kick Pedal
Brake Pedal
Water Pump Cover
Impeller
Muffler (KX250)
• Unscrew the KIPS cover bolt {A] and remove the KIPS cover IB] from
the right side of the cylinder.
Remove the shaft lever in accordance with the following procedure.
KX1 25:
o Remove clip (A] and pull out the governor shaft lever [8] from the Idle
gear lever.
KX 250:
o Remove the E-clip [A], Itat washer IBI and wave washer from the
operating rod.
o For KX25o-l2 '" L4, remove the E-Clip [AJlrom the operating rod.
1
1
o Put a 9 mm spanner wrench [AI on the shaft lever upper end.
o Turn the shaft lever [B] counterclockwise with the wrench, and lake
off the operating rod collar (C) by pushing the operating rod into the
cylinder.
ENGINE RIGHT SIDE 5·9
Right Engine Cover
o Before pulling the shaft lever (AJ free, turn the remaining E-clip (8] to
a suitable position as shown in the figure to prevent the shaft lever
boss (C] and the E-clip from hitting.
o Remove the cover bolts [AJ and take off the right engine cover (8]
and gasket.
Cover Installation
• There are two knock pins of the mating surfaces of the crankcase
and right engine cover.
• In case the exhaust advancer assembly has been removed, install it
and turn the gear so as to level the gear drive pin [AJ.
CAUTION
If the gear drive p in is n o t positioned level , it m ay fall out when
installing the right engine cover.
• Apply a high-temperature grease to the kick pedal oil seal lips and
kick shaft spline.
• Tighten the right engine cover bolts and kick shaft mounting bolt.
Torque -
Right Engine Cover Boils: 8.8 N·m (0.9 kg'.m, 78 In- Ib)
Kick Pedal Mounllng Bolt,
KX125: 8.8 N·m (0.9 kg!·m, 78 In·lb)
KX250: 25 N·m (2.5 kg' ·m, 18 ft·lb)
KX125:
• Using the 14 mm spanner wrench (A), install the governor shaft lever
(81 as shown.
• Install the clip and KIPS cover.
Torque - KIPS Cover Botts: 8.8 N·m (0.9 kg'·m, 78 In·lb)
5-10 ENGINE RIGHT SIDE
Right Engine Cover
KX250:
• Pul a 9 mm spanner wrench [AJ on the shaft lever upper end.
• Turn the shaft lever counterclockwise with the wrench and fil the
groove 01 the operating rod collar [8] to the boss of the shaft lever,
and install the collar on the operating rod while turning the shaft lever
clockwise.
• After installing the collar, instalilhe wave washer [Bj, fl al wasner (C),
and E-clip [01 on the operating rod [AI.
• TIghten the KIPS Cover botts.
• For KX25O-l2 ,.,. L4, after installing the collar, install the E-ctip [OJ on
the operating rod (AJ.
Torque -
KIPS Cover Bolts: 2.5 N·m (0.25 kgf·m , 22ln·lb)
,
• Tighten the water pump impeller bolt.
Torque -
Water Pump Impeller Bolt: 6.9 N·m (0.7 kgf·m, 61 In·lb)
• Apply grease to the inside of the brake pedal boss.
• Tighten the brake pedal mounting bott.
Torque·
Brake Pedal Mounting Bolt: 25 N·m (2.5 kgf·m, 18 In.lb)
• Fill the cooling system with coolant (see Cooling System chapter).
• Fill the transmission with oil (see Engine Bottom EndlTransmissioo
chapter).
• Check the rear brake.
Right Engine Cover Disassembly
• Remove the right engine cover.
• Turn the lever shaft [A) to the right, and remove the exhaust advancer
assembly (8).
• Remove the Allen bolts [C). and take off the advancer lever.
• Pull the dust cover (DJ.
•
j
1
j
1
ENGINE RIGHT SIDE 5-11
Right Engine Cover
• Remove the plug screw [AI and take out the positiooing pin.
• Pull the lever shaft [B] out of the right engine cover.
• Pull off the water pump shaft (see Cooling System chapter).
e n ' GU ll l
Exhaust Advancer Assembly Disassembly/Assembly
• The exhaust advancer assembly [A] consists of the following parts.
A. Pins
G. Needle Bearing
B. Rod
H. Spacer
I. Collar
C. Guide
O. O·ring
J. Spring
E. Steel Balls
K. Gear
F. Holder
L. Outer Spring
M. Inner Spring
• Check the exhaust advancer assembly parts for damage.
Any damaged parts should be replaced with new ones.
• When assembling, apply molybdenum disulfide grease between the
rod and inside/outside diameter parts of the holder, needle bearing
and spacer.
*
On and after KX125-l3. KX250-L2:
Right Engine Cover Assembly
• Apply high temperature grease to the oil seal lips before inserting the
lever shaft.
• Apply molybdenum disulfide grease to the surface oltha lever shaft,
and insert the lever shaft [AI into the right engine cover hate.
• Insert the positioning pin [BI into the hole then fit it to the grove [C]
01 the shaft.
• Tighten the exhaust valve advancer shaft plug screw [01 securely.
• Instailihe dust cover.
A
C
5·12 ENGINE RIGHT SIDE
Right Engine Cover
• Apply a non-permanent locking agent to the threads cllhe advancer
mounting Allen botts.
• TIghten the advancer lever mounting Allen bolts [D].
Torque·
Advancer Lever Mounting A llen Bolts:
3.9 N·m (0.4 kgf.m, 35 in·ib)
• Fit the advancer Lever pin [AI into the groove [B] on the exhaust
advancer assembly [C!, and inSlall lhe assembly in the engine cover
while turning the lever shaft to the left.
ENGINE RIGHT SIDE 5-13
Clutch
Clutch Removal
• Remove the clutch cover (see Clutch Cover Removal).
• Remove the clutch spring bolls [A}, spring, and clutch pressure plate
I"J·
• Remove the push rod holder [A}, flat washer (B) (if provided), friction
plates, steet plates, and push rod [Cj.
KX25O-l3 .... L4:
• Remove the collar [B], push rod holder assy [AI, friction plates, steel
plates. and push rod [Cj.
• Remove the clutch hub nut [AI and washer.
NOTE
Use the clutch holder to prevent the clutch hub from rotating.
Special Tools · Clutcn Holder: 57001-1243 (8].
n Gu,lIs, C
5-14 ENGINE RIGHT SIDE
Clulch
• Remove the clutch assembly, needle bearings (AJ, sleeve (B). and
thrust washer [C),
'''.OI'U' C
Clutch fnstalla tion
• Apply molybdel"M.Jm disulfide grease to the outside of the sleeve.
• Apply transmission oil to the inside of the clutch housing gear and
Kickstarter driven gear.
• Tighten the clu tch hub nul [AJ.
Torque·
Clutch Hub Nut: 98 N·m (10 kgl·m. 72 ft·lb)
NOTE
o Use the clutch holder rB} to prevent the clutch hub from rotating.
Special Tool·
Clutch Holder: 57001-1243
U OlO'ltS '
C
• Then stake the clutch hub nul (AJ in three points [B] the spline grooves
to secure it in place.
A
B
1
CAUTION
1
When staking the nut, be careful not to apply shock to the
shaft and bearings. Such a shock could damage the shaft
andlor bearings.
tl n l'Oll'
C
• Instalilhe frictioo plates and steel plates. starting with a friction plate
and alternating them. Finishing with a friction plate.
CAUTION
If dry steel plates and friction plates are installed, applv
transmission oil to the surfaces of each plate to avoid clutch
plate selz.ure.
o For KX 125, the grooves [AI on the friction plate surfaces are cut
tangentially and radially, install the first and last friction plates [81 so
that the grooves run toward the center in the direction of the clu tch
housing rotation (counterclockwise viewed from the engine right side).
~
I
ENGINE RIGHT SIDE 5-15
Clutch
• Apply molybdenum disulfide grease to the rubbing portion of the push
rod holder.
• For KX125, align the punch mark [A] on the pressure plate with the
punch mark IBI on the clutch hub.
• Tighten the clutch spring bolts fixing the flywheel with the Special
Tool.
Torque'
Clutch Spring Botti!: 8.8 N·m (0.9 kgf·m . 78 In·lb)
Speclill Tool·
Flywheel Holder: 57001-1313
nu ... ". e
Friction and Steel Plates Wear, Damage Inspection
• Visually inspect the friction and sleel plates to see if they show any
signs of seizure, or uneven wear.
II any plates show signs of damage, replace the friction plates and
*
steel plates
a set. [AJ of the friction plates [8J and steel plates
• Measure
theasthickness
with vernier calipers.
~~~~~:::~:::::==:::,
®
* If they have worn past th e service limit, replace them with new ones.
.......u. c
Frktion Plate Thickness
KX12S:
Standard :
Service limit:
2.72 ,"", 2 .88 mm
Standard:
Service Limit:
2.92 '"" 3.08 mm
2.8mm
2.6mm
KX2SO:
StHI Plate Thickness
KX125:
Standard:
Service Limit:
KX250:
Standard:
Ser vice Limit :
1.5 '""' 1.7 mm
1.4mm
1.46 '""' 1.74 mm
1.36 mm
Friction and Steel Plate Warp Inspection
B
• Place each friction plate or steel plate on a surlace plate, and measure
the gap between the surlace plate [Al and each friction plate or steel
plate IB] with a thickness gauge [C] The gap is the amount of friction
or steel plate warp.
II any plate is warped over the service limit, replace it with a new one.
*
Friction and Steel Plates Warp
Friction Plate
Standard:
Not m ore than 0.15 mm
Service Limit:
0.3 mm
Steel Plate
Not more t han 0.2 mm
0.3 mm
c
•
•••••
I
. ro'. '~lS'
5-16 ENGINE RIGHT SIDE
Clutch
Spring Free Length Measurement
• Since the spring (A] becomes shorter as it weakens, check its free
length to determine its condition.
If any of the springs is shorter than the service limit, it must be
*
replaced.
Clutch Spring Free Length
KX125:
Standard :
Service Limit:
38.4 mm
36.9 mm
KX250:
Standard:
Service l.lmlt:
35mm
33.6 mm
''''110 01 ,
~
Friction Plate/Clutch Housing Clearance
• Measure the clearance between the tangs [Alan the friction plate and
the fingers (BJ of the clutch housing.
If this clearance is excessive, the clutch will be noisy.
If the clearance exceeds the service limit, replace the Iriction plates.
*
*
Friction Plate/Clutch Housing Clearance
KX12S:
Standard:
Senllell Limit:
0.04 ..... 0.55 mm
O.9mm
Standard:
ServiclI Limit:
0.15 ..... 0.45 mrn
0.8 mm
KX250:
11 01"0111 C
Clutch Hub Spline Inspection
• Visually inspect where the teeth on the sleel plates wear against the
splines [AJ of the clutch hub.
If there are notches worn into the splines, replace the clutch hub.
Also, replace the clutch plates if their teeth are damaged.
*
110 ' . " 011
0
;
ENGINE RIGHT SIDE 5·17
External Shift Mechanism
External Shift Mechanism Removal
• Remove:
Shift Pedal
Right Engine Cover
Clutch Housing
Idle Gear
• Pull out the external shift mechanism tAl.
• Remove the nut [Bj, and take off the gear set lever (C].
..•• u,n . c
External Shift Mechanism Installation
• Before installing the shift shaft, apply high temperature grease to the
oil seal lips and shift shaft splines.
• Tighten the gear sel lever nul.
Torque · Gear Set Lever Nut: 8.8 N·m (0.9 kgf·m, 78 in·lb)
External Shift Mechanism Inspection
• Check the shift shaft (AI for bending or damage 10 Ihe splines.
If the shaft is bent, straighten or replace it. If the splines are damaged,
reptace the external shift mechanism.
• Check the relurn spring IBI and arm spring Ic] for cracks or distortion.
If the springs are damaged in any way, replace them.
• Check the shift mechanism arm (D) for distortion.
If the shift mechanism arm is damaged in any way, reptace the shift
mechanism.
*
*
*
• •• uu, s . c
NOTE
KX125 ,
KX2 50 ,
A
A
Install the arm spring IA] as shown in the figure.
I U •• I OIS , C
• Check that the relurn spring pin [AI is not loose.
If it is loose, unscrew it, apply a non-permanent locking agent 10 the
threads, and lighten it.
*
Torque -
Return Spring Pin: 42 N·m (4.3 kg'·m, 31 tU b)
. ... tu n. c
5-18 ENGINE RIGHT SIDE
External Shift Mechanism
• Check the gear set lever and its spring for cracks or distortion.
It the lever or spring is damaged in any way, replace them .
• Visually inspect the shift drum cam.
If they are badly worn of if they show any damage, replace it.
*
*
,
1
ENGINE RIGHT SIDE 5-19
Primary Gear
Primary Gear Removal
• Remove the right engine cover (see Right Engine Cover Removal)
• Remove the clutch (see Clutch Removal).
• For KX125 model; remove the primary gear nul [A], spring washer,
woodruff key, primary gear [B], and O-ring.
NOTE
o Use the flywheel & pulley holder to prevent the crankshaft from the
rotating.
Special Tools - Flywheel" Pulley Holder: 57001-1343
• For KX250 model; remove the circlip [A), and take off the wa ter pump
drive gear [B) and primary gear [C[.
Special Tools - Outside CircUp Plie,..: 57001-144
11 . . . . . . 11
Primary Gear Installation
KX125:
• Inslal the O-ring.
• Fit the woodruff key [B) on the crankshaft groove.
• Install the spring washer so that concave side faces 1Al inward.
• Tighten the primary gear nut.
Torqlol8 •
Primary Gear Nut: 59 N-m (6.0 kgf·m, 43 ft ·lb)
NOTE
Use the flywheel & pulley holder to prevent the crankshaft from the
rotating.
Special Tools - Flywheel" Pulley Holder: 57001-1343
KX2S0:
• Install the primary gear [A[ so that chamfered side [B[ fa ces outward.
• Install the water pump drive gear 1c[ so that the chamfered side [0]
faces outward.
• Replace the old cirdip with a new one.
Special Tools - Outside Circlip Pile,..: 57001-144
C
5-20 ENGINE RIGHT SIDE
Klckstarter
Kickshaft Removal
• Remove:
Right Engine Cover
Clutch Housing
• Pull the end of the kick spring [A) oul 01 the hole in the crankcase.
• Remove the kickstarter assembly [B).
• Remove the bolts [A]. lake off the ratchet guide [8].
•
•
Kickstarter Assembly Disassembly/Assembly
• The kickslarter assembly consists of the following parts.
• Check the kickstarter assembly parts lor damage. Any damaged
parts should be replaced with new ones.
A. Idle Gear
F. Kick Gear
B. Cirdip
G. Kick Shaft
C. washer
H. Kick Spring
D. Spring
I. Spring Guide
E. Ralchet Gear
• Apply molybdenum disulfide grease to the inside 01 the kick gear and
ratchet gear.
• When assembling the ratchet gear [A] onto the kick shaft (B]. align
the punch mark [C] on the ratchet gear with the punch mark (Cj on
the kick shaft.
• Replace the circlips that were removed with new ones.
Special Tools· Outside Cin:lip Pllen: 57001-144
KX 1 2 5 :
C
~-1
~l~\;X
t! S;;F B
~ ~.
1
\
1
ENGINE RIGHT SIDE 5-21
Kickstarter
Idle Gear Removal
• Remove:
Right Engine Cover (see Right Engine Cover Removal)
Clutch Housing (see Clutch Removal)
• For KX125, pull off the idle gear.
• For KX250 remove the circlip [AJ and pull off the idle gear [BJ.
Special Tools· Outside Clrcllp Pliers: 57001- 144
Idle Gear Installation
• Apply molybdenum disulfide grease to the inside of the idle gear.
• Replace the circtip with a new one.
Special Tools· Outs ide Clrc lip Pliers: 5700 1- 144
ENGINE REMOVAL I INSTALLATION 6-1
Engine Removal/Installation
Table of Contents
Exploded View .. ....... ................................................................................................. .. ... ........................ ... .... .... .. .. ......... 6·2
Engine RemovaVlnstaliation ......................... ......... ............................................ ... .............................................................6·3
Engine Removal .........................................................................................................................................................6-3
Engine Installation ......................................................................................................................................................6-3
6·2 ENGINE REMOVAL I INSTALLATION
Exploded View
,
3
1. Frame
G: Apply grease.
2. Engine Bracket
T1 : 29 N'm (3.0 kgf·m, 22 ft·lb)
3. Pivot Shaft
T2 : 44 N·m (4.5 kgf·m, 33 ft ·lb)
4. Swingarm
T3 : 98 N·m (10.0 kgf·m, 72 ft·lb)
ENGINE REMOVAL !INSTALLATION 6·3
Engine Removall1nstallation
Engine Removal
• Drain the transmission oil (see Engine Bottom EndfTransmission
chapter).
• Drain the coolant (see Cooling System chapter).
• Remove:
Radiator Shrouds
Side Covers
Seat
Fuel Tank
Cooling Hoses
Radiators
Expansion Chamber
Spark Plug
Carburetor (with Cables and Hoses)
Clutch Cable l ower End
Drive Chain
Engine Sprocket
Shift Pedal
Brake Pedal
• Disconnect the magneto output lead, and free the leads from the
clamp at the feft side of the cyfinder.
• Unbolt the mounting bolts [AI and remove the engine brackets IB].
• Place a jack IA] under the frame to lift the motorcycle off the ground ,
and put blocks under the front and rear tires to steady the motorcycle.
AWARNING
The swingarm pivot shaft also serves as the engine mounting
boll . Take precautions to insure the frame is well supported,
and that the motorcycle will not fatl over when the pivot shaft
is removed.
Special Tools - Jack: 57001-1238
• Remove the engine mounling bolts IBI.
• Pull out the swing arm pivot shaft Ic].
• lift the engine out to the right.
Engine Installation
• Tighten the fOllowing nuts.
To rque -
Engine Mounting Nuts: 44 N·m (4.5 kgf·m, 33 ft ·lbj
Engine Bracket Nuts:
10 mm: 44 N·m (4.5 kg! m , 33 ft·lb)
8 mm: 29 N m (3.0 kgf·m , 22 ft ·lb)
Pivot Shaft Nut: 98 N·m (10.0 kgf·m, 72 ft ·lb)
• To route the leads, cables and hoses, refer to the General Information
chapter.
• To install parts removed, refer to the appropriate chapters.
• FiU the cooling system with coolant (see Cooling System chapter).
• Fill the engine with transmission oil (see Engine Bottom EndfTransmission chapter).
• Adjust:
Throttle Cable
Clutch Cable
Drive Chain
Rear Brake
ENGINE BOnOM ENOITRANSMISSION 7-1
Engine Bottom EndlTransmission
Table of Contents
Exploded View .. ................................................................................................ ....... ..................................... .... .. ............... 7·2
Exploded View .. ....... ................................. ... ..... .. ............................................................................................................. 7·3
Specifications .................................................................................................................................................. ................ 7-4
Transmission Oil ................................................................................................................................................................7-5
Oil Level Inspection ....................................................................................................................................................7·5
Oil Change .................. _.............................................................................................................................................. 7·5
Crankcase .......................................................................................................................................................... .............. 7-6
Crankcase Splitting....................................................................................................................................................7-6
Crankcase Disassembly ........................................................................................................................................... 7-7
Crankcase Assembly ..................................... .......................................... ... .... ............................................................ 7-7
Crankshaft, Connecting Rod ................................................................................................................... ..... .... ... .. ...... .. 7- 10
Crankshaft Removal ................................................................................. ...... ................................. .. ..... ... ............ 7- 10
Crank shaft Inslallalion .................................... ..................................................................................
.. ............. 7·1 0
Crankshaft Disassembly........................................................................................................................... ............. 7· 10
Crankshaft Assembly ...............................................................................................................................................7-10
Connecting Rod Big End Radial Clearance .............................................................................................................7- 11
Connecting Rod Big End Seizure ............................................................................................................................ 7-1'
Connecting Rod Big End Side Clearance ................................................................................................................7- '1
Crankshaft Runout ....................................................................................................................................................7- "
Crankshaft Alignmenl ............................................................................................................ .................................. 7- 12
Transmission ....... ..... ............................................. ...........................................................................................................7- ' 3
Shalt Removal ........................................ ................................................................................................................ 7- 13
Shaft Inslallation ....................................................................................................................................................... 7-1 3
Shaft Disassembly ....................................... ....... ..................................... .. .... .... ...................................................... 7- 13
Shaft Assembly ............................................................................................ ............................................................. 7- 13
Shift Drum and Fork Inslallalion .............................................................................................................................. 7-1 4
Shift Fork Bending ....................................................................................................................................................7-1 5
Shift Fork/Gear Groove Wear ...................................................................................................................................7- 16
Shift Fork Guide Pin/Shift Drum Groove Wear ........................................................................................................7- 16
Gear Damage ..........................................................................................................................................................7-16
Gear DogfGear Dog Hole Damage ..........................................................................................................................7- 17
Ball Bearing Wear .................................................................................................................................................... 7- 17
~
~
7-2 ENGINE BOTTOM ENDITRANSMISSION
Exploded View
KX125
•
1
j
A: KX125-l.3 .... L4
1. Crankshaft Assembly
2. Ststor
3. Magneto Flywheel
4. left Crankcase
5. Right Crankca se
6. Drive Shaft
7. Output Shaft
8. Engine Sprocket
9. Shift Rod
10. Shift Fork
11 . Operating Plate
, 2. Shift Drum
13. Shift Shaft
14. Shift Pedal
M: Apply molybdenum disulfide
grease.
0 : Apply 2·stroke engine oil.
TO: Apply transmission oil to the
transmission gears and shift forks, etc
G: Apply high temperature grease.
l : Apply a non-permanent locking
agent.
LG : Apply liquid gasket to the lett and
right case mating surface.
R: Replacement parts
Tl : 20 N·m (2.0 kgf·m, 14.5 ft ·lb)
T2: 22 N·m (2.2 kgf·m, 16.0 ft ·lb)
T3 : 8.8 N·m (0.9 kgf·m , 78 in·lb)
T4: 5.4 N·m (0.55 kgf·m, 48 in·lb)
ENGINE BOTTOM ENOrrRANSMISSION 7-3
Exploded View
KX250:
A: KX25D-L2 ..... L4
1. Crankshaft Assembly
2. Stator
3. Magneto Flywheel
4. Left Crankcase
5. Right Crankcase
6. Drive Shaft
7. Output Shaft
8. Engine Sprocket
9. Shift Rod
10. Shift Fork
11 . Operating Plate
12. Shift Drum
13. Shift Shaft
14. Shift Pedal
M: Apply molybdenum disulfide
grease.
0 : Apply 2·stroke engine oil.
TO: Apply transmission oil to the
transmission gears and shift forks, etc.
G: Apply high temperature grease.
L: Apply a non-permanent locking
agent.
LEG: Apply liquid gasket to the left
and right case mating surface.
R: Replacement parts.
T1: 20 N·m (2.0 kgf.m , 14.5 ft·lb)
T2: 65 N·m (6.6 kgf·m , 48 ft·lb)
T3: 8.8 N·m (0.9 kgf·m , 78 in·lb)
T4: 5.4 N·m (0.55 kgf·m, 48 in·lb)
T5: 24 N·m (2.4 kgf·m, 17 ft·lb)
7-4 ENGINE BOTTOM ENDITRANSMISSION
Specifications
Item
Standard
KX125/2So-L1 ...... L3
KX12512SO-L4
Service Limit
Transemission Oil
Type
SE. SF or SG
Viscosity
SAE10W·30 or 10W-40
API SE, SF or SG
API SH or SJ with
JASO MA
SAE 10W-40
capacity:
KX125
10(250
Crankshaft, Connecting Rod:
---
...
0 .7 L
. ..
0.85 L
---
Connecting rod bend
Not more than 0.03 mmfl00 mm
0 .2 mmt! 00 mm
Connecting rod big end radial clearance:
Not more than 0 .03 mm/IOO mm
0.2 mm/tOO mm
0.036· 0.047 mm
0 .037 . 0.049 mm
0.10 mm
0.10 mm
0.40·5.00 mm
0.45 - 0.55 mm
0 .70 mm
0.70 mm
Not more than 0.03 mm
0.05 mm
0.06 '" 0.23 mm
0.30 mm
KX. 125
0.49 ..... 5.00 mm
KX250
0.40 '" 4.50 mm
4.80 mm
4.30 mm
KX125
5.05 ", 5.15 mm
5.25 mm
KX250
4.55 ..... 4.65 mm
4.75 mm
KX125
KX250
Connecting rod big end side clearance:
KX125
KX250
Crankshaft runoul
Transmission:
Gear backlash:
Shift fork ear thickness:
Gear shift fork groove width:
Shift fork guide pin diameter
Shift drum Qroove width
5.90 ...... 6.00 mm
---
6.05 .... 6.20 mm
6.25 mm
Special Tools - Outside Circlip Puners : 57001-144
Bearing Puller : 57001-158
Bearing Puller Adapter: 57001-136
Crankcase Splitting
Tool Asaembly : 57001-1098
Bearing Driver Set : 57001-1129
Crankshaft Jig : 57001-1174
Sealant - Kawasaki Bond (Uquid Gasket-Silver): 92104-002
ENGINE BOTTOM ENOrrRANSMISSION 7·5
Transmission Oil
In order for the transmission and clutch to function properly, always
maintain the transmission oil at the proper level and change the oil
periodically.
AWARNING
Motorcycle operation with insufficient, deteriorated, or con·
taminated transmission oil will accelerated wear and may r~
suit in transmission seizure, and i njury.
Oil Level Inspection
• Situate the motorcycle so that it is perpendicular to the ground .
• II the motorcycle has just been used, wait several minutes until the
oil settles.
• Check that the oil level comes up between the upper level [A) and
lower level [S] through the oil level gauge (C] on the clutch cover,
If the oil level is too high. remove the excess oil using a syringe or
some other suitable device.
II the oil level is too low, add the correct amount 01 oil through the oil
filler opening. Use the same type and make 01 oil that is already in
Ihe engine.
*
*
I"IOOOIS'
NOTE
o If the transmission oil type and make are unknown, use any brand
of the specified oil to top up the level in preference to running the
engine with the oil level low. Then at your earliest convenience,
change the oil completely.
Oil Change
•
• Warm up the engine thoroughly so that Ihe oil will pick up any
sediment and drain easily. Then stop the engine.
• Place an oil pan beneath the engine.
• Remove the transmission oil drain plug [A] on the bottom 01 the
engine, and let the oil drain completely.
NOTE
o Hold the motorcycle upn·ght so that the oil may drain completely.
• Check the gasket at the drain plug lor damage.
Replace the gasket with a new one if it is damaged.
• After the oil has completely drained out, install the drain plug with the
gasket. and tighten it
A
*
Torque -
1'"001", •
Transmission Oil Drain Plug: 20 N·m (2.0 kgf·m , 14.5 ft·lb)
• Fill the engine wi th a good quality motor oil specified below.
• Check the oil level.
Recommended Transmission Oil
KX1251250-L1 ..... l 3
Typo
SE, SF or SG
SA' 20W - 50
SA' 20' - 40
SA' lOW - 50
KX125125()"'L4
API SE, SF or SG
API SH or SJ with
I
JASO MA
SA' 10W - 40
Viscosity
SAE10W-30 or 10W-40
SAE10W-40
Capacity
KX 125: 0.7 L
-20 1
-0
KX250: 0.85 l
,
NOTE
o Depending on the atomospheric temperature of your riding area,
the transmission oil viscosity should be changed according to the
chart.
