Instruction/ maintenance manual of the product KX125 (2004) Kawasaki
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KX125 KX250 KX500 Motorcycle Service Manual.
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This quick reference gu i de will Issist you in locating e desired topic or procedure . • Bend the pages back to match the black tab of th e desired chap t er nu mbe r wi th the black tab on the edge at each table of contents page . • Refer to the sectional table of contents for the exact pages to locate the specif i c top ic req u i red .
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Kawasaki KX125 KX250 KX500 Motorcycle Service Manual.
A ABDC AC ATDC BBDC BDC BTDC 'C DC F ' F It 9 h L LIST OF ABB REV I ATI O NS ampere(s) Ib Pound(s) after bottom dead center m meter(s) alternating current min minute(s) after top dead center.
Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However , it contains enough detail and basic in formation to make it useful to the owner who desires to perform his own basic main- tenance and repair work.
NOTE o This note symbol indicates points of partic - ular interest for more eff i cient and con- venient operation . -Indicate a procedural step or work to be done . o lndicates a procedural sub - step or how to do the work of the procedural step it follows .
GENERAL INFORMATION , - , D General Information Table of Contents Before Servicing ... . ......... _ , _ . . . ..... . .•. . ... . ... . • ... .... _ ,_... ... . . .. ... . . . . .. .. . 1 - 2 Mode l I dentification ...... . ...... . .............
1·2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle. carefu l reading of the applicable section is recommended to eliminate unnecessary work . Photographs , diagrams , notes, cautions , wa rn ings, and detailed des- criptions have been included wherever necessary .
GENERAL INFORMATION 1 -3 (11) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal gene r ally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out.
1 -4 GENERAL INFORMATION Model Identification KX 125 · F1 Left Side View KX125 - Fl Right Side VIew.
GENERAL INFORMATION 1 - 5 KX250 · F 1 left Side View KX250 - F 1 Right Side View.
1-6 GENERAL INFORMATION KX500 - Dl Left Side View KX500 - 01 Right Side View.
General Specification s Items Dimens i on s: Overall length Overall width Overall height Wheelbase Road clearance Seat height Dry weight Curb weight : Front Rear Fuel tank capacity Engine : Type Cooli.
1 · 8 GENERAL INFORMATION Item Frame : Type Steering angle Caster trake angle) Trail Fr ont tire: Make/Type Size Rear tire: Make/Type Size Front suspension: Type Wheel travel Rear suspension : Type W.
Items Dim ens ion s : Overall length Overall w i dth Overall height Wheelbase Road clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity Eng i ne : Type Cooling system Bore and s.
' - '0 GENERAL INFORMATION Item Frame : Type Steering angle Caster (rake angle) Trail Front tire : MakelType Size Rear tire : Make / Type Size Front suspension: Type Wheel travel Rear suspen.
Item s Dimensions : Overall length Overall width Overall height Wheelbase Road clearance Seat hei g ht Dry weight Curb weight: Front Rear Fuel tank capacity Eng i ne : Type Coo ling system Bore and st.
1 - 12 GENERAL INFORMATION Item Frame : Type Stee r ing angle Caster (rake angle) Trail Front type : T ype Rear t ype : Size Type Size Front suspension : Type Wheel tra vel Rear suspension : Type Wheel travel Brake type : Front and Rear Effective disc diameter : Front KX500 - 01 Tubular.
GENERAL INFORMATION 1-1 3 P e ri od ic M ai nt e na n ce Ch a rt FREQUENCY Each Every Every E very A, OPERATION race 3 races 5 ra c es 10 races required Clutch·-adjust • Clutch and friction plates-.
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GENERAL INFORMATION 1 - 15 Torqu e Fa stene r N -m kg-m It - Ib Remarks Eng in e Right Side : External Sift Mechanism Return Sp ring Pin (KX 125 , 250) 22 2 , 2 1 6,0 L IKX500) 20 2 , 0 14 , 5 L Clutc.
1 - 16 GENERAL INFORMATION Torque Fastener N - m kg-m It-Ib Remarks Brakes : Caliper Mounting Bolts(Front . Rear) 25 2 . 5 18 .0 Brake Hose Banjo Bolts 25 2.5 18 . 0 Front Master Cylinder Clamp Bolts 8 . 8 0.9 78 in - Ib Brake Lever Pivot Locknut 5 . 9 0 .
GENERAL INFORMA T ION 1- 17 The table below , re l ating tig h ten in g torque to t hr ea d d i amete r , lists t h e basic torq ue f o r t h e bo l ts a n d n ut s . Use this tab l e for o n ly t h e bo l ts and nut s w hi c h do not r equire a speci fi c to r que va l ue .
1- 18 GENERAL INFORMATION Cable Routing KX 125 : KX250 : 1 . Throttle Cable 2. Brake Hose 3 . Clutc h Cable 4 . Ignit io n Coil 5 . Stator lead 1. Throttle Cable 2.
GENERAL INFORMATION 1 - 19 KX500: 1 . Ignition Coil 2 . Thrott le Cable 3 . Radiato r Beather Hose 4 . Stator Lead.
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FUEL SYSTEM 2-1 Fuel System Table of Contents E x ploded V ie w ................. ... ..... , .. ". _._ ...... . ... . . ... .. . . _ . _ . .. ... .. ... 2 - 2 Specifications ..................... . .................... _,_ . .. " ... •. •.
2 - 2 FUEL SYSTEM ....... ExPIOd ·· . ·· d · · · V ··:······ .. •· .. •··•··· lew ······ · ·· · ·· ·· · · ··· · · .... . ... ... . ..... . .. .. . .. .. . .. . .. . . . . .... . .... ....... ..... .. - , I I I I I I I I I I I I I I _____ J r- --- I -I !Al'f~ i j : ~ I I' ~ KX1 2 5 I ' .
r- I I I I I I I I I I I I I I I I I I I I I I I I I I I I I ________ 1 __ _ l.... - KX 2 5 0 , 5 00 T 2 --- --, I I I I I I I I I I I I I I FUEL SYSTEM 2 - 3 r I I j~ I I I I I I I I I I I I : ~ ifi! I ' L~~ : ------ --T- - - - ~ - KX12 5 • - ----, I I I I I I I I I I I I I I I I I I I I I I _-.
2-4 FUEL SYSTEM Specifications KX125 ' Item Standard Service Limit Thronle Grip Free Play 2 - 3 mm - - - Carburetor Specifications : Make / type KEIHIN PWK35 - - - Main jet 148 - - - Throttle val.
FUEL SYSTEM 2-5 KX500 ' . Item Standard Service Limit Throttle Grip Free Play 2- 3mm - -- Carburetor Specifications : Make / type KEIHIN PWK39 - - - Main jet 175 - - - Throttle valve cutaway 7 - .
2 · 6 FUEL SYSTEM ......... . .. . .. . ..... . ...... . .. ... . .. . .. .................... Special Tools ............ . .. ... ... . ......... . .... .. .. . .. . . ............... Along with common hand tools , the following more specialized tools are required for complete fuel system servicing .
Throttle Grip and C a bl e If the throttle grip h as excessive free play due to cab l e s tr etch or m i sadjustment, t he r e will be a de l ay in throttle response .
2 - 8 FUEL SYSTEM Throttle Cable In s tallat ion Notes - Install the throttle cable in accordan ce with the Cable Routing sect i on in the General Information c hapt e r.
Carburetor ..................... . ........................................ Since the ca r buretor re gulates and mixes the fuel and air going to the engine, there are two gene ra l types of carburetor trouble : too rich a mixture (too much fuel), and too lean a mix ture (too l ittle fuel) , Such troub l e can be caused by dirt.
2·10 FUEL SYSTEM Service Fuel level (below the bottom edge of the carbo body) KX125 : 1 . 0 ± , mm KX250: 1 .0 ± 1 mm KX500: 1 .0 ± , mm 1 . Fuel level Gauge: 5700 1 -122 2. Service Fuel level Service Fuel Level Adjustment I WARNING' oGasoline Is extremely flammable and can be ex - plosive under certain conditions.
Fue l System Clean I WARNING' o Gasoline Is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke . Make sure the area Is well ventilated and free from any source of flame or sparks; this Includes any appliance with 8 pilot light.
2 · 12 FUEL SYSTEM Carburetor Installation Notes -In stallation is the reverse o f removal . - Being careful not to bend or otherwise damage the jet need l e . Check to see that the t hr ottle valve goes all the way down i nto the carbureto r body , and slides smoothly .
Carburetor Disassembly . Remove the carburetor. - Remove the throttle va l ve assembly and carburetor cap from the carbu retor cable lower end . · Oisassemble t he throttle valve assembly ; spring , retainer , connector.clip . jet needle . circlip and throttle valve .
2- 14 FUEL SYSTEM Ca r bu r etor Assembly No t es - Assembly is the reverse of disassembly . - Clean the disassemb l ed parts before assembling . - Replace the f l oat bowl O-ring with a new one if it i s deteriorated or damaged. - Turn in the air screw fully but not t i ghtly , and then back it out 1 1f2 turns .
- Remove the float valve needle . - Check the float valve need le for wear . * If the needle is worn as shown below , replace the valve needle . - Push the rod in the valve needle , then release it . * If the rod does not came out fully by spring tension , replace the va l ve n eedle .
