Manuale d’uso / di manutenzione del prodotto Eliminator 125 (2006) del fabbricante Kawasaki
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ELIMINA T OR 125 Motorcycle Service Manual.
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This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired chapter num- ber with the black tab on the edge at each table of contents page. •Refer to the sectional table of contents for the exact pages to locate the spe- cific topic required.
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ELIMINA T OR 125 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mec.
LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) AT D C after top dead center N newton(s) BBDC before bottom dead center Pa .
EMISSION CONTROL INFORMA TION T o protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board.
WE RECOMMEN D THA T ALL DE ALERS OBSER VE THESE PROVISIONS OF FEDERAL LA W , THE VIOLA TION OF WHICH IS PUNISHABLE BY CIVIL PENAL TIES NOT EXCEEDING $10,000 PER VIOLA TION.
Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However , it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work.
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GENERAL INFORMA TION 1-1 1 General Information T able of Contents Before Servicing ................................................................................................................ ..... 1-2 Model Identification.........................
1-2 GENERAL INFORMA TION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the preca utions given below .
GENERAL INFORMA TION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly .
1-4 GENERAL INFORMA TION Before Servicing Tightening Sequence Generally , when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which c an lead to malfunction.
GENERAL INFORMA TION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area.
1-6 GENERAL INFORMA TION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified.
GENERAL INFORMA TION 1-7 Model Identification BN125-A1 (Europe) Left Side View BN125-A1 (Europe) Right Side View.
1-8 GENERAL INFORMA TION Model Identification BN125-A1 (Singapore) Left Side View BN125-A1 (Singapore) Right Side View.
GENERAL INFORMA TION 1-9 General Specifications Items BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ Dimensions Overall length 2 150 mm (84.6 in.) Overall width 780 mm (30.7 in.) Overall height 1 020 mm (40.2 in.) 1 035 mm (40.8 in.) ← 1 050 mm (41.3 in.
1-10 GENERAL INFORMA TION General Specifications Items BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ Maximum torque 9.7 N·m (0.99 kgf·m, 7.2 ft·lb) @8 000 r/min (rpm) (US)– ← 9.
GENERAL INFORMA TION 1-1 1 General Specifications Items BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ Gear ratios: 1st 2.700 (27/10) 2nd 1.705 (29/17) 3rd 1.300 (26/20) 4th 1.090 (24/22) 5th 0.952 (20/21) Final drive system: Ty p e Chain drive Reduction ratio 3.
1-12 GENERAL INFORMA TION General Specifications Items BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ T rail/brake light 12 V 5/21 W Alternator: Ty p e Single-phase AC Rated output 8.75 A/12 V @4 000 r/min (rpm): BN125-A1 15 A/14 V @8 000 r/min (rpm): BN125-A2 ∼ Specifications subject to change without notice, and may not apply to every country .
GENERAL INFORMA TION 1-13 T echnical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) Description ○ Unlike the conventional CDI, the DC-CDI uses a battery instead of a magneto as a power source. ○ The DC-CDI powered by a battery generates strong ignition spark even at low engine speeds.
1-14 GENERAL INFORMA TION T echnical Information-DC-CDI (Direct Cu rrent-Capacitor Discharge Ignition Sys- tem) Operation The DC-CDI circuit consists of a battery , a DC-DC converter , a d iode, a cap.
GENERAL INFORMA TION 1-15 T echnical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) This sudden change in the primary current induces a primary voltage (counterelectromotive force) which is equal to the capacitor voltage (about 225 V) but against the discharging current.
1-16 GENERAL INFORMA TION T echnical Information-DC-CDI (Direct Cu rrent-Capacitor Discharge Ignition Sys- tem) Diode A diode functions as an electrical check valve. It conducts current easily from its cathode to its anode, but it will not permit current flow in the opposite direction.
GENERAL INFORMA TION 1-17 T echnical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) Every time either end of the timing plate on the rotor passes by the crankshaft sensor , a pulse is generated and sent to the CDI unit, that is, two pulses are generated per one revolution of the rotor .
1-18 GENERAL INFORMA TION T echnical Information-DC-CDI (Direct Cu rrent-Capacitor Discharge Ignition Sys- tem) The crankshaft sensor generates a crankshaft sensor sig- nal and sends it to the signal generator . The signal genera- tor generates A and B signals synchronized with the crank- shaft sensor signal.
GENERAL INFORMA TION 1-19 T echnical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) (Ignition T iming Advancing) A signal and B signal in the comparator advance the igni- tion timing. The signal generator decreases A signal as the engine rpm increases from N1, to N3 as shown, but keeps B signal unchanged.
1-20 GENERAL INFORMA TION T echnical Information-Coasting Enricher The coasting enricher [A] prevents backfiring during en- gine braking by supplying a rich fuel mixture to the engine. When the motorcycle is cruising or accelerating, the engine vacuum is low , and the return spring [3] pushes the valve in its opened position [5].
GENERAL INFORMA TION 1-21 T echnical Information-Coasting Enricher Fuel and Air Supply of Enricher System.
1-22 GENERAL INFORMA TION Unit Conversion T able Prefixes for Units Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units of Mass kg × 2.205 = lb g × 0.03527 = oz Units of V olume L × 0.
PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T able of Contents Periodic Maintenance Chart .............. 2-2 T orque and Locking Agent ................. 2-4 Specifications .................................... 2-9 Special T ools ...................
2-2 P ERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.
PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever comes first *O D O M E T E R READING × 1 000 km ( × 1 000 mile) 1 6 12 18 24 30 36 OPERA TION Every (0.
2-4 P ERIODIC MAINTENANCE T orque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the "Remarks" column mean: L: Apply a non-permanent locking agent to the threads.
PERIODIC MAINTENANCE 2-5 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Oil Pipe Banjo Bolts M8 9.8 1.0 87 in·lb Oil Pipe Banjo Bolts M10 25 2.5 18 Oil Pipe Mounting Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb Oil Pipe Mounting Bolts (BN125-A4 ∼ ) 8.
2-6 P ERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Engine Removal/installation Engine Mounting Bolts, Nuts (M10) 44 4.5 33 Engine Mounting Bolts, Nuts (M8) 25 2.5 18 Engine Mounting Bracket Bolts, Nuts 25 2.
PERIODIC MAINTENANCE 2-7 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Brake Pedal Bolt 9.8 1.0 87 in·lb Suspension Front Fork T op Plugs 23 2.3 17 Front Fork Bottom Allen Bolts 20 2.0 15 L Front Fork Clamp Bolts (Upper) 20 2.
2-8 P ERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks T urn Signal Light Holder Nuts 5.9 0.60 52 in·lb Neutral Switch 15 1.5 11 Sidestand Switch Screws 3.9 0.40 35 in·lb L The table below , relating tightening torque to thread diameter , lists the basic torque for the bolts and nuts.
PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Fuel System Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Idle Speed 1 300 ±50 r/min (rpm) ––– Air Cleaner Element Oil: Grade SE, SF or SG class ––– Vis c os it y SAE 30 ––– Engine T op End V alve Clearance: Inlet 0.
2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit (BN125-A6 ∼ ) 4.1 mm (0.161 in.) 1 mm (0.04 in.) Rear 7.3 mm (0.29 in.) 2 mm (0.08 in.) Final Drive D r i v eC h a i nS l a c k 25 ∼ 40 mm (0.98 ∼ 1.57 in.) ––– 20 Link Length 254.
PERIODIC MAINTENANCE 2-1 1 Special T ools Steering Stem Nut Wrench: 57001-1 100 Jack: 57001-1238 Fork Oil Level Gauge: 57001-1290.
2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose and Conn ection Inspection ○ The fuel hose is designed to be used throughout the mo- torcycle’s life without any maintenance, however , if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leaks [A] or the hose to burst.
PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Throttle Grip Free Play Adjustment • Loosen the locknut [A]. • T urn the adjuster [B] until the proper amount of free play can be obtained.
2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment • Start the engine and warm it up thoroughly . • T urn the idle adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range.
PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Remove the canister mounting bracket bolts [A] and re- move the brackets [B] and canister [C] together . • Disconnect the hoses from the canister . • Visually inspect the canister for cracks and other damage.
2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cylinder Head Bolt Tightness Insp ection • Check that 6 mm [A] and 9 mm [B] cylinder head bolts are tightened evenly . Standard head bolts tightening torque are shown below . Tighte ning T orque 6 mm Cyl in der Head Bolts: 12 N· m (1.
PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures V alve Clearance Adjustment If the valve clearance is not within the specified range, adjust the clearance by loosening the locknut and turning the adjusting screw . • T ighten the nuts to the specified torque and check the valve clearance again.
2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pull the clutch cable [A] tight and tighten the adjusting nuts [B] against the clutch cable bracket. • T urn the adjuster at the clutch lever until the free play is correct. • T ighten the knurled locknut at the clutch lever .
PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Recommended Engine Oil Grade: (BN125- A1 ∼ A3): API SE, SF or SG (BN125- A4 ∼ ): API SE, SF or SG API SH, SJ or SL with JASO MA Vis co s it y: SAE 10W-4 0 Capacity: 1.1 L (1.16 US qt) (When filter is not removed) 1 .
2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the O-ring [A] with new one. • Apply grease to the O-ring and the grommet [B]. • Install the cover [C] and tighten the cover bolts. T o rque - Oil Filter Cover Bolts (BN125-A1 ∼ A3): 9.
PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Wheels/Tires Spoke Tightness Inspection • Check that all the spokes are tightened evenly . If spoke tightness is uneven or loose, tighten the spoke nipples evenly . T orque - Spoke Nipples: 2.
2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Pressure Inspection/Adjustme nt • Remove the air valve cap. • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours).
PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Tire Wear Inspectio n As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn).
2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Set the motorcycle up on its center stand. ○ Rotate the rear wheel to find the position where the chain is tightest. ○ Measure the vertical movement (chain slack) [A] midway between the sprockets.
PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Bend the cotter pin [A] over the nut [B]. • Check the rear brake effectiveness. WA R N I N G If the axle and torque link nuts are not securely tightened and the cotter pin and snap pin are not installed, an unsafe riding condition may result.