I
0
10
20
30
40("\:)
_"'-~'~"-','~'--;5~;----':;I'I,C'""''''~4( 'f )
,
'
,
,
'
'nolOoolS'
7-6 ENGINE BOTTOM ENDfTRANSMISSION
Crankcase
Crankcase Splitting
• Remove the engine (see the Engine RemovaVlnslallalion chapter).
• Set the engine on a clean surface while parts are being removed.
• Remove:
Magneto Cover
Cylinder Head (see Engine Top End Chapter)
Cylinder (see Engine Top End Chapter)
Piston lsae Engine Top End Chapler)
Right Engine Cover (see Engine Righi Side Chapter)
Clutch (see Engine Right Side Chapter)
Primary Gear (see Engine Right Side Chapter)
Kickstarter Assembly (see Engine Right Side Chapter)
Kickstarter Idle Gear (see Engine Righi Side Chapter)
Gear Set Lever (A}
Shift Drum Plate [S]
Output Shaft Sleeve Ie] and O'ring (DI (KX250, O-rings)
Magneto Flywheel and Stator (see Electrical System Chapter)
Reed Valve (KX125) (see Fuel System Chapter)
• Remove the c rankcase bolts [A].
..
,
• Install the crankcase splitting 1001 {A] and bearing puller adapler rB]
inlo the lett side of the crankcase. Be certain 10 screw Ihe 1001 in all
Ihe way.
Special Tools - Crankcase Splitting Tool Assembly: 57001-1098
Bearing Puller Adapter: 57001-136
• Tighten Ihe bolt on the c rankcase splitting 100110 split the crankcase
halves.
• Once Ihe crankcase is split, remove the crankcase splitting tool, and
lift off the left crankcase half.
ENGINE BOTTOM ENOfTRANSMISSION 7·7
Crankcase
• Pull out the shift rods [A] .
• Disengage the shift fork guide pins from the shift drum grooves.
• Take off the shift drum [B]
• Remove the shift forks (C] from the transmission gears.
• Take out the drive shaft (01 and output shaft [E] together with their
gear meshed.
• Remove the cranksha ft from the right crankcase half using a press.
Crankcase Disassembly
CAUTION
Do not remove the bearings and the oil seats unless it is
necessary.
Removal may damage them.
Crankcase Assembly
• Before fitting the left case on the right case, noi e the following:
o Chip off the old gasket from the mating surfaces of the crankcase
halves, and clean off the crankcase with a high flash-point solvent.
After cleaning, apply transmission oil to the transmission gears, shift
drum. shift forks and so on .
o Be sure to replace any oil seal removed with a new one. Press in Ihe
new oil seal using a press and suitable lools so that the seal surface
is flush with the surface of the crankcase.
o Apply high tempe rature grease to the oil seal lips.
o Press in the ball bearings using the bearing driver set until the bearing
is bottomed.
Special Tools - Bearing Driver Set: 57001- 11 29
o Install the bearing for the output shaft inlo the left crankcase half so
that slepped side faces [A] inside.
CAUTION
Install the bearings for the crankshaft in the right and left
crankcase so that their sealed sides fa ce toward the oil seal
side.
o Tighten the output and drive shaft bearing retaining bolls/screws
securely.
Torque -
Bearing Retaining Bolt: 8.8 N·m (0.9 kg'·m. 78 in·tb)
Bearing Retaining Screws: 5.4 N·m (0.55 kgf·m, 48 in·lb)
o If the crankshaft bearings stay on the crankshaft when splitting the
crankcase, remove Ihe bearings from the crankshaft and reinstall
them in the crankcase, and then assemble the crankcase (see
Crankshaft Removal and Installation).
7-8 ENGINE BOTTOM ENDfTRANSMISSION
Crankcase
• Turn the crankshaft [AJ to BOC, and install the crankshaft jig [C]
between the flywheels opposite the connecting rod [B) big end to
protect flywheel alignment as shown.
o If the crankshaft has been removed from the crankcase, install the jig
betwe9fl the crankshaft flywheels before pressing the crankshaft into
the right crankcase half.
Special Tools - Crankshaft Jig: 57001-11 74
• Install the transmission shaft as a set (see this chapter).
• Inslall the shift fork, shift drum and shift rod.
• Check to see Ihatthe crankcase knock pins (A) and O-ring [B] (KXI25)
are in place on the right crankcase half. II any of them has been
removed, replace it with a new one.
• Apply liquid gasket to the mating surface [AI 01 the crankcase half.
Sealant -
Kawasaki Bond (LIquid Gasket - Silver): 92104-002
KX125:
L.case
o
KX250:
• Using a suitable tool on the left crankcase to press [AJ around the
hole for the crankshaft, fit the crankcase halves together with a press
on the tool.
NOTE
o Constantly check the alignment of the two crankcase halves, and
the position of the transmission shafts, and shift drum. The front
and rear of the crankcase must be pushed together evenly.
., • • • ,1151
C
ENGINE BOTTOM ENDITRANSMISSION 7-9
Crankcase
• Remove the crankshaft jig from the flywheels.
• Tighten the crankcase bolts starting with the ones around the
crankshaft, and then the farther ones.
o At this time, tighten the crankcase bolt [AJ and clamp [B] for the
breather hoses together.
Torque -
Crankcase Botts: 8.8 N·m (0.9 kgt·m, 78 tn·tb)
" .. ~, .."
• Check to see thai the crankshaft, drive shalt, and output shaft all turn
freely (in the neutral position).
If the crankshaft will nolturn, probably the crankshaft is not centered:
tap the appropriate end of the crankshaft with a mallet to reposition
*
it.
• Spinning the output shafl, shift the transmission through all the gears
to make certain there is no binding and that all the gears shift properly.
• Install the parts removed in the reverse order of removal, and refer to
the appropriate chaplers.
o Replace the O-ring on the output shaft with a new one.
e
7-10 ENGINE BOnOM ENDfTRANSMISSION
Crankshaft, Connecting Rod
Crankshaft Removal
• Split the crankcase (see Crankcase Splitting).
• Remove the transmission shafts (see Transmission Shaft Removal).
• Using a press, remove the crankshaft from the right crankcase.
o If the bearings stay on the crankshaft when splitting the crankcase
or removing the crankshaft from the right crankcase, remove the
bearings from the crankshaft with a bearing puller tAJ and adapter
lSI·
Special Tools· Bearing Puller: 57001-158
Bearin g Puner Adapter: 57001- 136
Crankshaft Instal/ation
• When installing the crankshaft bearings [B). apply high temperature
grease to the outer sides of the bearings, and then press them into
the crankcase using the bearing driver [A] untillhe bearing bottoms
against the step.
o Position the crankcase half so that the main bearing housing is seated
on a suitable press fixture.
o Install the crankshaft bearing so that the sealed side in (to the oil seal
[C] side).
Special Tools - Bearing Driver Set: 57001-11 29
• Insert the crankshaft jig [C] between the crankshaft fl ywheels opposite
the connecting rod IBI big end to protect fl ywheel alignment as shown,
and press the crankshaft IA) into the right crankcase.
When pressing, position the jig in the crankcase opening so the jig
does not hit the c rankcase.
o
Special Tools - Crankshaft Jig: 57001-1174
• Apply 2-stroke oil to the connecting rod big end bearing.
Crankshaft Disassembly
Since assembly of the crankshaft demands exacting tolerances, the
disassembly and reassembly of the crankshaft can only be done by a
shop having Ihe necessary lools and equipment.
• If it should be necessary to disassemble the crankshaft, use a press
10 remove the crankpin.
Crankshaft Assembly
Since the assembly of the crankshaft demands exacting tolerances,
the disassembly and reassembly of the crankshaft can only be done by
a shop having the necessary tools and equipment.
• Reassemble the crankshaft according to the standard tolerances in
Specifications.
o Connecting rod bend, twist
o Connecting rod big end radial clearance.
o Cold-filting tolerance between crankpin and flywheels.
o Side clearance between the connecting rod big end and one of
flywheels.
o Crankshaft runout.
c
ENGINE BOTTOM ENDITRANSMISSION 7-11
Crankshaft, Connecting Rod
Connecting Rod Big End Radial Clearance
• Set the crankshaft in a flywheel alignment jig or on V blocks, and
place a dial gauge against the connecting rod big end.
• Push the connecting rod first towards the gauge and then in the
OPPOSite direction. The difference between the two gauge readings
is the radial clearance.
Jf the radial clearance exceeds the service limit, the crankshaft should
be either replaced or disassembled and the crankpin, needle bearing,
and connecting rod big end examined for wear.
*
Connecting Rod 8 ig End Radial Clearance
Standard:
KX125: 0.036 ...... 0.047 mm
" ....... ,
0
KX250: 0.037 .... 0.049 mm
Service Limit
KX 125: 0.10 mm
KX250: 0. 10 mm
Connecting Rod Big End Seizure
* In case of serious seizure with damaged flywheels. the crankshaft
must be replaced.
* In case of less serious damage, disassemble the crankshaft and
replace the crankpin, needle bearing, side washers, and connecting
rod.
Connecting Rod Big End Side Clearance
• Measure the side clearance [A) of the connecting rod with a thickness
gauge.
If the clearance exceeds the service limit, replace the crankshaft.
"I"
*
Connecting Rod Big End Side Clearance
Standard:
KX125: 0.40 ", 0.50 mm
I):]
~
I
r--fl=CL
KX250: 0.45 .... 0.55 mm
Service Limit
Crankshaft Runout
*
Crankshaft Runout
Standard:
Service L.imit
(Al: KX125 - 8.0 mm
KX250 - 8.5 mm
-~
L
0.70 mm
• Set the crankshaft in a flywheel alignment jig or on V blocks, and
place a dial gauge against the pOints indicated.
• Turn the crankshaft slowly. The maximum difference in gauge
readings is the crankshaft runout.
If the runout al either point exceeds the service limit, align the
flywheets so thai the runout lalls within the service limit.
®
"'........ 0
"Q
~
11:
~I
~
I
L
Not more than 0.03 mm
0.05 mm
"'.'.'0'" 0
7· 12 ENGINE BOTTOM ENDITRANSMISSION
Crankshaft, Connecting Rod
Crankshaft Alignment
• In the case of horizontal misalignment, which is the most common,
strike the projecting rim of the flywheel with a plastic. soft lead, or
brass hammer as indicated in the figure.
• Recheck the runout with a dial gauge, repealing the process until the
runout falls within the service limit
o Vertical misalignment is corrected either by driving a wedge in
between the flywheels or by squeezing the flywheel rims in a
vise, depending on the nature 01 the misalignment. In cases 01
both horizontal and vertical misalignment, correct the horizontal
misalignment firs!.
' ' '111111 1 C
CAUTION
Don't hammer the flywheel at point MA M.
* II flywheel misalignment cannot be corrected by the above method,
replace the crankpin or the crankshaft itself.
o
(::1
D
A
.. tUOII IJ C
,
ENGINE BOTTOM ENDITRANSMISSION 7-13
Transmission
Shaft Removal
• Split the crankcase (see Crankcase Splitting).
• Pull off the shift rods [Aj, and disengage the shift fork guide pins from
the shift drum grooves.
• Remove the shift drum [61
• Remove the shift forks IC] from the transmission gears.
• Take out the drive shaft [D] and output shaft [E]together, with their
gears meshed.
Shaft Installation
• Hold the drive shaft [AI and output shaft [Bltogether, with their gears
meshed, and fit them into the right crankcase half.
• To install the shift forks and shift drum, see the Shift Drum and Fork
Installation.
Shaft Disassembly
• Remove the transmission shafts (see Shaft Removal).
• Using circlip pliers to remove the circlips, disassemble the transmission shaft.
Special Tools - Outside Circlip Pliers: 57001-144
Shaft Assembly
• Apply transmission oil liberally to the transmission shaft, gears and
bearings.
• Replace any circlips that were removed with new ones.
o Always install circlips [A] so that the opening [61 is aligned with a
spline groove [C].
Special Tool s - Outside Circlip Pliers: 57001-144
• The drive shaft gears can be identified by size; the smallest diameter
gear is 1st gear, and the largest is 5th (KX250) or 6th (KX12S). Be
sure that all parts are put back in the correct sequence, and facing
the proper direction, and that all circlips and the washers are properly
in place.
KX 125:
F
F
7-14 ENGINE BOTTOM ENDITRANSMISSION
Transmission
10(250:
A.
1st gear
B.
5th gear
c. 3m gear
D.
E.
F.
4th gear
2nd gear
Clrclip
(1ST; part of drive shaft)
(24T; dog recesses face left)
(18T: for1l. groove goes 10 the left side of
the gear teeth)
(22T: dog recesses face right)
(16T; chamfered side faces right)
l, nfl"S, C
• The output shaft gears can be identified by size; the largest diameter
gear is lsi gear, and Ihe smallesl is 51h (KX250) or 61h (KXI25). Be
sure that all parts are put back in Ihe correct sequence and facing
the proper directioo, and that all circlips are properly in place.
KXI25:
A. 2nd gear
B. 6th gear
C. 3rd gear
D. 4th gear
E. 5th gear
F. 1st gear
G. Circlip
(26T; dog recesses face right)
(25T; for1l. groove goes to the right side of Ihe gear teeth)
(26T; dog recesses face left)
(22T; dog recesses face right)
(27T; for1l. groove goes to the left side of the gear teeth)
(3tT; plain side faces right)
KX25O:
A. 2nd gear
B. 4th gear
C. 3rd gear
O. 5th gear
E. 1st gear
F. Circlip
G. Collar
(26T; dog recesses face right)
(25T; fork groove goes to the right side of the gear teeth)
(24T; dog recesses face left)
(24T; for1l. groove goes to the left side of the gear teeth)
(27T; dog recesses face left)
• Check Ihat each gear spins or slides freely on the transmission shaft
without binding after assembly.
Shift Drum and Fork Installation
• Apply a little transmission oil to the shift fork [AJ ears, and fit the shift
forks into the gear grooves.
ENGINE BOTTOM ENDITRANSMISSION 7-15
Transmission
Shift Fork Identification
KX 125:
Drive shaft 3rd gear and 4th gear shift
ears are shorter ItIan those 01
forK (A)
the other two shift iofks
Output shaft 6th gear shift lark [B)
guide pin goes to left side of the
Output shaft 5th gear shift fork [C]
®
®
®
®
'"''
guide pin goes to right side of
the ears
KX250:
Drive shalt 3rd gear and 4th gear shift
ears are shafter than those of
forK [A)
the other two shift forks
Output shaft 4th gear shift fork [B)
guide pin goes to left side 01 the
ears
Output shaft 5th gear shift fork [C]
guide pin goes to right side 01
the ears
" " •• ,111 t
®
®
• Tighten the shift drum bearing retaining bolls.
Torque ·
Shift Drum Bearing Retaining Screws: 5.4 N·m (0.55 kg'·m,
48 in·lb)(KX125)
Shift Drum Bearing Retaining boilS: 8.8 N·m (0.9 kgf·m, 78
In·lb)(KX2S0)
• Install the shift dram [A].
• Fit the shift fork guide pins into Ihe corresponding Shift drum grooves.
• Apply a little transmission oil to the shift rods [A], and slide them into
the shift forks (B].
• Holding the shift drum with the suitable too and tighten Ihe shift drum
operating plate bolt.
Torque·
Shift Orum Operating Plate Bolt: 22 N·m (2.2 kgf·m , 16 ft·lb)
Shift Fork Bending
• Visually inspect the shift forks, and replace any fork that is bent. A
bent fork could cause difficulty in shifting, or allow the transmission
to jump out of gear when under power.
A.90°
I. ,•• "U,
7· 16 ENGINE BOTTOM ENDfTRANSMISSION
Transmission
Shift Fork/Gear Groove Wear
• Measure the thickness of the shift fork ears [A]. and measure the
width [61 of the shift fork grooves in the transmission gears.
If the thickness of a shift fork ear is less than the service lim~ , the
shift fork must be replaced.
*
A
Shift Fork Ear Thickness
Standard:
KX125 • 4.9 - 5.0 mm
KX250 • 4.4 - 4.5 mm
Service L.imit
KXI25 • 4.8 mm
KX250 • 4.3 mm
1,,10 , 0111 C
* If a gear shift lork groove is worn over the service limit, the gear must
be replaced.
Shift Fork Groove Width
Standard:
KX125· 5.05 - 5.15 mm
KX250 • 4.55 - 4.65 mm
Service Limit:
KX125 • 5.25 mm
KX250 • 4.75 mm
Shift Fork Guide Pin/Shift Drum Groove Wear
• Measure the diameter [A] of each shift lork guide pin, and measure
the width IB] 01 each shift drum groove.
If the guide pin on any shift fork is less than the service limit, the fork
must be replaced.
*
Shift Fork Guide Pin Diameter
Standard:
Service Limit:
5.90 ~ 6.00 mm
5.80 mm
",nO' 1S1
* If any shift drum groove is worn over the service limit, the drum must
be replaced.
Shift Drum Groove Width
Standard:
Service Limit:
6.05 - 6.20 mm
6.25 mm
Gear Damage
• Visually inspect the gear teeth on the transmission gears.
Repair lightly damaged gear teeth with an oilstone. The gear must
be replaced if the teeth are badly damaged.
When gear is repaired or replaced, the driving gear should also be
inspected and repaired or replaced if necessary.
*
*
ENGINE BOTTOM ENDITRANSMISSION 7-17
Transmission
Gear Dog/Gear Dog Hole Damage
• Visually inspect the gear dogs [Al and gear dog holes [8J.
Replace any damaged gears or gears with excessively worn dogs or
dog holes.
*
Ball Bearing Wear
• Check the ball bearing on the crankcase.
Since the bal1 bearings are made to extremely close tolerances, the
wear must be judged by feel ralher than measurement. Clean each
bearing in a high flash-point solvent, dry it (do nol spin the bearing
while it is dry) , and oit it with transmission oil.
o Spin the bearing by hand to check its condition.
If the bearing is noisy, does not spin smoothly, or has any rough spots.
replace it
*
*
B
WHEELS I TIRES 8-1
Wheels I Ti res
Table of Contents
Exploded View... .. .. ... .... ... ... ... ....... ....... .... .. .. .. .. .. ... ... .. ... ... ...... ..
............................................................................ 8-2
Specifications ..................................................................................................................................................................8-3
Wheets (Rims)...........................................................................................
............................................... 8-4
Front Wheel Removal .....................................................................................
....... ... .. .. ............ ..... .... .. .... .... .. ... 8·4
Front Wheel Installation ............... .................... ......................................................................................................... 8-5
Rear Wheel Removal .... .. ... ................................................................................. ....... .... .. ...... .... .. .. .. ...... .... ..... .... ... ... 8-5
Rear Wheel Installation .............................................................................................................................................. 8-6
W heels Inspection ............................................................................ ......................................................................... 8-6
Spoke Inspection ........................... ................................... ..........................................................................................8-7
Rim Inspection. ............................................................................................ ............ ...................
Axle Inspection ...................................................................
.. ................ ...................... ....
.......................... 8-7
......................... 8·7
Tire~i~·p·;~·~~~~··I~·~~t[~~iAdi~~i~~~i::::::::::::::::::::: . :::::::::::::::::::::::::....::::::::::::::::::... :::::::::::::::::..... .......::::::::::::::::::::::::::: [ i l
Tires Inspection .. ... .. ... .... .... ..... ... .. ... .. .... .. ... ..... .. .. .. .. ...... .. ... ............ ............................................... ... .... .... ............. ..8-8
Tire Removal .......... ............................................................................... ...............................
............ .................. 8·9
Installation ... ....... .... ..... ...... .. ............ ................................................................... .... . .... .. .... .. .. .. ..... ......... .. ..... .... .... .. 8- 10
Hub Bearings ........................................................ ............................. ......... ........ ...............
Hub Bearing Removal ............... ................................................... ............ ,... "., .......... .
Hub Bearing Installation ..
...................................... ,..................... ....
................... " ........ ,.................................................. ..
Bearing Inspection... .....
.......................... ,... 8-11
.. 8-11
.. 8·11
..8·11
8-2 WHEELS I TIRES
Exploded View
5
1. Nipple
6. Swingarm
2. Spoke
7. Rear Tire
WL: Apply soap and water solution, or rubber lubricant.
3. Front Tire
8. Rear Axle
T1 : 1.5 N·m (0.15 kgf·m, 13 in·lb)
G: Apply Grease
4. Rim
T2: 78 N·m (8.0 kgf·m, 58 ft·lb)
5. Front Axle
T3: 20 N·m (2.0 kgf·m. 14.5 ft·lb)
T4: 110 N·m (11 kgf·m, 80 ft·lb)
WHEELS I TIRES 8·3
Specifications
Item
Sta ndard
Servi ce Limit
Wheels (Rims):
Rim runout:
Axial
1.0 mm or less
2 mm
Radial
1.0 mm or less
2 mm
0. 1 mm
O.2mm
Axle runouV 100 mm
Tires Air Pressure:
Front and Aear
100 kPa (1.0 kgf/cm' , 14 psi)
---
Size
80/100-21 51M
---
Make
DUNLOP
Type
K490, Tube (EU) D755FJ, Tube
Tires:
Standard lire:
KX125
Front:
D739FA, Tube (l2 ...., l4 Model)
Rear:
Size
100/9O-1957M
Make
DUNLOP
Type
0739. Tube (EU) D755G, Tube
Size
80/1OO-2151M
Make
BAIDGESTONE (EU) DUNLOP
Type
M77, Tube (EU) D755FJ, Tube
Size
110/90-1962M
-.-
KX250
Front:
Rear:
Make
BAIDGESTONE (EU) DUNLOP
Type
M78A, Tube (EU) D7S5J, Tube
(EU) Europe Model
Special Tools - Inside Circlip Pliers: 57001-143
Rim Protet:lcr: 57001- 1063
Bead Breaker Assembly: 57001- 10n
Bearing Driver Set : 57001-1129
Jack: 57001- 1238
---
- --
8-4 WHEELS I TIRES
Wheels (Rims)
Front Wheel Removal
• Using the jack [AJ under the frame, and stabilize the motorcycle.
Special Tools - Jack: 57001- 1238
• Place a stand under the engine to raise the front wheellhe ground.
• Unscrew the guard screw (AJ and remove the guard [BJ.
• Unscrew the axle nul [AI.
• Loosen the left axle clamp bolts (B).
• l oosen the right axle clamp Bolts (A), remove the axle [B), and pull
out the wheel. Take oft the collar [C] and cap [DJ from each side of
the front hub.
CAUTION
Do not lay the wheel on the ground with the disc facing down.
This can damage or warp the di sc. Place blocks under the
wheel so the disc does not touch the ground.
I JGUU ll l
• Insert a wood wedge between the disc brake pads this prevents Ihem
from being moved out of their proper poSition, should the brake lever
be squeezed accidentally.
WHEELS I TIRES 8-5
Wheels (Rims)
Front Wheel Installation
• Apply grease to the seals.
• Fit the projection on the cap to the groove on the collar.
• Install the caps [AJ collars ISJ on the left (longer collar) and right
(shorter collar) side of the hub.
• Inset the axle Ie] fro m right side.
• Unbolt the right axle clamp bolts [0] temporally.
• Tighten the axle nuts IE] .
Torque -
Front A xle: 78 N·m (8.0 kgf.m, 58 ft·lb)
• Remove the jack. Push and release the handlebars live times or
more apply the front brake to move the front forks so that the axle
O-o. 5m
;JO ' O,O,s, C
shaft has a snug fit with the axle holder.
• Tighten the left clamp bolts [F] first, and tighten the righ t clamp bolts.
Torque ·
Clamp Botts; 20 N·m (2.0 kgf·m, 14.5 tt.lb)
• Check the front brake for good braking power and no b rake drag.
AWARNING
Do not attempt to drive the motorcycle until a full brake lever is
obtained by pumping the brake lever until the pads are against
the disc. The brake will not function on the first application of
the lever if this is not done.
Rear Wheel Removal
• Using the jack under the frame so that the rear wheel is raised off
the ground.
Special Tools - Jack: 57001- 1238
• Remove the dip [AJ from the master link using pliers, and free the
drive chain [BJ from the rear sprocket.
I Jo ' Gun, C
• Remove the cotter pin [AJ.
• Remove the axle nut [B).
• Pull out the axle [C].
• Move the rear wheel back with the rear caliper installed.
• Take off the collar and cap from the each side of the rear hub.
CAUTION
Do not lay the wheelan the ground with the disc facing down.
This can damage or warp the disc . Place blocks under the
wheel so the di sc does not touch the ground.
• Insert a wood wedge between the brake pads. This prevents them
from being moved out of their proper position, should the brake pedal
be squeezed accidentally.
8·6 WHEELS I TIRES
Wheels (Rims)
Rear Wheellnstaffation
• Fit the brake holder stop [AI with the stop grooves [8] against the
swingarm slop space [C] with the stop projection [0].
• Fit the projection on the cap to the groove on the collar.
• Install the collars [A] on the left and right side of the hub.
• Install the drive chain. Inslallthe master link clip [AI so that the closed
end of the · U· [B] points in the direction of chain rotation [CJ.
UO'QQUlt
• Check the drive chain slack (see Final Drive chapter).
• Tighten the axle nul.
Torque ·
Rear Axle Nut: 110 N·m (It kg·m , 80 ft ·lb)
• InslaUthe new cotter pin.
• Check the rear brake for good braking power and no brake drag.
AWARNING
Do not attempt to drive the motorcycle until a full brake pedal is
obtained by pumping the brake pedal until the pads are against
the disc. The brake will not function on the first application of
the pedal if this is not done .
Wheels Inspection
• Place the jack under the frame so that the front/rear wheel is raised
off the ground.
Special Tool·
Jack: 57001- 1238
• Spin the wheel lightly, and check for roughness or binding.
If roughness or binding is found, replace the hub bearings.
• Visually inspect the fronl and rear axles for damage.
If axle is damaged or bent, replace it.
*
*
~
WHEELS I TIRES 8-7
Wheels (Rims)
Spoke Inspection
• Check that all the spokes are lightened evenly.
11 spoke lightness is uneven or loose, lighten the spoke nipples evenly.
*
Torq ue·
Spoke Nipples: 1.5 N·m (0. 15 kg'·m, 13 in·lb)
• Check the rim runout.
AWARNING
If any spoke breaks, it shou ld be replaced Im mediately. A
missing spoke places an additional load on the oth er spokes,
which will eventually ca use other spokes to break.
Rim Inspection
• Place the jack under the frame so that the front/rear wheel off the
ground.
Special Tool·
Jack: 57001- 1238
• Inspect the rim for small cracks, denis, bending, or warping.
II there is any damage to the rim, it must be replaced .
*
• Set a dial gauge against the side 01 the rim, and rolate the rim to
measure the axial runout [AJ. The difference between the highest
and lowest dial readings is the amount of runout.
• Set a dial gauge against the outer circumference of the rim, and
rotate the rim to measure radial runout [B\. The difference between
the highest and lowest diat readings is the amount of runout.
If rim (unout exceeds the service limit, check the wheel bearings first.
Replace them if they are damaged. II the problem is not due to the
bearings, correct the rim warp (runout) . A certain amount 01 rim warp
can be corrected by recentering the rim. loosen some spokes and
tighten others within the standard torque to change the position of
different parts of the rim. lithe rim is badly bent , however, it must be
replaced.
*
Rim Runout (with t ire installed)
Standard
Service Limit
A;.:ia!
unclel 1.0 mm
2 mm
Radia!
unclel 1.0 mm
2 mm
Axle Inspection
• Visually inspectlhe front and rear axle for damages.
II the axle is damaged or bent, replace it.
• Place the axle in V blocks that are 100 mm [AJ apart, and set a dial
gauge on the a;.:le al a point halfway between the blocks. Turn the
axle to measure the runout. The difference between the highest and
lowest dial readings is the amount of runoul.
II runout exceeds the service limit. replace the axle.