2 - 16 FUEL SYSTEM Ai, Cleaner Element Installation Notes -I nstallation is the reverse of removal. - W hen installing the element , coat the lip of the e l em en t with a t hi c k l ayer of all purpose grease to assu r e a co mp lete seal against the air c leaner e l e- ment base .
Fuel Tank Fuel Tank R emoval - Remo v e the seat. -T u rn the fue l tap to the OFF po s ition . -P ul l the f uel ho se o ff the fuel tap . I WARNING' oG8501lne Is extremely flammable and can be ex- plosive under certain conditions. Always stop the engine and do not smoke.
2 - 18 FUEL SYSTEM Fuel Tap 1. D-ring 2 . Filter Sc r een '* If the fuel tap screen has any breaks or is deterio- rated . it may allow dirt to r each the carburetor, causing poor runni n g _ Replace the fue l tap . * I f the fuel tap l eaks. or allows fue l to f l ow w h en i t is at OFF position , replace the damaged D-ri ng.
Reed Valve Reed Valve Remov al - Rem ove the ca rburet o r from the carbu r etor holder and air cleaner duct . -R emove the ca rburetor holder mounting bolts , and move the holder rearward . - Take the reed va l ve out of th e cy lind e r . -F or KX125 model ; remo ve the reed valve out of the c rankcase .
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COOLING SYSTEM 3-1 Cooling System Table of Contents Exploded View ........... . .. . ..• . ... . .... . .•••... ... ....... ".................... . ..... 3·2 Specif i cations ........ .. . . .. . .... . • . .. . ...... . .•. . ......
3 - 2 COOLING SYSTEM ... . . . . . . . . Exploded ~i~~ """""""""""""""""""" KX125 :.
KX250 : TEM 3-3 COOLING SYS.
3-4 COOLING SYSTEM KX500: T1: T2: T3: 87 I.-Ibl 9 8 N-m 11,0 k g -m'll a ft-Ibl . (I 5 kg-m , . I 1 5 N- m. 78 in-Ib (0 9 kg-m. 9 N-m ..
COOLING SYSTEM 3 -5 Spe ci fication s Item Standard Coolant : Type Pe r manent type of antifreeze for al uminum engines and radiators Color G r een Mixed ratio Soft wate r 50%, Coolant 50% Total amo u nt : KX125 O.SS l KX250 1 . 1 l KX 5 00 1.3 l Radiator : Cap r elief p r essu r e 95 - 125 k P a 10.
3 - 6 COOLING SYSTEM Coolant Check the coo lant l evel each day before riding the motorcycle . and replenish coolant if the level is low . Change the coo lant in accordance with the Periodic Maintenance Cha rt (see the General Information chapte r ).
e place a can t amer under the coolant drain p l ug. and d r ain the coolant from the r a diator a nd engine by re moving the drain plug at the bottom of the wate r pu m p cover. Immed iate ly w ipe o r was h out any coo lant t hat spills on the frame , engine , o r w heel.
3 - S COOLING SYSTEM ,:r If hard water I. used in the system, It causes scale accumulation In the water passages , and considerably reduces the efficiency of the cool - Ing system .
- Remo ve the pre ssu re teste r, repleni s h the coolant, and install the radiator cap * If the pressure drops and no external sou r ce is found, check for internal leaks.
3 - 10 COOLING SYSTEM KX500 : A . Wa t er Pump Cove r B. B olts Water P ump Cover Ins t alla t io n No t es 'I nstallat i on is the reverse of removal. - Replace the pump cover gasket with a new one. - Fill the cooling system (see Coolan t Fi ll ing) .
Water Pump Shaft In sta llation KX125 , 250 : 1 1 . Oil Seal 3. Marked Side 2. Wate r Pump Shaft 4 . Right En gine Cover KX500 , 1 2 3 1 . Oil Seal 3. Marked Side 2 . Wate r Pump Shaft 4 . Right Engine Cover o Be sure to apply a molybednum disulf i de grease to the water pump s haft when installing .
3 - 12 COOLING SYST EM · Press the ball bearing into the hole with a bearing driver set (specia l too l: 57001-1 1 29) untif the bear - ing is bottomed against the step . Radiato r Radia t or Removal - Remove the radiator cover(s). - Drain the coolant ( see Coolant Draining) .
a Keep t he air nozzl e over 0 . 5 m 120 in . 1 away from the radiator . a Blow air perpendicularly to the rad i ator core. a Navar blow air at an angle against the fins but straight through them in the direction of natural air flow . a N a var s hake the air nozzle at a right angle against the fins .
3 - 14 COOLING SYSTEM Cooling Hoses, Breather Hose Installation Notes - In sta ll the coo ling noses or breather hose being careful to follow the preformed bends (see Exploded View , H ose Rout ing in the Cenerallnformation cha~ ter1 Avoid sharp bending.
ENGINE TOP END 4- 1 Engine Top End Table of Conten t s E x ploded View ......................................... _ ......... .. ............ . ...... . Specifications .....................• _ . . . .... . .•••.. . .. .. .... . . ... .... .•• .
4-2 ENGINE TOP END Exploded View T1 : 25 N - m 12 . 5 kg -m . 18 .0 ft - Ib) T2 : 26N -m 12 . 6 kg - m . 19 .0 ft - Ibl T3 : 6 . 9 N - m (0 . 7 kg - m. 81 In - Ibl T4 : 9 . 8 N - m 11 . 0 kg -m . 87 In - fbI T5 : 25 N -m 12 . 5 kg - m . 18 . 0 ft - Ibl T6 : 8 .
KX250 : 18 . 0 ft - Ibl 25 N-m 12 . 5 kg -m . 19 . 0 ft - Ibl T1 : 25 N-m (2 .6 kg -m . 61 I n - Ib) T2 : 6 9 N -m 10 . 7 kg - m , 87 in - Ib) T3 : 9 ' S N -m (1 . 0 k g - m ' 26 ft - Ibl T4 : 34 N -m 13 . 5 k9 : ~ : 11 fHb) T5 . 15 N - m 11 .
4-4 ENGINE TOP END KX500 : n : T2: T3: T4 : T5 : T6: T7 : 26 N - m (2 6 k 25 N-m (2'S k g - m • 18 ft-Ib) 6.9 N-m (0 7 :-m . 19 ft - Ib ) 34 N-m (3 6 k g-m , 61 in - Ibl 20 N -m (2 ' O k g-m . 25 ft - Ib) 9 . 8 N -m 11 0 :-m. 14 . 5 fHb) 9 .
ENGINE TOP END 4-5 Specifications KX125: Item Standard Service Limit Cylinder Head: Cylinder compression ( usable range) --- 770 - 1200 kPa (7.7 - 12 kg / cm 2 • 109-171 psil Cylinder head warp --- 0 . 03 mm Cylinder. Piston: Cylinder inside diameter 56 .
4-6 ENGINE TOP ENO KX250 : Item Cylinder Head : Cylinder comp ression Cylinder head warp Cylinder . Piston : Cylinder inside diameter: Piston diameter : Piston / cylinder clearance Piston ring / groov.
ENGINE TOP ENO 4-7 KX500 : Item Standard Service Limit Cylinder Head: Cylinder compression (usable range) --- 735- 1150 kPa 17.35- 11.5 kg / em', 105 - 1 64 psi! Cylinder head warp --- 0 . 03 mm Cylinder. Piston: Cylinder inside diameter 86 . 020-86.
4 - 8 ENGINE TOP END .. .. . .. . . . . . . .. .. .. . . . .... .... ................. . ...... . . .. .. . Special Tool Compres s ion Gauge : 57001 · 221 Adapter : 57001 · 1159 Piston Pin Puller As.
.. . ....... .............................. . ... . . .. .. . ........... Cylinder Head Cylinder Compression Measurement - Start the engi n e - T hor oughly wa rm up the engine so that the engine oil between the piston and cylinder wa ll wi ll he l p seal comp r ession as it does during normal running .
4-10 ENGINE TOP END - Tighten the cylinder head bolts o r nuts to t h e spe- cified to r que. Tighten i ng T o rqu e: 25 N-m (2 . 5 kg · m. 18 ft - Ibl - Tighten the spark plug to the specified torq u e .
ENGINE TOP ENO 4 - " KX500: - Remove the idle gear. - Lift up the right and left exhaust va l ves until the gear surfaces a re flush with cylinder surface . p A. Shaft Lever C. Retaining Sc rew . B. Shaft lever Mounting Nut 0 KX'25 : - Remove the main exhaust valve cover bolts, and remove the cover and gasket.
4 - 12 ENGINE TOP END - Remove the cylinder. and remove the main exhaust va l ve . A. Main Exhaust Va l ve KX250 : - Up side dow n the cylinder . ' Remove the plug and gasket. A. Plug B . Gasket ' Push in the operati n g rod as far as it will go .
KX50 0 : - Up si de down the cy lind er . - Remove the plug and gasket. - Remove the pin on the cylinder . - Remove the va l ve guide from the exhaust va lve . A. Exhaust Valve C. Pin B. Valve Gui d e - Unbolt the left plug . - Pull up the exhaust valves , and then pull out the va l ve operating rod to t he right side .
4-14 ENG.lNE TOP END KX1 2 5 Model E x hau s t V a lv e Op e ratin g R od In s tall a t io n 3 @) 00 I D~D I' D ) 1 . Ex h a u s t Va l v e s 2. Idle Ge ar 3 .
aFo r KX2S0 model ; tighten the main exhau st valve b r acket mounting bolts secu rely . Check that there is no gap between the bracket and cyli nder. 00 1.