2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Lubrication • The chain should be lubricated with a lubricant which will both prevent the exterior from rusting and also absorb shock and reduce friction in the interior of the chain.
PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Check that the front brake cam lever [A] comes to an 80° ∼ 90° angle [C] with the rear brake rod [B] when the rear brake is fully applied. If it does not, remove the adjusting nut [D] and lever , then adjust the rear brake cam lever angle.
2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Le vel I nspe ction • Check that the brake fluid level in the brake reservoir [A] is between the upper [B] and the lower [C] level line. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level.
PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Remove the clear plastic hose. • Install the reservoir cap. • T ighten the bleed valve, and install the rubber cap. T orque - Caliper Bleed V alv e: 7.8 N·m (0.80 kgf·m, 69 in·lb) Front Brake Reservoir Cap Screws: 2.
2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ The fluid level must be checked often during the bleed- ing operation and replenished with fresh brake fluid as necessary .
PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Brake/Master Cylind er Cup and Dust Seal Replacement • Refer to the Master Cylinder section in the Brakes chapter for Brake/Master Cylinder Cup and Dust Seal Replace- ment.
2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Oil Change • Remove the front fork (see Suspension chapter). • Hold the outer tube vertically in a vise.
PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Install the fork spring [A] with the smaller end facing [B] downward. • Install: Fork Spring Seat Spacer • Repeat the same procedure for another front fork. • Install the front fork (see Suspension chapter).
2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection • Check the steering. ○ Lift the front wheel off the ground using the jack [A]. Special T ool - Jack: 57001-1238 ○ With the front wheel pointing straight ahead, alternately tap each end of the handlebar .
PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Steering S tem Bearing Lubrication • Remove the steering stem (see Steering chapter). • Using a high-flash point solvent, wash the upper and lower steel balls. • Wipe all the old grease off the upper and lower outer races.
2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant.
PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness Inspection Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter p in is in place and in good condition.
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FUEL SYSTEM 3-1 3 Fuel System T able of Contents Exploded View ................................................................................................................... ..... 3-2 Specifications ...............................................
3-2 FUEL SYST EM Exploded View.
FUEL SYSTEM 3-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Upper Chamber Cover Mounting Screws 3.5 0.36 31 in·lb 2 Spring Seat Screws 0.8 0.080 7i n · l b 3 Choke Lever Set Screw 0.8 0.080 7i n · l b L 4 Choke Lever Pivot Screw 2.
3-4 FUEL SYST EM Exploded View Except the California Model.
FUEL SYSTEM 3-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Fuel T ap Plate Screws 0.8 0.080 7i n · l b 2 Fuel T ap Diaphragm Cover Screws 1.0 0.10 9i n · l b 2.5 0.25 22 in·lb with White W asher 3 Fuel T ap Mounting Bolts 4.9 0.
3-6 FUEL SYST EM Exploded View California Model.
FUEL SYSTEM 3-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Fuel T ap Plate Screws 0.8 0.080 7i n · l b 2 Fuel T ap Diaphragm Cover Screws 1.0 0.10 9i n · l b 2.5 0.25 22 in·lb with White Washer 3 Fuel T ap Mounting Bolts 4.9 0.
3-8 FUEL SYST EM Specifications Item Standard Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.1 2 in.) Carburetor Make, T ype MIKUNI BS28 Idle Speed 1 300 ±50 r/min (rpm) Pilot Screw (Turns Out) 15 / 8 3.0 (BN125-A7 ∼ ,N ,N U ) (US, CA, CH) – Service Fuel Level 1 ∼ 3 mm (0.
FUEL SYSTEM 3-9 Specifications Pilot screw [A] P l u g[ B ]( U S ,C A ,C H ) Pilot air jet [C] Jet needle [D] Throttle valve [E] Pilot jet [F] Needle jet [G] Main jet [H] Float [I] V alve seat [J] V a.
3-10 FUEL SYSTEM Special T ools Fuel Level Gauge: 57001-101 7 Carburetor Drain Plug Wrench, Hex 3: 57001-1269.
FUEL SYSTEM 3-1 1 Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Grip Free Play Inspection in the Pe- riodic Maintenance chapter . Free Play Adjustment • Refer to the Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter .
3-12 FUEL SYSTEM Carburetor Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance c hapter . Idle Speed Adjustment • Refer to the Idle Speed Adjustment in the Periodic Main- tenance c hapter .
FUEL SYSTEM 3-13 Carburetor Service Fuel Le vel Adjustment WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smo ke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
3-14 FUEL SYSTEM Carburetor Fuel System Cleanliness Inspection WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
FUEL SYSTEM 3-15 Carburetor • Loosen the carburetor holder clamp [A] and air cleaner duct clamp. • Pull the carburetor out of the air cleaner duct end [B], and then pull it out of the carburetor holder [C] from the vehicle’s right side. • T ake out the carburetor .
3-16 FUEL SYSTEM Carburetor • Remove: Upper Chamber Cover [A] V acuum Piston and Diaphragm CAUTION During carburetor disassembly , the careful not to damage the diaphragm. N ever use a sharp edge to remove the diaphragm. • Remove the spring seat screws [D].
FUEL SYSTEM 3-17 Carburetor • Remove the coasting enricher cover . • Remove the diaphragm [A]. Carburetor Assembly • T urn in the pilot screw [A] fully but not tightly , and then back it out the same number of turn counted during dis- assembly .
3-18 FUEL SYSTEM Carburetor • Align the diaphragm tang [A] with the notch in the upper chamber , and fit the diaphragm sealing lip into its groove. • After installing the upper chamber cover , check that the vacuum piston slides up and down smoothly without bind- ing in the carburetor bore.
FUEL SYSTEM 3-19 Carburetor Carburetor Inspection WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smo ke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
3-20 FUEL SYSTEM Carburetor • Check the tapered portion [A] of the pilot s crew [B] for wear or damage. If the pilot screw is worn or damaged on the tapered por- tion, it will prevent the engine from idling smoothly . Re- place it. • Check that the vacuum piston [A] moves smoothly in the carburetor body .
FUEL SYSTEM 3-21 Air Cleaner Air Cleaner Element Remova l • Remove the left side cover . • Remove the element cover [A]. Front [B] • Pull out the air cleaner element [A]. • Push a clean, lint-free towel into the air cleaner housing to keep dirt or other foreign material from entering.
3-22 FUEL SYSTEM Air Cleaner Air Cleaner H ousing Removal • Remove: Side Covers and Seat (see Frame chapter) Fuel T ank (see Fuel T ank Removal) Battery (see Electrical System) and Battery Seat [A] .
FUEL SYSTEM 3-23 Fuel T ank Fuel T an k Removal WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smo ke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
3-24 FUEL SYSTEM Fuel T ank Fuel T ank Cleaning WA R N I N G Clean the tank in a well-ventllated area, and take care that there are no sparks or flame anywhere near the w orking area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank.
FUEL SYSTEM 3-25 Fuel T ank Fuel T ap Inspection • Remove the fuel tap. • Check the fuel tap filter screen [A] for any breaks or dete- rioration. If the fuel tap screens have any breaks or are deterio- rated, they may allow dirt to reach the carburetor , c ausing poor running.
3-26 FUEL SYSTEM Evaporative Emission Control Sy stem ( California Model Only) The Evaporative Emission Cont rol System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped.
FUEL SYSTEM 3-27 Evaporative Emission Co ntrol System ( California Model Only) Separator Operation T est WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions.
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ENGINE TOP END 4-1 4 Engine T op End T able of Contents Exploded View ................................... 4-2 Specifications .................................... 4-6 Special T ools ..................................... 4-9 Clean Air System (For A T , CH, DE of BN125-A1 ∼ A2 and other than the CAL).
4-2 ENGINE TOP END Exploded View.
ENGINE TOP END 4-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 V alve Adjusting Cap Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb V alve Adjusting Cap Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb 2 Camshaft Chain Cover Bolts (BN125-A1 ∼ A3) 9.
4-4 ENGINE TOP END Exploded View.
ENGINE TOP END 4-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Camshaft Bearing Holder Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb Camshaft B earing Holder Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb 2 Camshaft Sprocket Bolts 12 1.2 104 in·lb 3 Camshaft Chain Holder Screw 4.
4-6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air Sytem V acuum Switch V alve Closing Pressure: Open → Close ––– (A T , CH, DE, of the BN125-A1 ∼ A2 and othe r than the CAL) 45 ∼ 53 kPa (340 ∼ 400 mmHg, 6.5 ∼ 7.7 psi) ––– (CAL) 41 ∼ 52 kPa (310 ∼ 390 mmHg, 6.
ENGINE TOP END 4-7 Specifications Item Standard Service Limit Width: Exhaust 0.8 ∼ 1.2 mm (0.03 ∼ 0.05 in.) ––– Inlet 0.8 ∼ 1.2 mm (0.03 ∼ 0.05 in.) ––– V alve Spring Free Length: Exhaust 43.51 mm (1.713 in.) 42.1 mm (1.66 in.) Inlet 43.
4-8 ENGINE TOP END Specifications Cam Height Cam Height [A] V alve Head Thickness V alve Stem Diameter [A] V alv e Head T hicknes s [B] 45° [C] Camshaft Runout Va l v e S t e m B e n d Dial Gauge [A].
ENGINE TOP END 4-9 Special T ools Compression Gauge, 20 kgf/cm²: 57001-221 V alve Spring Compressor A ssembly: 57001-241 Piston Pin Puller Assembly: 57001-910 V alve Seat Cutter , 45°- 27.
4-10 ENGINE TOP END Special T ools Fork Oil Level Gauge: 57001-129 0 Compression Gauge Adapter , M10 × 1.0: 57001-131 7 V alve Seat Cutter Holder , 4.
ENGINE TOP END 4-1 1 Clean Air System (For A T , CH, DE of BN125-A1 ∼ A2 an d other t han the C AL) AT : A u s t r i a CAL: California CH: Switzerland DE: Germany Air Suction V alve Installation • Install the air suction valve so that its number [A] of the read faces outside and downward.