*
*
Ax le Runout/l 00 mm
Standar d:
Service Limit:
Under 0. 1 mm
0.2 mm
o
8-8 WHEELS I TIRES
Tires
Air Pressure Inspection/Adjustment
• Using lire air pressure gauge IA}, measure the tire pressure when the
tires are cold.
Adjust the tire air pressure to suit track conditions and rider preference, but do not stray too tar from the recommended pressure.
*
Track Condition
Tire Pressure
When the lfack is weI, muddy, sandy or slip-
80 kPa (0.8 kgl/cm , 11 psi)
pery, reduce the lire pressure to increase
the tire tread surface on the ground.
When the track is pebbly or hard, increase
lIle tire pressure to prevent damage or punctures, through the tires will skid more easily.
1
100 kPa (1.0 kgllcm 2 , 14
Tires Inspection
As the lire tread wears down, the lire becomes more susceptible the
puncture and failure.
• Remove any imbedded stones or other foreign particles from the
tread.
• Visually inspect the lire lor cracks and cuts, replacing the tire in case
of bad damage. Swelling or high spots indicate internal damage,
requiring tire replacement.
AWARNING
To ensure safe handling and stability, use only the recommended standard tires for replacement, inflated to the standard pressure.
NOTE
o Check and balance the wheel when a tire is replaced with a new
one.
Standard Tire
KX125:
Front:
Size:
801100-21 51M
Make:
DUNLOP
Type:
K490, Tube (EU) D755FJ, Tube
D739FA, Tube (L2 "" L4 Model)
Rear:
Size:
1ool9O-1957M
Make:
DUNLOP
Type:
D739, Tube (EU) D755G, Tube
Size:
8O/100-2151M
Make;
BRIDGESTONE (EU) DUNLOP
Type:
Mn, Tube, (EU) D755FJ, Tube
KX250:
Front:
Rear:
(EU): Europe Model
Size:
110190-1962M
Make:
BRIDGESTONE (EU) DUNLOP
Type:
M78A, Tube, (EU) D755J, Tube
,
.
WHEELS I TIRES 8-9
Tires
Tire Removal
CAUTION
Do not lay the wheel on the ground with the disc facing down.
This can damage or warp the disc. Place blocks under the
wheel so the disc does not touch the ground .
• Remove the wheel from the motorcycle (see Wheels Removal).
• To maintain wheel balance, mark [A) the valve stem position on the
tire with chalk so that the tire can be reinstalled in the same poSition.
• Take out the valve core [B) to let out the air.
• Remove the valve stem nut [C].
o When handling the rim, be careful nollo damage the rim flanges.
• Loosen the bead protector nut.
• Lubricate the tire beads and rim flanges on both sides with a soap
and waler solution or rubber lubricant. This helps the l ire beads slip
off the rim flanges.
..0...... '
CAUTION
Never lubricate with mineral oil (engine oil) or gasoline beca use they will cause deterioration of the tire.
• Break the beads away from both sides of the rim wilh the bead breaker
IAI·
Special Tools· Bead Breaker Assembly: 57oo1 - 10n
• Step on the side of the tire opposite valve stem, pry the tire off the
rim with the tire iron [A] of the bead breaker protecting the rim with
rim protectors (B].
Special Tools - Rim Protector: 57001- 1063
Tire Iron Protection of the Bead Breaker Assembly:
57001- 1072
CAUTION
Take care not to inset the tire irons so deeply that the tube
gets damaged.
• Remove the tube when one side of the l ire is pried off.
• Pry the lire off the rim.
B
<
8-10 WHEELS I TIRES
Tires
Installation
• Inspect the rim and lire, and replace them if necessary.
• Inslall the tube.
• Apply a soap and waler solution, or rubber lubricant to the rim flange
and tire beads.
• Position the tire on the rim so that the valve (AJ is al the lire balance
mark [B) (the chalk mark made during removal , or the yellow paint
mark on a new lire. see Removal).
• Insert the valve stem into the rim, and screw the nut on loosely.
• Fit the rim protectors and use lire irons to install the lire bead.
NOTE
o To prevent rim damage, be sure to place the rim protectors al any
place the tire irons are applied.
• Pry one side of the tire bacl< onlo the rim. Fit the bead protector into
the tire.
• Pry the other side of the tire onto the rim, starting at the side opposite
the valve.
e Take care nol to insert the tire irons so deeply that the tube is
damaged.
• Install the other side of the tire bead onto the rim in the same manner.
• Check that the tube is not pinched between the tire and rim.
• Tighten the bead protector nut and valve stem nut, and put on the
valve cap.
• Check and adjust the air pressure after installing.
U OODIOU,
C
WHEELS I TIRES 8-11
Hub Bearings
Hub Bearing Removal
• Remove the wheel (see Wheel Removal) .
CAUTION
Do not lay Ihe wheelan the ground with the disc facing down.
This can damage or warp the disc. Place blocks under the
wheel so that the disc does not touch the ground.
• Remove the oil seals and circlips.
• Remove the hub bearing by tapping evenly around the bearing inner
race as shown.
IAJ Bar
IB} Distance Collar
(e] Hub Bearing
Hub Bearing Installation
• Before installing the wheel bearings, blow any dirt or foreign particles
out of the hub [B) with compressed air to prevent contamination of
the bearings.
• Replace the bearings with new ones.
• Lubricate them and install them using the bearing driver set [AJ so
that the marked or shielded sides face out.
o Press in the bearings until they are bottomed.
Special Tool-
Bearing Driver Set: 57001-1129
A
B
IJ . ' .OI U,
e
IJDI •• US'
C
• Replace the circlips and oil seals with new ones.
• Press in the oil seals [AJ so that the seal surface is flush IB] with the
end of the hole.
• Apply high temperature grease to the oil seal lips.
Special Tool -
Bearing Driver set: 57001-11 29 [C]
A
Bearing Inspection
NOTE
o It is not necessary to remove any bearings for inspection . If any
B
bearings are removed, they will need to be replaced with new ones.
• Spin [AJ it by hand to check its condition.
If it is noisy. does not spin smoothly, or has any rough spots. it must
be replaced.
• Examine the bearing seal [B) for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
*
*
FINAL DRIVE 9-1
Final Drive
Table of Contents
Exploded View ........................................ ... .. .... ... ...... .. .. ... .. ..... .... ..... . ..... ..... .... .. ............................................................... 9-2
Specifications.................................. .................................. ............. ..................... ... ............ ................
... .................... 9-3
Drive Chain...........................
...........................
............................................................................................9-4
Slack Inspection. .................. ..... .... .. ...... .. ... ..... ... .... ...
................................................................................ 9-4
Slack Adjustment. ...................... .... ....... ...
............ ... .. .. ... ...... .. ... ... ....................................................................... 9·4
Wheel Alignment Inspection .................................................................................................................... ...... ........ .9-5
Wheel Alignment Adjustment ............
............................................................................................................ 9-5
Drive Chain Wear Inspection .... ... ... ......... ... .. .... ...... .. .. ..... ... .. ...... .... ..... ... .... .. .. ........................................................... 9·5
Drive Chain Lubrication ...........................................................................................................................................9·6
Drive Chain Removal .......................................... ... .......... .. ................................. ... ........ .. .. . ..... ... ... ...... .... .... ... ...... .. 9·6
Drive Chain Installation ..................... ....................................
. ... .... .... ... . .... ........ .. .. ... ... ............................... 9·6
Sprockets............................. ......... .. ..... ... ..
...... ... ....
..... .... .... ..... .... .............................................................. 9-7
.... ...........................
.. .. ........ .. .. . 9·7
Engine Sprocket Removal ............
............. .. ...
Engine Sprocket Installation ..............
.............................................. .. ..... ..... ..... ..... ... .. ... .... ....... 9-7
............. ............
.................... 9·7
Rear Sprocket Removal... ................................. ..... .... ....... .... ............ .........
Rear Sprocket Installation
...... ... ... ........ .... ... ... ..... ....... ... ... .. .... .. .......... ... ........................................................... 9·7
Sprocket Wear Inspection .............................
........... ............ .......... .... ................ ... .... .... ...
. .. ........ 9·8
Rear Sprocket Warp Inspection........................................................... .................................. ....................
...... 9·8
9-2 FINAL DRIVE
Exploded View
11
1. Engine Sprocket
6. Locknut
G: Apply grease.
2. Output Shaft
7. Adjusting Bolt
0 : ApplV oiL
3. Swingarm
8. Chain Adjuster
n : 34 N'm (3.5 kgf·m, 25 ft·lb)
4. Chain Slipper
9. Drive Chain
T2 : 110 N·m (11 kgf·m , 80 tUb)
5. Chain Guide
10. Rear Sprocket
11. Rear Axle
FINAL DRIVE 9·3
Specifications
Item
Standard
Service Limit
Drive Chain :
Chain sla ck
60 -.. 70 mm
Chain 20·link length
317.5 ..... 318.2 mm
Less than 60 mm, or
more than 75 mm
323mm
Standard Chain:
Make:
Type:
DAIDO
KX125
0.1.0 520DMA
KX250
0. 1.0 520DM
-------
KXt25
110 Links
- ----
KX250
114 Links
- --
Engine sprocket diam-
KX1 25
50.98 ...... 51.18 mm/12T
50.7 mm
eter
KX250
60.98 ,,- 61.18 mm/13T
60.7 mm
(AS)(EU)(FA ) 60.99 '" 61.19 mml14T
60.7 mm
0. 1.0 520DMA (L4 Model)
length:
Sprocket
Rear sprocket diameter
KX125
232.62 _ 233.12 mml48T
232.1 mm
KXI2S-l2 '" L4
237.54 ....,238.04 mml49T
237.0 mm
KX250
232.62 .... 233.12 mml48T
(AS)( EU)( FR) 237.54 '" 238.04 mm/49T
232.1 mm
237.0 mm
Under 0.4 mm
O.5mm
Rear sprocket warp
(AS): Australia Model
(EU): Europe Model
(FA): France Model
Special Tools· Outside Circlip Pliers: 57001 - 144
Bearing Dri ver Set: 57001-1129
Jack: 57001 - 1238
9·4 FINAL DRIVE
Drive Chain
Slack Inspection
• Support the motorcycle on its side stand.
• Check the wheel alignment (see Wheet Alignment Inspection), and
adjust it if necessary (see Wheel Alignment Adjustment).
NOTE
o Clean the drive chain if it is dirty, and lubricate it if it appears dry.
• Rotate the rear wheel to find the position where the chain is tightest.
• Measure the space (chain slack) [A] between the chain and the swing
arm at the rear allhe chain slipper as shown.
II the drive chain slack exceeds the standard, adjust it.
*
Chain Slack
Standard:
60 ",70mm
Too Tight:
Less than 60 mm
Too Loose:
More than 75 mm
Slack Adjustment
• loosen the left and right chain adjuster locknuts [C}.
• Remove the cotter pin IF] and loosen the axle nut [AJ.
If the chain is too light, back out the left and righ t chain adjusting boNs
[BJ evenly, and push the wheel forward until the chain is too loose.
If the chain is too loose, turn both chain adjusting bolls evenly until the
drive chain has the correct amount 01 slack. To keep the chain and
wheel properly aligned, the notch on the left chain adjuster should
aUgn with the same swingarm mark [OJ as the right chain adjuster
notch (El.
*
*
• Check the wheel alignment.
• Tighten both chain adjuster locknuts securely.
• Tighlen the axle nul.
Torque·
Rear Axle Nut: 110 N·m (11 .0 kgf.m, 80 ft·lb)
• Rotate the wheel, measure the chain slack again at the tightest
position, and readjust if necessary.
• Instal! a new cotter pin through the axle nut and axle, and spread its
ends.
If the axle nut is not securely tightened, or the cotter pin is not
I
an unsafe
condition may result.
• Check the rear brake (see Brakes chapter).
NOTE
o In wet and muddy conditions, mud sticks to the chain and sprockets
resulting in an overly tight chain, and the chain may break. To
prevent this, adjust the chain to 70 '" 80 mm of slack whenever
necessary.
,,0" '0'" 0
FINAL DRIVE 9-5
Drive Chain
Wheel Alignment Inspection
\
• Check thal lhe notch [Alan the left chain adjuster [B] aligns with the
same swing arm mark {C] as the right chain adjuster.
NOTE
o Wheel alignment can also be checked using the straightedge or
string method.
A
Misalignment of the wheel will result in abnormal
may result in an unsafe riding condition.
Wheel Alignment A djustment
This procedure is the same as Drive Chain Slack Adjustment.
Drive Chain Wear Inspection
• Rotate the rear wheel 10 inspect the drive chain lor damaged rollers,
and loose pins and links.
If there is any irregularity, replace the drive chain.
Lubricate the drive chain it it appears dry.
*
*
[A]
Bushing
[D]
Pin link
[6]
Roller
[E]
Roller li nk
[C]
Pin
B
• Stretch the chain taut by hanging a 98 N (10 kgf, 20 Ib) weight (Al on
the chain.
• Measure the length of 20 links [S] on the straight part [C] of the chain
from the pin center of the 1st pin to the pin center of the 21st pin.
Since the chain may wear unevenly, take measurements at several
places.
Chain 2o-link length
Standard :
Service l imit:
317.5", 318.2 mm
323 mm
* If any measurements exceed the service limit, replace the chain. Also,
replace the front and rear sprockets when the drive chain is replaced.
AWARN[NG
If the drive chain wear exceeds the service limit, replace the
chain or an unsafe riding condition may result. A chain
that breaks or jumps off the sprockets could snag on the
engine sprocket or lock the rear wheel, severely damaging the
motorcycle and causing it to gO out of control .
Standard Chain
OAIOO
Make:
Type:
KX1 25
0 .1.0 5200MA
KX250
0 .1.0 5200M
0 .1.0 5200MA (l4 Model)
link:
KX125
110 links
KX250
114 links
~
1s t
21st
'"~ ' Otoll '
t
9-6 FINAL DRIVE
Drive Chain
Drive Chain Lubrication
• If the chain appears especially dirty, it should be cleaned before
lubrication with high flash-point solvent.
• If a special lubricant is not available, a heavy oil such as SAE90 is
preferred to a lighter oil because it will stay on the chain longer and
provide better lubrication.
• Apply oil to the sides 01 the rollers so that oil will penetrate to the
roliers and bushings.
• Wipe off any excess oil.
Oil applied area (AJ
.u . ~lonl
Drive Chain Removal
• Remove the engine sprocket cover.
• Remove the clip rA] from the master link using pliers, and free the
drive chain from the rear sprocket.
• Remove the drive chain from the chassis.
Drive Chain Installation
• Fit the drive chain back onto the sprockets with the ends at the rear
sprocket.
• Install the master link from the frame side.
• Install the clip (AI so that the closed end of the ' U' (B] pointed in the
direction of chain rotation (C).
• Adjust the drive chain slack (see Drive Chain Slack Adjustment).
• Check the rear brake (see the Brakes chapter).
c
FINAL DRIVE 9-7
Sprockets
Engine Sprocket Removal
• Remove:
Engine Sprocket Cover [A)
Drive Chain [BJ (Iree of engine sprocket)
• Remove the circfip {C], and puff off the engine sprocket [DJ .
Special Toofs· Outside Circlip Pliers : 57001-144
Engine Sprocket Instaflation
• Replace the circiip with a new one.
• Install the circlip so that the tooth is aligned with a spline groove.
Special Tools· Outside Circlip Pliers: 57001-144
Rear Sprocket Removal
• Remove the rear wheel (see WheelslTires chapter).
CAUTION
Do not lay the wheelan the ground with the disc facing down.
This can damage of warp the disc. Place blocks under the
wheel so that the disc does not touch the ground.
• Unscrew the rear sprocket bolts IAJ. and remove the rear sprocket
[9] .
Rear Sprocket Installation
• Instaff the rear sprocket [AJ so that the marked side IBJ faces out.
• Tighten the rear sprocket bolts.
Torque·
Rear Sprocket Bolts: 34 N·m (3.5 kg'·m , 25 ft ·lb)
A
9·8 FINAL DRIVE
Sprockets
Sprocket Wear fnspection
• Visually inspect the front and rear sprocket teeth for wear and
damage.
* II they are worn as illustrated or damaged , replace the sprocket.
A. Worn Tooth (Engine Sprocket)
B. Worn Tooth (Rear Sprocket)
C. Direction of Rotation
©
I U SD",.,
• Measure the diameter of the sprocket at the base of the teeth.
lithe sprocket is worn down to less than the service limit, replace the
sprocket.
*
Engine Sprocket Diameter
KX12S;
Standard;
50.98"" 51 .18 mml12T
Service Limit:
50.7 mm
KX250:
Standard:
60.98 .... 61.18 mml13T
(ASXEU)(FR) 60.99 .... 61 .19 mml14T
Service Limit:
60.7 mm
Rttar Sprocket Diameter
KXl25:
Standard:
232.62 ..... 233.12 mml48T
237.54 ... 238.04 mml49T (L2 .... L4 Model)
Service Limit:
232.1 mm
237.0 mm (L2 .... L.4 Model)
KX2SO;
Standard:
232.62 .... 233.12 mm/48T
(AS)(EU)(FR) 237.54 .... 238.04 mml49T
Service limit:
232.1 mm
(AS)(EUXFR) 237.0 mm
NOTE
o If a sprocket requires replacement, the chain is probably worn also.
When replacing a sprocket, inspect the chain.
Rear Sprocket Warp Inspection
• Using the jack, raise the rear wheel off the ground.
Special Tool ·
Jack : 57001-1238
• Set a dial gauge [AI against the rear sprocket IB) near the teeth as
shown and rotate Ic] the rear wheel to measure the sprocket runout
(warp) , The difference between the highest and lowest dial gauge
readings is the amount 01 runout (warp).
If the runout exceeds the service limit, replace the rear sprocket.
*
Rear Sprocket Warp
Standard:
Service Limit:
Under 0.4 mm
0.5 mm
C
BRAKES 10-1
Brakes
Table of Contents
Exploded View ................................................................................................................................................ .. ... .. ....... .. . 10-2
Specifications ............................................ ...... .... ..... ... ..... .... .. .. .. .. ... .... .. ....... ......... .. .. .... ..... ..... .. .. ... ... .... ........... .... ........ 10-4
Brake Lever, Brake PedaL ... .. ..... ....... .. ..... .... ............................................................................................................... ... 10-5
Brake lever Play Adjustment ................... " .............................................. ............................. ... ........... ... ..... .. .. ....... .. 10-5
Brake Pedal Posilion I Pedal Play Adjustment. ............................................................................. ... ... ..................... to-5
Brake Pedal Removal ............................. ... ............. .... .....................................•..................... .. _.. ... .. ......... .. ... ........... 10-6
Brake Pedal Installation .. ........ .... ..... ... ....... ...... ......................................................................................................... 10-6
Brake Auid .............................................................. ................ ................. .. ........................................ .. .... .... .... ...... ......... 10-7
Fluid level Inspection ............................................................. .............................................. ... .. .... ... ........ .... .......... .. 10-7
Fluid Change ............................................... ......... .......... .................................................................... .......... ............ 10-8
Bleeding the Brake Line .......... .... .... .. .. _.................................................................................................................. 10-10
Caliper .................................. ................ ............................................................................................. ..................... ....... 10-11
Caliper Removal ..................................................... ............. .. .............. _.............................................. ........... ...... ... 10-11
Caliper Installation ........................................... ... .................................................................................................... 10-11
Caliper Disassembly ............................. ......... ......................................................................................................... 10-12
Caliper Assembly ......................................................................................................................................... ........... 10-1 2
Fluid Seal Damage ................................................... ... ... .. ... ................................................................................... 10· 13
Dust Seal and Cover Damage .............................................. .. ..... .. ................................................... ..................... 10-13
Piston Cylinder Damage ........................................................................................................................................ 10-13
Caliper Holder Shaft Wear ... ................................................................................................ ..... .... ......................... 10-13
Brake Pad RemovaL... ................. .. ..... .............
.. ............................................................. ................. ....... 10-14
Brake Pad Installation................ .. .. ..... ...........
..... ........................................................ _.............................. 10-14
Brake Pad Inspection ...... .. ... ........ ....................
..... .......... .. .. .................................. ....... ........... ....... ........... 10-14
Master Cylinder .. .. .......... ....... .... .. ..................... .......... ......................... ............ .. ......................... .. ... .. ... .....
............. 10-15
Front Master Cylinder RemovaL. ........................... ........ .. .............. ....... ........ .... ..... ...... ..... ........... .... .. ...... ..... ......... 10·15
Front Master Cylinder Installation .......................................................................................................................... 10-15
Rear Master Cylinder Removal ... ..... ..... ............................ ..................................................................................... 10-15
Rear Master Cylinder Installation ....................................................................................................................... .... 10- 16
Front Master Cylinder Disassembly ...................... .......... .... ........ ... ............................. .. ..... ....... ... ........................ 10-16
Rear Master Cylinder Disassembly .......... .. .... ... ... ... ...... ......................................................................................... 10-16
Master Cylinder Assembly ..... ......... ....... ..... .... ... ... .. .. ..... ..... .. .................................................................................. 10-17
Master Cylinder Inspection (Visual Inspection) ................................................................................................ ... ... 10- 17
Brake Disk ..................................................... ................................................................................................................ 10- 18
Brake Disc Inspection .............................................................................................................................................10- 18
Brake Hose ....................................................................................................................................................................10-19
Brake Hose AemovaVlnstaliation ...... ..... ........ .......... .............................................................................................. 10-1 9
Brake Hose Inspection ............ .. .. .. .. .............. .............................................................._.......................................... 10- 19
[!Q]
10
10-2 BRAKES
Exploded View
A: KX12512SO-U "" l4
1. Front Brake Reservoir
2. Brake Lever
3. Brake Lever Adjuster
4. Locknut
5. Brake Hose
6. Clamps
7. Brake Pad
8. Front Caliper
9. Piston
10. Front Disc
Si : Apply Silicone grease.
R : Replacement Parts
T1 : 25 N·m (2.S kgf·m, 18.0 ft ·lb)
T2: B.8 N·m (o.g kg'·m, 78 in·lb)
T3: 7.8 N·m (0.8 kgf·m, 69 in·lb)
T4: 18 N·m (1 .8 kgf·m , 13.0 ff.lb)
T5: 9.8 N'm (1 .0 kgf·m, 87 In.lbl
BRAKES 10-3
Exploded View
6
<=<'./' P
rJf)
~o
___ T6
~\)
1. Rear Brake Reservoir
2. Rear Master Cylinder
8. Brake Pad
3. Bra ke Hose
9. Rear Disc
4. Brake Pedal
5. Rear Caliper Cover
Si : Apply Silicone grease.
6. Rear Caliper
R: Replacement Parts
7. Pisto n
G: Apply high temperature grease.
T1 ! 25 N·m (2.5 kgf·m , 18.0 ft ·lb)
T2: 2.5 N·m (0.25 kgf·m , 22 in ·lb)
T3: 9.8 N·m (1.0 kg'·m , 87 in·lb)
T4: 18 N'm (1.8 kgf·m , 13.0 ft·lb)
T5 : 9.8 N·m (1 .0 kgl·m , 87 in·lb)
T6 : 27.5 N·m (2.8 kgf·m , 21.5 in·lb)
TI : 7.8 N·m (0.8 kgf·m , 69 in ·lb)
10-4 BRAKES
Specifications
Item
Standard
Service Limit
Brake adjustment:
Adjustable (10 suit ride r)
---
Type
DOT3 or DOT4
---- -
Front
3.8 mm
1 mm
Rear
6.4 mm
1 mm
Front
2.85 ,..., 3.15 mm
2.5 mm
Rear
4.35 '" 4.65 mm
3.8mm
lever play
Brake Fluid:
Recommended disc brake fluid:
Brake Pads:
lining thickness:
Brake Disc:
Thickness:
Runoul
Special Toot -
Not more than 0.25 mm
Jack: 57001-1238
Inside ClrcUp Pliers: 57001-143
O.3mm
BRAKES 10-5
Brake Lever, Brake Pedal
Brake Lever Play Adjustment
• Adjust the front brake lever (AI to suit you.
• Slid the clutch lever dust cover IB] out 01 place.
• Loosen the adjuster locknut Ie] and turn the adjuster [01 to either
side.
• After adjustment, tighten the locknut.
(KX125125O-Llonly)
Torque·
Brake Lever Adju ster Locknut : 3.5 N·m (0.35 kgf·m 30 in·lb)
(KX12SI250-L2 '"" L4)
To rque ·
Brake Lever Adjuster Locknut : 5.0 N·m (0.5 kgf·m 43 in·lb)
AWARNING
Always maintain proper brake adjustment. If adjustment is
improper, the brake could drag and overheat. This could
damage the brake assembly and possibly lock the wheel
resulting in loss of con trol.
Brake Pedal Position / Pedal Play Adjustment
The brake pedal position and pedal play should not be adjusted.
There is no pedal position adjustment device as such. The only
adjustment is master cylinder push rod length.
o
A
o
NOTE
o Usually it is not necessary to adjust the push rod length, but always
adjust it when the rear master cylinder fA] is disassembled.
o When the brake pedal is in its rest position, measure the length fBJ
c)---,,!!i
®
indicated in the figure.
B: S2 mm
68.5:1: 1 mm (KX125/2SQ-L4)
C: Push Rod Locknut
* If the length is not within the specified length, adjust the clevis [A] as
follows.
o Loosen the push rod locknut [B] .
o Pull out the cotter pin [C] and the joint pin IDJ.
D Turn the clevis to obtain the specified length.
o Tighten the locknut.
Torque ·
Push Rod Locknut: 18 N·m (1 .8 kgf·m, 13.0 ft ·lb)
o Install the joint pin and new cotter pin.
NOTE
o If the pedal poSition is incorrect after adjusting the master cylinder
push rod, the brake pedal may be deformed or incorrectly installed.
.c . . ..... ,
10-6 BRAKES
Brake Lever, Brake Pedal
Brake Pedal Removal
• Remove:
Cotter Pin [AJ
Joint Pin [81
Washer
• Remove the mounting bolt IAI and lake off the brake pedal and return
spring [BJ.
Brake Pedal Installation
• Check the pedal D·ring for signs of damage. If necessary, replace
them with new one.
• Apply high temperature grease to the shaft portion 01the brake pedal,
and install the pedal with return spring onto the frame.
Torque ·
Brake Pedal Mounting Bolt : 25 N·m (2.5 kgf·m , 18 h .lb)
• Check the brake pedal position .
• Install the joint pin, washer and a new cotler pin.
BRAKES 10-7
Brake Fluid
AWARNING
When working with the disc brake, observe the precautions
listed below.
1. Never reuse old brake fluid .
2. Do nol use fluid from a container that has been left unsealed
or that has been open for a long time.
3. Do not mix two types and brands of fluid for use in the brake.
This lowers the brake fluid boiling point and could cause the
brake to be ineHective. It may also cause the rubber brake
parts to deteriorate.
4. Don'! leave the reservoir cap off for any length of time to avoid
moisture contamination 0 1 the fluid.
5. Don't change the fluid in the rain or when a strong wind is
blowing.
6. Except lor the disc pads and disc, use only disc brake fluid,
isopropyl alcohol , or ethyl alcohol for cleaning of the brake
parts. Do not use any other fluid lor cleaning these parts.
Gasoline, engine oil, or any other petroleum distillate will
cause deterioration 01 the rubber parts. Oil spilled on any
part will be difficult to wash off completely and will eventually
deteriorate the rubber used in the disc brake.
7. When handling the disc pads or disc, be careful that no disc
brake lIuid or any oil gets on them. Clean off any lIuid or oil
that inadvertently gets on the pads or disc with a high flashpoint solvent. Do nol use one which will leave an oily residue.