4 - 16 ENGINE TOP END T ig htening Torque 20 N- m 12 . 0 kg-m. 14 .5 ft - Ibl A . Valve Opera t ing Rod D. Exhaust Va l ves B . Oil Seal E . Va l ve Guides C. O - Ring O Put the exhaust va l ves into the holes in the cyl- i nd er. o AppJya 2 -s troke eng i ne oi l to the teeth of the valve operating rod .
Cylinde r Installation Notes - Installation is (he reverse of removaL - Scrape any carbon out of the exhaust port . - Check for a crust of minerals and rust in the cy linder water jacket, and r emove them if necessary . - Replace the cy lind er base gaske t with a new one .
4-18 ENGINE TOP END - When installing the piston rings on the piston , note the following ; o lf installing the piston rin gs by hand . first fit one end of the piston ring against the pin in the ring groove , spread the ring opening with the other hand and then s lip the ring into the groove .
KX125 : Standard : SelVice Umit: KX250 : Standanl : 56 . 015 - 56 . 030mm , and less than O . 01mm difference between any two measurements . 66 . 10mm. or more than O.05mm difference between any two measurements . 67 . 400 - 67 . 415mm . and leas than O .
4-20 ENGINE TOP END Piston Ring . Piston R ing Groove Inspection • Visuallv inspect the piston rings and the piston ring grooves . * If the rings are worn uneven l y or damaged , they must be replaced . * If the piston ring grooves are worn unevenly or damaged , the piston must be rep l aced and fitted with new rings .
Pi s ton Pin Diameter KX1 2 S, Standard : Service lim i t : KX2S0 , Standard : Servi c e L i m i t : KXSOO , Standard : Service Lim i t : 15 . 995 - 16 .
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ENGINE RIGHT SIDE 5 - ' Engine Right Side Table of Contents E xpl oded View .......... . • . .. .. .......••............ ,..... . . .••• .. ........ . .... .. ...... 5 -2 Specifications ........... " ........... , .. . .. . .....
~ : 2 ENGINE RIGHT SIDE ... "" . Exploded ~·i. · · · ·· · "· · ·· .. . .... . ... ... . .. . ............ . . .. ... ... . . . . . w . .. . KX . . . . 125 : . . . . . . . . . . . .. .. . .. ... . ..... .. .......... o ~ ? ",,~(i)'~ o ®~i/~' ~ .
KX250 T1, 9 . 3 N·m 10 . 95 kg -m. 82 In·lbl T2: 9 .8 N -m 11 .0 kg -m , 87 In - Ib) T3: 98 N -m (10 kg -m , 60 ft - Ib) T4 : 9 . 8 N - m (1.0 kg -m . 87 in - Ibl T5 : 3 . 9 N - m (0 . 4 kg -m . 35 in - Ibl T6 : 2 .0 N-m (0 . 2 kg -m . 17 in - Ibl T7 : 9 .
5 · 4 ENGINE RIGHT SIDE KX500 : ~(8 ~ T1: 9 . 8 N-m 11 .0 kg - m . 87 In - Ibl T2 : 3 . 9 N-m 10.4 kg-m. 36 In - Ibl T3 : 2 . 0 N-m (0 .2 kg-m . 17 In-Ibl T4 : 9 . 8 N-m 11 .0 kg-m. 87 in - Ib) T5 : 9 . 3 N-m 10 . 96 kg -m , 82 In-Ibl T6 : 98 N-m (10 kg - m .
. .......... . .............. . .... . ............... . . • •. • •..• ••• • Specifications Item Clutch : Clutch lever free play Clutch Spring free length KX125 KX250 KX500 Friction plate thickness KX125 KX250 . 500 Friction plate / clutch housing clear- ance Friction and steel plate warp .
5 · 6 ENGINE RIGHT SIDE Right Engine Cover Right Eng i ne Cover Remo va l - Drain the t ran smission oil (see Transmission Oi l Change in the Engine Bottom End{Transmission chapter) . - Drain the coo l ant (see Coolant Change in the Coot- ing System chapter) , e Remove the fo ll owing parts .
- For K X 12 5 model ; turn the cl utch release lever to- ward the r ear . - Install the right engine cove r using the kick s haft oil se al guide (sp eci al t oo l ) to protect the cove r oi l sea l. A . Kick Shaft Oi l Sea l Guide : 5700 1- 263 - Fit t h e s haft le ve r bo ss in the groove of the va lve ope r ating (a d col la r.
5 · 8 ENGINE RIGHT SIDE KX500 : A. lever S haft C. Allen Bolts B . Exhaust Advance r Assemb l y - Remove the p lu g sc r ew and take out the pos iti on· i n g pin . - Pull the lever shaft out of the right e ng i n e cove r. ! 8 A. Plug Screw C. l eve r S haft B .
Exhaust Advancer Assembly Disassembly /Assem bly Notes - The exhaust advancer assembly consists of the fo ll owing parts . E x haust Advancer A ss embly A . Exhaust Advance r Assembly 1 . P ins 2 . Rod 3 . Guide 4 . O-ring 5. Steel Balls 6 . Ho l der 7.
5 · '0 ENGINE RIGHT SIDE Clut c h Proper clut c h le ve r play between the clut c h lever and the clutch lever holder is 2-3 mm . Play in - c r ease with cab le st ret c h and friction plate wear , necessitating adjustment. When there i s too much lever play, first try adjusting the cab le at the clutch le ver .
KX125 : - Remove the fta t washe r and cl u tch p u sher in the clutch hub . A. C lut c h Pusher B . flat Washer - Remove the mag n eto cove r. - Use the r oto r ho lder and a d apter " A U (s pe cia l tools) to prevent the clutch from rotating, loosen the clutch hub nut (see E l ectrical System chapte r).
5 - 12 ENGINE RIGHT SIDE Clutch Installation Note s -I nstallation is th e reverse of r e mo v al. - Apply mo l ybdenum disulfide grease to the outside of the s l eeve . - Apply transmission oil to the in side of the cl u tch housing gear and kick starter driven gear .
Friction Plate Thicknes s Measurement 1 . Friction Plate F ric t ion an d St e el Pl a t e Warp In s p ection • P l ace each friction p l ate o r steel plate on a surface plate , and measure the gap between the surface plate and each f r iction plate or steel plate .
5 - 14 ENGINE RIGHT SIDE External Shift Mechani s m External Shift Mechanism Removal - Remove the following parts . Shift Pedal Magneto Cover Right Engine Cover Clutch Housing . Pull out the shift shaft with the shift mechanism arm and arm sp ring . and remo ve the return spring .
Prim a ry Gear Primary Gear Removal - Remove the righ t engine cove r (see Right Engine Cover Remo v al) . - Remove the clutc h (see C lutch Removal) . e For KX125 model; remo ve t h e primary gear nut, spring washer, woodruff key, primary gear, and D- r ing.
5 - 16 ENGINE RIGHT SIDE A . Chamfe r ed Side eF o r KX250 , 500 ; replace the o ld ci rclip with a new one . Klckstarter Kickstarter Assembly Removal - Remove the following part s. Right Engine Co v er C lut c h Housing . Pull the end of the kick s pring out of the hole in the crank c ase .
KX500 : A . Kick Spring B. Kicks t arte r Assembly C. Ratchet Guide D . Bolts - Remove the ratchet guide and bolts . - Remove the kicksta r ter assembly _ Kickstarter A ssembly I nstall at io n No tes -In sta ll ation is the reve r se o f removal. - Apply a non-permanent locking agent to the threads of the ratchet guide bolu .
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ENGIN E REMOVAL II NSTALLATION 6 -' Engine Removal/Installation Table of Content s Expl o ded View .... . ......... . .................. . .......... . ..... ......... .... ... . . 6 - 2 Eng i ne Removal / I nstallation ......... .. ... ... ... .
6 - 2 ENGINE REMOVAL/INSTALLA TION .. . .. .. .... ............ .. . .. . ... . . ............. . ... . ....... Exploded View ... .... . . ... . . ............... . . .... . . .... . . ...... ..... .. ... . . r------------------, I T1 I KX125 Model I I I I I I I I I I I I I I I I L ________ ---"" / / / T1 : 25 N -m (2 .
Engine Removal / Installation Engine Removal - Drain the transmission oil (see Tran smission Oi l Cha n ge in t he Engine Bottom End{Transmission chap- ter). - Drain the coolant (see Coolant Change in the Cool- ing System chapter) . - Remove the fo ll owing parts .
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ENGINE BOTTOM END/TRANSMISSION 7 · ' Engine Bottom End/Transmission Table of Contents Exploded View .......................... . .............. . ... . ..... .. . ................. .. 7-2 Specificat i ons ................ . ... . .. ... .. . .. .
DITRANSMISSION 7 - 2 ENGINE ... .. .. ... . .. . .... . . . . .. . .. . .. .. . BOTTOM EN . . .. .. .. .. ....... . .......... d View .. . .. . ... . . . . . . . . .. .. . .. ... ... . . Explode .... ..... . ................ KX125 : y! ~,,~ ~ b ~ / anent locking av-nt .
KX250 : l : Apply a non-permanent locking agent . f1 : 5 . 9 N -m (0.6 kg-m . 52In - lb) T 2: 9 . 8 N-m 11.0 kg-m. 87 In - Ib) T 3 : 9 . 8 N -m 11.0 kg-m . 87 i n - Ib} T4 : 20 N -m 12 . 0 kg-m , 14 .5 ft - Ib) T5 : 9 .8 N-m 11.0 kg -m. 87 In - Ib) T6 : 22 N -m (2 .