4-12 ENGINE TOP END Clean Air System (For A T , CH, DE of BN125-A1 ∼ A2 an d other th an the C AL) V acuum Switch V alve Unit T est • Remove the vacuum switch valve (see V acuum Switch V alve Removal). • Connect a commercially available vacuum gauge [A] and syringe [B] (or fork oil level gauge) to the vacuum hoses as shown.
ENGINE TOP END 4-13 Clean Air System (California Model) Va c u u m S w i t c h Va l v e T e s t • Remove the vacuum switch valve. • Connect the vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown.
4-14 ENGINE TOP END Camshaft Chain T ensioner Camshaft Chain T ensioner Removal CAUTION This is a non-return type cam chain tensioner . The push rod does not return to its original position once it moves out to take up camshaft chain slack.
ENGINE TOP END 4-15 Camshaft Chain T ensioner • Install the O-ring in the tensioner body . • Install the tensioner so that the arrow mark [B] faces up- ward, and tighten the mounting bolts. T orque - Chain T ensioner Mounting Bolts (BN125-A1 ∼ A3): 9.
4-16 ENGINE TOP END Camshaft Camshaft Removal • Remove: Fuel T ank [A] (see Fuel System chapter) Camshaft Chain Cover [B] V alve Adjusting Caps [C] • Holding the camshaft center bolt [A] with a wrench, loosen the camshaft sprocket bolts [B].
ENGINE TOP END 4-17 Camshaft • Using a screw [A] (M5 × P0.8 mm), remove the rocker shafts [B]. ○ Mark the rocker shafts so that they can be installed later in the same position. • Remove: Rocker Arms [A] Camshaft Bearing Holder [B] ○ Mark the rocker arms so that they can be installed later in the same position.
4-18 ENGINE TOP END Camshaft • Install the camshaft bearing holder [A]. • Apply engine oil to the rocker shaft surface and cam por- tion of the rocker arm, and then install them at the original position. ○ Install the rocker shafts [B] so that the screw threads face outward.
ENGINE TOP END 4-19 Camshaft • Remove the crank balancer gear [A]. Special T ool - Outside Circlip Pliers: 57001-144 ○ Stuff a clean cloth into the hole [B] so that the balancer damper springs will not fall into it. • Remove the camshaft chain holder [A], and pull the camshaft chain [B] upward.
4-20 ENGINE TOP END Camshaft ○ Align the three punch marks [D] on the balancer shaft gear [A], crank balancer gear [B], and coupling [C]. • Install the alternator (see Electrical System chapter). • Align the punch mark [A] on the crankcase with the “T” mark [B] on the rotor .
ENGINE TOP END 4-21 Cylinder H ead Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged • W arm up the engine thoroughly .
4-22 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove: Fuel T ank (see Fuel System chapter) Exhaust Pipe [A] (see Muffler Removal) Carburetor [B] (see Fuel System chapter) Oil Pipe [C] (s.
ENGINE TOP END 4-23 Cylinder H ead Cylinder Head Installation • Install: Dowel Pins [A ] New Cylinder Head Gasket [B] • Apply molybdenum disulfide g rease to the threads of the 9 mm cylinder head bolts [1 ∼ 4], and engine oil to both sides of the washers.
4-24 ENGINE TOP END Cylinder Head Cylinder Head Assembly • Install the rubber dampers as shown. Dampers [A] Fins [B] Front [C] Cylinder Head Cleaning • Remove the cylinder head (see Cylinder Head Removal). • Remove the valves (see V alve Removal).
ENGINE TOP END 4-25 Cylinder H ead Cylinder Head Warp • Clean the cylinder head (see Cylinder Head Cleaning). • Lay a straightedge across the lower surface of the cylinder head at the positions as shown. • Use a thickness gauge [A] to measure the space between the straightedge [B] and the cylinder head.
4-26 ENGINE TOP END Va l v e s V alve Clearance Inspection • Refer to the V alve Clearance Inspection in the Periodic Maintenance chapter . V alve Clearance Adjustment • Refer to the V alve Clearance Adjustment in the Periodic Maintenance chapter .
ENGINE TOP END 4-27 Va l v e s V alve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). CAUTION Do not heat the cylinder head with a torch.
4-28 ENGINE TOP END Va l v e s V alve Seat In spection • Remove the valve (see V alve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat.
ENGINE TOP END 4-29 Va l v e s Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair . Therefore the cutter must not be used for other purposes than seat repair . 2. Do not drop or shock the valve seat cutter , or the dia- mond particles may fall off.
4-30 ENGINE TOP END Va l v e s • Measure the outside diameter of the seating surface with a v ernier caliper . If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range.
ENGINE TOP END 4-31 Va l v e s If the seat width is too wide, make the 60° grind [A] de- scribed below . If the seat width is within the specified range, lap the valve to the seat as described below . • Grind the seat at a 60° angle until the seat width is within the specified range.
4-32 ENGINE TOP END Va l v e s.
ENGINE TOP END 4-33 Cylinder , Piston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) • T ap lightly up the cylinder [A] with a plastic mallet to sep- arate from the crankcase. • Remove the cylinder base gasket. Piston Removal • Remove the cylinder (see Cylinder Removal).
4-34 ENGINE TOP END Cylinder , Piston ○ When installing the piston pin snap ring, compress it only enough to install it and no more. CAUTION Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.
ENGINE TOP END 4-35 Cylinder , Piston • Apply engine oil to the cylinder bore. • Position the piston ring openings. • Install the cylinder [B] while compressing [A] the piston rings with your thumbs.
4-36 ENGINE TOP END Cylinder , Piston Piston/Cylinder Clearance • Subtract the piston diameter from the cylinder inside di- ameter to get the piston/cylinder clearance.
ENGINE TOP END 4-37 Cylinder , Piston Piston Ring Thickness • Measure the piston ring thickness. ○ Use a micrometer to measure at several points around the ring. Piston Ring Thickness (T op, Second) Standard: 0.77 ∼ 0.79 mm (0.0303 ∼ 0.031 1 in.
4-38 ENGINE TOP END Carburetor Holder Carburetor Hold er Installation • Apply grease to the O-ring [A], and install the carburetor holder . ○ T ake care not to pinch the O-ring.
ENGINE TOP END 4-39 Muffler WA R N I N G T o avoid a serlous burn, do not remove the muffler when the engine is still hot. Wait until the muffler cools down. Muffler Removal • loosen the muffler body clamp bolt [A]. • Remove the muffler body mounting bolt and nut [B].
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CLUTCH 5-1 5 Clutch T able of Contents Exploded View ................................................................................................................... ..... 5-2 Specifications .........................................................
5-2 CLUTCH Exploded View.
CLUTCH 5-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Clutch Hub Nut 98 10.0 72 2 Clutch Spring Bolt 8.8 0.90 78 in·lb Clutch Cover Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 3 Clutch Cover Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb Oil Seal Retaining Plate Bolts (BN125-A1 ∼ A3) 9.
5-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Clutch Friction Plate Thickness 2.92 ∼ 3.08 mm (0.1 15 ∼ 0.121 in.) 2.8 mm (0.1 1 in.) Friction and Steel Plate Warp 0.2 mm (0.008 in.
CLUTCH 5-5 Special T ools Gear Holder , m1.75: 57001-1015 Clutch Holder: 57001-1243.
5-6 CLUTCH Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. Clutch Lever Free Play Inspection • Refer to the Clutch Lever Free Play Inspection in the P e- riodic Maintenance chapter .
CLUTCH 5-7 Clutch Cover Clutch Cover Removal • Drain the engine oil (see Periodic Maintenance chapter). • Remove: Front Footpeg Oil Pipe Banjo Bolt [A] • Screw the clutch lever adjuster in completely s o as to give t h ec l u t c hc a b l ep l e n t yo fp l a y .
5-8 CLUTCH Clutch Cover • With the shaft pulled a little out of the cover , turn the lever until it becomes hard to turn. ○ The release lever should have about 1 1 mm (0.43 in.) [A] clearance between the lever and the washer . • T ighten the cover bolts and clutch cable holder bolts.
CLUTCH 5-9 Clutch Clutch Removal • Remove the clutch cover (see Clutch Cover Removal). NOTE ○ If the primary gear is to be removed, remove the pri- mary gear nut before clutch removal (see Primary Gear Removal).
5-10 CLUTCH Clutch • Install the washer [A] as shown. Crankcase Side [B] • T ighten the clutch hub nut [C], while holding the clutch hub with the clutch holder .
CLUTCH 5-1 1 Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 35.0 mm (1.38 in.) Service Limit: 34.
5-12 CLUTCH Primary Gear Primary Gear Removal • Remove the clutch cover (see Clutch Cover Removal). • Using the gear holder [A], hold the primary gear and loosen the primary gear nut [B].
ENGINE LUBRICA TION SYSTEM 6-1 6 Engine Lubrication System T able of Contents Exploded View ................................................................................................................... ..... 6-2 Engine Oil Flow Chart............
6-2 ENGINE LUBRICA TION SYSTEM Exploded View.
ENGINE LUBRICA TION SYSTEM 6-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Oil Drain Plug 18 1.8 13 Oil Screen Cover Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 2 Oil Screen Cover Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb 3 Oil Pressure Relief V alve 15 1.
6-4 ENGINE LUBRICA TION SYSTEM Engine Oil Flow Chart 1. Oil screen 2. Oil pump 3. Clutch Cover Oil Passage 4. Oil Pressure Relief V alve 5. Oil Fi lter 6. Crankshaft Oil seal 7. Oil Pipe Banjo Bolts 8. Camshaft 9. Drive Shaft 10. Output Shaft 1 1. C amshaft C hain T unnel 12.
ENGINE LUBRICA TION SYSTEM 6-5 Specifications Item Standard Engine Oil Grade: (BN125-A1 ∼ A3) API SE, SF or SG (BN125-A4 ∼ ) API SE, SF or SG API SH, SJ or SL with JASO MA Vis c os i ty SAE 10W-40 Capacity 1.1 L (1.16 US qt) (when filter is not r emoved) 1.
6-6 ENGINE LUBRICA TION SYSTEM Special T ools Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Oil P re ssure Gauge Adapter , M10 × 1.25 : 57001-1 182.