Replace the pads with new ones if they cannot be cleaned
satisfactorily.
8. Brake lIuid quickly ruins painted surfaces; any spilled fluid
should be completely wiped up immediately.
9. 11 any of the brake line fittings or the bleed valve is opened
at any time, Ihe AIR MUST BE BLED FROM THE BRAKE
LINE.
Fluid Level Inspection
In accordance with the Periodic Maintenance Chart, inspect the brake
fluid level in the front and rear brake fl uid reservoirs.
• Check the brake flu id level in the front brake reservoir [AJ.
NOTE
B
o Hold the reservoir horizontal when checking brake fluid level.
o The front reservoir must be kept above the lower level line {BI. If
the fluid level ;n front reservoir is lower than the lower level line,
fill the reservoir to the upper level line. Inside the front reservoir is
stopped end showing the upper leve/line {C].
1<010.0'"
C
10-8 BRAKES
Brake Fluid
• The rear reservoir [AI must be kept more than half full with brake Huid.
If the amount of brake fluid is insufficient, add brake fluid.
A
Fluid Change
In accordance with the Periodic Maintenance Chart, change the brake
fluid. The brake lIuid should also be changed if it becomes con taminated
with dirt or water. Furthermore, the brake fluid should be changed to
bleed the air quickly and completely whenever the brake line parts are
removed.
AWARNING
Change the brake fluid in the brake line completely if the brake
fluid must be refilled but the type and brand of the brake fluid
that already is in the reservoir are unidentified. After changing
the fluid, use only the same type and brand of fluid thereafter.
Mixing different types and brand of brake fluid lowers the brake
fluid boiling point and could cause the brake to be Ineffective.
It may also cause the rubber brake parts to deteriorate.
Recommended Disc Brake Fluid
Type:
DOT3 or OOT4
NOTE
o The procedure to change the front brake flu. Changing the rear
brake fluid is the same as for the front brake.
•
•
•
•
Level the brake fluid reservoir.
Remove the reservoir cap.
Remove the rubber cap [A] on the bleed valve [B].
Anach a clear plastic hose to the bleed valve on the caliper, and run
the other end 01 the hose into a container.
BRAKES 10-9
Brake Fluid
• Change the brake fluid as follows:
o Repeat this operation until fresh brake lIuid comes out from the plastic
hose or the color oltha fluid changes.
1. Open the bleed valve IAJ
2. Apply the brake and hold it IB]
3. Close the bleed valve [C)
4. Release the brake [01
o Fill the reservoir w ith fresh specified brake fluid.
NOTE
o The fluid level must be checked often during the changing operation
and replenished with fresh brake fluid. If the fluid in the reservoir
runs out any time during the changing operation, the brakes will
need to be bled since air will have entered the brake line.
• Remove the clear plastic hose.
• Tighten the bleed valves, and install the rubber caps.
Torque -
Caliper Bleed Valve : 7.8 N·m (0.8 kgf·m . 69 in-Ib)
• After changing the fluid, check the brake for good braking power. no
brake drag. and no fluid leakage.
If necessary. bleed the air from the lines.
*
AWARNING
Do not mix two brands of fluid. Change the brake fluid in the
brake line completely if the brake fluid must be refilled but the
type and brand of the brake fluid that is already in the reservoir
are unidentified.
1<0I010 0l f C
10-10 BRAKES
Brake Fluid
Bleeding the Brake Line
The brake fluid has a very low compression coefficient so thai almost
all the movement of the brake lever or pedal is transmitted directly to the
caliper for braking action. Air, however, is easily compressed. When air
enters the brake lines, brake lever or pedal movement will be partially
used in compressing the air. This will make the lever or pedal feel
spongy, and there will be a toss in braking power.
AWARNING
Be sure to bleed the air from the brake whenever brake lever
or pedal action feels soft or spongy, after the brake fluid is
changed. or whenever a brake line fitting has been loosened
for any reason.
NOTE
o The procedure to bleed the front brake line is as follows. Bleeding
the rear brake line is the same as for the (ront brake.
• Remove the reservoir cap, and check that there is plenty of fluid in
the reservoir.
• With the reservoir cap off, slowly pump the brake lever several times
until no air bubbles can be seen rising up through the fluid from the
holes althe bottom of the reservoir.
o Bleed the air completely from the master cylinder by this operation.
• Instal1lhe reservoir cap.
• Attach a clear plastic hose 10 the bleed valve on the caliper, and run
the other end of the hose into a container.
• Bleed the brake line and the caliper as follows:
o Repeat this operation until no more air can be seen coming out into
the plastic hose.
1. Pump the brake lever until it becomes hard, and apply the brake
and hold it (A).
2. Quickly open and close the bleed valve while holding the brake
applied IB).
3. Release the brake [C].
NOTE
o The fluid level must be checked often during the bleeding operation
and replenished with fresh brake fluid as necessary. If the fluid in
the reservoir runs almost out any time during bleeding operation,
the bleeding operation must be done over again from the beginning
since air will have entered the line.
D Tap the brake hose lightly from the caliper to the reservoir for easier
bleeding.
• Remove the clear plastic hose.
• Tighten the bleed valves, and inslallthe rubber caps.
Torque·
Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 In·lb)
• Check the fluid level.
• After bleeding is done, check the brake for good braking power, no
brake drag , and no fluid leakage.
AWARNING
Do not attempt to drive the motorcycle until a full brake lever
or pedal is obtained by pumping the brake lever or pedal unti l
the pads are against the disc. The brake will not fun ction on
the first application o f the lever or pedal if this in not done.
nOIO I On! c
BRAKES 10-11
Caliper
Caliper Removal
Front Brake:
• loosen the banjo bolt [A] so as nol to spill brake fluid.
• Remove Ihe caliper mounting bolts [BJ.
• Remove the banjo bolt and lake off the brake hose from Ihe caliper
(e].
• If the caliper is to be disassembled after removal and if compressed
air is not available, remove the pislon using Ihe following steps before
disconnecting the brake hose from the caliper.
o Remove the pads.
o Pump the brake lever to remove the piston.
Rear Brake:
• Unbolt the guard bolts [A) and remove the rear caliper guard [8].
• loosen the banjo bolt [C) so as nollo spill brake ftuid.
• Loosen the brake pad boll [AJ and caliper assembly bolt [B] before
Ihe caliper removal if the caliper is to be disassembled.
NOTE
o If the caliper is to be disassembled after removal and compressed
air is not available, disassemble the caliper before brake hose
removal (see Caliper Disassembly).
• Remove the rear wheel. (see Wheels/Tires chapter)
• Unscrew the banjo bolt and remove the brake hose [C] from the
caliper (see Brake Hose Removal/Installation).
uOIOOU l ,
CAUTION
Immediately wipe up any brake fluid that is spilled.
Caliper Installation
• Tighten the brake pad bolts if it was removed.
Torque ·
Brake Pad Bolts: 18 N·m (1.8 kgf.m, 13 ft·lb)
• Install the caliper, and Ihe brake hose lower end.
o Replace the washers that are on each side of hose fitting with new
ones.
Torque·
Caliper Mounting Bo lts : 25 N·m (2.5 kg'·m, 18.0 ft ·lb)
Brake Hose Banjo 801t: 25 N·m (2.5 kg'·m, 18.0 ft·lb)
• Bleed the brake line (see Bleeding the Brake Line).
• Check the brake for good braking power, no brake drag, and no fluid
leakage.
AWARNING
Do not attempt to drive the motorcycle until a full brake lever
or pedal is obtained by pumping the brake lever or pedal until
the pads are against the disc. The brakes will not function on
the first application of the lever or pedal if this is not done.
10-12 BRAKES
Caliper
Caliper Disassembly
• Remove the front/rear caliper (see Caliper removal).
• Aemove the pads and spring (see Pad Removal).
• Remove the caliper holder, shaft rubber f riction boot and cover.
• Using compressed air, remove the piston(s).
o Cover the caliper opening with a clean, heavy cloth [AJ.
o Remove the piston(s) by lightly applying compressed air IB) to the
hose joint opening.
1l010l0ll, C
AWARNING
To avoid serious injury, never place your fingers or palm inside
the caliper opening . If you apply compressed ai r into the
caliper, the pistan(e) may crush your hand or fingers.
NOTE
o If the caliper is to be disassembled after removal and compressed
air is not available, remove the piston(sj using the following three
steps before disconnecting the brake hose from the caliper.
o Prepare a container for brake fluid, and perform the work above it.
o Remove the pads and spring (see Pad Removal).
o Pump the brake lever or pedal to remove the caliper piston(s).
• Remove the dust seal(s) and fluid seal(s).
• Remove the bleed valve and rubber cap.
Caliper Assembly
• Clean the caliper parts except for the pads.
CAUTION
For c leaning the parts, use only disc brake fluid, isopropyl
alcohol, or ethyl alcohol.
• nghten the bleed valve with rubber cap.
Torque -
Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lbj
• Replace the fluid seals which are removed with new ones.
o Apply brake flui d to the fl uid seals [AJ , and install them into the
cylinders by hand.
• Replace the dust seals with new ones il they are damaged .
o Apply brake fluid to the dust seals [8J, and install them into the
cylinders by hand.
• Apply brake fluid to the outside of the pistons [C], and push them into
each cylinder by hand.
B
OlO.OO' . . ,
C
BRAKES 10-13
Caliper
• Install the anti-rattle spring [A] in the caliper as shown.
IlUOOU51 •
• Replace the shaft rubber friction boot [A] and dust cover [S] if they
are damaged.
• Apply a thin coat of silicone grease to the caliper holder shafts [C]
and holder holes (PSC is a special high temperature, wateHesistant
grease).
• Install the pads (see Pads Installation).
• Wipe up any spilled brake fluid on the caliper.
Fluid Seal Damage
The fluid seal around the pislon maintains the proper pad/disc
clearance. If this seal is not in good condition, pad wear will increase,
and constant pad drag on the disc will raise brake and brake fluid
temperature.
• Replace the fluid seals under any of the following conditions: (a)
fluid leakage around the pad; (b) brakes overheat; (c) there is a large
difference in left and righ t pad wear; (d) the seal is stuck to the piston.
If the fluid seal is replaced, replace the dust seal as well. Also, replace
all seals every other time the pads are changed.
Dust Seal and Cover Damage
• Check that the dust seals and covers are not cracked , worn, swollen,
or otherwise damaged.
If they show any damage, replace them.
*
Piston Cylinder Damage
• Visually inspect the piston and cylinder surfaces.
Replace the cylinder and piston if they are badly scored or rusty.
*
Caliper Holder Shaft Wear
The caliper body must slide smoothly on the caliper holder shafts.
If the body does not slide smoothly, one pad will wear more than the
other, pad wear will increase, and constant drag on the disc will raise
brake and brake fluid temperature.
• Check too see if the caliper holder shafts are nol badly worn or
stepped, or the rubber friction boot is not damaged .
If the shafts or rubber friction boot are damaged. replace the shafts,
rubber friction boot, and the caliper holder.
*
10-14 BRAKES
Caliper
Brake Pad Removal
• Remove the pad boll [AJ.
• Take the piston side pad [B].
• Push the caliper holder toward the piston, and then remove another
pad [CJ from the caliper holder.
Brake Pad Installation
• Push the caliper pistons in by hand as far as they will go.
• Install the piston side pad first, and then another pad.
• Tighten the brake pad bolt.
Torque ·
Brake Pad Bolt: 18 N·m (1.8 kgf·m, 13 ft·lb)
• Check the brake for good braking power, no brake drag. and no fluid
leakage.
AWARNING
Do not attempt to drive the motorcycle until a full brake lever
or pedal is obtained by pumping the brake lever or pedal until
the pads are against the disc. The brake will not function on
the first application of the lever or pedal if this is not done.
Brake Pad Inspection
• Check the lining thickness and condition of the pads in each caliper.
If either pad is damaged, replace both pads in the caliper as a set.
If the lining thickness [Al of either pad is less than the service limit
[8], replace both pads in the caliper as a set.
*
*
Lining Thickness
Front
Rear
Standard:
3.8 mm
6.4mm
Service Limit:
, mm
, mm
B
I lU . . . . . ,
C
BRAKES 10-15
Master Cylinder
CAUTION
Brake fluid quickly ruins painted or plastic surfaces; any
spilled fluid should be completely wished up immediately.
Front Master Cylinder Removal
• Remove the banjo bolt IA] to disconnect the upper brake hose from
the master cylinder (see Brake Hose RemovaVlnstallation).
• When removing the brake hose, temporarily secure the end of the
brake hose to some high place to keep fluid loss to a minimum.
• Unscrew the clamp bolts IB], and take off the master cylinder [C] as
an assembly with the reservoir and brake lever.
IlGl000UI C
Front Master Cylinder Installation
• Position the master cylinder so that the vertical parting line [A] 01 the
Iront and rear master cylinder clamps align with the punch mark [B]
on Ihe handlebar.
1<oIO,O'SI C
• The master cylinder clamp must be installed with the arrow mark [A]
upward.
o Tighten the upper clamp bolt [B] first, and then the lower clamp bolt
re] There will be a gap at the lower part of the ctamp after tightening.
Torque -
B
Master Cylinder Clamp Bolts: 8.8 N·m (0.9 kgt·m, 78 in·lb)
• Replace the washers that are on each side of hose fitting with new
ones.
• Tighten the brake hose banjo bolt.
Torque -
Brake Hose Banjo Bolt: 25 N·m (2.5 kgt·m, 18.0 ft ·lb)
• Bleed the brake line (see Bleeding the Brake Une).
• Check the brake for good braking power, no brake drag, and no fluid
leakage.
Rear Master Cylinder Removal
• Remove the reservoir guard and the reservoir mounting bolt [AI.
• Remove the cotter pin [BI.
• Pull off Ihe joint pin [C] with washer.
NOTE
o Pull off the joint pin while pressing down the brake pedal.
• Unscrew the brake hose banjo bolt [D] (see Brake Hose Remova V
Installation).
• When removing Ihe brake hose, temporarily secure the end 01 the
brake hose to some high place to keep fluid loss to a minimum.
• Unscrew the master cylinder mounting screws [EJ, and remove Ihe
master cylinder IF] with Ihe reservoir.
• Remove the reservoir cap. and pour the brake lIuid into a container.
• Remove the reservoir and its hose from the master cylinder.
Il010IO'"
C
10-16 BRAKES
Master Cylinder
Rear Master Cylinder Installation
• Replace the cotter pin with a new one.
• Replace the washers are on each side of hose fitting with new ones.
• Tighten the following:
Torque ·
1
1
Brake HOSII Banjo Bolt: 25 N·m (2.5 kgf.m, 18.0 tt.lb)
• Bleed the brake line (see Bleeding the Brake Line).
• Check the brake for good braking power, no brake drag, and no fluid
leakage.
• Check the brake pedal position (master cylinder push rod length).
Front Master Cylinder Disassembly
B
• Remove the fronl master cylinder.
• Remove the reservoir cap and diaphragm, and pour the brake flu id
into a container.
• Unscrew the locknut and pivot bolt, and remove the brake lever.
• Push the dust cover [AI oul of place, and remove the cirdip [B].
Special Tool ·
Inside Cin:lip Pliers: 57001-143
• Remove the washer [C], pull out the piston [0], secondary cup [E],
primary cup [F] , and return spring [G].
CAUTION
1l.'. 'D .. ' C
Do not remove the secondary cup from the piston since
removal win damage it.
Rear Master Cylinder Disassembly
• Remove the rear master cylinder.
• Slide the dust cover [A] on the push rod IB] out of place, and remove
the retainer [C].
Special Tool-
Inarde Circllp Pliers : 57001-143
• Pull out the push rod with the piston stop [OJ.
• Take off the piston [E], secondary cup [F] , primary cup [G), and return
spring [H].
CAUTION
Do not remove the secondary cup from the piston since
removal will damage It.
• Remove the circlip [I), and take off the connector [J) and O-ring [K).
IUI.,nn c
BRAKES 10-17
Master Cylinder
Master Cylinder Assembly
• Before assembly, clean all parts including the master cylinder with
brake fluid or alcohol.
• Apply brake fluid to the removed parts and to the inner wall of the
cyhnder.
CAUTION
Except for the disc pads and disc, use only disc brake
fluid, isopropyl alcohol . or ethyl alcohol for cleaning brake
parts. Do not u se any other fluid for cleaning these parts.
Gasoline, engine oil, or any other petroleum distillate will
cause deterioration of the rubber parts. Oil spilled on any part
will be difficult to the wash off completely, and will eventually
deteriorate the rubber used in the disc brake.
• Take care nol lo scratch the piston or the inner wall 01 the cylinder.
• Tighten the brake lever pivot bolt and the locknut securely.
Master Cylinder Inspection (Visual Inspection)
• Disassemble the front and rear master cylinders.
• Check that there are no scratches, rust or pilling on the inner wall of
each master cylinder [AJ and on the outside of each piston (BJ.
If a master cylinder or piston shows any damage. replace them.
• Inspect the primary (C] and secondary [DJ cups.
II a cup is worn, damaged, softened (rotted), or swollen, the piston
assembly should be replace to renew the cups.
If fluid leakage is noted at the brake lever, the piston assembly should
be replaced to renew the cup.
• Check the dust covers [EJ for damage.
If they are damaged , replace them.
• Check that the relie f {GJ and supply [HJ ports are not plugged .
If the small relief port becomes plugged, the brake pads will drag on
the disc. Blow the ports clean with compressed air.
• Check the piston re turn springs [F} for any damage.
If a spring is damaged, replace it.
[KJ Rear Master Cylinder.
*
*
*
*
*
*
®
A
C )---+ rF~~
no,." " . c
10-18 BRAKES
Brake Disk
Brake Disc Inspection
• Visually inspect the disc [AI.
If it is scratched or damaged, replace the disc.
• Measure the thickness of each disc at the point [8] where it has worn
*
the most.
* Replace the disc if it has worn past the service limit.
Thickness
Front
Rear
Standard:
2.85 .... 3.15 mm
4.35 .... 4.65 mm
Service Limit:
2.5 mm
3.8 mm
• Place a jack under the motorcycle so that the front/rear wheel is raised
off the ground.
Special Tool ·
Jack : 57001-1238
• Set up a dial gauge against the disc {A] as illustrated.
o For the front disc, turn the handlebar fully to one side.
• Measure the disc (unout while rotating the wheel slowly (SI.
If the runout exceeds the service limit, replace the disc.
*
Runout
Standard :
S8fVice Limit:
Not more than 0.25 mm
O.3mm
BRAKES 10-19
Brake Hose
Brake Hose Removal/Installation
CAUTION
fluid quickly ruin s painted or plastic surfaces; any spilled
flu id should be completely wiped up immediately with watered
cloth.
• When removing the brake hose, take care not to spill t he brake fluid
on the painted or plastic parts.
• When removing the brake hose, temporarily secure the end 01 the
brake hose to some high place to keep fluid loss to a minimum.
• There are washers on each side of the brake hose fitting. Replace
them with new ones when installing.
• When installing the hoses, avoid sharp bending, kinking , fl attening or
twisting, and route the hoses according to the Cable, Harness, Hose
Routing section in the General Information chapter.
• Torque the banjo bolts at the hose fittings.
Torque·
Brake Hose Banjo Bo ils : 25 N·m (2.5 kgf·m , 18.5 ft·lb)
• Bleed the brake line after installing the brake hose (see Bleeding the
Brake Line).
Brake Hose Inspection
• The high pressure inside the brake line can cause flui d to leak [A]
or the hose to burst if the line is not properly maintained. Bend and
twist the rubber hose white examining it.
Replace it if any c racks [BJ or bulges [C] are noticed
*
Ill.' ... '
C
SUSPENSION 11-1
Suspension
Table of Contents
Exploded View...... .. ..... .
.... ...... ... .. ... ... ... ...... .. .... 11-2
Specifications ... ..... .... ... .... .. ....... ....... .. .. ... ... ... .. .. .. .... 11-4
Front Fork ................................................................. 11·7
Air Pressure .. ...... .. ..... ...... .... ... ......... .. .. ... ... .. .... 11-7
Rebound Damping Adjustment.. .... ..... ... .......... . 11 -7
Compression Damping AdjustmenL. ................ 11 · 8
Fork Oil level Adjustment (Simplify) .... ... ...... .... 11-8
Oil Change/Oil Level Adjustment (each fork
leg) ............................ .. .................. .. ... .............. 11 · 10
Front Fork Removal. ........................................ 11·13
Front Fork Installation ....... .... ... ................. .. ... .. 11·14
Front Fork Disassembly (each fork leg) ... .. .. .. 11 ·14
Cy linder Unit Removal .... ...... ...... .. .. ...... .... .. .... . l l·15
Front Fork Assembly ....................................... 11 · 17
Inner Tube Inspection .. .................................... 11 · '9
Guide Bush Inspeclion .... .... ... ... .. ... ... .. ... ... .. .. .. 11·19
Dusl SeaVOil Seallnspeclion ... ... .. ..... ... ... ..... .. l1·20
Spring Tension .................. ............................... 11·20
Rear Suspension (Uni·Trak) .... ... ... .. ... ............. .... .. . 11·2 1
Rear Shock Absorber: ......... ... ... .. ... ... ..... ... ........ . 11·21
Rebound Damping Adjustmenl ... ...... .............. 11 ·21
Compression Damping Adjuslmenl ...... ........... l1 · 21
Spring Preload Adjuslment... .................. ... .... 11·22
Spring Tension ... ......... ...... .... ... ..... .... .. .. ...... .. .. . 11-23
Rear Shock Absorber Removal. ...................... 11 -23
Rear Shock Absorber Inslallalion ............... ..... 11-24
Spring Replacement .... ... ..... .. ...... ... ......... .... .. 11-24
Rear
Shock
Absorber
Disassembly
(Oil
Change) ..................................... ................. .. .. 11 -25
Rear Shock Absorber Assembly ............. ... ..... 11 -26
Spring Tension ... .. .... .. ...... .... .. ... ... .... ... ..... .... .. .. 11·29
Rear Shock Absorber Scrapping ..................... l'-29
Swingarm ............... .... .... .. .. ........ ... .. .. .. .... ... ... .. ....... 11-30
Swingarm Removal ... ........... .... .... .... ... ..... ... ... . 11-30
Swingarm Installation .. .. .. ..... ... .. ........ ...... ..... ... 11·30
Swingarm Bearing Removal ............................ 11-3O
Swingarm Bearing Installalion ........ ... ... ... ... ..... l'-3O
Drive Chain Guide, Chain Slider, Chain Roller
Wear .. .. .... .. ......... ..... .. .. ... ... ..... .. .. .... ... .... .. ...... .. 11 -30
Tie-Rod , Rocker Arm ............................................. 11-31
Tie-Rod Removal ... .... ... ... ...... ... ... ... .... ..... ...... .. l!-31
Tie-Rod Installation ....... .. .... ..... .... ... .... .. ... ... ..... l'·31
Rocker Arm Removal ......... ... ... ............ .......... 11-31
Rocker Arm Installation ............. .............. .... ... . 11-31
Needle Bearing Inspection .. .... .. ... ... .... ... ... .. ... 11-31
Uni-Trak Maintenance .. .. .. .... .. ... ... .. .... ..... ...... ........ 11 ·32
Rocker Arm Sleeve WeaL..... ... ........
.......... 11-32
Rocker Arm Mounting Boll Bend ....... ... .... .. .. .. 11 -32
11·2 SUSPENSION
Exploded View
8
o
A: KX1251250-l2 ..... L4
1. Screw
2. C-Ring
3. Top Plug
14. Outer Tube
4. Spring Seat
5. Spring
17. Oil Seal
15. Guide Bush
16. Washer
9. Oil Lock Piston
18. Retaining Ring
19. Dust Seal
20. Inner Tube
21 . Gasket
22. Fork Cylinder Valve Assembly
10. Split Ring Keeper
11 . Piston Holder
24. Fork Guide
6. Push Rod Nut
7. Spring Guide
8. Guide Stay Nut
12. Push Rod
13. Fork Cylinder
23. Cap
25. Fork Protector
26. Steering Stem Head
(KX250 and KX125-L4)
27. Steering Stem
28. Steering Stem Head (KX12S)
L : Apply a non-permanent locking
agent to the threads.