7 -4 ENGINE BOTTOM ENO/TRANSMISSION KX500 : l : Apply. non - J*menent locking egent . T 1 : 5 . 9 N ' m (0 . 6 kg - m , 62 In-lbl T 2 : 9 .8 N-m 11.0 kg - m , 87 In-lbl T3 : 20 N ' m {Z .O kg -m . 14 .6 ft·lbl T4 : 22 N ' m 12 . 2 kg -m.
ENGINE BOTTOM ENOITRANSMISSION 7-5 Specifications Item Standard Service limit Transmission Oil : Grade SE class - -- Viscosity SAE 10W 30 o r 10W 40 --- Amount : KX 125 0 . 65 L -- - KX250, 500 0.8 L - -- Crankshaft . Connecting Rod : Connecting rod : Bend and twist not more than O.
7 - 6 ENGINE BOTTOM ENOITRANSMISSION Special Tools .. . .... ... .............. . ........ .. ..... . .................. . . Along with common hand tools and precision instruments . specia li zed tools are required for com- plete crankshaft/transmission servicing.
Transmission Oil I n order for the transmission and clutch to function p r operly, always maintain the transmission oil at the proper level and change the oil periodica l ly.
7 -8 ENGINE BOTTOM ENDITRANSMISSION KX250, KX500 , A. Tran s mission Oil Drain Plug • Check the gasket at the drain plug for damage . * Repla ce the gas k et with a new o n e if it is damaged . • After the oi l has co mpletely drained out, i n stall the drain p lu g with the gasket, and tighten it to the specified to r que .
KX600 , A. Crankcase Bolts -I nstall the crankcase splitting tool and adapter (s pe cia l tools) i nto the left side of the crankcase . Be certain to screw the tool in all the way . A. Crankcase Splitting Tool Set: 57001- 1 096 B . Adapter : 5700 1 -136 - Tighten the bolt o n the c r ankcase splitting tool to split the c rank case halves .
7-10 ENGINE BOTTOM ENO/TRANSMISSION NOTE 0 00 nor remove the bearings unless it is necessary . Removal may damage them. o lnstall the bearings for the crankshaft in the right and left crankcase so that their sealed sides face toward the oil sea/ side.
Crankshaft . Connecting Rod Crankshaft Removal - Split the crankcase (see Crankcase Splitting) . - Remove the transmission shafts (see Transmission Shaft Removal) .
7 - 12 ENGINE BOTTOM ENO/TRANSMISSION Cra n ks h aft A sse mbl y No t es Since the assembly of the cra nk shaft dema n ds ex - acting tolerances . the disassembly and reassembly of the crankshaft can on l y be done by a shop having the necessary too l s and equip m ent.
Crankshaft Runout 7.5 mm Turn the crankshaf t slowly. Crankshaft Alignmen t 7.5 mm * If the run ou t at eithe r point exceeds the serv i ce limit, a l ign the flywheels 50 that the runout falls wi thi.
'-'4 ENGINE BOTTOM END/TRANSMISSION Transmission Transmission Shaft Remo val - Split the c r ankcase (see Crankcase Splitting) . -Pull off the shift rod. and disengage the shift fo rk guide pins from t h e shift drum grooves . - Remove t he s h ift drum .
_The drive s haft gears ca n be identified b y size ; the s mallest diameter gear is 1st gear, a nd the l argest is 5th (KX250, 500) or 6th (KX125). Be sure that all pa r ts are put back in the co rre ct sequence, facing the proper di r ect i on, and that a ll c irciip s a nd the washer are properly in place .
7 - 16 ENGINE BOTTOM ENOITRANSMISSION KX500, 1. 2nd gear (29 T; dog re cesses face right ) 2 . 4th gear (2 1T ; fork groove goes to the rig ht side of the gea r teeth) 3. 3rd gear (26T ; dog recesses face left ) 4. 5th gear (19T; fork groove goes to the left side of the gear teeth ) 5.
® A . Drive Shaft 3rd Gear Shift Fork B . Output S haft 4th Gear Shift Fork C. Output Shaft 5th Gear Shift Fork Drive shaft ', d gea r fingers a re s horter than shift fork t ho se of the other .
7 - 1B ENGINE BOTTOM ENDITRANSMISSION A. S h ift Fo rk F i nge r * If a gear shift fo rk groove is worn over t h e serv - ice limit , the gear must be rep l aced . Gear Shift Fork Gr oov e Width Standard : IKX1 25 1 4.06 - 4 . 16 mm IKX 2 50 . 5001 4 .
A . Dog Hole B . Dog Ball Bearing Wear • C h eck the ball bearing o n both sides of t he s hift dr um , drive shaft an d o u tput shaft . o Si nc e the ball bearings are m a d e to extreme ly close tolerances. t h e wea r must be judged by feel rather tha n measurement.
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WHEELSfTlRES 8 - 1 Wheels/Tires Table of Contents Exploded View .... . . .. ............. . ...... . _ ...... . .. . .............. . ................. . Specifications Specia l Tool s ...... . ............ .... .... . .. .. ........ . .• •• .. .
8 - 2 WHEELSITIRES Exploded View T1 : 5' N-rn (5.5 kg-rn, 40 fNb) T2 : 9.3 N-rn (0 . 96 kg"," , 82 In-4bl T3 : 26 N-rn (2:.5 kgom, 18 ft-tb) T4: 98 N-rn (10 kg-rn, 72 ft~bl 1'5 : 1.
WHEELS/TIRES 8 · 3 Specifications Item Standard Service Limit Whoels: Rim runout : Axial Under 0 .5 mm 2mm Rad i al Under 0 . 8 mm 2mm Axle runou t/ l00 rnm Under 0 .
8-4 WHEELSITIRES Special Tools Bearing Driver Set: 67001 · 1129 Bead Breaker A .. ' y : 57001-'072 Tire Iron : 67001 - 1073 Rim Protector: 57001·1063 ClrcUp Pliers : 67001·143 NOTE o The t i re i rons (P I N 5 7 001 · 10 73 ) are i nc luded in the bead breaker assembly (P I N 57001 · 1072J .
Whe e ls F ro n t Wheel Removal _ P l ace a stand or block under the motorcycle so that the front wheel is raised off the ground. - Rem ove the axle clamp nuts , a nd remove the wheel with t he axle. _ Remove the axle n ut, a nd remove the wh eel. 0 00 I1bt lay the wheel on the ground wrth the disc facing down .
8 · 6 WHEELSITIRES Rear Whee/Installation Notes - Installatio n is the reverse of removal . - Fit the brake holder stop against the swi ng arm stop . A . Brake Holder C. Swing Arm B . Stop (B r ake Holder) O. Stop (Swina Arm) - Fit the caps to the irooves on the co ll ar .
I WARNING. otf any spoke breaks, it should be replaced immedi- ately. A missing spoke pklces an additional load on the other spokes, which wi! eventualy cause other spokes to break. Rim Inspection • Inspect the rim for small c rack s, dents. bending, or warping .
8·8 WHEELSITIRES Tires Tire Removal 0 00 not lav the wheelan the ground with the disc facing down , This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground . - Remove the whee l from the moto r cycle (see W h ee l s) .
- Position the tire on the rim so that the valve is at the ti re balance mark (the chal k mark made during removal or the yellow paint mark on a new tire) . A . Balance Mark - Tighten the bead protector nut securely , - C heck and adjust t he ai r pressure after in sta llin g .
8-10 WHEELSITIRES Hub Bearing 000 not lily the wheelan the ground with the disc facing down . This can damage or wrap the disc. Place blocks under the wheel so the disc does n01 touch the ground . Hub Bearing Removal Notes -R emove the hub bearing by tapping evenly around the bearing inner race as shown .
Hub Bearing Inspection and Lubrication Since the wheel bearings are made to extremely dose tolerances, the clearance cannot normally be measured_ • For front hub bearing, turn each bearing back and forth while checking for roughness or bind ing . * If roughness or binding is found, rep l ace the bearing.
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FINAL DRIVE 9 - 1 Final Drive Table of Contents E x ploded V i ew ......................................... . .................. . ..... . ..... . Spec i fication s Special Tools Drive Chain .. .. .... ..... ..... . ....................... .. . _ ._ .
9 · 2 FINAL DRIVE Exploded View /1 __ - - ~ KX250 . 500 _-- ~' -- I - --- ~. --- I . _ I Ii) I,) -- I ,...... ..... (" I I I I ......... ....- I L.-....... .... ...... .... I _- I ____ KX125 - I -- -- I ..J I _- 1 -- -- T1 : 29 N- m (3 .0 kg -m .
FINAL DRIVE 9 - 3 Specifications Item Standard Service Limit Drive Chain: Make Daido - -- Type 0 . 1.0 520 OS - 5 --- Length : KX125 112link --- KX250 , KX500 114 link -- - Chain slack 50-60 mm less than 50mm, or more than 65mm 20 - link length 317 . 5 mm 323 mm Sprockets : Engine sprocket diameter KX125 50 .
9 - 4 FINAL DRIVE ... ..... ................... ... ... . . ... . . . . .. . .. .. . .. .... .... . .. Drive Chain Drive Chain Slack Inspection - Support the motorcycle on its side stand . - Check the wheel alignment (see Whee l Alignment Jnspection l and adjust it if neces s ary ( see Wheel Alignment Adjustment) .