ENGINE LUBRICA TION SYSTEM 6-7 Engine Oil and Oil Filter WA R N I N G Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury .
6-8 ENGINE LUBRICA TION SYSTEM Oil Screen Oil Screen Removal • Refer to the Oil Screen Cleaning in the Periodic Mainte- nance chapter . Oil Screen Installation • Refer to the Oil Screen Cleaning in the Periodic Mainte- nance chapter .
ENGINE LUBRICA TION SYSTEM 6-9 Oil Pump Oil Pump Removal • Remove the clutch cover (see Clutch chapter). • Remove the mounting screws [A] and remove the oil pump assembly [B]. ○ T urn the pump gear so that the pump mounting screws can be removed through the pump gear holes.
6-10 ENGINE LUBRICA TION SYSTEM Oil Pump Oil Pump Assembly • Install the oil pump gear [A]. • Fill the rotors [B] with engine oil. • Install the cover and tighten the oil pump assembly screw . T orque - O il Pump Assembly Screw: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the washer and circlip.
ENGINE LUBRICA TION SYSTEM 6-1 1 Oil Pressure Oil Pressure Me asureme nt • Remove the air suction valve [A] (see Engine T op End chapter). • Replace the oil pipe banjo bolt of the clutch cover [B] with the oil pressure gauge adapter (special tool) [C].
6-12 ENGINE LUBRICA TION SYSTEM Relief V alve Relief V alve Inspection • Remove the relief valve from the clutch c over . • Check to see if the valve [A] slides smoothly when push- ing in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure.
ENGINE LUBRICA TION SYSTEM 6-13 Oil Pipe Oil Pipe Removal • Remove: Oil Pipe Banjo Bolts (Cylinder Head) [A] Oil Pipe Banjo Bolt (Clutch Cover) [B] Oil Pipe Mounting Bolt [C] • Remove: Engine Sprocket Cover (see Final Drive chapter) Oil Pipe Banjo Bolt (Left Crankcase) [A] • Remove the oil pipe from the right side of the engine.
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ENGINE REM OV AL/INST ALLA TION 7-1 7 Engine Removal/Installation T able of Contents Exploded View ................................................................................................................... ..... 7-2 Special T ool ............
7-2 ENGINE REMOV AL/INST ALLA TION Exploded View.
ENGINE REMOV AL/INST ALLA TION 7-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Mounting Bolts, Nuts ( M10) 44 4.5 33 2 Engine Mounting Bolts, Nuts (M8) 25 2.5 18 3 Engine Mounting Bracket Bolts, Nuts 25 2.5 18 4 Engine Ground T erminal Bolt 9.
7-4 ENGINE REMOV AL/INST ALLA TION Special T oo l Jack: 57001-123 8.
ENGINE REMOV AL/INST ALLA TION 7-5 Engine Removal/Installation Engine Removal • Place the jack [A] under the frame to lift the rear wheel [B] off the ground. Special T ool - Jack: 57001-1238 • Squeeze the brake lever slowly and hold it with a band [A].
7-6 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Remove: Engine Mounting Bolts [A] Engine Mounting Bracket Bolts [B] ○ Pull out the mounting bolts while lifting the engine. • Lift up the engine and move it to the right side of the frame.
ENGINE REMOV AL/INST ALLA TION 7-7 Engine Removal/Installation If the engine sprocket is hard to install, remove the master link and the clip from the drive chain, and then install the engine sprocket. ○ Install the clip [A] so that the open end [B] of the "U" points in the opposite direction of chain rotation [C].
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CRANKSHAFT/TRANSMISSION 8-1 8 Crankshaft/T ransmission T able of Contents Exploded View ................................... 8-2 Specifications .................................... 8-6 Special T ools and Sealant ................. 8-7 Crankcase ........
8-2 CRANKSHAFT/TRANSMISSION Exploded View.
CRANKSHAFT/TRANSMISSION 8-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Primary Gear Nut 69 7.0 51 2 Balancer Shaft Gear Nut 78 8.0 58 EO 3 Crankcase Bolts 8.8 0.90 78 in·lb 4 Crankcase Bearing Retainer Screws 4.9 0.50 43 in·lb 5.
8-4 CRANKSHAFT/TRANSMISSION Exploded View.
CRANKSHAFT/TRANSMISSION 8-5 Exploded View T orque No. Faste ner N·m kgf·m ft·lb Remarks 1 Neutral Switch 15 1.5 11 2 Shift Drum Cam Screw 4.9 0.50 43 in·lb L 3 Gear Set Lever Nut 11 1.1 95 in·lb 4 Engine Sprocket Holder Bolts 12 1.2 104 in·lb 5 Shift Shaft Return Spring Pin 29 3.
8-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rod Connecting Rod Big End Side Clearance 0.20 ∼ 0.35 mm (0.008 ∼ 0.014 in.) 0.5 mm (0.020 in.) Connecting Rod Big End Radial Clearance 0.005 ∼ 0.017 mm (0.
CRANKSHAFT/TRANSMISSION 8-7 Special T ools and Sealant Outside Circlip Pliers: 57001-144 Gear Holder , m1.75: 57001-1015 Bearing Driver Set: 57001-1 129 Crankshaft Jig: 57001-1 174 Crankcase Splitting.
8-8 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Disassembly • Remove: Clutch (see Clutch chapter) Primary Gear (see Clutch chapter) Starter Motor (see Electrical System chapter) Alternator (see Elec.
CRANKSHAFT/TRANSMISSION 8-9 Crankcase • Remove the transmission shaft [A], gears and balancer shaft from the right crankcase half [B]. • Remove: Shift Drum Cam Screw [A ] Shift Drum Cam [B] Woodruf f Key [C] Shift D rum [D] Gear Set Lever [E] • Support the right crankcase half [ A] with a suitable re- tainer .
8-10 CRANKSHAFT/TRANSMISSION Crankcase • Press the damper [A] into the crankcase with the bearing drier set. Special T ool - Bearing Driver Set: 57001-1 129 • Chip off the old gasket from the mating surfaces of the crankcase halves and clean them off with a high-flash point solvent.
CRANKSHAFT/TRANSMISSION 8-1 1 Crankcase • Using compressed air [A], blow out the oil passage in the right crankshaft [B]. • Positioning the connecting rod [A] big end at BDC, put in the crankshaft jig [B] between the crankshaft flywheels. • Press the crankshaft [C] in the right crankcase half [D].
8-12 CRANKSHAFT/TRANSMISSION Crankcase • Check to see that the crankshaft, drive shaft, and output shaft all turn freely (in the neutral position). If the crankshaft will not turn, probably the crankshaft is not centered; T ap the mount portion [A] of the crankcase with a plastic hammer to reposition it.
CRANKSHAFT/TRANSMISSION 8-13 Crankshaft Crank Balancer Gear Removal/Installation • Refer to Camshaft Chain Removal/Installation in the En- gine T op End chapter . Crankshaft Removal • Refer to the Crankcase Disassembly in this chapter . Crankshaft Installation • Refer to the Crankcase Assembly in this chapter .
8-14 CRANKSHAFT/TRANSMISSION Crankshaft • First correct the horizontal misalignment by striking the projecting crank half [A] with a plastic, soft lead, or brass hammer as shown. • Recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit.
CRANKSHAFT/TRANSMISSION 8-15 Balancer Shaft Gear Balancer Shaft Ge ar Removal • Remove: Alternator Rotor (see Electrical System chapter) Clutch Cover (see Clutch chapter) • Using the gear holder , hold the primary gear [A] and loosen the balancer shaft gear nut [B].
8-16 CRANKSHAFT/TRANSMISSION Starter Motor C lutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal and Installation in the Electrical System chapter . Starter M otor Clutch Disassembly • Remove the alternator rotor [A] (see Electrical System chapter).
CRANKSHAFT/TRANSMISSION 8-17 External Shift Mechanism Shift Pedal Heigh t Adjustment • Adjust the length of the shift linkage rod so that the dis- tance between the shift pedal [A] and the front left footpeg [B] shall be 26.5 ∼ 29.5 mm (1.04 ∼ 1.
8-18 CRANKSHAFT/TRANSMISSION External Shift Mechanism • T urn the shift drum and position the neutral groove [A] as shown. • Remove the shift shaft [D] while pushing [C] the shift mechanism arm [B] toward the shaft. External Shift Mechanism Inspection • Examine the shift shaft [A] for any damage.
CRANKSHAFT/TRANSMISSION 8-19 T ransmission T ransmission Shaft Removal • Split the crankcase (see Crankcase Disassembly). • Pull out the shift rod [A] allowing the shift fork guide pins to free from the shift drum [B]. • Remove the shift forks [C].
8-20 CRANKSHAFT/TRANSMISSION T ransmission T ransmission Assembly • Replace any circlips removed with new ones. ○ Install the circlips [A] so that the opening [B] is aligned w i t has p l i n eg r o o v e[ C ] . ○ Install the toothed washer [D] so that the teeth [E] are not aligned with the opening of the c irclip.
CRANKSHAFT/TRANSMISSION 8-21 T ransmission Shift Drum Removal/Installation • Refer to the Crankcase Disassembly/Installation in the Crankshaft/T ransmission chapter . Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent.
8-22 CRANKSHAFT/TRANSMISSION Ball Bearing, and Oil Seal Ball Bearing Replacement CAUTION Do not remove the ball bearings unless it is neces- sary . Removal may damaged them.
WHEELS/TIRES 9-1 9 Wheels/T ires T able of Contents Exploded View ................................................................................................................... ..... 9-2 Specifications ............................................
9-2 WHEELS/TIRES Exploded View.
WHEELS/TIRES 9-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Ti r e A i r V a l v e N u t s 1.5 0.15 13 in·l b 2 Spoke Nipples 2.0 ∼ 3.9 0.20 ∼ 0.40 17 ∼ 35 in·lb 3 Front Axle Nut 78 8.0 58 4 Rear Axle Nut 98 10.0 72 5. For DE of BN125-A1 ∼ A2 and On and after BN125-A3 of EUR Models G: Apply grease.