T1 : 20 N·m (2.0 kgf·m, 14.5 ft·lb)
T2: 29 N·m (3.0 kgf·m , 22 ft·lb)
T3: 78 N·m (8.0 kgf·m , 58 fHb)
T4: 54 N'm (5.5 kgf·m, 40 ft·lb)
T5: 28 N'm (2.85 kgf·m, 20.6 tUb)
SUSPENSION 11-3
Exploded View
17
2
1. Pivot Shaft
2. Swingarm
3. Rocker Arm
4. Tie-Rod
5. Rear Shock Absorber Cylinder
6. A ir Bleeder Bott
7. a·Ring
8. Bladder
9. Cap
10. Circlip
19. Q·Ring
11. Valve Cap
12. Locknut
13. Adjusting Nut
14. Spring
15. Spring Guide
16. Circtip
, 7. Rod As sembly
20. Oil Seal
21 . Stopper
le. Piston
22. Rear Shock Ab sorber
M: Apply grease
Tl : 98 N' m (10 kgf·m , 72 ft·lb)
T2: 39 N·m (4.0 kgf·m , 29 ft·lb)
T3 : 83 N·m (8.5 kgf·m, 61 ft ·lb)
T4: 34 N·m (3.5 kgf·m, 25 fUb)
11-4 SUSPENSION
Specifications
KX125/2SG-Ll :
Item
Standard
Service Limit
Front Fork:
Air pressure
Atmospheric pressure
Rebound damping adjustment
(Adjustable Range)
(from the seated position adjuster turned
11 clicks counterclockwise
18 clicks
fully clockwise)
(Adjustable Range)
Compression damping adjustment
(from the seated position adjuster turned
KX12S; 10 clicks counterclockwise
lully clockwise)
KX125: 9 clicks counterclockwise
Oil viscosity
KAYABA 01 or SAE 5W
Oil capacity
603:t 4 mL
(Adjustable Range)
Oil level (fully compressed, spring removed)
110 ± 2 mm (from lOP of outer tube)
Fork spring free length
18 clicks
470mm
102 ..... 145 mm
460mm
Rear Suspension (Uni-Trak):
Rear Shock Absorber:
Rebound damping adjustment
(Adjustable Range)
(from the seated position adjuster turned
KX125 : 12 clicks counterclockwise
fully clockwise)
KX250: 10 clicks counte rclockwise
20 clicks
(Adjustable Range)
Spring preload adjustment
(Adjusting nut position from the
center of the upper mounting hole)
Rear shock spring free length
KX125: 113.5 mm
102.5 ..... 12 1 mm
KX250: 11 5.5 mm
102.5 .... 121 mm
280mm
275mm
Gas Re servoi r:
(Adjustable Range)
Compression damping adjustment
(from the seated position adjuster turned
fully clockwise)
Low Speed:
10 clicks counterclockwise
High Speed:
KX125: 2 i
turns out
18 clicks
o . . . 3 ~ turns out
KX250: 1 ~ turns out
980 kPa (10 kgllcm 2 , 142 psi)
Gas pressure
Tie-Rod, Rocker Arm:
Sleeve outside diameter:
Rocker Arm Mounting Boll Runout
Long
21.987 ,"", 22.000 mm
21 .85 mm
Short
15.989 '" 16.000 mm
15.85 mm
under 0.1 mm
0.2 mm
Special Tools - Hook Wrench: 57001-1101
Jack: 57001-1238
Fork Spring Holder: 57001-1286
Fork Cylinder Holder: 57001-1413
HOlder-Front Fork Cylinder: 57001-1442
Fork Oil Seal Driver, 048 57001-1395
Fork Oil Seal Driver, 048 57001-1509
Fork Piston rod Putter, M1 .25: 57001-1289
Fork 011 Levet Gauge: 57001-1290
Steering Stem Nut Wrench : 57001-1100
Fork Outer Tube Weight: 57001-1218
SUSPENSION 11·5
Specifications
KX125125()-L2:
Item
Standard
Service Limit
Front Fork:
Air pressure
Atmospheric pressure
(Adjustable Range)
Rebound damping adjustment
(from the seated position adjuster turned
KX125: 13 clicks counterclockwise
fully clockwise)
KX250: 12 clicks counterclockwise
Compression damping adjustment
18 clicks
(Adjustable Range)
(from the seated position adjuster turned
KX 125: 11 clicks counterclockwise
lully clockwise)
KX250: 8 clicks counterclockwise
Oil viscosity
KAYABA 0 1 or SAE 5W
Oil capacity
KX125: 474:t 4 mL
18 clicks
KX250: 496 :t 4 mL
(Adjustable Range)
Oil level (fully compressed, spring removed)
KX125: 110 ± 2 mm (from top of outer tube)
60 .... 120 mm
KX250: sa :t 2 mm (from top of outar tube)
470mm
Fork spring free length
460 mm
Rear Suspension (Uni-Trak):
Rear Shock Absorber:
(Adjustable Range)
Rebound damping adjustment
(from the seated position adjuster turned
13 clicks counterclockwise
20 clicks
fully clockwise)
(Adjustable Range)
Spring preload adjustment
(Adjusting nut position from the
center of the upper mounting hole)
Rear shock spring free length
KXt25: 112.5 mm
102.5 ..... 121 mm
KX250: 111.5 mm
102.5 ", 121 mm
280mm
275 mm
(Adjustable Range)
Gas Reservoir:
Compression damping adjustment
(from the seated position adjuster turned
fully clockwise)
Low Speed:
KX125 : 11 clicks counterclockwise
18 clicks
KX250: 13 clicks counterclocl<wise
High Speed:
KX125: 1 ~ turns oul
KX250: 2 turns out
Gas pressure
980 kPa (1a kgf/cm2, 142 psi)
a ,..... 3 ~ turns out
11·6 SUSPENSION
Specifications
KX125125G-L3 ~ L4-Standard
Item
Service Limit
Front Fork:
Air pressure
- --
Atmospheric pressure
Rebound damping adjustment
(from the seated position adjuster
(Adjustable Range)
KX125:
turned fully clockwise)
13 clicks counterclockwise (L3 Model)
18 clicks
12 clicks counterclockwise (L4 Model)
KX250:
12 clicks counterclockwise (L3 Model)
10 clicks counterclockwise (L4 Model)
Compression damping adjustment
KX 125:
13 clicks counterclockwise (L3 Model)
(Adjustable Range)
11 clicks counterclockwise (L4 Model)
18 clicks
turned fullV clockwise)
KX250:
10 clicks counterclockwise (L3 Model)
Oil viscosity
KAYABA 01 or SAE 5W
Oil capacity
KX,25:
(from the sealed position adjuster
9 clicks counterclockwise (L4 Model)
--- --
494 ± 4 mL (l 3 Model)
565 ± 4 mL (l4 Model)
KX250:
514 ± 4 mL (L3 Model)
581 :z: 4 mL (L4 Model)
Oil level {fully compressed, spring removed)
(Adjustable Range)
KX125:
go:!: 2 mm (from top of outer tube)
KX250:
70 :!: 2 mm (from top of outer tube)
6O ", 120mm
75 :!: 2 mm (from top of outer tube)
(l 4 Model)
Fort< spring free length
470 mm
460mm
Rear Suspension (Uni-Trak):
Rear Shock Absorber:
Rebound damping adjustment
(from the seated position adjuster
(Adjustable Range)
KX125:
urned fully clockwise)
13 clicks counterclockwise
KX250:
12 clicks counterclockwise
Spring preload adjustment
(Adjusting nut positiOf'l from the
20 clicks
12 clicks counterclockwise (L4 Model)
(Adjustable Range)
KX 125:
center of the upper mounting hole)
101 mm
94 ....., 120.5 mm
100.5 mm (l4 Model)
KX250:
106 mm
94 ..... 116.5 mm
106.5 mm (l4 Model)
Rear shock spring free length
275 mm
270 mm
Gas Reservoir:
Compression damping adjustment
(from the seated position adjuster
turned fully clockwise)
Low Speed:
(Adjustable Range)
KX125:
12 clicks counterclockwise
KX250:
10 clicks coun terclockwise
18 clicks
11 clicks counterclockwise (L4 Model)
High Speed:
KX125:
1-314 turns out
,
3 1 turns out
2-112 turns out (l4 Model)
KX250:
1-1 /21 urns out
2-1/4 turns out (l4 Model)
Gas pressure
980 kPa ( 10 kgf/cm2, 142 psi)
---
SUSPENSION 11-7
Front Fork
Air Pressure
The standard air pressure in the fork legs is atmospheric pressure.
The air pressure in the fork legs increases as the fork heats up. so the
fork action will get stiffer as the vehicle operation progresses.
• Place the jack under the frame so that the fronl wheel off the ground.
Special Tool -
Jack: 57001-1238
• Remove the screws [AJ at the top of the front fork top plugs to let the
air pressure equalize.
NOTE
o Do not use the side stand when adjusting the air pressure.
o Adjust the air pressure when the front forks are cold.
• Check the O-ring 01 the screw. Replace the O-ring with a new one if
damage.
• Install the screw.
Rebound Damping Adjustment
• Place the jack under the frame so that the front wheel off the ground .
Special Tool -
Jack: 57001-1238
• To adjust rebound damping, lurn the adjuster [AJ on the front fork top
plugs with the blade of a screwdriver until you feel a click. Adjust the
rebound damping to suit you preference under special condition.
CAUTION
The left and right fork legs must have the same shock damping.
Seated positions: adjuster turned fully clockwise [AJ.
Rebound Damping Adju ster Sening
KX125:
11 clicks
Standard:
13 clicks (L2IL3 Models)
12 clicks (L4 Model)
KX250:
11 clicks
(Counterc: lock . i SOl)
(C lock. i SOl )
Softer ••o----------------o.-Her der
125.250
'TO
+
!1I7UI5U!312!!I0' 8 1 8 5 •
t
12 clicks (L2IL3 Models)
10 clicks (L4 Model)
3
1"1I ! I I I I I I I I I I I I
( KX 125 / 250-L 1 Mode I s )
®
UO ' OIUII C
11-8 SUSPENSION
Front Fork
Compression Vamping Adjustment
• Place the jack under Ihe frame so Ihallhe front wheel off the ground .
Special Tool -
Jack: 57001- 1238
• Clean Ihe bottom of the fork tubes.
• Remove the caps on Ihe bottom of the fork lubes.
• To adjust compression damping, turn the adjuster [A) on the front
fork cylinder valve with the blade of a screwdriver until you feel a
click. Adjust the compression damping to suit your preference under
special condi tion.
no.oOlll1
CAUTION
C
The left and right fork legs must have the same shock damping.
(C ounte~clockwile )
Softer ..
Sealed positions adjuster turned fu lly clockwise [Aj.
• Put the caps into the bottom of Ihe fork tubes.
Compression Damping Adjuster Sen rng
Standard
KX125:
10 clicks
11 clicks (L2 and L4 Models)
125 250
STD srD
H
e 1 e 5 4 3 2 1
I- I ( I I I I I I I I I I I I I I 1" 1
111718151413121110 $
t
13 clicks (Ll Model)
KX250:
9 clicks (L 1 and L4 Models)
8 clicks (1.2 Model)
10 clicks (L3 Model)
Fork Oil Level Adjustment (Simplify)
• Raise the front wheel off the ground using a jack,
Special Tool ·
Jack: 57001-1238
• Remove:
Front Fender
Brake Hose Guard (A]
Brake Hose Clamps [B]
Fork Protectors fC]
Number Plate
Handlebar
• loosen the upper fork clamp bolts.
• Remove the front fork top plugs.
• Slowly compress the fronl fork fully by pushing up the inner tubes [A)
until they are stepped portion contacts the dust seals (B] on the lower
end 01 the outer tubes [C).
(C I ockw i se)
.. He~de~
(K XI25!Z50 -L l "ode l s)
®
. . . . 0.0 . . '
0
SUSPENSION 11·9
Front Fork
• Place a stand or other suitable support [A] under the front wheel.
• While holding the push rod nut with a 19 mm wrench (A] , loosen and
remove the front fork top plug [B] from the top of the push rod.
• Remove the fork spring seat [C] and fork spring [DJ.
• Remove the other fork spring in the same way as described above.
• Use the oil level gauge to measure the fork oil level.
o With the fork lully compressed, put the oil level gauge [AJ and the
stopper [B], and adjust the distance from the top of the inner tube to
oil.
Special Tool·
Fork Oil L.evel Gauge: 57001-1290
Front Fork Oil Level (fullV compressed, without spring)
Standard:
KX125:
108 ", 112 mm (LllL2 Models)
88 .... 92 mm (L3 "" L.4 Models)
108 _1 12 mm
KX250:
In_ cnll' •
86 '" 90 mm (L2 Model)
68 '" 72 mm (L3 Model)
73 ", n mm (L.4 Model)
Adjus table Range
KXl251250:
102 ", 145 mm
60 '" 120 mm (L2 ...., L.4 Models)
* If no oil is drawn out, there is insufficient oil in the fork tube. Pour in
enough oil, then pump oul the excess oiL
Recommended Fork Oil :
B
KAYABA 01 or SA E5W20
• Install the push rod puller {AJ onto Ihe push rod (B}.
• Slowly pull up the push rod.
• Let the fork oil overflow through the hole in the push rod until it stops.
11 -10 SUSPENSION
Front Fork
• Insert the fork spring [A] into the lork tube with the closed coil end
IB] upward.
• Remove the push rod puller.
• Install the fork spring seat [A) on the fork spring [8].
• Check both lop plug a-ring [C] for damage and replace them if
necessary.
• While holding the push rod nut [AJ with a 19 mm wrench [B). lighten
the lOp plug re) against the push rod.
• Tighten the fork top plug .
Torque .
Push Rod Nut : 28 N·m (2.85 kgf.m, 20.6 ft·lb)
Front Fork Top Plug; 29 N·m (3.0 kgf.m, 22 ft ·lb)
• Assemble the other fork tube in the same way as described above.
• Tighten the upper fork clamp bolts.
Torque -
Front Fork Upper Clamp Blots : 20 N·m (2.0 kg'.m , 14.5 ft ·Jb)
• Install the parts removed.
Oil Change/Oil Level Adjustment (each fork leg)
• loosen the front fork upper clamp bolls
• Place the handlebar on one side, and loosen the fork top plug.
• Remove the front fork.
• Hold the inner tube lower end in a vise.
• Unscrew the top plug out of the outer tube.
• Push the outer tube all the way down away from the top plug and
hold it there throughout the following procedure.
• Pull the fork spring [Al away from the top plug a little and slip the
spanner wrench [B] in on top of the spring seat and under the push
rod nut [C].
• Use wrenches on the rod nut and the top plug [Alto loosen the push
rod nut.
• Remove the top plug from the push rod.
• Lift the fork spring [B) and its top spring seat [C] out of the outer tUbe.
A
SUSPENSION 11-11
Front Fork
• Take the rebound damping adjuster rod [A] out of the push rod.
• Hold the fork [AI tube upside down over a clean container [Bl and
pump it to drain the oil.
NOTE
o To discharge the fork oil, pump the push rod up [C] and down ten
times.
• Remove (KXt25/25o-l2 '"" L4)
Washer [DI
Spring Guide rEI
Push Rod Nut [F]
KXt 25125D-L2 ..... L4:
• Hold the fork tube upright, press the outer tube and the push rod all
the way down.
• Insert the rebound damping adjuster rod into the push rod.
NOTE
o The spring should not be installed.
o For KXI251250-1.2 .... L4, the washer and spring guide should not
be installed.
• Fill the specified oil to the outer tube.
Recommended Oil
KAYABA 01 or SAE 5W
Front Fork Oil Capacity
KX125:
603 %4 mL.
474 %4 mL. (KX125-L.2)
494 :1: 4 mL. (KX125-L3)
565 %4 mL (KX125-L.4)
KX250:
603:1:4 mL.
496 :1:4 mL. (KX25D-L.2)
514:1:4 mL. (KX25G-L.3)
581 :1:4 mL (KX2SG-L.4)
"
11-12 SUSPENSION
Front Fork
NOTE
o While doing this, take care to keep the oi/level topped off so that it
stays above the two large holes [A} near the top of the inner tube
[B}.
110"'01$1
0
100 . . , UII
0
• ... 011'"
C
110.0 . . . . '
C
KX1251250-L2 "" L4 :
• Screw the fork piston rod puller [AI onto the end of the rod.
Special Tool s · Fork Piston Rod Puller, M12 x 1.25: 57001-1289 {AJ
• Purge the air from the fork cylinder by gently moving the piston rod
puller up and down five times.
• Remove the fork piston rod puller.
KX125I2SD-L2_ L4:
• Purge the air from between the inner and outer lubes by pumping the
outer lube [AJ up and down.
• After purging the air f rom the assembly, let it sit for about five minutes
so thai any suspended air bubbles can surface.
• Install (KX 125J250-L2 ....., L4)
Washer (Spring Seal).
Spring Guide.
Screw the fork Piston Rod Nut
D
100.0,,011 t
SUSPENSION 11·13
Front Fork
• Adjust the oil level.
o With the fork fully compressed, put the oil level gauge [AJ and the
stopper [8]. and inspect the distance from the top of the inner tube
to the oiL
A
Special Tool s· Fork all Level Gauge: 57001-1290
011 Leve l (fully compressed, without spring)
Standard
KX125:
108 ..... 112 mm (L1 .... L2 Models)
88 .... 92 mm (La .... L4 Models)
KX250:
108 .... 112 mm
86 "" 90 mm (L2 Model)
68 "" 72 mm (La Model)
B
73 ..... 77 mm (L4 Model)
Adjustable Range
KX125f250:
102 "" 145 mm
60 .... t20 mm
(L2 .... L4 Models)
* If no oil is drawn out, there is insufficient oil in the outer tube. Pour
in enough oil, then drawn out the excess oiL
• Install the parts removed (see Front Fork Assembly)
I U .. " ...
Front Fork Removal
•
•
•
•
Remove the fork protectors (AI and hose guard IS].
Remove the front brake hose clamps [C).
Remove the front wheel (see Wheels/Tires chapter).
Remove the caliper [DJ from the fork leg to be removed, and rest the
caliper on some kind of stand so that it doesn'l dangle.
• Remove the number plate.
• Loosen the upper and lower fork clamp bolts [Aj.
• With a twisting motion, work the fork leg down and out.
,
11-14 SUSPENSION
Front Fork
Front Fork Instatlation
• II the fork leg was disassembled, check the fork oil level.
• Inslall the fork so that the distance IB] between the top end (AI of
the outer tube and the upper surface [Cj of the steering stem head is
specified dimension.
B .. 5mm
8 mm (KX1251250-L4)
• Aoute the cables and hose according to the Cable, Harness, Hose
Routing section in the General Information chapter.
• Install the front wheel (see WheelsITires chapter).
• Tighten the following:
Torque·
Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 14.5 ft ·lb)
Front Caliper Mounting Bolts: 25 N·m (2.5 kgt· m, 18 ft·lb)
• Check the front brake operation after installation.
Front Fork Disassembly (each fork leg)
Spring Guide Removal
•
•
•
•
•
Place the handlebar on one side, and loosen the each fork top plug.
Remove the front lorie::.
Hold the inner tube lower end in a vise.
Unscrew the top plug out of the outer tube.
Push the outer tube all the way down away from the top plug and
hold it there through out the following procedure.
o Pull the fork spring [AI away from the top plug a little and sip the
spanner wrench [BI in on top of the spring seat and under the push
rod nut {CJ.
• Use wrenches on the rod nut and top plug {AI loosen the push rod
nul.
• Remove the top plug from the push rod.
• Uft the fork spring [BI and its top spring seat [C] out of the outer tube.
• Take the rebound damping adjuster rod [AI out of the push rod.
SUSPENSION 11-15
Front Fork
• Hold the fork tube [AI upside down over a clean container [B} and
pump ilia drain the oil.
• Remove (KX125/250-L2 ~ L4)
Washer [D]
Spring Guide [E]
Push Rod Nut [F]
NOTE
o To discharge the fork oil, pump the push rod up {C] and down ten
times.
KX125J25G-L2 "'" L4:
• Remove:
Push Rod Nut [AI
Spring Guide [B]
B
Cylinder Unit Removal
•
•
•
•
Clean the bottom of the inner tube.
Remove the cap on the bottom of Ihe inner tube.
Hold the front fork horizontally in a vise.
Stop the cylinder unitlAI from turning by using the fork cylinder holder
[B] . Unscrew the cylinder valve assembly [C], and take the cylinder
valve assembly and gasket out altha bottom of the inner tube.
Special Tool·
B
A
Fork Cylinder Holder; 57001-1413 (KX1251250-l1 only)
Holder·Front Fork cylinder: 57001-1442 (On and aher
KX1251250-L2)
OIo.. ,nS, C
A. Inner Tube
B. Cylinder Valve Assembly
C. a·ring
D. Gasket
11-16 SUSPENSION
Front Fork
• Pull the cylinder unit [AJ out the lop of the inner lube.
C 00 not disassembly the cylinder unit as the push rod and cylinder are
consisted of as the single assembly.
A
KX125J250-L2 _ L4:
CAUTION
00 not disassemble the air chamber [AJ by removing the spring
(B] because the sealed air into the cylinder unit may be leaked.
Inner Tube Removal
• Separate the inner tube !AJ from the outer tube (B) as follows:
o Slide up the spring band [C].
o Slide up the dust seal [OJ.
B
nOOG. U ,. e
o Remove the retaining ring IB] from the outer lube [AJ.
110. . ,.111
C
o Grasp the outer tube and stroke the inner tube up and down several
limes. The shock to fork seal separates the inner tube from the outer
lube.
* If the lubes are tight, use a fork ouler tube weigh t [AJ.
Special Toot ·
Fork Outer Tube Weight: 57001-1 218
fr
D
.. 0 . . " . . ,
c
SUSPENSION 11·17
Front Fork
• Remove the guide bushes (A], washer [8), oil seal [C), retaining ring
[0] . and dust seal (E] from the inner tube.
Front Fork Assembly
Inner to Outer Tube Assembly
• Replace the following with new ones:
Dust Seal [A]
Re taining Ring [BJ
Oil Seatlc)
Guide Bushes [OJ
• Place an oil coated plastic bag lEI over the end of the inner tube to
protect the oil seals.
o The inner lube guide bush groove has a sharp edge [F] that can out
the sealing tip of the seals as they are pushed down over the inner
tUbe.
• Inslall in order these parts on the inner tube.
• When assembling the new outer tube guide bush (A), hold the washer
against the new one, and tap the washer with the fork oil seal driver
[B) unlil it stops.
Special Tool ·
B
Fork all Seal Driver, 046: 57001-1395 (KX1251250-l1 ....
")
Fork Oil Seal Driver, 048: 57001-1509 (KX125125D-L4)
• After installing the washer, instali the oil seal by using Ihe fork oil seal
driver.
Special Tool -
Fork Oil Seal Driver, 046: 57001-1395 (KX125125D-L1 .....
L3)
Fork Oil Seal Driver, 048: 57001 - 1509 (KX I 25125O--l.4)
U O' OU OS1
• Install the retaining ring to the outer tube.
• Push the dust seal into the outer tube, and put the spring band on
the dust seal.
Cvlinder Un it Installation
• Check the O-ring [A] on the guide stay nut, and replace it with a new
one if damaged.
• Install the inner cylinder unit.
A
c
11-18 SUSPENSION
Front Fork
Install Inner Cylinder
• Check the Q.ring (A} on the cylinder valve assembly (B], and replace
it with a new one.
• Replace the gasket Ic] with a new one.
• Apply a non·permanent locking agenllo the threads [OJ of the cylinder
valve assembly and screw the valve assembly into the bottom of the
inner lube.
• Hold the inner cylinder with the fork cylinder holder, and tighten the
cylinder valve assembly.
Special Tool ·
Torque·
Fork Cylinder Holdet: 57001-1413
Cylinder Vatve Assembly: 54 N·m (5.5 kgf·m, 40 It·lb)
• Install the spring guide (AI so that the thinner portion end IB] is down.
• Screw on the push rod nut (C) fully.
o For KX 125125o-l2 "'" L4, the spring guide (AI and push rod nut [C]
should not be installed.
A
IUUUlt 1 C
• Insert the rebound damping adjuster rod (AJ into the push rod.
• Pour in the type and amount 01 fork oil specified and adjust the oil
level (see Oil Level Ad justment).
• Screw the fork piston rod puller IAJ onlo the end of the push rod.
Special Tool · Fork Piston Rod Puller, M12 x 1.25: 57001-1289
• Pull the push rod up with the special tool for the next procedures.
o Pull up the push rod slowly so as not to spill the fork oil out 01 the
lark lube.
• For KX 1 2512~ ..... L4, install the washer and spring guide and
tighten the push rod nut.
KX1251250-L2 _ l4:
SUSPENSION 11 -19
Front Fork
• Install the fork spring [AJ so that the closed coil end [BI is facing
toward the top plug.
• Pull the fork spring away a little and slip the fork spring holder in on
lop of the spring seat and under the push rod nut.
• Remove the fork piston rod puller.
• Check the O-ring [AI on the top plug and replace it with a new one if
damaged.
• Unscrew the rebound damping adjuster fully. then screw the front fork
top plug onto the push rod.
• Holding the top plug (BI with a wrench, tighten the push rod nut [CI
against the lop plug.
Torque -
Push Rod Nut: 28 N·m (2.85 kgf·m, 20.6 ft·lb)
• Pull out the fork spring holder, raise the outer tube and screw the top
plug into it.
• After installing the front fork, lighten the lop plug.
Torque -
Fork To p Plug: 29 N·m (3.0 kgf·m, 22 ft·lb)
Inner Tube Inspection
• Visually inspect the inner tube [A], repair any damage.
• Nick 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 nol repairable, replace the inner lube. Since damage
to the inner tube damages the oil seal, replace the oil seal whenever
the inner tube is repaired or replaced.
• Temporarily assemble the inner and outer tubes, and pump them back
and forth manually to check for smooth operation.
*
~~ .
~
" ",' 1/
CAUTION
100 _011",
~
1-0. 0" . . '
0
If the inner tube is badly bent or creased, repla ce it. Excessive
bending, followed by subsequent straightening, can weaken
the inner tube.
Guide Bush Inspection
• Visually inspect the guide bushes [AI. and replace them if necessary.
A
11-20 SUSPENSION
Front Fork
Dust SeaVOif Seal Inspection
• Inspect the dust seal [Aj for any signs of deterioration or damage.
Replace it if necessary.
*
• Replace the oil seallBl with a new one whenever it has been removed.
nou " .. , e
Spring Tension
• Since a spring becomes shorter as it weakens, check its free length
[AlIO determine its condition.
If the spring of either lark leg is shorter than the service limit, it
*
must be replaced. If the length of a replacement spring and that
of the remaining spring vary greatly, the remaining spring should also
be replaced in order to keep the lork legs balanced fro motorcycle
stability.
Fork Spring Free Length
Standard :
Service Limit:
470 mm
460 mm
SUSPENSION 11 -21
Rear Suspension (Uni-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 rocker arm.
To suit to various riding conditions, the spring preload of the shock
absorber can be adjusted or the spring can be replaced with an optional
one. Also the damping force can be adjusted easily so changing oil
viscosity unnecessary.
Rebound Damping Adjustment
• Turn the rebound damping adjuster [A] on the rear shock absorber
lower end with the blade of a screwdriver until you feel a click.
II the damper setting feels too soft or too stiff, adjust it in accordance
with the following table:
*
10 01000 . . '
Seated position: adjuster turned fully clockwise fA].
Rebound Damping Adjuster Setting
Standard:
KX125:
( Counterc I ockJl ; s e )
12 clicks (l1 and L.4 Models)
125
250
5TO
STO
++
13 clicks (L2 .... L.3 Models)
KX250:
( C I ockJl i Ie )
Softer ·4. .----------------.~ H . rder
10 clicks (L.l Model)
13 clicks (L2 Model)
181 71 815141312 1 110V 8 1 8 5 .
321
1"1 I I I I I I I I I I I I I I I 1"1
t
12 clicks (L.3 _ L.4 Models)
®
(KX125 i 250-ll Models )
n OlOI OU1
Compression Damping Adjustment
There are two adjustments you can make to the rear shock absorber
gas reservoir.
High Speed Compression Damping Adjuster fA]
Low Speed Compression Damping Adjuster [S]
• Adjust the high speed compression damping, turn the high speed
compression damping adjuster with a 17 mm wrench.
If the damping feels too soft or too stiff, adjust it in accordance with
the foll owing table.
Seated position: adjuster turned fully clockwise [A].
*
High Speed Compresssion Damping
Standard:
KX125:
2114 turns out(L.l Model)
1 112 turns out (L.2 Model)
1 3/4 turn s out (Ll Model)
2 112 lurns oul (L.4 Model)
Standard:
KX 250:
1 112 turns out (L.l and L.3 Models)
2 turns oul (L.2 Model)
2 114 turns out (L.4 Model)
"."".,.,. .@ ,. ~. ,
e 0 e
H.,d . ,
Sefh,
2 '"
Adjwotlbl. ' " nIO
3 111
( U 1U / 2S0-l1 Io dolo)
1"1
.......,.,
~
11 ·22 SUSPENSION
Rear Suspension (Uni-Trak)
• Adjust the low speed compression damping, turn the low speed
*
compression damping adjuster with a flal-head screwdriver.
II the Q3.mping feels 100 soft or too stiff, adjust it in accordance with
the following tabl e.
Seated position: adjuster turned fully clockwise [AJ.
Low Speed Compression Damping
Standard:
KXl25:
10 clicks (1..1 Modlll)
(Co untereloekwi . , j
(Cloc kwi'e )
O---------------...
~ Herd.r
Soft.r ••
125 ,250
STD
+
111118151413121110 e I
1 $ 5 .
Standard :
KX250:
10 clicks ( 1..1 and L3 Models)
13 clicks (L.2 Model)
11 clicks (L4 Model)
Spring Preload Adjustment
• Remove:
Radiator Shrouds
Seat
Side Covers
Silencer
Rear Frame [AJ with Air Cleaner Housing
• Using the jack under the trame, raise the rea r wheel off the ground.
Special Tool·
Jack: 57001-1238
• Using the hook wrenches [Aj. loosen the locknut IB] on the rear shock
absorber.
Special Tool-
Hook Wre nch: 57001-1101
• Using the stem nut wrench [Aj, turn the adjusting nut (B) as required.
Turning the adjusting nut downward marks the spring action harder
and upward softer.
Special Tool-
Steering Stem Nut Wrench : 57001-1100
1
t
11 clicks (L2 Model)
12 cUcks (L3 ..... 1..4 Models)
32
1"1I I I I I I I I I I I I I I I 1"1
( KX125 / 250 -LI IIodel .)
®
1I00eUII, c
SUSPENSION 11·23
Rear Suspension (Uni-Trak)
Spring Preload Adju stment
(Adju sting nut position (A] fro m the center of the mounting hole)
KX 125:
11 3.5 mm
Standard:
112.5 mm (L2 Model)
101 mm (13 Model)
100.5 mm (L4 Model)
11 5.5 mm
KX250:
11' .5 mm (1.2 Model)
106 mm (13 Model)
106.5 mm (L4 Model)
Adju stabl e Range
KX125 :
102.5 _ 121 mm
94 - 120.5 mm (L3 - L4 Models)
KX250 :
102.5 - 121 mm
94 _ 116.5 mm (L.3 _ L4 Models)
• Tighten the locknut securely.