Wheel Alignment Inspection - Check that the notch on the l eft cha in adjuster aligns with the same swing arm mark as the right chain adjuster. A. Marks B .
9 -6 FINAL DRIVE Dr ive Ch a in Make Daido Type 0.1. 0 52005-5 links: KX125 112 KX250 114 KX500 114 Drive Chain LubriC8tion - If the cnain appears especially dirty , it should be cleaned before lubrication with high flash-point sol- vent - Apply oil to the si des of the rollers so that oil wi l l penetrate to the rollers and bushings .
Sprocket Engine Sprocket Removal - Remove the following parts . Engine Sp ro cket Cover Drive C hain(free of e n gine s procket ) - Remove the c irclip , and pull off the engine sprocket . Engine Sprocket Installation Notes -In sta ll ation is the reverse of removal.
9 -8 FINAL DRIVE Sprocket Oiamete, (Engine) 10(125 Standard : Service lImtt : 10(250. 500 Standard: Service limit: IR •• r) Standard : Service limit : 50.98-61.18 mm 50 . 7 mm 60.99 - 61 . 19 mm 60.7 mm 227.43-227.93 mm 227.1 mm NOTE o lf IJ sprocket requires replacement , the chain is probably worn also.
BRA KES 1 0 · 1 Brakes T a ble of Con t ent s Exp loded V ie w .............................. , ............... . ................... . ... . 10 -2 Spec i f ica ti ons . ......• •• ....................................... . ......••.. , ....
' ~~~I~~~'~' ~ : I~~ . .. ...... . ... .. . . .. . . . .. . ............. . . ............ . . . 10 - 2 BRAKES ........ . ....... . . ..
D isc Brake Rear j---@ " . ~ ~ I [!l . W fIJfIJ l..Jr I 'I 52 in - Ib ) 9 N -m (0 .6 k g -m . 18 . 0 ft - Ib ) T1 : ~ 5 N -m 12 . 5 kg - rn. 78 In - Ibl T2 : 8 N -m 10 .9 kg -m . 18 .0 ft - Ib) T3 : ~ 5 N-m 12 . 5 kg -m . 69 in - Ibl T4 : 78 N-m (0 .
10·4 BRAKES ...... ............. .. .... . . ...... . .. . ........... .. . .. . . .. .. . . Specifications D isc Brake Item Standard Service limit Brake Adjustment : Brake lever p l ay Adjustable (t.
Disc Brakes [ WARNING' o When working with the disc brake. observe the precautions listed betow . 1 . Never reuse old brake fluid . 2. Do not use flu id from a conta in e r that ha s been left unsealed o r that has been ope n for a long time . 3, Do n ot mix two types and brands of fluid for use i n the brake .
10 · 6 BRAKES R ea r B rake Ped a l Pl ay Ad j u s tment - Adjust t h e rear brake peda l p l ay to suit you . - Loosen the adjuster locknu t and turn t he ad ju ste r o n t he rear master cy l inder . - After adj u stme n t, t i gh te n t he l ock nut sec ur e l y .
A . App l y compressed air . B . Cloth NOT E o lf t h e caliper is to be disassembled after removal and compressed air is not available, remove the piston using the following three steps before disconnecting the brake hose from the caliper. o Prepare a suitable dished container for brake fluid, and perform the work above it.
10 · B BRAKES Brak e Ped s: P ad Removal - Remove the caliper from the disc . and take out the piston side pad from the caliper holder . • Push the caliper holder toward the piston , and then remove the pad from the ca liper holder shaft. A. Pads C.
A. Banjo Bolt C. Rese r voi r B. Master Cylinder - When removing the brake hose , temporarily secu r e the end of the brake hose to some high p l ace to keep fluid loss to a minimum . - Unscrew the damp bolts, and take off the master cy linder as an assembly with the reservo i r and b r ake leve r .
10 - 10 BRAKES - When removing the brake hose , tempora r ily secure the end of the brake hose to some high place to keep fluid loss to a minimum . - Unscrew the master cylinder mounting bolts , and remove the master cylinde r with the reservoir .
Master Cylinder A ss embly Notes - Assembly is the r everse of disasse mbl y . - Take care not to damage the i nn e r s urf ace of the cy lind er , or the pi sto n . - Clean all parts with brake fluid o r alcohol , and apply brake fluid to the inner surface of the cylinder before assembly .
'0 - '2 BRAKES Brake Disc : Disc I ns p ection • Visually inspect the disc. * If it is scratched or damaged , repla ce the disc . • l1easure the thickness of each disc at the lX>int where it has worn the most * Rep l ace t he disc if it has worn past the serv i ce l imit .
Brake Fluid Level Inspect i on In spect the brake fluid level in the f ron t and r ea r brak e fluid re se rvoir s per io d ica lly . - Check the brake fluid level in the reservoir . NOTE o Hold the reservoir horizontal when checking brake fluid level.
10-14 BRAKES Filling up the Brake line , . Open the bleed valve . 2. App ly the brake and hold it . 3. Close the bleed valve with the brake held app lied . 4. Then quickly release the brake . Bleeding the BrBke Line The brake fluid has a very low compression coeffj.
Brake Hose : Brake Hose RemovaVlnstallation Notes - When r emovi ng the brake hose , take care not to spill the brake fluid on the frame or other painted parts . - When removing the brake hose , temporarily secure the end of the brake hose to some high place to keep fluid los s to a minimum .
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SUSPENSION ,, - , Suspension Table of Contents Exploded View ............ . _ .............................................. . ...... . .. ... 11-2 Specifi ca tions ..............• _ .......... .. .............. ..... . •• • • . .........•.
11 - 2 SUSPENSION . .. . ...••••••••• • •. . . .. . . . . . . .••••••••••..... .. . . . .... . .•.. . . Ex~loded View .... .. . . . . ........ .. .. . . ... . . . . ..................... . . . . ... . . • T1: 20 N · m 12 .
SUSPENSION 11 -3 Specifications Item Standard Service limit Front Fork : Air pressure Atmospheric pressure (Maximum air pres sure) 40kPa (0 .4 kg / cm 2 , Spsi) Oil viscosity: SAE 5W --- Oil capacity : KX 125 535 ± 4mL -- - 10(250 535 ± 4 mL --- 10(500 597 ± 4 mL --- (adjustable range) Oil le v el : K X 125 130 ± 2mm 100 - 160 mm ( full .
11 -4 SUSPENSION Spec i al Tools Front Fork Cylinder Holder : 5700' - '245 Front Fork Oil Seal Driver ; 57001 - 1219 Front Fork Outer Tube Weight : 5700, - '218.
Front Fork Front Fork Adjustment The front fork shou ld always be adjusted for the rider's weight and track co nditions by using one or more of the fo ll owing methods .
11-6 SUSPENSION Softer E o 2 i Standard ..,. Harder 4 6 8 10 1 2 14 16 Number of turns clockwise u sab l e r8nge · 16 clicks Seated position adjuster turned fully counterc lockwi se o The left and right fork lega must have the same shock damping . -P ut the caps into the bottom of the outer tubes .
Fork Spring Different fork springs are available to achieve ~itable front fork action in accordance wit h t h e rider's weig h t and track co ndition. e Harder s prings make the fork stiffer, and rebound action quicker. e Softer sp rings make the fork softer, and rebound aciton slower.
" · 8 SUSPENSION A. Top Bolt B . O·Ring C. Sp r ing Se at D . Spacer E. S pring F. Push Rod C . Up pe r H ole H. Si d e Hole - Pour in the type and amount of fo rk oi l s pecif ied .
- Mount the axle clamp s, and tighten the clamp nuts , first tighten the upper clamp nuts and t h en the lower clamp nuts to the specified torque . The arrow mark on the axle clamp must point upwards . A. Arrow Mark B . Upper Clamp Nuts C. lower Clamp Nuts Tightening Torque 9 .
11 · 10 SUSPENSION ecJC i n the bottom of the outer tube . - Remove the caps on the bottom of the outer tubes . eH old the front fork with a vise. - Stop the cy linder from turning by u si ng the cylinder holder (specia l tool) .
A . Inner Tube D . Washer B . Outer Tube Seal E. Outer Tube Guide Bu sh C. Oil Seal F . Inn er Tube Guide Bush - Remove the cy lin der base from the bottom of the outer tube . A . Outer Tube B . Cylinde r Base Front Fork Assembly Notes - Assembly is the reverse of disassembly .
11·12 SUSPENSION - After in s talling the wa s her , install the oi l se al b y u s ing the fork oi l s eal driver (s pe c ial tool : 57(X)1· 1219, - Using the fork oil sea l dri ve r (s pecial tool : 57 001 · 1219) , in sta ll the du st sea l.
Fork Spring Free Length Standard : KX125 , 250 : 548 mm KX500 , 553 mm Service Limit : KX125 , 250 : 537 mm KX500 : 542 mm . .. " ...,.~-~ SUSPENSION 11 - 13 Rear Suspension IUni-Trak) Rear Shock Absorber : The rear suspension system of this motorcycle is Uni-trak .
11 - 14 SUSPENSION A . Rebound Damp i ng A dju ste r B . Mark Gas Reservoir Compression Damp ing Adjustment To adjust compression damping. turn the co mpre s- sio n damping adjuster on the gas r eservoi r with the blad e of a sc rewdri ve r until you feel a click .