9-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Size: Front 17 × 1.85 ––– Rear 15 × 2.75 ––– Rim Runout (with tire installed): Axial TIR 0.8 mm (0.03 in.) or less 2 mm (0.08 in.) Radial TIR 1.0 mm (0.04 in.) or less 2 mm (0.
WHEELS/TIRES 9-5 Special T ools Rim Protector: 57001-1063 Bead Breaker Assembly: 57001-1072 Bearing Driver Set: 57001-1 129 Jack: 57001-1238 Bearing Rem over Shaft, 9: 57001-1265 Bearing Remover Head,.
9-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove the cotter pin and axle nut [A]. • Remove the speedometer cable lower end [B]. • Raise the front wheel [B] off the ground using the jack [A]. Special T ool - Jack: 57001-1238 • Pull out the axle and drop the front wheel [A] out of the forks.
WHEELS/TIRES 9-7 Wheels (Rims) • Fit the fork leg stop [A] between the speedometer gear housing stop [B] and install the front wheel. • Install the axle from the right side and tighten the axle nut. T orque - Front Axle Nut: 78 N·m (8.0 kgf·m, 58 ft·lb) • Insert a new cotter pin [A].
9-8 WHEELS/TIRES Wheels (Rims) • Remove: Chain Cover Cotter Pin [A] and Axle Nut [B] T orque Link Bolt, Nut (rear) [C] Brake Adjusting Nut [D] • Remove the brake rod [E] from the brake cam lever [F]. • Remove the drive chain [A] from the rear sprocket, then remove the rear wheel [B] to the rear .
WHEELS/TIRES 9-9 Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. • Adjust the brake pedal free play (see Brakes chapter). • Check the rear brake effectiveness. WA R N I N G If a full brake pedal is not obtained, disassemble and inspect the brake parts.
9-10 WHEELS/TIRES Ti re s Air Pressure Inspection/Adjustme nt • Refer to the Air Pressure Inspection/Adjustment in the Pe- riodic Maintenance chapter . Tire Inspection • Refer to the T ire Wear Inspection in the Periodic Mainte- nance chapter . Tire R emo va l • Remove the following.
WHEELS/TIRES 9-1 1 Ti re s ○ For easier removal, always drop the tire bead opposite the valve stem into the rim well [A], and pry the tire bead a little at a time. • Do the same for the other side of the tire, then remove the rim from the tire. • Remove the protectors.
9-12 WHEELS/TIRES Hub Bearings (Wheel Bearings) Removal • Remove the wheel, and take out the following. Speedometer Gear (from front hub) [A] Collars [B] Grease Seals [C] ○ Use a screwdriver for the grease seal removal. • Remove the hub bearings [A].
WHEELS/TIRES 9-13 Hub Bearings (Wheel Bearing s) Inspection ○ Since the hub bearings are made to extremely close tol- erances, the clearance cannot normally be measured. NOTE ○ Do not remove any bearings for inspection. If any bear - ings are removed, they will need to be replaced with new ones.
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FINAL DRIVE 10-1 10 Final Drive T able of Contents Exploded View ................................................................................................................... ..... 10-2 Specifications ............................................
10-2 FINAL DRIVE Exploded View.
FINAL DRIVE 10-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks Engine Sprocket Cover Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 1 Engine Sprocket Cover Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb 2 Engine Sprocket Cover Damper Bolts 8.8 0.
10-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Standard Chain: Make/type: ENUMA CHAIN (BN125-A1 ∼ A2) ––– Joint Endless EK428SH-R DAIDO (BN125-A3 ∼ ) Joint Endless DID424HG Link: 132 links ––– 130 links (BN125-A7 ∼ ,N ,N U ) ––– Chain Slack 25 ∼ 40 mm (0.
FINAL DRIVE 10-5 Special T ools Bearing Driver Set: 57001-1 129 Jack: 57001-1238.
10-6 FINAL DRIVE Drive C hain Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter . Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter . Wear Inspection • Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter .
FINAL DRIVE 10-7 Sprocket, Coupling Engine Sprocket Removal • Remove the engine sprocket cover bolts [A] and sprocket cover [B]. • Remove the engine sprocket bolts [A].
10-8 FINAL DRIVE Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheels/T ires chapter). • Remove the drive chain (see Drive Chain Removal). • Remove the rear sprocket nuts [A] and separate the rear sprocket [B] from the coupling.
FINAL DRIVE 10-9 Sprocket, Coupling Coupling Installation • Grease [A] the following and install the coupling. Coupling Grease Seal Lips. Coupling Internal Surface • Install the rear sprocket and the coupling (see this chap- ter). • Install the rear wheel (see Wheels/Tires chapter).
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BRAKES 1 1-1 11 Brakes T able of Contents Exploded View ................................... 1 1-2 Specifications .................................... 1 1-6 Special T ools ..................................... 1 1-7 Caliper ............................
1 1-2 BRAKES Exploded View.
BRAKES 1 1-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Brake Disc Bolts 27 2.8 20 L 2 Caliper Mounting Bolts 25 2.5 18 3 Caliper Holder Shaft Bolts 18 1.8 13 4 Caliper Pad Bolts 18 1.8 13 5 Caliper Bleed V alve 7.8 0.80 69 in·lb 6 Brake Hose Banjo Bolts 25 2.
1 1-4 BRAKES Exploded View.
BRAKES 1 1-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Brake Pedal Bolt 9.8 1.0 87 in·lb 2 T orque Link Bolt and Nut 34 3.5 25 G: Apply grease.
1 1-6 BRAKES Specifications Item Standard Service Limit Front Brake Pad Lining Thickness: 4.5 mm (0.177 in.) (BN125-A1 ∼ A2) 1m( 0 . 0 4i n . ) 6.0 mm (0.236 in.) (BN125-A3 ∼ ) 1m ( 0 . 0 4i n . ) Disk Thickness 3.8 ∼ 4.2 mm (0.150 ∼ 0.165 in.
BRAKES 1 1-7 Special T ools Inside Circlip Pliers: 57001-143 Jack: 57001-1238.
1 1-8 BRAKES Caliper Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely . • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose Removal/Installation).
BRAKES 1 1-9 Caliper ○ Insert a w ooden board [A] 5 mm (0.2 in.) thick inside the caliper opening. ○ Apply compressed air [B] to the banjo bolt hole to allow the pistons [C] to protrude and stop at the w ooden board. ○ Remove the wooden board and pull out the pistons by hand.
1 1-10 BRAKES Caliper • Apply brake fluid to the inside of the cylinders and to the outside of the pistons and push the pistons [A] into the cylinders. • Check the friction boot [B] and dust boot [C] and replace them with new ones if they are damaged.
BRAKES 1 1-1 1 Caliper Caliper Dust Seal/Friction Boo t Damage • Check that the dust seal and friction boot [C] are not cracked, worn, swollen, or otherwise damaged. • If they show any damage, replace it. Caliper Piston and Cylinder Damage • Visually inspect the piston [D] and cylinder surfaces for damage.
1 1-12 BRAKES Front Brake Pads Brake Pad Removal (BN125-A1 ∼ A2) • Remove the caliper with the hose attached. • Remove: Caliper Pad B olts [A] Outer Pad [B] • Remove the inner pad (piston side pad) [C]. Brake Pad Removal (BN125-A3 ∼ ) • Loosen the caliper pad bolts [A].
BRAKES 1 1-13 Master Cylinder Master Cylinder Removal • Remove the brake fluid from the reservoir with a syringe or other suitable device. • Disconnect the front brake light switch connectors [A]. • Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder (see Brake H ose Removal/In- stallation).
1 1-14 BRAKES Master Cylinder Master Cylinder Assembly • Before assembly , clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts.
BRAKES 1 1-15 Front Brake Disc Brake Disc Removal • Remove the wheel (see Wheels/T ires chapter). • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the m arked side [A] faces out.
1 1-16 BRAKES Brake Fluid Brake Fluid Le vel I nspe ction • Refer to the Brake Fluid Level Inspection in Periodic Main- tenance c hapter . Brake Fluid Change • Refer to the Brake Fluid Change in Periodic Maintenance chapter . B r a k eL i n eB l e e d i n g • Refer to the Brake Line Bleeding in Periodic Maintenance chapter .
BRAKES 1 1-17 Brake Hose Brake H ose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts.
1 1-18 BRAKES Rear Brake Pedal and B rake Cable Brake Pedal Po sition Inspection/Adjustment • Check that the brake pedal [A] is in the correct position. Pedal Position [C] Standard: About 80 mm (3.15 in.) above footpeg top [B] If it is incorrect, adjust the brake pedal position.
BRAKES 1 1-19 Rear Brake Pedal and Brake Cable • Remove the brake pedal [A] and return spring [B]. Brake Pedal Installation • Apply grease to the brake pedal pivot. • T emporarily install the brake return spring onto the brake shaft and hook the spring onto the brake pedal.
1 1-20 BRAKES Rear Brake Pedal and B rake Cable • Remove: Cotter Pin and Joint Pin Brake Cable Nut [A] • Remove the silencer (see Engine T op End chapter). • Remove the adjusting nut on the end of the brake rod, and take off the joint pin and brake rod from the brake cam lever .
BRAKES 1 1-21 Rear Brake Panel and Drum Brake Panel Removal • Remove the rear wheel (see Wheels/T ires chapter). • Separate the brake panel from the wheel hub. Brake Panel Installation • Fit the brake panel into the rear wheel, and then install the rear wheel (see Wheels/T ires chapter).
1 1-22 BRAKES Rear Brake Panel and Drum • Install the brake cam seal and fit the indicator [A] on the serration so that it points to the extreme right of the US- ABLE RANGE [B]. • Install the cam lever in its original position on the camshaft, and tighten its bolt.
BRAKES 1 1-23 Rear Brake Panel and Drum Brake Shoe Spring s Inspection • Visually inspect the brake shoe springs for breaks or dis- tortion. If the springs are damaged in any way , replace them. • Measure the free length of the brake shoe springs.
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SUSPENSION 12-1 12 Suspension T able of Contents Exploded View ................................................................................................................... ..... 12-2 Specifications ..............................................