• After adjusting, move the spring up and down to make sure that the
spring is seated.
• Install the parts removed.
• Tighten the rear frame mounting bolts.
Torque ·
Rear Frame Mounting Bolts: 29 N·m (3.0 kgf·m 22 ft·lb)
Spring Tension
• Since the spring becomes shorter as it weakens. check its free length
{AJ to determine its condition.
If the spring of either rear shock absorber is shorter than the service
limit, it must be replaced. If the length of replacement spring and that
of the remaining spring vary greatly, the remaing spring should also
be replaced in order to keep the rear shock absorbers balanced of
motorcycle stability.
*
Shock Ab sorber Spring Free Length
Standard:
275 mm
Service Limit:
270 mm
Rear Shock Absorber Removal
• Remove:
Radiator Shrouds
Seat
Side Covers
Silencer
Rear Frame with Air Cleaner Housing
• Using the jack under the frame, raise the rear wheel off the ground.
Special Tool-
Jack: 57001- 1238
• Remove the tie-rod fronl mounting boll [AJ .
CAUTION
When pulling out the mounting bolts, lift the rear wheel slightly.
Forcing or tapping on a bolt could damage the bolt, sleeve, and
bearing
• Remove the rear shock absorber lower mounting bolt [8J.
-- •
....0' .... t
11-24 SUSPENSION
Rear Suspension (Uni-Trak)
• Remove the rear shock absorber upper mounting bolt (A], nut, and
pull out the rear shock absorber [BJ down and oui.
Rear Shock Absorber Installation
• Pack the rocker arm needle bearings with grease.
• Tighten the following:
Torque. Rear Shock Absorber Upper Mounting Bolt:
39 N·m (4.0 kgf.m, 29 fHb)
Rear Shock Absorber Lower Mounting Nut:
34 N·m (3.5 kg'.m, 24 ft·lb)
Tie-Rod Mounting Nut: 83 N·m (8.5 kgf.m, 61 ft·lb)
Rear Frame Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft.lb)
Spring Replacement
In addition to the standard spring, heavy and light springs are
available. If the standard spring is improper for your purpose, select
a proper one according to the rider's weight or course conditions.
• Remove
Radiator Shrouds
Side Covers
Seat
Silencer
Aear Frame with Air Cleaner Housing
• Remove the rear shock absorber.
• Clean the threaded portion on the upper of the rear shock absorber.
• Hold the lower of the rear shock absorber with a vise.
• Using the hook wrenches [C], loosen the locknut [B} and turn the
adjusting nut [A] ali way up.
Special Tool -
Hook Wrench: 57001-1101
nouotll! C
• Remove the rear shock absorber from the vise.
• Slide down the rubber bumper [A).
• Remove the spring guide [B] from the shock absorber and lift off the
spring [C).
SUSPENSION 11-25
Rear Suspension (Uni·Trak)
• Exchange the spring for an optional part. Install the spring so thai
•
•
•
•
closed coil end [AI faces upward.
Install the spring guide.
Adjust the spring preload (see Spring Preload Adjustment).
Install the rear shock absorber.
Install the parts removed.
. . •••• , . . ,
0
Rear Shock Absorber Disassembly (Oil Change)
The oil should be changed in the rear shock absorber al least once
per racing season. The frequency for best performance must be based
upon riding conditions and rider ability.
• Remove the rear shock absorber from the frame (see Rear Shock
Absorber Removal) .
• Aemove the shock absorber spring (see Spring Replacement) .
• Point the valve [AI away from you. slowly release nitrogen gas
pressure by pushing down the valve core with a screw driver.
B
A
...... , .. , c
AWARNING
Do not to point the reservoir valve toward your face or body
when releasing nitrogen gas pressure. An oil mist is often
released with the nitrogen. Always release nitrogen gas
pressure before disassembling the rear shock absorber to
prevent explosive separation of parts.
• Adjusllhe gas reservoir damping adjusters (AJ to the softest position.
• Remove the air bleeder boll IB] and pump the rear shock to drain the
oil out of the rear shock body.
• Install the air bleeder bott.
• .........
• Using the suitable 1001 [AJ and press [8J. push the reservoir cap in 10
mm.
• Remove the circlip ICJ from the gas reservoir.
0
11-26 SUSPENSION
Rear Suspension (Uni-Trak)
• Pull the gas reservoir cap [B] out of the gas reservoir using the pliers
[A].
• Pry or tap [A] al the gaps [B] in the stop Ie] with suitable tools to free
the stop from the rear shock body [0].
• Slide the stop up the top of the push rod then lightly lap around the
seal with a suitable rod and mallet, and push the seal assembly 10
mm down.
A
• Remove the circlip {AI.
• Lightty move the push rod back and fo rth, and pull out the push rod
assembly.
• Pour the oil out of the rear s hock body.
Rear Shock Absorber Assembly
• Adjust the gas reservoir damper adjuster to the softest position.
• Inslallthe air bleeder boll.
o Check the O-ring on the air bleeder boll, and replace it if necessary.
• Pour KYB K2-C (SAE SW or Bel-Ray SE2 #40) oil into the gas
reservoir to 60 ~ 70 mm [AI from the gas reservoir upper end.
,
--
\
-)
•• ' G'G '" ;
• Check that the bladder [Alan the gas reservoir cap is not partially
collapsed.
II it is, push down the valve core with a screwdriver.
• Check the bladder for sign of damage or crack.
II necessary, replace it with a new one.
*
*
CAUTION
00 nol use a damaged or partiaUy collapsed bladder, because
il may burst, gently reducing rear shock performance ..
• Apply grease to the lip 161 of the bladder.
A) - - - I
SUSPENSION 11-27
Rear Suspension (Uni~Trak)
• Push the bladder into the gas reservoir slowly until it just clears the
circlip groove. Wipe out any spilled oil.
CAUTION
Ensure that no air remains in the system.
• Check the circlip for weakening, deformity and flaws.
* If necessary, replace it with a new one.
CAUTION
If weakened, deformed or flawed circtip 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 circlip [AJ in the groove in the gas reservoir.
• Pull up the gas reservoir cap [A] against the circlip. The end of the
gas reservoir cap must align [C] with Ihe end ollhe gas reservoir [BI.
AWARNING
If the end of the gas reservoir cap and the end of the gas
reservoir are not aligned, the circlip is not correctly fitting in
the groove in the gas reservoir or is deformed. In this case, the
oil and internal parts could explode out of the reservoir when
injecting the nitrogen gas or while riding the motorcycle.
-+--<'C
.. ••• "." c
11 -28 SUSPENSION
Rear Suspension (Uni·Trak)
• Pour KYB K2-C (SAE SW or Bel-Ray SE2 #40) oil into th e rear shock
body to 45 mm [A] from the lower end [BJ oltha rear shock body.
I
• Insert the piston end [A] of the push rod assembly into the rear shock
body slowly. Do not insert the seal assembly [B] yel. Pump the push
B
rod until alilhe air is forced out of the rear shock body.
• Push the seal assembly Into the rear shock body until it just clears
the circlip groove.
• Check the circlip.
If it is deformed or damaged. replace it with a new one.
• Rlthe circlip [AJ into the groove in the rear shock body [B].
*
CAUTION
If the circlip Is not a certain fit in the groove in the rear
shock body, the push rod assembly may come o ut of the
shock absorber when injecting the nitrogen gas or riding the
motorcycle.
• Pull up the push rod assembly [C] against the circlip (A).
• Force the stop (DI into the rear shock body by lightly tapping around
the edge of the stop with a mallet.
• Hold the lower end of the push rod assembly with a vise.
• Pump the rear shock. up and down seyeral times, and then leave il in
the fully extend position for about three minutes.
• Remove Ihe air bleeder bolt lEI from the upper part of Ihe rear shock
body.
If oil comes out of the air bleeder boll hole, lei il overflow until it stops.
*
A
+--{c
B
SUSPENSION 11-29
Rear Suspension (Uni-Trak)
• Install the suitable oil cup [Al ia the air bleeder bolt hole, and fill the
specified oil into the cup.
• Purge the air from between the gas reservoir [BJand rear shock body
[el by slowly pumping the push rod (DJ in and out
• Install the air bleeder bott securely.
• Fully extend the p ush rod assembly.
IIUtllll, t
• Inject nitrogen gas to a pressure of 50 kPa (0.5 kgf/cm2, 7 psi) through
the valve on the gas reservoir.
• Check the rear shock body and gas reservoir for oil and gas leaks.
If there are no leaks, inject the n itrogen gas up to the 1 000 kPa ( 10
kgf/cm 2 , 142 pSi) pressure.
*
AWARNING
Pressurize the gas reservoir with nitrogen gas only. Do not
use air or other gases, since they may cause premature wear,
rust, fire hazard or substandard performance.
High pressure gas is dangerous. Have a qualified mechanic
perform this procedure.
• Install the spring and spring guide.
• Adjust spring preload. Reinstall the rear shock absorber.
• Install the parts removed .
Spring Tension
Since a spring becomes shorter as it weakens, check its Iree length
[A) to determine its condition.
If the spring is shorter than the service limit, it must be replaced.
*
Rear Shock Ab sorber Spring Free Length
Standard:
280 mm
275 mm (L3 .... L4 model)
275 mm
Service Limit:
270 mm (L3 .... L4 Model)
n ooo ""' t
Rear Shock Absorber Scrapping
AWARNING
Since the reservoir tank of the rear shock absorber contains
nitrogen gas, do not incinerate the reservoir tank without first
releasing the gas or it may explode .
• Remove the shock absorber (see Rear Shock Absorber Removal).
• Remove the valve cap [A) and release the nitrogen gas completely
from the gas reservoir.
• Remove the valve.
Since the high pressure gas is dangerous, do not point the
valve toward your face or body_
B
A
..010"1" ,
11-30 SUSPENSION
Swingarm
Swingarm Removal
• Place the jack under the frame so that the rear wheel is off the ground .
Special Tool ·
Jack : 57001-1238
• Remove the rear wheel (see WheelsITires chapter).
• Remove the brake pedal [AJ.
• Remove the tie-rod rear mounting bolt (8].
CAUTION
When pulling out the mounting bolts, lift the rear wheel slightly.
Forcing or tapping on a bolt could damage the bolt, sleeve, and
bearing.
• Pull out the swing arm pivot shaft [C], and remove the swing arm (OJ.
• Separate the chain guide and chain slipper from the swing arm.
Swingarm Installation
• Apply plenty of grease to the inside cllhe needle bearings, sleeves,
and oil seals.
• Tighten the following:
Torque·
Swlngarm Pivot Shaft Nut: 9.8 N·m (10.0 kgf·m , 72 ft·lb)
Tie-Rod Mounting Nut: 83 N·m {8.5 kgf.m, 61 ft.lbj
• Refer to the WheelslTires, Final Drive, and Brakes chapters for wheel
inslalling.
Swingarm Bearing Removal
• Remove:
Swingarm
Collars [A]
Grease Seals IB]
Sleeves IC]
Oil Seals [0]
• Remove Ihe needle bearings using the oil seal & bearing remove [E].
Special Tool ·
all Seal & Bearing Remover: 57001- 1058
Swingarm Bearing Installation
• Replace the needle bearings, grease seals and oil seals wi th new
ones.
• Apply plenty of grease to the grease seals, oil seals and needle
bearings.
Left Side
l mm
NOTE
o Install the needle bearings so that the manufacturer's marks face
out.
o Install the grease seals so that the deep groove side of the rip inward.
Special Tool ·
CUU IOIII C
Bearing Driver Set: 57001-1129
• Install the needle bearings [AJ grease seals [81 and oil seals [C]
position as shown.
o The installation procedure is the same as the counter side.
Drive Chain Guide, Chain Slider, Chain Roller Wear
• Visually inspect the guide, sliders and roller.
If they are damaged, cuted or abnormal weared, replace them.
*
6mm _.->'1'
A
SUSPENSION 11-31
Tie--Rod , Rocker Arm
Tie-Rod Removal
• Using the jack under the frame, raise the rear wheel off the ground.
Special Tool -
Jack: 57001-1238
• Remove the tie-rod front mounting bolt [AJ.
CAUTION
When pulling out the mounting bolts, lift the rear wheel slightly.
Forcing or tapping on a bolt could damage the bolt, sleeve, and
bearing.
• Remove the tie·rod rear mounting boll (8), and Ihen lake out the lierods {C].
Tie-Rod Installation
• Apply plenty of grease to the inside of the needle bearings and oil
seals.
• Be sure seated the washers to the rocker arm mating surfaces.
• Tighten the tie-rod front and rear mounting nuts.
Torque - Tie-Rod Mounting Nuts: 83 N·m (8.5 kgl·m, 61 ft.lh)
Rocker Arm Removal
• Using the jack under Ihe frame, raise the rear wheel off the ground.
Special Tool·
Jack: 57001-1238
• Loosen the swingarm pivot shaft nut.
• Remove the tie-rod front mounting bolt [A].
CAUTION
When pulling out the mounting bolts, lift the rear wheel slightly.
Forcing or tapping on bolt could damage the bolt, sleeve, and
bearing,
• Remove the rear shock absorber lower mounting bolt [B].
• Remove the rocker arm pivot shaft (C].
• Remove the rocker arm (0 ).
Rocker Arm Installation
• Apply plenty of grease to the inside of the rocker arm holes. needle
bearings, oil seals and grease seals outside of the sleeve.
• Install the needle bearing [A], grease seals [B] and oil seals (C]
position as shown.
• Tighten the following:
Torque - Rocker Arm Pivot Nut: 83 N·m (8.5 kgf·m, 61 ft·lh)
Rear Shock Absorber Lower Mounting Bolt:
34 N·m (3.5 kg!·m, 25 ft·lh)
Tie-Rod Mounting Nut: 83 N·m (8.5 kgf·m, 61 It·lh)
Swingarm Pivot Shaft Nut: 98 N·m (10.0 kg!·m, n ft·lh)
Needle Bearing Inspection
* If there is any doubt as to the condilion of either needle bearing ,
replace the bearing and sleeve as a set.
11 -32 SUSPENSION
Uni·Trak Maintenance
Check the uni-trak component parts for wear periodically, or whenever
excessive play is suspected.
• Using the jack under the frame, raise the rear wheel off the ground.
Special Toot · Jack: 57001 - 1238
• Push and pull on the swing arm (AJ, up and down, to check for wear.
A small amount of play on the swingarm is normal and no corrective
action is needed. However, if excessive play is felt, remove the unitrak parts from the frame and check lor wear.
*
Rocker Arm Sleeve Wear
• Pu11 out the sleeves [A] of the rocker arm, and measure the outside
diameter oltha sleeve.
If the sleeve is worn past the service limit, replace the sleeve.
*
Sleeve Outside Diamete r
(Long)
Standard;
21.987 - 22.000 mm
Service Limit:
21.85 mm
(Short}
Standard:
15.989 _ 16.000 mm
Service Limit:
15.85 mm
Rocker Arm Mounting Bolt Bend
A bent bolt causes vibration, poor handling, and instability.
• To measure the bolt runout, remove the bolt, place it in V blocks, and
set a dial gauge to the bolt at a point halfway between the blocks.
Turn (A] the bolt to measure the runoul. The amount of dial variation
is the amount of runout.
If runout exceeds the service limit, replace the boll.
*
Bolt Runout
Standard:
Service L.imit:
Under 0. 1 mm
0.2 mm
; I OIC01II,
c
STEERING 12-1
Steering
Table of Contents
Exploded View ............................................................................................................................. .. .. ............................. 12-2
Specifications .. .. ...... ...... .. ..... .... ... .. ... .. .. ... ................ .. .. . .. ......... ..... ... ... ... .. ............................... .... ....... .... ..... ... ................ 12-3
Steering .............................................................................. .............................................. .... ... ....... ........ .... ... .. ......... .... ... 12·4
Steering Inspection .................................................................................... ........ .. .. ... ......... .. ..... ... ... ... ............. ... ....... 12·4
Steering Adjustment (KXI2512So-Ll "" L3) .... .................. ... ............ ......... ...... ... .. ................................................. 12-4
Steering Adjustmen t (KXI25125O-L4).... .. ... ..... .. .. .. .. .. .... ...... .. ..... ... ................................ .. .. ...... .. .. ..... ... .. ... .... ... .. .... t2-5
Steering Slem, Stem Bearing Removal ...............................................
..... .. ... .. ..... .... .. ..... .. .. .. ...................... 12-6
Steering Stem, S tem Bearing Installation ............................................ .. .... .... .. ... ... .... .. ............. .. ... ... ....................... 12-7
Steering Maintenance........
.................................................
.......................................................................... 12-9
Stem Bearing Lubrication .. ... .. .... .. .. ... .... ..... ... .... .... .... ... .. ... .... .. .. ......................................... ..... ..... ...... ... ....... .. ..... ... 12-9
Stem Bearing Wear, Damage ..................................................................... ..... ... .. .. .... ... .... ...... ..... ....................... 12-9
Stem Warp .... ... ... ..... .... ..... ..... ....... ...................................... ... .. ... ....... ....... .................................... ' ...................... 12-9
Handlebar. ................. ........... ... ... ....... .......... .. ........ .... ..........
.... ............. ................................... ... .. ... .... 12-10
........................................................................... 12·10
Handlebar Removal .... ... ... ..... .... .. .. .. .. ..... ... ...... ... .... .
Handlebar Installation ... ........................................................................................ .... .... .. .. .. ...... .. ... ....................... 12-1 0
12-2 STEERING
Exploded View
KX125-L4
I
KX250
KX125-L4
IOGIOG" . .
1. Handlebar Clamp
10. Handlebar Holder
2. Handlebar
AD: Apply adhesive cement
3. Steering Stem Head Nut
G : Apply grease
4. Steering Stem Head Bracket
0 : Apply 2 Stroke 011
5. Stem Locknut
T1 : 78 N·m (8.0 kgf-m , 58 ft.lb)
6. Tapered Roller Bearing
T2: 20 N·m (2.0 kgf·m , 14.5 ft ·lb)
7. Head Pipe
8. Tapered Roller Bearing
9. Steering Stem
T3: Tighten all snugly, then loosen.
Retighten to 4.9 N·m (0.5 kgf.m, 43 in·lb)
T4: 25 N'm (2.5 kgf·m , 18.0 ft ·lb)
e
STEERING 12-3
Specifications
Special Tools· Steering Stem Bearing Driver : 57001-137
Steering Stem Bearing Driver Adapter : 57001-1074
Head Pipe Outer Race Press Shaft : 57001-1075
Head Pipe Outer Race Driver : 57001-1076
Steering Stem Nut Wrench : 57001-1100
Head Pipe Outer Race Driver : 57001-10n
Head Pipe Ouler Race Remover: 57001-1107
Jack : 57001-1238
12-4 STEERING
Steering
Steering Inspection
• Using the jack, raise the Irani wheel offlh e ground.
Special Tool · Jack: 57001-1238
• With the fronl wheel pointing straight ahead, alternately nudge each
end cllhe handlebar. The Iront wheel should swing fully left and right
from the force 01 gravity untillhe fork hits the stop.
It the steering binds or catches before the stop. check the routing of
the cables, hoses, and harnesses.
If the steering feels light, adjust or lubricate the steering.
• Feel for steering looseness by pushing and pulling the forks.
II you feel looseness, adjusllhe steering.
*
*
*
Steering Adjustment (KX12512SD-L 1 ""' L3)
• For KX250 model: remove the number plate.
• Using the jack. raise the front wheel off the ground.
Special Tool·
Jack : 57001-1238
• Remove the handlebar.
• For KX125 model: loosen the front fork lower clamp bolts [A] and
steering stem head nut [B].
• For KX250 model: loosen the front fork upper clamp bolts [A], and
remove the steering stem head nut IB] and steering stem head (C].
• Turn the steering stem locknut (AI wi th the steering stem nut wrench
[81 to obtain the proper adjustment.
If the steering is too l ight , loosen the stem locknut a fraction of a turn;
if the steering is too loose, tighten the locknut a fraction of a turn.
*
Special Tool -
Steering Stem Nut Wrench: 57001-11 00
NOTE
o Turn the locknut 118 turn at a time maximum.
• For KX250 model; install the steering stem head.
• Tighten the following:
Torque -
Steering Stem Head Nut: 78 N·m (8.0 kg'·m, 58 h ·lb)
Front Fork Clamp Botts:
Upper: 20 N·m (2.0 kgf·m, 14.5 h ·tb)
Lower: 20 N·m (2.0 kg'·m , 14.5 ft·tb)
STEERING 12-5
Steering
• For KX125 model; mount the handlebar clamps (B) so that the arrow
(CJ on the clamp point at the front (AI.
• For KX250 model; mount the handlebar clamp {A) so that the cut side
(B] on the clamp points at the rear.
B
.... oo'IS'
• Tighten the handlebar clamp bolts.
Torque · Handlebar Clamp Botts : 25 N·m (2.5 kgl·m, 18 ft·tb)
o Tighten the clamp bolts, front first and then the rear. If the handlebar
clamp is correctly installed, there witl be no gap (A] at the front and
a gap (B] at the rear after tightening.
Steering Adjustment (KX125/2S0-L4)
• Using the jack. raise the front wheel off the ground.
Special Tool·
Jack: 57001-1238
• Loosen the front fork tower clamp bolls (A).
/
t
12-6 STEERING
Steering
• Remove the handlebar nuts [AI, and remove the handlebar holders
[S] together with the handlebar.
• Loosen the steering stem head nul [Allurn the steering stem locknut
IB] with the steering stem nul wrench [C] to obtain the proper
adjustment.
* If the steering is 100 tight, loosen the stem locknut a fraction of a turn;
if the steering is too loose, lighten the locknut a fraction 01 a turn.
Special Tool -
Steering Slem Nut Wrench: 57001 - 1100
NOTE
o Turn the locknut VB turn at a time maximum.
• Tighten the front fork clamp bolts and the steering stem head nut.
Torque·
Steering Stem Head Nul: 78 N-m (8.0 kg'·m, 58 ft·lb)
Front Fork Lower Clamp Bolts: 23 N·m (2.3 kgf-m, 16 ft ·lb)
• Check the steering again.
* If the steering is too light or too loose, repeal the adjustment as
mentioned above.
• Install the handlebar holder [AI together wi th the handlebar so that
the cut side IBI on the clamp points at the rear.
• Tighten the handlebar clamp botts.
Torque·
Handlebar Clamp Bolt!l: 25 N·m (2.5 kgt·m, 18 h ·lb)
o Tighten the clamp bolts, front first and then the rear. If the handlebar
clamp is correctly installed, there will be no gap at the front and a
gap at the rear after tightening.
B
10 04 01111. C
Steering Stem, Stem Bearing Removal
• Remove:
Fron t Wheel (see WheelslTires chapter)
Brake Hose Clamp (see brake System chapter)
Caliper Mounting Bolts (see Brake System chapter)
Master Cylinder Clamp (see Brake System chapter)
Front Fender
Handlebar (see Handlebar Removal)
Front Fork (see Suspension chapter)
• Remove the steering stem head nut and washer.
• Remove the steering stem head .
• Pushing up on the stem base [A], and remove the steering stem
locknut [B). with the steering stem nut w rench IC], then remove the
steering stem [0] and stem base.
Special Tool-
Steering Stem Nut Wrench : 57001-1100
STEERING 12-7
Steering
• Take off the upper stem bearing inner race (tapered roller bearing)
[A[.
• Drive out the bearing outer races from the head pipe.
o Remove the outer races pressed into the head pipe, using the head
pipe outer race remover [A), and hammer the head pipe outer race
remover to drive it out.
Special Too l -
Head Pipe Outer Race Remover : 57001-1107
NOTE
o If either steering stem bearing is damaged, it is recommended that
both the upper and lower bearing (including outer races) should be
replaced with new ones.
• Remove the lower stem bearing inner rase (tapered roller bearing)
[A) with its grease seal from the stem using suitable lools.
Steering Stem, Stem Bearing Installation
• Replace the bearing outer race with new ones.
o Apply grease to the outer races, and drive them into the head pipe
at the same time using the head pipe outer race press shaft (A] and
the drivers [BJ[CJ.
Special Tool -
Head Pipe Outer Ra ce Press Shaft : 57001 - 1075
Head Pipe Outer Race Driver : 57001- 1076 (B]
Head Pipe Outer Race Dri ver : S7001- 10n [C]
B
COOl0 40fJ' C
• Replace the lower inner races with new ones.
o Apply grease to the lower tapered roller bearing [AI, and drive it onlo
the slem using Ihe steering stem bearing driver [B) and adapter (CJ.
Special To ol -
Steering Stem Bearing Dri ver : 57001-137
Steering Stem Bearing Dri ver Adapter: 57001- 1074
B
C
12-8 STEERING
Steering
• Apply grease to the upper inner race, and install it in the head pipe.
• Install the stem through the head pipe and upper bearing, install the
slem cap and hand·tighten the locknut while pushing up on the stem
base.
• Install the stem head and washer, and lighten the stem head nut
lightly.
• Settle the bearing in place as follows;
o Tighten the stem locknut to 39 N·m (4.0 kgf·m, 29 ft·lb) of torque.
(To tighten the steering slem locknut to the specified torque, hook the
wrench [AJ on the stem locknut, and pull the wrench at the hole by
22.2 kg force [BJ in the direction shown.)
Special Tool -
Steering Stem Nut Wrench: 57001-1100
o Check that there is no play and the steering stem turns smoothly
without rattles. If not, the steering slem bearings may be damaged.
o Again back out the stem locknut a fraction of a turn until it turns lightly.
o Turn the stem locknut lightly clockwise until it just becomes hard to
turn. Do not overtighten, or the steering will be too tight.
Torque·
Steering Stem l.ocknut : 4.9 N·m (0.5 kgf·m , 43 In·lb)
• Install the front fork (see the Suspension chapter).
NOTE
o Tighten the fork upper clamp bolts first, next the stem head nut,
last the fork lower clamp bolt.
Torque·
Steering Stem Head Nut : 78 N·m (8.0 kgf·m , 58 ft·lb)
Front Fork Clamp Bolt :
Upper : 20 N·m (2.0 kgf·m, 14.5 ft·lb)
l.ower: 20 N·m (2.0 kgf·m, 14.5 h·lbj
• Install the parts removed (see the appropriate chapter).
AWARNING
Do not impede the handlebar turning by routing the cables,
wires and hoses improperly (see the General Information
chapter).
• Check and Adjust :
Steering
Front Brake
Clutch Cable
Throttle Cable
A
021------- 90·®
. . 01010 0$'
e
STEERING 12-9
Steeri ng Maintenance
Stem Bearing Lubrication
• Remove the steering stem (see Steering Stem Removal).
• Using a high flash-point solvent, wash the upper and lower tapered
roliers in the cages. and wipe the upper and lower outer races. which
are press-litted into the frame head pipe, clean off grease and dirt.
• Visually check the outer races and the rollers.
Replace the bearing assemblies if they show wear or damage.
• Pack the upper and lower tapered roller bearings (AI in the cages with
grease, and apply a light coat of grease to the upper and lower outer
races.
• Install the steering stem, and adjust the steering (see Steering Stem,
Stem Bearing Installation, Steering Adjustment).
*
Stem Bearing Wear, Damage
• Using a high flash-point solvent, wash the upper and lower tapered
rollers in the cages, and wipe the upper and lower outer races, which
are press-fitted into the frame head pipe, clean off grease and dirt.
• Visually check the outer rase and the rolters.