I WARNING' O US8 onlv nitrogen ga s. 0 00 not incinerate the gas re se rvoir . Spring Prelo ad Adju stment - Remove the seat, right and left s id e covers . -l oosen the air clea ne r duct clamp screw. - Remove the silencer . - Remove the r ear frame a nd air cleaner case .
11 - 16 SUSPENSION A. Rear S h ock Abso rb er B . Rea r S h ock Absorber Uppe r Mounting Bo lt o When pulling out the mounting bolts , lift the resr wheel slightly. Forcing or tapping on a bolt could damage the bolt. sleeve. and bearing . Rear Shock Absorber Installation Notes - Instal l ation is the reverse of remo va l.
Rear Shock Absorber Disassembly ( Oil Change) The oil s hould be changed in the rear shock ab- sorbe r at least once per racing season . The f requenc y for best performan c e must be based upon riding conditions and rider ability . - Remove the rear shock absorbe r from the frame (see Rear Shock Absorbe r Removal) .
11 -1 8 SUSPENSION - Adjust t h e ga5 reservoir damp in g adjuste r to the softest position . -H o ld the upper end of the rear shock wit h the vise again . • Pry o r tap at the gap s in the stop with suitable tools to free t h e sto p from the rear s ho ck body.
- Check the circlip for weake nin g, deformity and flaws . If necessary , replace i t w ith a new one . I WARNING' o lf weakened . deformed or flawed clrclip is used , the gas reservoir cap may not hold when Injecting the nitrogen gas. This would allow oil and internal parts to explode out of the reservoir.
, , - 20 SUSPENSION [ CAUTlO~] o lf the circlip i s not 8 certain fit In the groove in the rear s hock body . the push rod .... mbly may come out of the shock absorber when in;actlng the nitrogen gas or riding the motorcycle .
- Separate the ch ain guides and chain s lip pe r s from the sw in g a rm . Swing Arm Installation Notes -I nsta ll ation is the reverse of removal. - Apply plenty of molybdenum disulfide grease to the inside o f the needle bearings and s l eeves .
, , - 22 SUSPENSION Rocker Arm In sta llat ion Nores . 'nstallation is the reverse of removal . - Apply plenty of mo l ybdenum disulfide grease to the inside of the rocker arm ho l e. outside of the s l eeve. and sp herical bearings . -T ighten the following parts to the specified torque .
A . S l eeves Sleeve Outside Diameter Stand a rd : Service limit : Rocker Arm: Mounting B ol t Bend 21 . 987 - 22.000 mm 21.85 mm A bent bolt causes vib r ation. poor handling, and in s tabil ity . T o measure bo lt run out. remove the bolt , place i t in V blocks .
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STEERING 12 -1 Steering Table of Contents Exploded V iew ............ . ...... . ..... , ' , . ....... . " ...... ,' . • . ••• ........ . . • • •• ...... , 2 - 2 Special T o ol s .... . ... . .................. . . . ...
12 - 2 STEERING Exploded View _1 , , KX250 . 500 ..... .., ... I --: ! iP~ KX250 , 500 , --------- -------7 I fl / / I / / I / / / .. / I I / I / I '- ______ ____ _ _ ...1 @ ,. Q Tl : 25 N · m {2.5 kg - m . 18 ft - Ibl T2: 44 N· m f4.6 kg - m, 33 ft · lbl T3 : 3 .
Special Tools Stem Nut Wrench: 5700' - 1100 Bearing Driver Set: 5700' - "29 Stem Bearing Driver : 57001-137 Stem Bearing Driver Adapter: 57001 · 1074 STEERING 12 - 3 Stem Bearing Remov.
12 -4 STEERING Steering Adjustment Steering Inspection . Place a stand or b l ock under the m otorcycle so that the front wheel is raised off the ground . - With the front wheel pointing st raight ahead, alte r - nately nudge each end of the handlebar.
Steering Removal / In sta llat i on ...... . ......................................... . .............. Steering Stem Remova/ - Remove the fo ll owing parts. F r ont Whee l Brake Hose Clamp Caliper Mounting Bo l ts Master Cylinder Clamp Front Fender Handlebar Front Fork - Remove the s teering stem head nut and washer .
1 2- 6 STEERING - Remove the tower inner race (with its grease seat) which is pressed onto the steering stem . A . Roller Bearing Steering S t em Race I nstallation N otes ' Installation is the reverse of removal.
. . .. . ............... . _ ....... . _ ............... ... . ....... _ .. . Steering Maintenance .... . .. . . .. .... . ...................... .... .... . . . ............ Steering Stem Bearing Lubrication • Remove the stee ring stem (see Stee rin g Stem Re- moval ).
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ELECTRICAL SYSTEM 13-1 Electrical System Table of Contents Wiring Diagram . . .. . . .... .. .. .. .. .. . . . .... .. .... . ..... .. ... . . . . .. .. . .. ........... .. ... 13-2 Exploded View ............... . .....................................
13 - 2 ELECTRICAL SYSTEM Wir i ng Diagram SPIn; Plug • __ .,. __ . ~".-.-. - ~-- 8 ''''' ~ B"'" ______ -(----') B.
.. . ..... . .... ..... . E "~ " PI ' O' " d ... d .. · V .. i .. . w ·· · ··· ···· ·· · ·· · ·· · .... ··· · ~~ ; ~~ . ,' ........ . . . .... . .. . . ........... . . . .. . . . ... . ....... . KX250 , IUK ) ~ ~ .
13 -4 ELECTRICAL SYSTEM KX500 , T3 T1 : 5.9 N-m (0.6 kg-m . 62 in - Ib) T2 : 22 N - m 12 . 2 kg -m . 16 ft - Ib) T3 : 9 . 8 N -m '1 .0 kg -m . 87 in - Ib) T4 : 27 N - m (2 . 8 kg - m . 20 ft - Ibl T5 : 27 N - m 12 . 8 kg -m . 20 ft - Ib) T6 : 78 N - m 18 kg - m.
SPECIFICATIONS Item Ignition System : Ignition timing : KX125 KX250 KX500 Ignition coil: 3 needle arcing distance Primary wi nding resistance Secondary winding resistance COt unit internal resistance Spark plug : KX125 KX250 KX500 Spark plug gap ©: Canadian model @' U .
13·6 ELECTRICAL SYSTEM Special Tools Along with common hand tools , the followin g more s peciali ze d tools are required for co mplete electrical syste m servici ng . Rotor Holder: 57001-1248 Rotor Holder Adapter "A": 57001 - 1108 Flywheel Puller : 57001 - 252 Coil Tester : 57001 - 1242 Hand Tester : 57001 - 983 Spark Plug Wrench.
Pr eca ut io n s There are a number of important precaut ions that are musts when selVicing the electrical system . learn and obselVe all the rule s below . o The electrical parts shou ld never be struck sharp l y, as with a hammer , or allowed to fall 00 a hard surface .
13 - 8 ELECTRICAL SYSTEM .. ... . .. .. .. . ..... .. ... . .. .... . . . . . ............ .. ...... ....... Ignition Timing ... . . .. . . ... ......... . ............. .... ... . .... . .. . .... ..... . . Ignition Timing Adjustment • Remove the magneto cover .
Flywheel Magneto Fl ywheel M ag neto Rem oval 'R emove the magneto cover. 'H old the flywheel st eady with the rotor holder and adapter " A " (specia l toolsl. and remo ve the fly- wheel bolt or nut _ A. Fl yw h eel H o ld er : 57001-1248 B.
13 - 10 ELECTRICAL SYSTEM A . Cl ean Off o Set the stator wiring grommet securely in the notch i n the left crankshaft half , and route the wires according to the Wire Routing section in the Genera l Inf ormation chapter . A. Stator Lead B. Grommet oFit the wood ru ff key securely in the slot in the crankshaft before installing the flywheel .
... . ........ ....... ............. .......... .... .... .. .... ... . . Ignition System ................ ......... ............ ....... ....... .... .. .... Safet y In s tru c tion s I WARNING' o Tho Ignition system produces ex1nHneIy high _. Do not touch the spark plugs.
13 - 12 ELECTRICAL SYSTEM Ignition Coil Winding Re s i s tance (J) 6 (5 -- ./ (j) 1 . Measure primary w in ding resistance . 2. Mea s ur e seco nd ar y win d i ng r esista n ce . 3 . i gnition Coil * If the meter reads as specified , the ignition coi l windings are probably good .
ELECTRICAL SYSTEM 13·13 COl Unit T es t Us ing the Kawasaki Hand T es ter KX125 : T ester Posi ti ve (+) l ea d Con n ect i on 0 lead Co l or Black/W h ite White / R ed W h i t e/ Gree n Bl ack .
13-14 ELECTRICAL SYSTEM KX500 : Tester Positive (+) lead Connection c lead Co lor Black/White White / Red 0 (Exciter) (Pickup) . ~ u ~ • c Black/White < 0 (Excite r) = u " • White / Red • ~ (Pickup) = - I - White / Green • > (Pickup) = .
APPENOIX 14 - 1 Appendix Table of Contents Tro u bl es h oo t ing Guide ...... ,' .... , .... , ..... "...... . .. ........ .... . . .. . ........ ... 14 -2 Genera l Lubricatio n ...... . . .. ..... " ................. " .. . .....