12-2 SUSPENSION Exploded View.
SUSPENSION 12-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Fork T op Plugs 23 2.3 17 2 Front Fork Bottom Allen Bolts 20 2.0 15 3 Front Fork Clamp Bolt (Upper) 20 2.0 15 4 Front Fork Clamp Bolt (Lower) 34 3.5 25 5. Fork cover (BN125-A1 ∼ A5) 6.
12-4 SUSPENSION Exploded View.
SUSPENSION 12-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear Shock Absorber Nuts and Bolts 34 3.5 25 2 Swingarm Pivot Nut 98 10.
12-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner T ube Diameter 33 mm (1.30 in.) Fork Spring Setting Non-adjustable Air Pressure Atmospheric pressure (non-adjustable) Damper Setting Non adjustable Fork Oil Viscosity SHOWA SS-8 or equivalent Fork Oil Capacity 191 ±2.
SUSPENSION 12-7 Special T ools Fork Cylinder Holder Handle: 57001-183 Fork Cylinder Holder Adapter: 57001-101 1 Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1 129 Fork Outer T .
12-8 SUSPENSION Front F ork Fork Oil Change • Refer to the Front Fork Oil Change in the Periodic Main- tenance c hapter . Fork Removal If the fork leg is to be disassembled, loosen the top plug beforehand. T o loosen the fork top plug, loosen the fork upper clamp bolts.
SUSPENSION 12-9 Front F ork • Check the front brake effectiveness after installation. WA R N I N G Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brake will not function to the first application of the lever if this is not done.
12-10 SUSPENSION Front F ork • Use the fork outer tube weight [A] to separate the outer tube [B] from the inner tube [C]. Holding the inner tube by hand, pull the outer tube several times to pull out the inner tube. Special T ool - Fork Outer T ube Weight: 57001-1218 • T ake out the cylinder base out of the outer tube.
SUSPENSION 12-1 1 Front F ork • Apply molybdenum disulfide grease to the oil seal lips and install the washer and oil seal [A] into the outer tube. Special T ool - Front Fork Oil Seal Driver: 57001-1219 [B] • Install the retaining ring and dust seal by hand.
12-12 SUSPENSION Front F ork Spring Inspection • Since the fork spring [A] becomes shorter as it weakens, check its free length [B] to determine its condition.
SUSPENSION 12-13 Rear Shock Absorbers Spring Preload Adjustment • T o adjust the spring force, turn the adjuster on each s hock absorber to the desired position.
12-14 SUSPENSION Swingarm Swingarm Removal • Remove: Chain Cover Rear Wheel (see Wheels/T ires chapter) Rear Shock Absorber Lower Mounting Bolts [A] (see this chapter) Silencer [B] (see Engine T op End chapter) Brake Cable [C] (see Brakes chapter) Pivot Nut [D] Front [E] • Pull out the swingarm pivot shaft, and remove the swingarm [A].
SUSPENSION 12-15 Swingarm Swingarm Pivot Check • Remove: Rear Wheel (see Wheels/T ires chapter) Rear Shock Absorber Bolts • Move the swingarm up and down to check for abnormal friction, and push and pull it to check for bushings play [A]. A small amount of play on the pivot is normal and no corrective action is needed.
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STEERING 13-1 13 Steering T able of Contents Exploded View ................................................................................................................... ..... 13-2 Special T ools ..................................................
13-2 STEERING Exploded View BN125-A1 ∼.
STEERING 13-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Steering Stem Head Bolts 44 4.5 33 2 Steering Stem Nut Hand-tight or 4.9 Hand-tight or 0.50 Hand-tight or 43 in·lb 3 Handlebar Nuts 34 3.5 25 4 Handlebar Weight Screws – – – L 5 Handlebar Switch Housing Screws 3.
13-4 STEERING Special T ools Steering Stem Bearing Driver: 57001-137 Steering S tem Bearing Driver Adapter , 34.5: 57001-107 4 Head Pipe Outer Race Press Shaft: 57001-107 5 Head Pipe Outer Race Driver , 51.5: 57001-107 6 Head Pipe Outer Race Driver , 46.
STEERING 13-5 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter . Steering Adjustment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter .
13-6 STEERING Steering Stem Steering Stem Removal • Loosen the steering stem head bolt [A]. • Open the headlight body and pull off the connectors in the headlight body (see Electrical System chapter). • Remove the clutch cable upper end and lead connector .
STEERING 13-7 Steering Stem Steering Stem Installation • Apply grease to the upper and lower outer races in the head pipe so that the steel balls will stick in place during stem insertion. Install the upper steel balls (23) [A] and lower steel balls (23).
13-8 STEERING Steering Stem • Install the front fork (see Suspension chapter). NOTE ○ Install the front fork at the correct position. Tighten the fork upper clamp bolts [A] first, next the stem head bolt [B], last the fork lower clamp bolts. T orque - Front Fork Clamp Bolts (Upper) : 20 N·m (2.
STEERING 13-9 Steering Stem Bearing Steering Stem Bearing Removal If the bearing is damaged, remove it. • T o remove the outer races [A] pressed in the head pipe, insert a bar [C] into the head pipe [B], and hammer evenly around the circumference of the opposite race to drive it out.
13-10 STEERING Handlebar Handlebar Removal (BN125-A1/A2) • Remove: Throttle Cables [A] (see Fuel System chapter) Brake Master Cylinder [B] (see Brakes chapter) Left Handlebar Switch Housing [C] Clutch Cable Upper End [D] Speedometer Unit [E] (with Cable) • Remove the handlebar nuts [A] and take off the handle- bar .
STEERING 13-1 1 Handlebar • The front half of the right and left switch housings [A] has a small projection [B]. Fit the projection into the small hole [C] in the handlebar . • Install the handlebar switch housing. • T ighten: T o rque - Handleb ar Switch Hous ing S cre ws: 3.
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FRAME 14-1 14 Frame T able of Contents Exploded View ................................................................................................................... ..... 14-2 Special T ool .........................................................
14-2 FRA ME Exploded View.
FRAME 14-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front F ootpeg Bolts 23 2.3 17 O: Apply oil..
14-4 FRA ME Exploded View.
FRAME 14-5 Exploded View IT : Italy SG: Singapore US: United States (BN125-A4 ∼ ).
14-6 FRA ME Special T oo l Jack: 57001-123 8.
FRAME 14-7 Side Covers Left Side Cover Removal • Remove the screws [A]. • Pull [B] the front part of the left side cover outward to clear the stopper . • Pull [C] the cover rearward to clear the hook, and remove it. Left Side Cover Insta llation • Slip the stopper [A] of the left side cover onto the hook [B].
14-8 FRA ME Seat Seat Removal • For the models other than the S ingapore and U.S.A. mod- els, remove the bolts [A] and loosen the bolts [B] on both sides. • Remove the pad assembly [C]. • For the Singapore and U.S.A. models remove the bolts [A], cover [B], and collar [C] on both sides.
FRAME 14-9 Fenders Front Fender Removal CAUTION Be careful not to scratch the pained surface during removal or installation. • Remove the mounting bolts [A] and take off the front fender [B]. Front Fender Installation • Install the front fender so that the narrower side [A] faces forward [B].
14-10 FR AME Fenders Rear Fender Rea r Disassembly • Remove the nuts [A] and take off the rear turn signal light assembly [B]. • Remove the nuts [C] and take off the tail/brake light as- sembly [D].
FRAME 14-1 1 Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WA R N I N G A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.
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ELECTRICAL SYSTEM 15-1 15 Electrical System T able of Contents Parts Location.................................... 15-2 Exploded View ................................... 15-4 Specifications .................................... 15-10 Special T ools and Sealant .
15-2 ELECTRICAL SYSTEM Parts Lo cation.
ELECTRICAL SYSTEM 15-3 Parts Lo cation 1. Speedometer 2. Starter lockout switch 3. Ignition coil 4. Starter motor 5. Ignition switch 6. Crankshaft sensor 7. Alternator 8. Neutral switch 9. Sidestand switch 10. Regulator/rectifier 1 1. Fuse unit 12. Starter circuit relay 13.
15-4 ELECTRICAL SYSTEM Exploded View.
ELECTRICAL SYSTEM 15-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Alternator Cover Bolts 8.8 0.90 78 i n·lb 2 Starter Motor Mounting Bolts 8.8 0.90 78 i n·lb 3 Starter Motor T erminal Locknut 6.9 0.70 61 i n·lb 4 Starter Motor Assembly Bolts 3.
15-6 ELECTRICAL SYSTEM Exploded View.
ELECTRICAL SYSTEM 15-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Neutral Switch 15 1.5 11 2 Sidestand Switch Screws 3.9 0.40 35 in·lb L 3 Handlebar Switch Housing Screws 3.4 0.35 30 in·lb 4. Ignition switch 5. T urn signal relay 6.
15-8 ELECTRICAL SYSTEM Exploded View.
ELECTRICAL SYSTEM 15-9 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Headlight Body Screws 2.9 0.30 26 in·lb 2 T urn Signal Light Holder Nuts 5.9 0.60 52 in·lb 3. Headlight unit 4. T urn signal lights 5. T ail/brake light 6. Canada and United Kingdom Models (BN125-A6 ∼ ) 7.
15-10 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Capacity 12 V 9 Ah –– – Electrolyte Level between level lines ––– Specific Gravity of E lectrolyte 1.
ELECTRICAL SYSTEM 15-1 1 Specifications Item Standard Service Limit Switches Rear Brake Light Switch T iming ON after about 10 mm (0.39 in.) pedal travel –––.
15-12 ELECTRICAL SYSTEM Special T ools an d Sealant Flywheel Puller , M 3 0 × 1.5: 57001-1 191 Rotor Puller , M16/M18/M20/M22 × 1.5: 57001-121 6 Timi ng Light: 57001-124 1 S p a r kP l u gW r e n c .
ELECTRICAL SYSTEM 15-13 Wiring Diagram Dummy Page.
15-14 ELECTRICAL SYSTEM Wiring Diagram BN125-A1.
ELECTRICAL SYSTEM 15-15 Wiring Diagram.