Replace the bearing assembly if it show damage.
*
Stem Warp
• Whenever the steering stem is removed, or if the steering cannot be
adjusted for smooth action, check the steering stem for straightness.
If the steering stem shaft is bent [AJ, replace the steering stem.
*
12-10 STEERING
Handlebar
Handlebar Removal
• Disconnect the engine stop switch connector.
• Remove :
Band [A]
Clutch Holder [B]
Throttle Grip Assy ICJ
Master Cylinder [OJ
Handlebar Holders IE]
Handlebar Instal/ation
• Apply adhesive cement to the inside of the left handlebar grip.
• Install the left handlebar grip so thai the arrow [A] on the grip points
to the upward.
100u, on, ,
• Apply grease to the throttle cable upper end and clutch cable upper
end.
• Apply a engine oil 10 the throttle grip inner wall.
• Install the throttle grip assy and master cylinder as show.
o Position the master cylinder so that the vertical parting line [A] of the
Iront and rear master cylinder clamps with punch mark [B] on the
handlebar.
• Install the handlebar holders (see Steering Stem Bearing Installation) .
Torque·
Handlebar Clamp Bolts: 25 N·m (2.5 kg'·m, 18 ft·lb)
---;>I--J.E;---More
than 28mm
uou,ou, ,
ELECTRICAL SYSTEM 13-1
Electrical System
Table of Contents
Wiring Diagram .......................................... ... ............................................................ .. ....... .... ............ ............... ......... .. ... 13-2
Exploded View ........................................................................................................................................ .. ... ..... ............. 13-5
Specifications ........ ...... ........... ................. ............. ........... .. .. .... ...... .. .... ..... ............... ..... ................................................... 13·7
Precautions .................................................................................................................................................................. 13-9
Electrical Wiring ............................................... ................... ............ .....................
............ ... ....... .... ... ..... . 13-10
Wiring Inspection ....................................................................................... ................ ........ .... ...... ... ... ..... ................ 13-10
Ignition Timing ... .. ............ ... ....... ....... ........ .. .. .... .... ..... ....... .. ... .......... .. ... .. ............ ..... ...................................................... 13- 11
Ignition Timing Adjustment. ..... ..... .. ... ........ .... ..... ... ... ...........................................
..... ........ ..... ... ..... ... .... 13-11
Rywheel Magneto ................................................................ .... ................. .... ... .... ... ...
.......................... 13·12
Flywheel Magneto Removal.......................... ................ ....... ....... ..... .. ..... ..... ......
............ 13- 12
Flywheel Magneto Installation. .... .. ... .. ... .... .... ..... .. .......... .. ... ..... ... .................................
...... .... .. . .. ...... ... .. 13-12
Flywheel Magneto Inspection...... ..... .. ................ .... ............................................
... ....... .. .. . .. .......... I 3· 13
RegulatorfRectifier Removal (Other than KX125-l3 ,.... L4).. .......... .. .... ........... .. .. ..... .....
.. ......... ........ ........ 13· 15
Regulator/Rectifier Output Voltage Inspection (Other than KX 125-l3 ,.... L4) ...................................................... . 13·15
Regulator/Rectifier Inspection (Other than KX125-l3 -.. L4) ... ....... ...................................................................... 13·16
Ignition System .......................................................................................................................................... .... ................ 13-17
Safety Instructions: . .. ...................................................................... .... ..................... ....... ..... ..... ....... ..... ....... ........ 13·17
Ignition Coil Aemoval ..... .. ..... ....... .. .. ........ .... ... ........ .. .. .... .... ........ .. ... .......... .. .......................................................... 13· t 7
Ignition Coil Inspection .. ..... .... ..... ... .... ....... ... ...... .. ... .... ... .. ... ... .... ... .. ..... ............................................. ..................... 13· 17
Spark Plug Cleaning and Inspection ................................................................................................................... 13· t 8
Spark Plug Gap Inspection ..................................................... ..... .. .. .... .. ... ... .. ........................................................ 13,18
C.D.I Unit Removal .................. ............. .. ..... ...... .... .. ................ .... .... .. .... .. ..... ...................................... .................. 13·18
C.D. I Unit Inspection ..
................................................................................................................................. 13-19
Throttle Sensor Output/Input Voltage Check: (Other than KX125-L3 "-' L4) ........................................................ 13·22
Engine Stop Switch Electric Current Check: ............................ .... .... ... .... .... ...... .... ... .............................................. 13·23
Pickup Coil Inspection .......................................................................................................................................... 13-23
Pickup Coil Air Gap Adjustment... .... .. .... ...............................................................
................................. ........ 13-23
Throttle Sensor ... ... ..... .. ... ... .. ........... .. ... ... .................... ................................... ....... ... ... ..... ....... .. ....... ... ... .... .. ................ 13-24
Throttle Sensor Inspection (Other than KX125-l3 '" L4) ..................................................................................... 13-24
Throttle Sensor Position Adjustment (Olher than KX125-l3 '" L4) ...................................................................... 13-24
Fuel Cut Valve and Capacitor ......................................................................................... ... .... ... .. ....... ........... .. .............. 13-25
Fuel Cut Valve Removal (Other than KXI25-l3,..., L4) ................. .. .... ............ ....... ............ .................................. 13-25
Fuel Cut Valve Installation (Other than KX125-L3 .... L4)................................................................................... 13-25
Fuel Cut Valve Inspection {Other than KX125-l3 '"" L4).. .................................
.. .. .. ..... .. .... .. ................... 13·25
Capacitor Inspection (KXI251250·Ll only) .... .. ... ................................ ..... ..... .. ... ... ................................................. 13-26
~
~
13-2 ELECTRICAL SYSTEM
Wiring Diagram
KX1 25/25G-L 1
,
,I
O'"ID'J
R"ur,tor l
R, ct i f l "
n il
Y/ I -
U / Y
Y/ I
~
~
,;, :
I
,; , I J'
Pick up
Co i I
--'-
~ u-o
-
'+--::::j:=tt=='
I
J I ;l)- ,
BR
u
I
~f-. J ~~gH~ll'
f- ,
I I
1-11 Y
~=tl=!t!th
1
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-----v
f~ .1
cut
vII ••
~l,
', .. , ,, .. :::111-;:,
{]<J-
Co ;1
i !l ~; L_Sut.Nappi r",or
..
11: :;'
~ _~
•
o--u11-i>£J-U I I
En,in, Stop Blltton
Co lor Cod e
BK
,,
,
BI.ek
OR
Bro ....
Gr •• n
O'in
I
I h ; tt
y
h II o.
Ro'
COl
Unit
•
"'O'. '~ ' U
C
ELECTRICAL SYSTEM 13-3
Wiring Diagram
KX12512SD-L2, KX2SG-L3 - L4
Fue I Cu t
v.
::I"Jl-::rc I N .
,m: !:' 0 ' "
~J LJ SuPllr • • , or
•
~ En ,i ne St Io...ca-e
p But ton
-L-
B K --0
0- 8 K
K/ .
r7
rh r-1C~~Wj~~~~~~
..
~
C. D
Colo r Code
BK
B l a ck
BR
B ro wn
G
G re e n
o
Oran
R
R. d
W
'/I hit e
Yello w
Y
I . Unit
.-.I I
,
e
CO
I.U n i t
( 98051 - 192"" , 9805' - ' 99JA )
IPnOf OI U
A: KX250-L3 ..... L4
C
13-4 ELECTRICAL SYSTEM
Wiring Diagram
KX125-L3 - L4
1I.,neto
ill:
:
~~~b~-n~
(]IF
~: ~ ~
Pickup
Co i I
:~~
~
I' rl
--9.im
:l
0 Iinition
--D<J- 0 Coi l I
•
~
Noise
~I LJSuppressor
':-"...1
~SP"k p",
--'-
~8K-o
o-BK / '~K / '
En,ine Stop Button
C.O . I Unit
Color Code
B K Bla ck
BR
Br own
G
Green
DOran e
R
Re d
W
White
Y
Ye l low
( 9BOSl-1992A . 98052-1075A)
ELECTRICAL SYSTEM 13-5
Exploded View
KX125J25O-L1/L2
KX125 :
11
4
KX250:
T6
11
T6
HotOtG1 U
A: KX125J2SD-L 1 only
1. Magneto Cover
7 . Spark Plug
T1 : 22 N·m (2.2 kgf.m , 16 ft .lb)
2. Magneto Flywheel
3. Starter
B. Regulator/ Rectifier
T2 : 65 N·m (6.6 kgf·m , 48 ft·lb)
9. Fuel Cut Valve
T3: 5.4 N·m (0.55 kgf·m, 48 in·lb)
4. C.D.I Unit
10. Capacitor
T4 : 4.4 N·m (0.45 kgf·m , 39 in·lb)
5. Ignition Coil
11. Throttle Sensor
T5 : 25 N·m (2.5 kgf·m , 18 ft·lb)
6. Spark Plug Cap
12. Main Harness
T6: 8.8 N·m (0.9 kgf·rn , 78 in·lb)
C
13-6 ELECTRICAL SYSTEM
Exploded View
KX12512SG-L3 - L4
KX125:
KX250 :
o
4
' PO I OI OI U
1. Magneto Cover
7. Spark Plug
2. Magneto Flywheel
8. Regulator/Rectifier
3. Starter
9. Fuel Cut Valve
T1 : 22 N' m (2.2 kgf·m , 16 fUb)
T2: 65 N·m (S.6 kgf·m , 48 tUb)
T3: 5.4 N·m (0.55 kgf.m , 48 in.lb)
4. C.D.I Unit
10. Throttle Sensor
14: 4.4 N·m (0.45 kgf·m , 39 in·fb )
5. Ignition Coil
11. Main Harness
T5: 25 N·m (2.5 kgf·m, 18 ft ·lb)
6. Spark Plug Cap
T6: 8.8 N·m (0.9 kgf·m, 78 in·fb)
C
ELECTRICAL SYSTEM 13·7
Specifications
Item
Standard
Magneto:
0.63 '" 0.67 mm
Pickup coil air gap:
t80 ..... 380n
Pickup coil resistance:
180 '" 280 f! (KX250-l4 Model)
Magneto output voltage:
16 V or more @ 4000 rpm
Magneto coil resistance:
in the text
Regulator I rectifier:
Internal resistance
in the text
Out put voltage
14.7;t 0.5 V
Ignition System:
Ignition timing:
(Disconnect the throttle sensor lead)
KX125
10.3" BTOC @1 1 000 r/min (rpm)
KX25Q
11.0" BTOC @7 000 r/min (rpm)
Ignition coil:
3 needle arcing distance
7 mm or more
Primary winding resistance:
KX125
0.24 f! ;t 15% (at 20"C)
KX250
0.53 n ;t 15% (at 20°C)
Secondary winding resistance:
KX125
8.3 kn ;t 15% (at 20°C)
KX250
12.6 kf! ;t 15% (at 20°C)
Spark plug:
KX125
Type
NGK BR9EVX
NGK BR9EIX (l4 Model)
G,p
0.6 ", 0.7 mm
0.7 '" 0.8 mm (l4 Model)
KX250
Type
NGK BRBEVX
NGK BABEl X (l4 Model )
G,p
0.6 ", 0.7 mm
0.7 ", 0.8 mm (l4 Model)
C.D.1. unit:
in the text
Noise suppressor resistance
3.75 ..... 6.25 n
Throttle Sensor: (Other than KX125-L3 ..... L4)
around SV
Input voltage
Output voltage:
(when the throttle valve completely
0. 4 ..... 0.6 V
closed).
(when the throttle fully opened).
KXI2S:
3.3 ..... 3.5 V
KX2S0:
3.S ..... 3.7 V
Fuel Cut Valve: (Other than KX125-L3 '" L4)
Resistance
49.7 __ 56.2 n
Protrusion:
When battery is disconnected
19.4 ..... 19.6 mm
When battery is connected
21 .3 '" 21 .7 mm
Capacitor: (KX12S/2SD-U only)
in the text
13-8 ELECTRICAL SYSTEM
Specifications
Special Tools · Spark Plug Wrench, Hex 21 : 57001-110
Flywheel Puller: 57001-252
Hand Tester: 57001-1394
Flywheel & puny Holder: 57001-1343
Throttle Sensor Adapter : 57001-1414
ELECTRICAL SYSTEM 13-9
Precautions
There are numbers of important precautions that are musts when
servicing electrical systems. Learn and observe all the rules below.
o The etectrical parts should never be struck sharply, as with a hammer,
or allowed to fall on a hard surface. Such a shock to the parts can
damage them.
o Troubles may involve one or in some cases all items. Never replace
a defective part without determining what CAUSED the failure. If the
failure was caused by some other item or items, they too must be
repaired or replaced, or the new replacement will soon fail again.
o Make sure all connectors in the circuit are clean and tight, and
examine wires for signs of burning, fraying , etc. Poor wires and bad
connections will affect electrical system operation.
o Measure coil and winding resistance when the part is cold (at room
temperature).
o Electrical Connectors
[AJ Female Connectors
A
1'0.0'0 '"
IB] Male Connectors
Safety Instructions:
AWARNING
The ignition system produces extremely high voltage. 00 not
touch the spark plug, high tension coil, or spark plug lead
while the engine is running, or you could receive a severe
electrical shock.
C
13-10 ELECTRICAL SYSTEM
Electrical Wiring
Wiring Inspection
• Visually inspect the wiring for signs 01 burning, fraying , etc.
• II any wiring is poor, replace the damaged wiring.
• Pull each connector {A] apart and inspect it for corrosion, dirt, and
damage.
If the connector is corroded or dirty, clean it carefully. If it is damaged,
replace it.
• Check the wiring for con tinuity.
o Use the wiring diagram to fi nd the ends of the lead which is suspected
*
of being a problem.
a Connect an ohmmeter between the ends of the leads.
o Set the meier 10 the x 111 range, and lead the meter.
If the meier does nol read 0 fl lhe lead is defective. Replace the lead
*
or the wiring harness II necessary.
ELECTRICAL SYSTEM 13-11
Ignition Timing
Ignition Timing Adjustment
• Remove the magneto cover.
• Check to see if the center mark of the three marks [Alan the magneto
stator is aligned with the mark [SIan the crankcase.
If the marks are not aligned, loosen the magneto stator screws [Cl
and turn the magneto stator [OJ.
• Tighten the screws securely.
*
Torque·
Stator Plate Mounting Screws:
KX125: 5.4 N·m (0.55 kgf·m , 48 In·lb)
KX250: 4.4 N·m (0.45 kgf·m , 39 In·lb)
• Install the magneto cover.
Torque ·
Magneto Cover Bolts: 8.8 N·m (0.9 kgf·m, 78 In·lb)
The ignition timing can be ad justed for different power band to suit to
rider's preference ability.
• Remove the magneto cover.
• Loosen the stator screws.
• Adjust the timing by shifting the stator position within the three lines
KX250 ,
IAI.
(,
KX125 ,
~@
o
I
~I"'.'."'O
NOTE
o For best engine performance, it is very important to adjust the
ignition timing within the adjustable range just explained.
[A] Crankshaft Rolation
[8] Stator Movement
[C] Retard
[0] Advance
• Tighten the stator screws securely (see Igniting Timing Adjustment).
• Install the magneto cover (see Ignition Timing Adjustment).
• Test ride the motorcycle and readjust the ignition timing if necessary.
I.no,ou,
13-12 ELECTRICAL SYSTEM
Flywheel Magneto
Flywheel Magneto Removal
• Remove the magneto cover.
• Hold the flywheel steady, with the flywheel holder [A], and remove the
lIywheel bolt (KX125) or nut (KX2S0) [BI.
Special To ol ·
Flyw heel Holder: 57001- 1343
• Remove the flywheel holder.
• Screw the flywheel puller [A] into the fl ywheel by turning it counterclockwise (Jefl-hand thread).
• Remove the flywheel from the crankshaft by turning in the puller
center boH and tapping the head of the bolt lightty with a hammer,
while holding the puller body steady. There is a woodruff key in the
crankshaft tapered portion.
Special Tool -
Flywheel Puller: 57001-252
CAUTION
Never strike the grab bar or the flywheel itself. Strike the bar
can bond it. If the flywheel is strike, the magnets may lose
their magnetism.
• Unscrew the mounting screws [Aj, and remove the stator plate [B]
and the wiring grommet [C].
• Remove the band.
• Disconnect the stator lead connectors from the harness.
Flywheel Magneto Installation
• Using a high flash-point solvent, clean off any oil or dirt that may be
on the crankshaft taper [AI or in the hole IB] in the flywheel. Ory them
with a clean cloth.
.~U.\.111
ELECTRICAL SYSTEM 13-13
Flywheel Magneto
• Fit the woodruff key [AI securely in the slot in the c rankshaft before
installing the stalor plate.
I U IO"OS '
• Apply silicone sealant around the circumference of the wiring grommet.
• Set the stator wiring grommet [A] securely in the notch [81 in the lett
crankshaft half, and roule the wires according to the Cable, Harness,
Hose Routing section in the General lnlormation chapter.
Torque -
Slator Plate Mounting Scre ws:
KX125: 5.4 N·m (0.55 kgf·m, 48In·lb)
KX250: 4.4 N·m (0.45 kgf·m, 39 in ·lb)
• Install the stator plate.
• Holding the flywhee l steady, wi th the flywheel holder, and tigh ten the
flywheel boll (KX I 25) or nut (KX2S0).
Special Too l Torque -
Flywheel Holder : 57001- 1343
Flywheel Bott (KX1 25): 22 N·m (2.2 kgt·m, 16 ft·lb)
Flywheel Nut (KX250): 78 N·m (8.0 kg/.m , 58 fHb)
• Measure the pickup coil air gap [AJ (Clearance between the flywheel
and the pickup coil [BJ core.
Pickup Coii A ir Gap
Standard
0.63 '" 0.67 mm
*
If the gap is incorrect, adjust it (see this chapter) .
• Replace the gasket wi th a new one.
Flywheel Magneto Inspection
• There are three types of magneto problems: short, open (wire burned
oul ), or toss in flywheel magnetism . A short or open in one of the coil
wires will result in either a low output, or no output at all. A loss in
flywheel magnetism , which may be caused by d ropping or hitting the
flywheel by leaving it near an electromagnetic field, or just by aging,
will result in low output.
• Check the magneto output voltage, do the following procedures.
o Oisconnect the magneto lead connector [AJ.
0
13·14 ELECTRICAL SYSTEM
Flywheel Magneto
o Connect the auxiliary leads between the magneto lead connector and
main harness connector.
o Connect the hand tester as shown in the table 1.
o Start the engine.
o Run it al the rpm given in the table 1.
o Note the vollage readings (Iotal 2 measurements).
o
Table 1 Magneto Output Voltage
(1)Other than KX125-L3 .... L4
Connections
Tester Range
50 VAC
Tester (+) 10
Tester {-I to
White lead
Red lead
YellowM'hite
lead
Yellow lead
Reading
0 4,000 rpm
16 V or more
(2)KXI25-l.3 ...... l4
Tester Range
SOVAC
Connections
Reading
Tester (+) to
Tester H 10
0 4,000 rpm
While lead
Red lead
16 V or more
* If the output voltage shows the value In the lable, the magneto
operates properly.
* II the output voltage shows a much higher Ihan the value in the table,
the regulator/rectifier is damaged. A much lower reading than that
given in the lable indicales Ihal the magneto is defective .
• To check the stalor coil resistance as follows.
o Stop the engine.
o Disconnect the auxiliary leads.
o Connect the hand tester as shown in the table 2.
o Note Ihe readings (Iolal 2 measurement).
Table 2 Magneto Res istance
(1) Other than KX125-L3 .... L4, KX250-L4
Tesler Range
x Hl
Connections
Reading
Tester (+)
Tester (-) to
While lead
Red lead
7 .... 15 n
YellowiWhile
lead
Yellow lead
1 _ 5 fl
(2)KX125-L3 ...... L4
Tester Ran ge
, '"
Connections
Tester (+) to
Tester (-) to
While lead
Red lead
Reading
7 .... 15 n
(3)KX250-L4
Tester Range
x,"
Connections
Reading
Tester (+) to
Tester (-) to
While lead
Red lead
10 .... 30 n
YellowlWhite
lead
Yellow lead
1 ..... 4fl
IPlI010tll
C
ELECTRICAL SYSTEM 13-15
Flywheel Magneto
* If there is more resistance than shown in the labie, or no hand tester
reading (infinity) the stator has an open lead and must be replaced.
Much less than this resistance means the stator is shorted, and must
be replaced.
• Using the highest resistance range of the hand lester, measure the
resistance between each leads and chassis ground.
Any hand tester reading less than infinity (DO) indicates a shorl,
necessitating stator replacement
II the stator coils have normal resistance, but the voltage check
showed the magneto to be defective; then the rotor magnets have
probably weakened, and the rotor must be replaced.
*
*
Special Tool ·
Hand Tester: 57001- 1394
Regulator/Rectifier Removal (Other than KX125-L3 "" L4)
• Remove:
left Radiator Shrouds
Band [AJ
• Disconnect the regulator/recti fier lead connector IB].
• Unscrew the mounting bolt, and remove the regulator/rectifier [C] .
Regulator/Rectifier Output
KXI25-L3 _ L4)
Voltage
Inspection
(Other than
• Warm up the engine to obtain actual magneto operating conditions.
• Stop the engine, and using an auxiliary wire, connect the hand tester
IA) as shown in the table.
• Start the engine, and note the voltage readings at various engine
speed is low and, as the engine speed rises, the readings should
also rise.
Regulator/Recti fier Output Voltage
Tester Range
2SV DC
Conn ections
Tester (+)
Tester (-) to
RedNlhite
81acWYeilow
Reading
14.2 _ IS.2V
• Push off the slop SWitch to stop the engme, and disconnect the hand
tester.
If the regulator/rectifier output voltage is kept between the values
given in the table, the charging system is considered to be working
normally.
If the output vol tage is much higher than the values specified in the
table, the regulator/rectifier is defective or the regulator/rectifier leads
are loose or open.
If the output voltage does not rise as the engine speed increases, then
the regulator/rectifier is defective or the magneto output is insufficient
for the loads. Check the magneto and regula tor/rectifier to determine
which part is defective.
*
*
*
D
®
~~\ R / W
13-16 ELECTRICAL SYSTEM
Flywheel Magneto
Regulator/Rectifier Inspection (Other than KX125-L3 "'" L4)
• Remove the regulator/rectifier.
• Set the hand lester x 100 11 range, measure the internal resistance
in both directions between the terminal.
Special Tool -
Hand Tester: 57001-1394
* If the reading is nol specified value, replace the regulator/rectifier.
Unit : fI
Internal Resistance
Tester (+) Lead
Terminal
( I·
V
RIW
RIW
500 "" 5K
y
500 .... 5K
YIW
500 ..... 5K
500 ..... SDK
BKIY
300 ..... 3K
200 .... 20K
VNI
BKIV
500 ..... 5K
300 - 3K
500 ..... SOK
SOO "" SK
500 ..... SK
200 .... 20K
H'; Tester (-) lead Connection
CAUTION
Use only Hand Tester 57001-1394 for this test. An ohmmeter
other than the Hand Tester may show different readings. If a
megger or a meter with a large.capacity baHery is used, the
regulator will be damaged.
:=G=:
ELECTRICAL SYSTEM 13-17
Ignition System
Safety Instructions:
.. WARNING
The ignition system produces extremely high voltage. Do not
touch the spark plug, high tension coil, or spark plug lead
while the engine is running, or you could receive a severe
electrical shock.
Ignition Coil Removal
• Remove:
Seat
Side Covers
Radiator Covers
Fuel Tank
• Disconnect the ignition coil prim ary lead [AJ.
• Pulithe plug cap [BJ off the spark plug.
• Unscrew the mounting bolts {C], and remove the ignition coil [OJ .
Ignition Coil Inspection
Measuring arcing distance:
The most accurate test for determining the condition of the ignition
coil is made by measuring arcing distance using the coil tester for the
3·needle method .
• Remove the ignition coil.
• Connect the ignition coil (with the spark plug cap left installed on the
spark plug lead) [AJ to the tester {BI, and measure Ihe arcing distance.
To avoid extremely high voltage shocks, do not touch the coil
or lead.
"* If the distance reading is less than the specified value, the ignition
coil or spark plug cap is defective.
3 Needle Arcing Distance
Standard
7 mm or more
• To determine which part is defective, measure the arcing distance
again with the spark plug cap removed from the ignition coil lead.
If the arcing distance is subnormal as before, the trouble is with Ihe
ignition coil itself. If the arcing distance is now normal, the trouble is
with the spark plug cap.
"*
13-18 ELECTRICAL SYSTEM
Ignition System
Measuring Coil Resistance:
If the arcing lester is not available, the coil can be checked for
a broken or badly shorted winding with an ohmmeter. However, an
ohmmeter cannot detect layer shorts and shorts resulting from insulation
breakdown under high voltage.
• Remove the ignition coil.
• Measure the primary winding resistance [AJ.
D Connect an ohmmeter between the coil terminals.
o Set the meter to the II 1 n range, and read the meter.
• Measure the secondary winding resistance [BJ.
D Puilihe spark plug cap off the lead .
o Connect an ohmmeter between the spark plug lead and the ground
lead terminal.
o Set the meier to the II 1 kn range, and read the meier.
lithe meier does nol read as specified, replace the coil.
If the meter reads as specified, the ignition coil windings are probably
good. However, if the ignition system still does not perform as it
should after all other components have been checked, test replace
the coil with one known to be good.
*
*
Ignition Coil Windin g Relllwnce
Primary wlndlngl:
KX125
0.24 n ~ 15 % (at 2O~C)
KX250
0.53 n ~ 15 % (at 2O C)
KX12S
8.3 kll ~ 15 % (at 2O~C)
KX250
12.6 kn ~ 15 % (at 20°C)
Secondary windlngl:
Q
• Check the spark plug lead for visible damage.
If the spark plug lead is damaged, replace the coil.
*
Spark Plug Cleaning and Inspection
• Remove the spark plug, and visually inspect it.
• Clean the spark plug, preferably in a sandblasting device, and then
clean off any abrasive particles. The plug may also be cleaned using
a high flash-point solvent and a wire brush or other suitable tool.
If the spark plug electrodes are corroded or damaged, o r if the
insulator is cracked, replace the plug. Use the standard spark plug.
*
Spark Plug Gap Inspection
• Measure the gap (AI with a wire-type thickness gauge.
II the gap is incorrect, carefully bend the side electrode (81 with a
suitable tool 10 obtain the correct gap.
*
Spark Plug Ga p
Standard
0.6 ..... 0.7 mm
0,7 ..... 0.8 mm (KX125125O-L4)
CD.I Unit Removal
• Remove:
left Radiator Shroud
left Side Cover
Seat
• Discoonect the main harness coonectors IAI.
• Unscrew the mounting boll [81 and remove the C.O.1 Unit [C).
®
®
;:=;
'-'
F=;
f"-./
&.
'v
1~
.. tl OJIl
c
ELECTRICAL SYSTEM 13-19
Ignition System
C.D.I Unit Inspection
CAUTION
When inspecting the C.O'!. unit observe the following to avoid
damage to the C.D.!. unit.
Do not disconnect the C.D.!. unit while the engine is running.
This may damage the C.D.!. unit.
Ignition Coil Primary Peak Voltage Check:
• Remove:
Radialor Shrouds
Side Covers
Seat
Fuel Tank
• Disconnect the spark plug cap from mounting the spark plug [A).
• Connect the good spark plug [B]to the spark plug cap, then touch
the engine with it.
NOTE
o Measure the voltage with each lead connected correctly.
The
correct value may not be obtained if disconnected.
o Maintain the correct value of compression pressure for the cylinder.