'4- 2 APPENDIX .............. , . . . . .. . . . ........ . ... . .. .... ...... ' .......... . Trouble s hoot i ng Guid e .. . ........ ... . . . . .. . . ..... . ....... .. . . . . . ................... NOT E o Th is is not a n exhaustive list, g ivi ng every possible cause for 6sch probl9m list8d.
Fuel / air mixture incorrect; Main jet clogged or wrong size Jet needle or need l e jet worn Jet needle clip in w r ong position Float level too high o r too l ow Air jet or air passage clogged Ai r c.
14-4 APPENDIX Jumps out of g8ar : Shift fork worn Gear groove worn Gear dogs and/Of dog holes worn Shift drum groove worn Gear positioning lever s pring weak Of broken Shift fork guide pin worn DriVf! shaft, output shaft. and/or gear splines worn 0. .
S hoc k absorption un sa tisf a ctory : (Too hard) Front fo rk o il excessive Front fo rk oi l v i scosity 100 high Front fork l eg be nt Tire air pressure 1 00 high Rear sh ock absorber maladjusted (.
14 -6 APPENDIX Unit Conversion Table .. . ..... ... . .. .. .. . .. . . . . . . . ..... . . .. ... ... ... . . . . .. .. . ... . . . Prefixes for Unit s; P r ef ix Sy mb ol Po we r mega ki lo centi mi.
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KX125 KX250 KX500 Motorcycle Service Manual Supplement This supplement is designed to be used in conjunction with the '88 KX125 / KX250 / KX500 Motor - cycle Service Manual (P I N 99924-1101-01). Th e maintenance and repair procedures described in this supplement are only those that are unique to '89 KX 125 / KX250 / KX500 motorcycle .
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Table of Contents General Information Before Serv i cing ... ... . . .. .• • . . ... . .. Model Identification .. ......• • . ....... General Specification ..........••• • •. . . Periodic Maintenance Chart ..... • ••.... .• Torque and lock i ng Agent .
2 Engine Top End Exploded View .. , .. •• ....... , • • • . . .. 23 Specifications, ...... , .. , ......••.... 24 Special Tools ...................... . • Cylinder Head ....•..........••...... 25 Cylinder Compression Measurement .
Crankshaft. Connecting Rod ..... . ...... . Crankshaft Removal .............. . Crankshaft In stallation Notes ........ . Crankshaft D isassemblv Note ...... . Crankshaft Assemblv Notes ........ . Connecting Rod Big End Radia l Clearance .......... • •.
4 Brake Pads .......... . .......••... Pad Removal ............... • ... Pad Installation .....•......•• • ... Pad Inspection ..... , ........... . Master Cylinder. .................... . Front Master Cylinder Removal .. , ... . Front Master Cylinder Insta l lation Notes .
Electrical Wiring .... . . . ..•.....•.•... Wiring Inspect ion ........ ...•••.. Ignition Tim ing . .... . ...........• • ... Ignition Timing Adjustment ..... • •.. FI,vwheel Magneto ................... . Flywheel Magneto Removal. .
6 WARNING CONTAINS AS8ESTOS 8,".I~'ng IlbIIIO. d~11 I . danlll'ou, 10 h.~th Follow Hft.ty inmuct ...... (U . K . model only) This warning ma y apply to any of the follow - ing component.
Except for the following description, the maintenance work for the KX125-G 1 is the same as for the KX 125-F 1 , for the KX250-G 1 is the same as for the KX250-F 1 , for the KX500·El i s the same as for the KX500-D1. General Information .............
8 KX250-G 1 (US and Can ad ian Model) Right S i de View KX250-Gl (Other than US and Canadian Model) Right Side View.
9 KX500·E1 (US and Canadian Model) Right Side View KX500·E1 (Other than US and Canadian Model) Right Side View.
10 General Specifications Items Dimensions: Overall length Overall width Overall height Wheelbase Road clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity Engine: Type Cooling .
Items Transmis sion: Type Gear ratios : Final drive system: Type 1st KX125 · G1 6 · speed, constant mesh, return shift 2.142 (30 / 14) 2nd 1.714(24 / 14) 3rd 4th 5th 6th Reduction ratio 1.400 (28 / 20) 1.181 (26 / 22) 1 .04 1 (25124) 0.920 (23125) Chain drive 3.
12 Items Dimensions: Overall l e ngth Overall wid th Overall height Wheelbase R oad clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity Engine: Typ e Co o ling system Bore and .
Items Transmission: Type Gear ratio s: Final drive system: Type 1st 2nd KX250 · G1 5 - speed , constant mesh, return shift 2. 133132 / 15) 1.687127 / 16) 3rd 1.388 125 / 18) 4th 1.136 (25122) Reduction ratio 5th 1.000 (24124) Chain driv e 3.357147 / 14) 9.
14 Items Dimen sions: Overall l ength Overall width Overall height Wheelbase Road clearance Seat height Dry weight Curb weight: Front Rear Fuel tank capacity Engine: Type Cooling system Bore and strok.
Items KX500-El Final drive system : Type Chain drive Reduction ratio 3.357 (47 / 14) Overall drive ratio 6.746 @ Top g e ar Transmission oil : Grade SE class Viscosity SAE 101'130 or 10W40 Capacity 0 .
16 Periodic Maintenance Chart FREQUENCY Each Every Every Every As OPERATION race 3 races 5 races 10 races required Clutch-adjust • ·Clutch and friction plates-check t • R Throttl e cable -a djust.
17 Torque and Locking Agent Tight en all bolts and nuts to the proper torque using a n accurate torque wrench. If i nsuffici e ntly tightened, a bolt o r nut may become damaged or fall out. possibly resulting in damage to the motor - cyc le and injury to the rider.
18 Fastener Torque Remarks N -m kg-m ft-lb Suspension Front Fork Top Bolts · 27 2. 8 20 Front Fork Top Bolts" 29 3.0 22 Front Fork Clamp Bolts * 21 2.1 15 . 0 Front Fork Clamp Bolts" (Upper) 21 2.1 15 . 0 (Lower) 20 2.0 14 .5 Front A x le Clamp Nuts B .
Cable Routing KX125: 1. Clutch Cable 2. Clamp 3. Strap 4. Radiator Breather H ose KX125,250: 1 1. CO l Unit 2. Throttle Cable 3. Engine Stop Switch l ead 4.
20 Fuel System Exploded Vi ew Specifications KX125: Item Carburetor Specifications: Make / type Main jet Throttle valve cutaway Jet needle Jet needle clip position Slow jet Air screw Service fuel level (below the bottom edge of the carbo body) Bore center Float height T1 : 34 N-m (3.
21 KX250: Item Standard Service Limit Carburetor Specifications: Make /type KEIHIN PWK38 -- - Main jet 172 --- Throttle valve cutaway 7 - -- Jet needle R 1368J --- Jet needle clip position 4th groove from the top --- S l ow jet 55 --- Air screw 1 % (turns out) --- Service fuel level 1.
22 Reed Va lve Reed Valve In stalla ti on • Ins ta l l the reed valve holder as shown. Upward )D D a a aup a a a a a D a a a a D ownward KX12S KX250 a a a aD-a KX500 1 . Projection j Cooling System Exploded View KX 500 : T1 : 6 , 9 N-m (0 . 70 kg .m, 61 in .
23 Engine Top End Exploded View ........... .... ........................ .... .......... ... .................... KX125: o KX25Q: ""- --.
24 KX500: • T1: 9,8 N.m (1.0 kg-m, 87 in-lb) Specifications KX125: Item Standard Service Limit Cylinder, Piston: Cylinder inside diameter 56 . 020 - 56 . 035 mm 56.10 mm Piston /cy linder clearance 0. 071 - 0.081 mm --- Piston ring groove width: Top 0.
............................................................................. Cylinder Head ............................................................................. Cylinder Head Installation Notes _F o r KX500 ·E l model, install th e cy lind er head gasket as shown.
26 . ..... ...... . ... ... ... . . . .. .... ......... ...... . . ..... ...... ........ .. .. ... .. Cylinder, Piston ....................... . ... . ......... ... ..... . ... ... ....... ........ .. ... . ... . Piston Diamet er Measurement e Measure the outside diameter of the piston 16 mm (KX12S), 20.
27 Engine Right Side Exploded View KX125 : T1 : 88 N-m (9 . 0 kg..,.. , 65 ft . lb) KX25Q : T1 : 98 N-m (10 kg..,.. , 60 ft-lb).
28 KX500: Specifications Item Standard Service Limit Clutch: Steel plate thickness 1.41 - 1. 59mm 1.31 mm Friction plate tang width: KX125 11 . 8 - 12.
..... . . . .......... R' .......• Ight Engine Co ....... . ....................... . ... . .. ver ....... . ... ... . .... . ..... . ........ .. Exhaust Ad ............. ....... . ......... . ................ . A vancer A ...... ssembl N ssembly D' o Th y otes lSassembly/ e exhaust adva lowing parts.
30 Engine Removal/Installation Exploded View KX125: Engine Bottom End / Transmission Exploded View KX125: KX250: KX250. KX500: T1 : 34 N-m (3.5 kg-m, 25 ft-Ib) T2: 26 N-m (2.
Crankcase Splitting Crankcase A s s embl y eF or KX500·El mode l , install t he bearing for the drive shaft into the left crankcase ha l f so that stepped side faces inside. e Apply non.pe r manen t lod;ing agent to the threads of the drive shaft bearing holder screws.