15-16 ELECTRICAL SYSTEM Wiring Diagram BN125-A2 ∼ (Singapore ) a nd BN125-A4 (United State s).
ELECTRICAL SYSTEM 15-17 Wiring Diagram.
15-18 ELECTRICAL SYSTEM Wiring Diagram BN125-A2 ∼ A5 (Europe).
ELECTRICAL SYSTEM 15-19 Wiring Diagram.
15-20 ELECTRICAL SYSTEM Wiring Diagram BN125-A5 (United States and Canada).
ELECTRICAL SYSTEM 15-21 Wiring Diagram.
15-22 ELECTRICAL SYSTEM Wiring Diagram BN125-A6 ∼ (U S, CA, N, NU).
ELECTRICAL SYSTEM 15-23 Wiring Diagram.
15-24 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below . ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts.
ELECTRICAL SYSTEM 15-25 Precautions ○ Electrical Connectors Connectors [A] Connectors [B].
15-26 ELECTRICAL SYSTEM Electrical Wiring Wiring Inspection • Visually inspect the wiring for signs of burning, fraying, etc. If any wiring is poor , replace the damaged wiring. • Pull each connector [A] apart and inspect it for corrosion, dirt, looseness and damage.
ELECTRICAL SYSTEM 15-27 Battery Battery Removal/Installation • Remove: Right Side Cover (see Frame chapter) Battery Holder • Disconnect the battery negative (–) cable [A] first, and t h e nt h ep o s i t i v e( + )c a b l e[ B ] .
15-28 ELECTRICAL SYSTEM Battery Initial Charging WA R N I N G Keep the battery away from sparks and open flames during charging, since the battery gives off an ex- plosive gas mixture of hydrogen and oxygen. When using a battery charger , connect the battery to the charger before turning on the charger .
ELECTRICAL SYSTEM 15-29 Battery Ordinary Charging • Remove the battery (see Battery Removal). • If any of the cells are low , fill them to the LOWER level line with distilled water only . The electrolyte will expand during charging, and the level will rise.
15-30 ELECTRICAL SYSTEM Battery Battery Charging Rate/Tim e T able (12 V 9 Ah).
ELECTRICAL SYSTEM 15-31 Charging System Alternator Cover Removal • Drain the engine oil (see E ngine Lubrication System chapter). • Remove: Engine Sprocket Cover (see Final Drive chapter) Alternator Lead Connector [A] • Remove: Alternator Cover B olts [A] Alternator Cover [B] • Remove the torque limiter [A].
15-32 ELECTRICAL SYSTEM Charging System • Using the flywheel puller [A] and rotor puller [B], remove the alternator rotor [C] from the crankshaft. Special T ools - Flywheel Puller , M30 × 1.
ELECTRICAL SYSTEM 15-33 Charging System Stator Coil Installation • T ighten: T orque - Stator Coil Bolts [A]: 13 N·m (1.3 kgf·m, 1 13 in·lb) Crankshaft Sensor Screws [B]: 3.9 N·m (0.40 kgf·m, 35 in·lb) Alternator Lead Holder Bolts (BN125-A3 ∼ ): 8.
15-34 ELECTRICAL SYSTEM Charging System • Check the stator coil resistance as follows. ○ Stop the engine. ○ Connect the hand tester as shown in the table. ○ Note the resistance readings. Stator Coil Resistance (BN125-A1/A2) Connections Te s t e r Range Meter (+ ) to Me ter ( − )t o Reading ×1 Ω Pink lead Engine ground 0.
ELECTRICAL SYSTEM 15-35 Charging System Regulator/Recti fier Internal Resistance (BN125-A3 ∼ ) Unit: k Ω T ester (+) Lead Connection Te r m i n a l W Y Y Y BK/Y W – ∞ ∞ ∞ ∞ Y 0.5 ∼ 10 – ∞ ∞ ∞ Y 0.5 ∼ 10 ∞ – ∞ ∞ Y 0.5 ∼ 10 ∞ ∞ – ∞ ( − )* BK/Y 0.
15-36 ELECTRICAL SYSTEM Charging System Charging System Circuit (BN125-A1/A2) 1. Ignition switch 2. Alt ernator 3. Regulator/rectifier 4. Controller 5.
ELECTRICAL SYSTEM 15-37 Charging System Charging System Circuit (BN125-A3 ∼ ) 1. Ignition switch 2. Alternator 3. Regulator/rectifier 4. Battery 5. Main fuse 30 A 6.
15-38 ELECTRICAL SYSTEM Ignition System CDI Unit Connectors [A] CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent CDI unit damage. Do not install the battery back- wards.
ELECTRICAL SYSTEM 15-39 Ignition System • Set the hand tester [B] to the × 25 V DC range, and con- nect it to the peak voltage adapter [C] as shown in the diagram. • Connect the black lead of the adapter to W/Y lead and red lead to G/W lead in the crankshaft sensor connector [A].
15-40 ELECTRICAL SYSTEM Ignition System Ignition Timing Engine speed Head timing mark [A] aligns with: 1 300 ±100 r/min (rpm) “T” mark [B] on cams haft sprocket If the ignition timing is incorrect, inspect the CDI unit and the crankshaft sensor .
ELECTRICAL SYSTEM 15-41 Ignition System If the coil tester is not available, the coil can be checked for a broken or badly shorted winding with the hand tester . NOTE ○ The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage.
15-42 ELECTRICAL SYSTEM Ignition System • T urn the ignition switch and engine stop switch on. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission gear in neutral to measure the igni- tion coil primary peak voltage.
ELECTRICAL SYSTEM 15-43 Ignition System CDI Unit Inspection CAUTION When inspecting the CDI Unit [A], observe the fol- lowing to avoid damage to the CDI Unit. Do not disconnect the CDI Unit with the ignition switch on. This may damage the CDI Unit. Do not disconnect the battery leads while the engine is run- ning.
15-44 ELECTRICAL SYSTEM Ignition System CDI Unit Internal Resistance (BN125-A1/A2) Unit: k Ω T ester (+) Lead Connection T erminal 1 2 3 4 5 6 7 8 1 – 10 ∼ 41 10 ∼ 41 11 ∼ 44 35 ∼ 140 14 ∼ 56 18.5 ∼ 74 ∞ 2 8.5 ∼ 34 – 0 0.5 ∼ 2.
ELECTRICAL SYSTEM 15-45 Ignition System Ignition System T roubleshooting.
15-46 ELECTRICAL SYSTEM Ignition System Ignition System Circuit (BN125-A1/A2) 1. Neutral switch 2. Interlock diodes 3. Sidestand switch 4. Starter lockout switch 5. Engine stop switch 6. Ignition fuse 10 A 7. Ignition switch 8. Regulator/rectifier 9. Crankshaft sensor 10.
ELECTRICAL SYSTEM 15-47 Ignition System Ignition System Circuit (BN125-A3 ∼ ) 1. Ignition switch 2. Starter lockout switch 3. Crankshaft sensor 4. Interlock diodes 5. Sidestand switch 6. Ignition fuse 15 A 7. Engine stop switch 8. Neutral switch 9. CDI unit 10.
15-48 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body . T apping the shaft or body could damage the motor . • Remove: Oil Pipe (see Engine Lubrication System chapter) • Slide back the rubber cap.
ELECTRICAL SYSTEM 15-49 Electric Starter System • Remove the terminal locknut [A] and terminal bolt [B], and then remove the brush with the brush plate from the yoke. Starter Motor Assembly • Replace the O-rings with new ones. • Apply a thin coat of grease to the oil seal [A] and needle bearing [B].
15-50 ELECTRICAL SYSTEM Electric Starter System Brush Inspection • Measure the length [A] of each brush. If any is worn down to the service limit, replace the carbon brush holder assembly [B]. Starter Motor Brush Length Standard: 9.5 ∼ 10.5 mm (0.
ELECTRICAL SYSTEM 15-51 Electric Starter System Brush Lead Inspection • Using the × 1 Ω hand tester range, measure the resis- tance as shown. T erminal Bolt and Positive Brush [A] Brush Plate and Negative Brush [B] Special T ool - Hand T ester: 57001-139 4 If there is not close to 0 Ω , the brush has an open.
15-52 ELECTRICAL SYSTEM Electric Starter System Starter Circuit Relay Inspection • Remove: Right Side Cover (see Frame chapter) Starter Circuit Relay • Connect the hand tester [A] and 12 V battery [B] as shown.
ELECTRICAL SYSTEM 15-53 Electric Starter System Electric Starter Circuit (BN125-A1/A2) 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Starter circuit relay 5. Ignition fuse 10 A 6. Starter lockout switch 7. Interlock diodes 8. CDI unit 9.
15-54 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit (BN125-A3 ∼ ) 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Starter circuit relay 5. Ignition fuse 15 A 6. Starter lockout switch 7. Interlock Diodes 8. CDI unit 9.
ELECTRICAL SYSTEM 15-55 Lighting System Headlight Beam Horizontal/V ertical Adjustment • T urn the horizontal adjuster [A] on the headlight with a screwdriver in or out until the beam points straight ahead. ○ T urn the horizontal adjuster clockwise to face the head- light left.
15-56 ELECTRICAL SYSTEM Lighting System • Replace the headlight bulb [A]. CAUTION When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode.
ELECTRICAL SYSTEM 15-57 Lighting System Headlight Circuit (BN125-A1/A2) 1. High beam indicator light 2. Headlight 3. Dimmer switch 4. Alternator 5. Regulator/rectifier 6. Headlight switch Headlight Circuit (BN125-A3 ∼ A5) 1. High beam indicator light 2.
15-58 ELECTRICAL SYSTEM Lighting System Headlight Circuit (BN125-A6 ∼ ) 1. High beam indicator light 2. Headlight 3. Dim mer switch 4. Alt ernator 5. Regulator/rectifier 6. Ignition switch 7. Headlight fuse 15 A T ail/Brake Light Bulb R epla cement • Remove the tail/brake light lens [A].
ELECTRICAL SYSTEM 15-59 Lighting System • With the front pin [A] down, insert the new bulb by aligning the front pin with the groove [B] in the walls of the socket. • Push the bulb in, turn it clockw ise, and replace it. It should lock in position.