(Be sure to measure the voltage with the spark plug install to the
cylinder head.)
o The correct value may not be obtained if disconnected.
• Connect the peak voltage adapter [A] between the terminal 01 primary
lead (orange) and ground connection of the unit with the lead 01 the
ignition coil [B] connected.
Recommended Tool :
Peak Voltage Adapter
Type:
KEK·54·9-B
Brand :
KOWA SEIKI
Connection :
Tester Positive - Ground Lead ICJ
Tester Negative - Orange Lead [0]
• Shift the gear to the neutral position, then free the engine stop switch.
• Crank the engine by kicking the pedal several limes to measure the
peak voltage of the primary ignition coil.
Peak Voltage
115 V or above
190 V or above (KX25o-L4)
AWARNING
Do root lauch the metal portion of the probe in case of
measuring the voltage, or you may receive a serious electric
shock.
* If the voltage is less than the specified value, see the next page.
13·20 ELECTRICAL SYSTEM
Ignition System
Troubleshooting
Faulty ignition (Malfunctioned engine)
~
'"
Wiring and connect portion of the ignition system
No good
Repair
inspection.
Spark plug inspection.
'"
Good
'"
Good
No good
No good
Noise suppressor inspection
~
Replace
Replace
Good
No good. Voltage is less
L... Ignition coil primary peak voltage inspection
~
than the specified
Good
value.
No good.
Voltage is specified
Voltage is none or almost
but faulty ignition
none.
~
Defective Ignition coit
Inspect
Inspect
1. Adapter connection is
'"
Replace
incorrect or adapter is
directive.
1. Speed of cranking engine is
slow.
(Increase force of kicking
engine.)
2. Engine stop switch
Replace the
3. Capacitor
malfunctioned -
4. Regulator/Rectifier
no good part
5. Pickup coil peak voltage
3. lacking of sampling .
6. Exciter coil peak voltage
(Sampling few times)
r-
2. lower resistance in the tester.
(Use KAWASAKI Hand Tester)
4. Capacitor
All good
5. Pickup coil peak voltage
6. Exciter coil peak voltage
All good
C.O.I Unit is defective
No good
Replace the malfunctioned part or inspect in proper way
E-
ELECTRICAL SYSTEM 13-21
Ignition System
PiCkUp Coil Peak Voltage Check:
• To check the peak voltage, do the following procedures.
o Disconnect the connector oltha main harness from the C.D.I. unit.
NOTE
o Measure the voltage with each lead connected correctly.
The
correct value may not be obtained if disconnected.
o Maintain the correct value of compression pressure for the cylinder
(Be sure to measure the voltage with the spark plug installed to the
cylinder head).
o The correct value may not be obtained if disconnected.
o Connect the peak voltage adapter [Aj of the tester to the terminals of
the main harness connector (8j.
Recommended Tool:
Peak Voltage Adapter
Type:
KEK-54-9-B
Brand:
KOWA SEIKI
Connection:
Adapter Positive -
GreenIWhite Lead ICI
Adapter Negative -
WhitelYeliow Lead [01
o Crank the engine by kicking the pedal several times to measure the
peak voltage of the pickup coil.
Peak Voltage
1.4 V or above
0.5 V or above (KX250L4)
AWARNING
00 not touch t.he metal portion of the probe in case of
measuring the voltage, or you may receive a serious electric
shock.
* If the voltage is less than the specified, check the pickup coil.
Exciter Coil Peak Voltage Check:
• Disconnect the connector of the main harness from the C.O.I. unit.
• To check the peak voltage, do the following procedures.
NOTE
o Measure the voltage with each lead connected correctly.
The
correct value may not be obtained if disconnected.
o Maintain the correct value of compreSSion pressure for the cylinder
(8e sure to measure the voltage with the spark plug installed to the
cylinder head).
o The correct value may not be obtained if disconnected.
o Connect the peak voltage adapter (AJ of the tester to the terminals of
the main harness connector [B].
Recommended Tool:
Peak Voltage Adapter
Type:
KEK-54-9-B
Brand:
KOWA SEIKI
Connection:
Adapter Positive -
Red Lead IC]
Adapter Negative -
White Lead 10]
o Crank the engine by kicking the pedal several times to measure the
peak voltage of the exciter coil.
Peak Voltage:
DC 17V or Above
23 V or above (KX2So-L4)
* If the voltage is less than the specified, check the exciter coil.
13·22 ELECTRICAL SYSTEM
Ignition System
Fuel Cut Valve Operation Check: (Other than KX125-l.3 "" l4)
• Disconnect the fuel cut valve connector [AI.
• Set the tester to the DC25V range, and connect ilia the fuel cut valve
of the main harness side.
Connecdonl :
Teller POlitive - RltdlWhite Lead (B)
TH Ier Negative -
Brown Lead [e)
• Start the engine.
• Run it al the rpm given below.
Fuel Cut Valve Operate Revolutions
KXI 25·Ll :
9 600 rpm
KX25().Ll :
" !UI!III
8 100 rpm
• Read the lesler, running the engine at the specified revolution.
Fuel Cut Valve Operation vollage:
When engine Is specilled revolutlonl or above: DC 12V
When engine I. r••• than specified revolutions: OV
* If the tester does not read as specified, check the magneto.
* If the magneto has normal fu nctions, replace the C.D.!. Unit.
Throttle Sensor OutpuVfnput Voltage Check:
KX125-L3 - L4)
(Other than
NOTE
o If the variable meostat is available, refer to thronle sensor inspection.
• Remove the thronle sensor lead connector.
• Connect the adapter IAJ between the connectors [8J.
Special Tool ·
Throttle Sensor Setting Ad apter : 57001 - 1414
• Set the tester to the DC 10V range, and connect it to the adapter.
Hand Tester (+) _ RedIGreen l.ead
Hand Tester H - BlackiGreen L.ead
• Start the engine.
• Check the sensor input voltage with the engine running.
Throttle Sensor Input Voltage
Standard
4 V or above
* If it is not wi thin the specified voltage range, check the magneto output
voltage. If it has normal functions, replace the C.D.I. Unit.
~
ELECTRICAL SYSTEM 13· 23
Ignition System
• To check the output voltage, do the following procedures.
o Connect the tester with the setting adapter rAJ.
Hand Tester (+) _ WhiteJBlack lead
Hand Tester (-) -
BlackIGreen L.ead
o Remove the spark plug.
o Crank the engine by kicking the pedal several times to measure the
throttle sensor output voltage with the throttle valve completely closed.
Throttle Sensor Output Voltage
Standard
0.4 '" 0.6 V
(when throttle valve is completely closed.)
* II it is not within the specified voltage range, adjusllhe throttle sensor
position (see Throttle Sensor Position Adjustment).
* If it is within specified voltage, go to next test.
o Crank the engine by kicking the pedal several limes to measure the
throttle sensor output voltage with the throttle fully opened.
Throttle Sensor Output Vo ltage (when the throttle fully open ed)
Standard
KX12S
3.3 _ 3.5 V
KX250
3.S_3.7V
* If it is not within the specified voltage, replace the throttle sensor.
Engine Stop Switch Electric Current Check:
• Disconnect the engine stop switch lead.
• Start the engine.
• Ground the stop switch lead of the main harness side while the engine
is running.
If does not stop the engine, replace the C.O.I Unit.
*
Pickup Coil Inspection
• Remove:
Pickup Coil Lead Connector (see Flywheel magneto Inspection).
• Set the hand tester [AJ to the x 100n range and connect it to the
GreenlWhite IBI and WhitelYellow ICI Leads in the connector.
Special To ol -
~ ~
Hand Tester: 57001-1394
* If there is more resistance than the specified value, the coil has an
open lead and must be replaced . Much less than this resistance
means the coil is shorted, and must be replaced.
Pickup Coil Re sistance :
180 .... 380 f!
180 ..... 280 11 (KX250-L4)
• Using the highest resistance range of the tester, measure the
resistance between the pickup coil leads and chassis ground.
Any lester reading less than infinity (00) indicates a short, necessities
replacement of the pickup coil assembly.
*
Pickup Coil Air Gap Adjustment
• Loosen the pickup coil screws (A] .
• Insert a 0.65 mm thickness gauge IB] between the pickup coit core
and the timing pial.
• While pressing the pickup coil toward the magneto flywheel, tighten
the coit screws and remove the thickness gauge.
• Check the air gap (see Flywheel Magneto Installation).
If the air gap is not within the specified range, readjust the gap.
*
D
I~
B
®
13-24 ELECTRICAL SYSTEM
Throttle Sensor
Throttle Sensor Inspection (Other than KX125-L3 ,.., L4)
NOTE
C
J
o If the variable rheostat is not available, refer to throttle sensor
1
output!input voltage check in the c.O.! Unit inspection.
o When inspecting the throttle sensor the throttle valve of the
11t)
~ '=~
carburetor shall be completely closed and remain the throttle cable
connected.
IOC5 Vl
• Remove the carburetor (see Fuel System chapter).
• Connect the throttle sensor connector (AJ with the battery [6J. variable
rheostat [C] and hand lesters (DJ as shown.
Variable Rheostat (+) ....... RIG Lead Terminal IE)
Hand Tesler (+) ..... WfBK lead terminal lFJ
Hand Tesler (-) ..... BKIG Lead terminal [G)
• Check the sensor input voltage.
®
10 '$
L
~
Throttle Sensor Input Voltage
Standard
aro und 5 V
• Check the sensor output voltage with the throttle valve is completely
closed.
Throttle Sensor Output Voltage
0.4 _ 0.6 V
Standard
(when the thronle valve completely closed.)
* If it is not within the specified voltage, adjust the throttle sensor
position (see Throttle Sensor Position Adjustment).
* If it is within specified voltage, go to next test.
• Check the sensor output voltage with Ihe Ihrottle lully opened.
Throttle sansOf' Output Voltage
Standard:
KX125
3.3 _ 3.5 V (When thronle fully opened.)
10(250
3.5 _ 3.7 V (When thronle fully opened.)
* If it is not within Ihe specified voltage, replace Ihe sensor.
Throttle Sensor Position Adjustment (Other than KX12S-L3 ""
L4)
• Remove Ihe carburetor.
• Check the throttle valve is completely closed.
• Loosen the Ihrottle sensor mounting screw (A].
• Connect the throttle sensor connector with the battery, variable
meostat and handtesters in the same manner as specified in the
throttle sensor Inspection.
• Adjust the position of Ihe sensor untillhe output voltage is within the
specified voltage range.
Throttle Sensor Output Voltage
Standard
0.4 _ 0.6 (when thronle valve is completely closed.)
• If it is not wilhin the specified voltage range, replace the sensor.
J,
0
$
®
I~uo'onr
e
ELECTRICAL SYSTEM 13-25
Fuel Cut Valve and Capacitor
Fuel Cut Valve Removal (Other than KX125-L3 ""' L4)
AWARNING
Gasoline is extremely flammable and can be explosive under
ce rtain conditions. Turn the ignition switch OFF. Do not
smoke. Make sure the area is well-ventilated and free from
any source of ftame or sparks; this includes any appliance
with a pilot light.
• Disconnect the connectors of the fuet cut valve and throttle sensor.
• Remove the carburetor.
• Drain the fuel from the float bowl removing the drain plug. After
draining, install the drain plug securely.
• Loosen the fuel cut valve [AJ and remove it.
Fuel Cut Valve Installation (Other than KX125-L3 "-' L4)
• Installation is reverse of removal.
Fuel Cut Valve Inspection (Other than KX125-L3 ....... L4)
• Remove the fuel cut valve [AI.
• Connect and disconnect one 12 V battery [BI to the fuel out valve
connector as shown. The valve rod moves.
If the protrusion exceeds the standard (too long or too short), the
valve is defective and must be replaced.
*
21 .3-21 .7mm
19.4-19.6
mm
Testing Fuel Cut Valve
Standard Protrusion
When battery is disconnected When battery is connected -
19.4 ..... 19.6 mm
21.3 ..... 21 .7 mm
+
®
A
13-26 ELECTRICAL SYSTEM
Fuel Cut Valve and Capacitor
Capacitor Inspection (KX125/2S0-L 1 only)
• Remove the capacitor [AI and disconnect the connector (9) .
• Set the hand tester to the x 1 kn range, connect the lester to the
leads 01 the condenser, and check the internal resistance following
the table.
Special Toot -
Hand Tlilter : 57001-1394
capacitor Internal Resistance
B
Tester Positive (+) Lead Connection
o
Tester Negative (-)
o
Lead Connection
BKJIN
BKIW
more than SkU
Should nol be inspected
"'
"2
*
-1 : Check the condenser after 2 minutes.
-2: 00 not check the resistance because of opposite of the polarity.
II the readings do nol correspond to the table, replace the capacitor
unit.
Capacitor Capacity
10000pFI5OV
APPENDIX 14·1
Appendix
Table of Contents
Troubleshooting Guide .......................................................................... ........................................................................ 14·2
General Lubrication ......................................................................................................................................................... 14-5
LUbrication (Periodic Maintenance) .......................................................................................................................... 14-5
Unit Conversion Table ..................................................................................................................................................... 14-6
14-2 APPENDIX
Troubleshooting Guide
NOTE
o This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting
for some of the mOfS common difficulties.
Engine Doesn't Start, Starting Difficulty:
Engine won't tum over:
Cylinder, piston seizure
Crankshaft seizure
Connecting rod small end seizure
Connecting rod big end seizure
Transmission gear or bearing seizure
Kick shaft return spring broken
Kick ralchet gear not engaging
No fuel flow:
No fuel in lank
Fuel lap turned off
Tank cap air vent obstructed
Fuel lap clogged
Fuel line clogged
Rool valve clogged
Fuel cut valve left close
Engine flooded:
Float level 100 high
Float valve worn or stuck open
Starting technique faulty
(when flooded, kick with the throttle lully open to
allow more air to reach the engine.)
No spark; spark weak:
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap not in good contact
Spark plug incorrect
C.O.I Unit trouble
Ignition coil trouble
Ignition coil resistor open
Rywheel magneto damaged
Wiring shorted or open
Fuel/air mixture Incorrect :
Idle adjusting screw maladjusted
Slow jet Of air passage clogged
Air cleaner clogged, poorly sealed, or missing
Starter jet clogged
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened down
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ringlland clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Cylinder base gasket damaged
Read valve damaged
Cylinder nut loose
Poor Running at Low Speed:
Spark weak:
Spark plug dirty, broken, or maladjusted
Spark plug cap or high tension wiring trouble
Spark plug cap shorted or not in good contact
Spark plug incorrect
C.D.! Unit trouble
Ignition coil t rouble
Flywheel magneto damaged
Ignition coil lead or C.O.! Unit lead not in good contact
Fuel/air mixture Incorrect :
Idle adjusting screw maladjusted
Slow jet or air passage clogged
Air cleaner clogged, poorly sealed, or missing
Starter plunger stuck open
Float level 100 high or too low
Fuel tank air vent obstructed
Fuel cut valve won'l fully open
Carburetor holder loose
Air cleaner duct loose
Compression Low:
Spark plug loose
Cylinder head not sufficiently tightened down
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ringlland clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Cylinder base gasket damaged
Reed valve damaged
Cylinder nut loose
Kips ports stuck open:
KIPS exhaust valve stuck open (valve seizure, or
carbon accumulation)
KIPS exhaust valves assembled incorrectly
Exhaust advancer spring damaged
Exhaust valve operating rod seizure
Rod (for KIPS) seized in cylinder
Other:
C.O.! Unit trouble
Transmission oil viscosity too high
Brake dragging
Poor Running or No Power at High Speed:
Firing incorrect:
Spark plug dirty, damaged , or maladjusted
Spark plug cap or high tension wiring damaged
Spar1< plug cap shorted or not in good contact
Spark plug incorrect
C.D.! Unit trouble
Ignition coil trouble
Flywheel magneto damaged
Ignition coil lead or C.O.1 Unit lead not in good con tact
FueVair mixture incorrect:
Main jet clogged or wrong size
Jet needle or needle jet worn
Jet needle clip in wrong position
Float level too high or too low
Fuel c ut valve won't fully open
Air jet or air passage clogged
Air cleaner clogged, poorly sealed, or missing
Starter plunger stuck open
Fuel to carburetor insufficient
Water or foreign matter in fuel
Fuel tank air vent obstructed
Carburetor holder loose
Air cleaner dUCI loose
Fuel tap clogged
Fuel line clogged
l
1
\
I
1
1,
j
APPENDIX 14-3
Troubleshooting Guide
Compression low:
Spark plug loose
Cylinder head not sufficiently tightened down
Cylinder, piston worn
Piston ring bad (worn, weak, broken, or sticking)
Piston ring/and clearance excessive
Cylinder head gasket damaged
Cylinder head warped
Cylinder base gasket damaged
Reed valve damaged
Cylinder nul loose
Engine rpm will not rise properly :
Starter plunger stuck open
Float level too high or too low
Main jet clogged
Throttle valve does not fully open
Air cleaner clogged
Muffler clogged
Waler or foreign matter in fuel
Cylinder exhaust port clogged
Brake dragging
Clutch slipping
Overheating
Transmission oil level too high
Transmission oil viscosity too high
Crankshaft bearing worn or damaged
KIPS ports stuck closed:
KIPS ports stuck closed
KIPS exhaust valves stuck closed (valve seizure, or
carbon accumulation)
KIPS exhaust valves assembled incorrectly
KIPS ports clogged (carbon accumulation)
Exhaust valve operating rod seizure
Rod (for KIPS) seized in cylinder
Knocking :
Carbon buill up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
C.D.I Unit trouble
Overheating:
Firing incorrect:
Spark plug dirty, broken , or maladjusted
Spark plug incorrect
C.D.I Unit trouble
Fuel/air mixture incorrect:
Main jet clogged or wrong size
Fuel level in carburetor float bowl 100 low
Fuel cui valve won't fully open
Carburetor holder loose
Air cleaner poorly sealed, or missing
Air cleaner duel poorly sealed
Air cleaner clogged
Compression high:
Carbon built up in combustion chamber
Engine load faulty:
Brake dragging
Clutch slipping
Transmission oil level too high
Transmission oil viscosity 100 high
lubrication inadequate:
Transmission oil level too low
Transmission oil poor quality or incorrect
Coolant incorrect:
Coolant level too low
Coolant deteriorated
Cooling system component incorrect :
Radiator clogged
Radiator cap trouble
Water pump not rotating
Clutch Operation Faulty :
Clutch slipping:
No clutch lever play
Clutch cable maladjusted
Clutch inner cable catching
Friction plate worn or warped
Steel plate worn or warped
Clutch spring broken or weak
Clutch release mechanism trouble
Clutch hub or housing unevenly worn
Clutch not disengaging properly:
Clutch lever play excessive
Clutch plate warped or too rough
Clutch spring tension uneven
Transmission oil deteriorated
Transmission viscosity too high
Transmission oil level too high
Clutch housing frozen on drive shaft
Clutch release mechanism trouble
Gear Shifting Faulty:
Doesn't Into gear; shift pedal doesn't return:
Clutch not disengaging
Shift fork bent or seized
Gear stuck on the shaft
Gear poSitioning lever binding
Shift return spring weak or broken
Shift return spring pin loose
Shift mechanism arm spring broken
Shift mechanism arm broken
Shift drum broken
Jumps out of gear:
Shift fork worn
Gear groove worn
Gear dogs and/or dog holes worn
Shift drum groove worn
Gear positioning lever spring weak or broken
Shift fork guide pin worn
Drive shaft, output shaft, andlor gear splines worn
Overshifts:
Gear positioning lever spring weak or broken
Shift mechanism arm spring broken
Abnormal Engine Noise:
Knocking :
C.D.I Unit trouble
Carbon built up in combustion chamber
Fuel poor quality or incorrect
Spark plug incorrect
Overheating
Piston slap:
Cylinder/piston clearance excessive
Cylinder, piston worn
Connecting rod bent
Piston pin, piston pin hole worn
14-4 APPENDIX
Troubleshooting Guide
Other noise:
Connecting rod small end clearance excessive
Connecting rod big end clearance excessive
Piston ring worn, broken or stuck
Piston seizure or damaged
Cylinder head gasket leaking
Exhaust pipe leaking at cylinder head connection
Crankshaft runout excessive
Engine mounts loose
Crankshaft bearing worn
Primary gear worn or chipped
Abnormal Drive Train Noise
Clutch noise:
Clutch housing/friction plale clearance excessive
Cutch housing gear/primary gear backlash excessive
Metal chip jammed in clutch housIng gear teeth
Transmission noise :
Crankcase bearing worn or damaged
Transmission gear worn or chipped
Metal chip jammed in gear teeth
Transmission oil insufficient or 100 thin
Kick ratchet gear not properly disengaging from kick
"""'
Output shaft idle gear worn or chipped
Drive chain noise:
Drive chain adjusted improperly
Chain worn
Aear and/or engine sprocket(s) worn
Chain lubrication insuffICient
Rear wheel misaligned
Abnormal Frame Noise:
Front fork noise:
Oil insufficient or too thin
Spring weak or broken
Rear shock ab sorber noise:
Shock absorber damaged
Disc brake noise:
Pad installed incorrectly
Pad surface glazed
Disc warped
Caliper trouble
Cylinder damaged
Other noise
Bracket, nut, boH, etc. not property mounted or
tightened
Exhaust Smoke:
Excessive white smoke :
Throttle cable maladjusted
Brownish smoke:
Air cleaner clogged
Main jet too large of fallen out
Starter plunger stuck open
Floallevel too high
Handling anellor Stability Unsatisfactory:
Handlebar hard to turn :
Control Cable routing incorrect
Wiring routing incorrect
Steering stem locknut too tight
Bearing ban damaged
Bearing race dented or worn
Steering stem bearing lubrication inadequate
Steering stem bent
Tire air pressure too low
Handlebar shakes or excessively vibrates:
Tire worn
Swingarm sleeve or needle bearing damaged
Rim wa rped, or not balanced
Front, rear axle runout excessive
Wheel bearing worn
Handlebar clamp loose
Steering stem head nut loose
Handlebar pulls to one side:
Frame bent
Wheel misalignment
Swingarm bent or twisted
Swing arm pivot shaft runcut excessive
Steering maladjusted
Steering stem bent
Front fork leg bent
Rightlleft front fori< oil level uneven
Shock absorption unsatisfactory:
(Too hard)
Front lork oil excessive
Front fork oil viscosity too high
Front fork leg bent
Tire air pressure 100 high
Rear shock absorber maladjusted
(Too soft)
Front fork oil insufficient and/or leaking
Front fork oil viscosity too low
Front fork, rear shock absorber spring weak
Rear shock absorber gas leaking
Rear shock absorber maladjusted
,
1
Brake Doesn 't Hold:
Disc brake:
Air in the brake line
Pad or disc worn
Brake fluid leak
Disc warped
Contaminated pads
Brake fluid deteriorated
Primary or secondary cup damaged
Master cylinder scratched inside
Brake maladjustment (lever or pedal play excessive)
1
,
I
1
APPENDIX 14-5
General Lubrication
Lubrication (Periodic Maintenance)
• Before lubricating each part, clean off any rusty spots with rust
remover and wipe off any grease, oil, dirt, or grime.
• lubricate the points listed below with indicated lubricant.
NOTE
o Whenever the vehicle has been operated under wet or rainy
conditions, O( especially after using a high-pressure water spray.
perform the genera/lubrication.
Pivots: Lubricate with Motor Oil
Clutch Lever
Brake Lever
Kick Pedal
Shift Pedal
Rear Brake Rod Joint
Drive Chain
Points: Lubricate with Grease [AJ.
Clutch Inner Cable Upper and lower Ends
Throttle Inner Cable Upper Ends
Swingarm Pivot
Tie-Rod Pivot
Rockerarrn Pivot
Steering Slem Bearing
Cables: lubrica te with Rust Inhibitor.
Throttle Cables
Clutch Cable
, . 0U' ' ' SI •
• With the cabte disconnected at the both ends, the cable should move
freely {A) within the cable housing.
If cable movement is not Irea after lubricating, if the cable is frayed,
or if Ihe cable housing is kinked, replace the cable.
*
........., .
14·6 APPENDIX
Unit Conversion Table
Units of Length:
Prefixes for Units:
Prefix
Symbol
mega
x
M
Pow.,
km
x
0.6214
1 000 000
m
x
3.281
mm
x
k
x
1 000
cenli
c
x
0 .01
mini
m
x
micro
~
x
0.00 1
0.000001
kilo
«
0.03937
•
•
•
mile
;n
Units of Torque:
Units of Mass:
N·m
x
0.1020
•
kgf·m
N·m
x
0.7376
•
N·m
x
8.851
x
9.807
•
•
•
•
ft·lb
in·tb
kg
x
2.205
•
'b
kgf·m
g
x
0.03527
•
0'
kgf·m
x
7.233
kgf·m
x
86.BO
N·m
ft-lb
in·lb
Units of Volume :
L
x
0.2642
L
x
L
x
0.2200
1.057
L
x
0.8799
x
L
2.113
Units of Pressure:
•
•
gal (US)
gal (imp)
kP,
x
0 .01020
•
•
•
Q' (US)
kP,
x
0.1450
ql (imp)
kP,
x
0.7501
pint (US)
kgf/cm 2
x
x
98.07
14.22
x
1.333
L
x
1.816
•
pint (imp)
kgflcm2
mL
x
0.03381
em Hg
mL
x
0.028 16
•
•
oz (US)
mL
x
0.06102
•
cu in
•
•
•
•
•
•
kgt/cm2
ps;
em Hg
kP,
psi
kP,
I
1
I
oz (imp)
Units of Speed:
kmlh
x
0.6214
•
mph
•
•
PS
J
Units of Force:
N
x
0 .1020
N
x
0.2248
kg!
x
9.807
kof
x
2.205
•
•
kof
•
•
Units of Power:
'b
N
kW
x
1.360
kW
x
1.341
'b
PS
x
0.7355
PS
x
0.9863
HP
kW
•
HP
j
I
J
Units of Temperature :
9( OC+40)
5
-4
32
20, ;, 40
68
60 I 00
4.4
26.7
-
"5.:...(o
.:...
F.:...+.:..:4O:!.)
9
104
176
- 40 . °C
212
248
284
100! 120 140 160 .1 180 200 ! 220 240 i 260 280 i 300 320
1
.. ~L.-H.~~111-+1r-~I·
~1~4
1 --~I-+IL1-H1-+
11-~..--~
1 01 I 1
,I I
ii
',
" I' ~I-r+I+-1~41+-~I~1
I ,
1 ,
1
-40
-2O !
20 I 4O ! 60 i 00
! 100
! 120
! 140
160
.40
-20"
101;
40. of
-17.8
48.9
71.1
93.3
116
j
138
1
MODEL APPLICATION
Year
1999
Model
KX125-L 1
KX250-L1
2000
KX125-L2
KX250-L2
2001
KX125-L3
KX250-L3
2002
KX125- L4
KX250-L4
8eainnina Frame No.
JKAKXRLC D XAOO0001 or
JKAKX125LLAOOOO01
JKAKXMLC D XAOOOOO1 or
JKAKX250LLAOOOO01
JKAKXRLC D YAOO90010r
JKAKX125LLA009001
JKAKXMLC D YA11001 0r
JKAKX250LLA011001
JKAKXRLC DIA02001 or
JKAKX125LLA02001
JKAKXMLC D IA0250010r
JKAKX250LLA025001
JKAKXRLC D 2A030001 or
JKAKX125LLA030001
JKAKXMLCD 2A036001 or
JKAKX250LLA36001
o : This digit in the frame number changes from one machine
to another.
• ---c Kawasaki
KAWASAKJ HEAVY INOUSTRIES, LTD.
Consumer Product. & Machinery Company
">