15-60 ELECTRICAL SYSTEM Lighting System T urn Signal Light Circuit (BN125-A1 /A2) 1. T urn signal indicator light 2. T urn signal relay 3. Ignition fuse 10 A 4. Front right turn signal light 5. Front left turn signal light 6. Rear right turn signal light 7.
ELECTRICAL SYSTEM 15-61 Lighting System T urn Signal Light Circuit (BN125-A3 ∼ A5) 1. T urn signal indicator light 2. T urn signal relay 3. Ignition fuse 15 A 4. Front right turn signal light 5. Front left turn signal light 6. Rear right turn signal light 7.
15-62 ELECTRICAL SYSTEM Lighting System T urn Signal Light Circuit (BN125-A6 ∼ ) 1. T urn signal indicator light 2. T urn signal relay 3. Ignition fuse 15 A 4. Front right turn signal light 5. Front left turn signal light 6. Rear right turn signal light 7.
ELECTRICAL SYSTEM 15-63 Meter , Gauge, Indicator Unit Speedometer Removal • Remove the speedometer cable upper end [A]. • Remove the meter unit [C] by taking off the mounting bolts [B]. CAUTION Place the m eter so that the face is up. If a meter is left upside down or sideways for any length of time, it will malfunction.
15-64 ELECTRICAL SYSTEM Switches an d Sensors Front Brake Light Switch Inspection • Refer to the Front Brake Light Switch Inspection in the Periodic Maintenance chapter . Rear Brake Light Timing Inspection • Refer to the Rear Brake Light T iming Inspection in the Periodic Maintenance chapter .
ELECTRICAL SYSTEM 15-65 Fuse Main Fuse 15 A Removal • Remove the right side cover (see Frame chapter). • Disconnect the starter relay connector . • Pull out the main fuse [B] from the s tarter relay [A] with needle nose pliers. Main Fuse 15 A Inspection • Remove the fuse (see Fuse Removal).
15-66 ELECTRICAL SYSTEM Fuse Fuse 10 A Inspection • Inspect the fuse element. If it is blown out, replace the fuse. Fuse Element [A] Blown Element [B].
APPENDIX 16-1 16 Appendix T able of Contents Cable, Wire, and Hose Routing .............................................................................................. 16-2 T roubleshooting Guide .....................................................
16-2 APPE N DIX Cable, Wire, a nd Hose Routing BN125-A1 ∼.
APPENDIX 16-3 Cable, Wire, and Hose Routing 1. Crankshaft Sensor 2. Oil Pipe 3. Clamp 4. Run the alternator lead under the oil pipe. 5. Alternator Lead 6. Run the neutral switch lead so that it shall not out of guide rib. 7. Guide Rib 8. Neutral Switch 9.
16-4 APPE N DIX Cable, Wire, a nd Hose Routing BN125-A1 ∼.
APPENDIX 16-5 Cable, Wire, and Hose Routing 1. CDI Unit 2. Ignition Coil Lead 3. Engine Breather Hose 4. T o Fuel T ap 5. Insulator 6. Run the ignition coil lead under the engine breather hose.
16-6 APPE N DIX Cable, Wire, a nd Hose Routing Clean Air System.
APPENDIX 16-7 Cable, Wire, and Hose Routing 1. V acuum Hose 2. Three-way Joint 3. T o Fuel T ap 4. Air Hose 5. Air Pipe 6. Engine Breather Hose 7. Air Cleaner Duct 8. Air Cleaner Housing 9. V acuum Switch 10. Carburetor 1 1. Air Suction V alve 12. Insulator 13.
16-8 APPE N DIX Cable, Wire, a nd Hose Routing BN125-A1 ∼ A4.
APPENDIX 16-9 Cable, Wire, and Hose Routing 1. Ignition Switch 2. Run the ignition switch lead to the right. 3. Sidestand Switch Lead 4. Run the sidestand switch lead to the right. 5. Body Ground 6. Ignition Coil 7. Alternator Lead Connector 8. Sidestand Switch 9.
16-10 APPENDIX Cable, Wire, a nd Hose Routing BN125-A5 ∼.
APPENDIX 16-1 1 Cable, Wire, and Hose Routing 1. Indicator Light Connector (Move it to the right side after connected.) 2. Horn 3. Sidestand switch connector 4. Ignition coil 5. Regulator/Rectifier 6. Ground Lead 7. Alternator Lead 8. Put the connectors into the gusset after c onnecting them.
16-12 APPENDIX Cable, Wire, a nd Hose Routing BN125-A1 ∼.
APPENDIX 16-13 Cable, Wire, and Hose Routing 1. Rear Left T urn Signal Light 2. T ail/Brake Light 3. Rear Right Turn Signal Light 4. Rear Fender Rear 5. Rear Fender Front 6. Throttle Cables 7. Carburetor Air V ent Hose 8. Engine Breather Hose 9. Right Handlebar Switch 10.
16-14 APPENDIX Cable, Wire, a nd Hose Routing BN125-A1 ∼.
APPENDIX 16-15 Cable, Wire, and Hose Routing 1. Throttle Cables 2. Clutch Cable 3. Speedometer Cable 4. Left Handlebar Switch H arness 5. Right Handlebar Switch Harness 6.
16-16 APPENDIX Cable, Wire, a nd Hose Routing BN125-A1 ∼ A2.
APPENDIX 16-17 Cable, Wire, and Hose Routing 1. T ail/Brake Light Connector 2. Rear Left T urn Signal Light Connector 3. White T ape 4. Ignition Coil Connector 5. Body Ground 6. Front Left T urn Signal Light Connector 7. Front Right T urn Signal Light Connector 8.
16-18 APPENDIX Cable, Wire, a nd Hose Routing BN125-A3 ∼ A4.
APPENDIX 16-19 Cable, Wire, and Hose Routing 1. Rear Left T urn Signal Light Connector 2. T ail/Brake Light Connector 3. Band 4. Ground Lead 5. Ignition Coil Lead 6. Regulator/Rectifier Connector 7. CDI Unit Connector 8. Left Handlebar Switch Connector 9.
16-20 APPENDIX Cable, Wire, a nd Hose Routing BN125-A5 ∼.
APPENDIX 16-21 Cable, Wire, and Hose Routing 1. Rear Left T urn Signal Light Connector 2. T ail/Brake Light Connector 3. Band 4. White T ape 5. Ground Lead 6. Regulator/Rectifier Connector 7. Ignition Coil Lead 8. Left Handlebar Switch Connector 9. Horn Connector 10.
16-22 APPENDIX Cable, Wire, a nd Hose Routing BN125-A5 ∼.
APPENDIX 16-23 Cable, Wire, and Hose Routing 1. Diode Connector 2. Fuse Box Connector 3. Battery Positive Lead 4. Clamp 5. T urn Signal Relay 6. Alternator Connector 7. Battery Negative Lead 8. Band 9. CDI Unit Connector 10. Ignition Coil Lead 1 1. Run the indicator light lead from left side.
16-24 APPENDIX Cable, Wire, a nd Hose Routing Evaporative Emission Control System (BN125-A5 ∼ : California Model).
APPENDIX 16-25 Cable, Wire, and Hose Routing 1. Fuel T ank 2. Separator 3. Canister 4. V acuum Switch V alve 5. Air Cleaner Housing 6. Label (Blue) 7. Label (Red) 8. Hose (with blue stripe) 9. Hose (with blue stripe) 10. Hose (with red stripe) 1 1. Hose (with white stripe) 12.
16-26 APPENDIX Cable, Wire, a nd Hose Routing Evaporative Emission Control System (BN125-A5 ∼ : California Model).
APPENDIX 16-27 Cable, Wire, and Hose Routing 1. V acuum Switch V alve 2. Go to the fuel tap 3. Carburetor Holder 4. Separator.
16-28 APPENDIX Cable, Wire, a nd Hose Routing Evaporative Emission Control System (BN125-A5 ∼ : California Model).
APPENDIX 16-29 Cable, Wire, and Hose Routing 1. Run the ignition coil primary lead under the throttle cables, secondary air hose and breather hose. 2. Go T o Left Side 3. Separator 4. Go T o The Fuel T ank 5. Breather Hose 6. Secondary Air Hose 7. Air V ent Hose 8.
16-30 APPENDIX Cable, Wire, a nd Hose Routing Evaporative Emission Control System (BN125-A5 ∼ : California Model).
APPENDIX 16-31 Cable, Wire, and Hose Routing 1. Main Harness 2. Breather Hose 3. Secondary Air Hose 4. Air V ent Hose 5. Go to the fuel tank 6. Separator 7.
16-32 APPENDIX T roubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties.
APPENDIX 16-33 T roubleshooting Guide Fuel level in carburetor float bowl too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Fuel tap clogged Air cleaner .
16-34 APPENDIX T roubleshooting Guide Fuel/air mixture incorrect: Main jet clogged or wrong size Fuel level in carburetor float bowl too low Carburetor holder loose Air cleaner duct loose Air cleaner .
APPENDIX 16-35 T roubleshooting Guide Abnormal Drive T rain Noise: Clutch noise: Clutch rubber damper weak or damaged Clutch housing finger/friction plate tang clearance excessive Clutch housing gear .
16-36 APPENDIX T roubleshooting Guide Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in mas- ter cylinder Brake master cylinder scratched inside Drum brake: Bra.
MODEL APPLICA TION Ye a r Model Beginning Frame No. 1998 BN125-A1 BN125A000001 or JKABN125AAA000001 1999 BN125-A2 BN125A016001 or JKABN125AAA016001 2000 BN125-A3 JKABN125AADA00001 2001 BN125-A4 JKABNR.
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Kawasaki Eliminator 125 (2006) è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Kawasaki Eliminator 125 (2006) - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Kawasaki Eliminator 125 (2006) imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Kawasaki Eliminator 125 (2006) ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Kawasaki Eliminator 125 (2006), ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Kawasaki Eliminator 125 (2006).
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Kawasaki Eliminator 125 (2006). Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Kawasaki Eliminator 125 (2006) insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