32 Wheels / Tires Exploded View ................ . ..... ....... . . ... ......... .... ... .. ... . .... .. ........ .. ..... Specifications Item Tires : ( KX125,250) Front : Size Make, type A ear: S.
Wheels Front Wheel Removal (other than US and Canadian models) e P l ace a stand.or block under the motorcycle so that the front wheel is raised off the groond. e Loo sen the axle clamp nuts on the right side of the wheel. e Loosen the a)::le. A. Axle Clamp Nuts B.
34 A. Arr o w Mark e T i ghten the upper clamp nuts first , and tighten the low e r clamp nuts t o the specified torque. Tight e ning Torque 8.8 N -m (0.
Brakes Exploded View .... ..... ......................... .......... .. .................. ... ... . .. .... I I I T2 Specifications Disc Brake: Ite m Brake Pad s; Pad li ning th ick n ess: Front R ea r Brake Discs: Disc thickne ss: Fr o nt T1 : 5.9 N-m (0.
36 Special Tool The following special too l is added for brake fluid change. Oil Syringe: 57001-1290 Disc Brakes Calipers : Caliper Removal - Loosen the brake pad bo l ts before the caliper remova l if the caliper is to be disassembled.
e For the front caliper, there are two pistons in the caliper. Holding the one piston in p l ace, l ightly apply compressed air to where the brake l ine fits into the caliper. Another piston comes out by air pressure. Temporarily in sta ll the removed piston.
38 Suspension . . . .... .......... . . . .... .. . . ... .... .. . ..... . . .. ............. . .... ........ ... . Exploded View . . ... .... .. ............ . ..... ... .......... .. .......... .. .... .. ........ ... .. . . , , , 0 • : cwJ 0 t© g j : , , L ____ _ _ _ ______ __ _ _ __ _ _ ___ .
39 Specifications Item Standard Service Limit Front Fork: Air pressure Atmospheric pressure --- Oil viscosity KAY ABA 01 - -- Oil capacity US and Canadian Models 605 ± 4mL --- Other than US and Canad.
40 ... . . .... . .. .. .. .... . ..... ... ... . ..... . ..... .. ...... ........... . ... ... ... ... . Special Tools ............... . ... ... .. ..
I WARNING I o Lift th e front wheel before unscrewing both top bolts, or·the front fork tubes compress all th e way and ha za rd can occ ur . _ Remove the following . Number Plate H andlebar Clamp Handlebar Front Fork Top Bolt A. Front Fork Top Bolt Front Fender Brake Hose Clamp (other than US and Canadian Models) Front Caliper A.
42 O At this ti m e, do no t hit th e front brak e pipe and other parts . • Pulling down the fork spring and insert th e s prin g holder (special tool) under the push rod nu t. A. Spri ng C. Spring Ho l der: 5700 1 · 1286 B. T op Bolt _ Unscrew the both right and l eft top bolts.
e Adj u st the oil level as requi r ed within the adjustable r ange us i ng one o f the fo ll owing oils. Re commend ed Oil KAYABA 01 el nstall t he spring guides and push rod nuts at the p u sh rods (other t h an US and Canadian Models). o l nsta ll the spring guide so that the hole comes l ower side.
44 Front Fork Disassembly (Oil Change) (US and Canadian Models) _ When f"cmoving the top bolt, insert the sp r ing holder (specia l tool) under the push rod nut. A. Top Bolt C. Spring Seat B. Spring Holder : 57001-1286 Front Fork Assembly (Oil Change) (US and Canadian Models) e After pouring in the fork oil specified, perform the following.
_ Remove the washer. ) A. Washer _ Remove the push rod nut, and remove the spring g uide. A. Push Rod Nut B. Spring G u ide _ Pour the fork oil into a container. _ Clean the bottom of the inner tube. _ Remove the caps on the bottom of the inner tubes.
46 o Hording the inner tube by hand in a vertical position, stroke the outer tube up and down several.t imes and pull it down . This shock t o the fork l eg separates the outer tube from the inner tube . e Remove the guide bushes, washer, oil scal, retaining ring, dust seal from the inner tube.
_ Install the gu id e, rollar, stopper, circlip, O-ring on the push rod. A. St opper D. Guide B. Co ll ar E. O-ring C. Circlip - Install the rollar on the guide, and tighten the stopper to the specified torque. Tightening Torque 26 N-m (2.7 kg-m , 19_5 ft - Ib) -I nsert the pus h rod and cy l inder unit into the outer tube.
48 A. Push Rod C. Hole B. Spring Guide e lnstall the push rod puller (special tool : 57001.1 289). e lnstall the washer into the outer tube. e lnstall the spring. _ Pull up the push rod. e lnsert the spring holder (special tool) under the push rod nut.
Steering Exploded View Electrical System .. ...... .... . . ..... ... . . . ........................................... ... ... . . Exploded View KX125: 11 : 5.9 N-m (0.6 k,'m. 52 in·lbl T2: 27 N-m 12.B kg·m, 20 ft · lbl 49 T1 : 25 N-m 12.5 kg-m, 18.
50 . .. . ............ .... . ... ............ . ... . .. .. ... .. ........ .. .. . . .. . .... ..... Wir i ng Diagram .. ..... .... ... . ..... . ...... .... . . . . ..... . .. . . .... .... . .... . ..... . .. .. .. .. ... KX125/250 1. Spark Plug 2.
Spec ificati o ns It e m Ig nition Sy stem : Ignition t iming: KX 1 25 KX25 0 CO l unit interna l resistance Spark plug: Ignition Syst e m Spark Plug Gap Inspection Spa r k Plug G a p 0 .5 - 0 . 6 mm COl Unit Inspection Spark p l ug gap 51 S ta nd a rd 1 3.
MODEL APPLICATION Year Model Beginning Frame Number KX 1 2S.G l JKAKXRG 1 DKAOOOOOl or KX 1 25G'{)()()()()1 1989 KX250.Gl JKAKXMG10KAOOOOOlor KX25QG.{)()()()()1 KX500-El JKAKXVE10KAOOOOO l or KX500E.()()OO() l o : Th is digit in the frame number changes from one machine to another.
Kawasaki KX500 Motorcycle Service Manual Supplement This supplement is designed to b e used in conjunction with the ' 88 KX125IKX250 / KX500 Motoorcycle Service Manual (P I N 99924-1101-01) . The maintenance and repair procedures described in this supplement are only those that are unique to ' 90 and up KXSOO motorcycles.
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Table of Contents Ge n eral Information Befor . Servi cing ..... . .......•....... Mode l Identificat i on ... . ... . ...•...... Ge nera' Spec ifi cat i on s .........•...•. . . Per i od i c Ma i ntenance Chart .... , ••• " ••.
2 Engine Top End E)(ploded V i ew •••.....•••••• . ..• . ..• SpeciflCltions .........••.... , ..• . ... Spec i. l Tools ...•....•...•...... . . . . Cylinder Held ... . .. . .. , ........ , ... . Cyl i nder ComprH. l on Measurement .
Crankshaft , Connecting R od .. .. ........ . Crankshaft Rem ov a l. ............. . Crankshaft I nstallation Notes ....... , . Crankshaft D isassembly N o te ........ . Crankshaft Assembly Not es ........•. Connecting Rod B ig End Radial Clearance .
4 R ea r Master Cylinder Remo val .. . . . .. . Rear Master Cy l inde r Installat i on N otes .. Front MISter Cy li nder Disassembly .... , Rear M.ster Cylinder Dl sassemblv . .. . . Ma s ter Cvllnder Assembly Not es ..... . Master Cylinder Inspection (Visual I nspecticn) .
A ABDC AC ATDC BBDC BDC BTDC ' c DC F ' F It 9 h L LIST OF ABBREVIATIONS ampere(s) Ib pound(s) after bottom dead center m meter(s) alternating current min minute!s) after top dead ce nter N .
6 General Information ..... . . ..... .... . ... ..... .. ........ ... . .............. ... ... ..... ... .. .... ... Model Identification ............
General Specifications Item s Dimensions : Overall length Overall w i dth Overall height Wheelbase Road clearance Seat height Dry weight Curb weight: F ront Rear Fuel tank capacity Engine : Type Cooli.
8 I tems Transmission : Type Gear rat ios: Final drive system : Type 1st 2nd 3,d 4th 5th Reduction ratio Overall drive ratio Tran smission oi l : Frame : Type Steering angle Caster (rake angle) Trail .
9 . . .. ... .. . ....... . .. ... ........ , .. ..... ..... . .... ................. , ......... . Periodic Maintenance Chart .. . . ...... .. , .... .
10 Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench . I f insufficiently tightened, a bolt or nut may become damaged or falloff, possibly resulting in damage to the motor - cycle and injury to the rider.
Fuel System ................................................................. ... ........ Exploded View ..... . ................................................ .. .... .. .............. ... . ................. ..... . ... ....... .. ................
12 Reed Valve ........ . ...... .. .. . . ... .. .. . .. ... . .............. . .. ... .... . .. .. ... .. . ...... Reed Valve In stallat;on _ In sta ll the reed valve holder as shown. Upward D D Downward o 0 o oD-o Engine Top End o . . . . . ... . ..
Specifications Item Cylinder, Piston : Pi sto n d ia meter P isto n / cylinder c learance P iston p in hole diameter Cylinder Head Cylinder Head Insta/lation Notes -Ins tall t he cy l inder head gasket as shown. o o ~ o ® 4 1 1. Metal Section 2 . Short 3 .
14 A : 26.S mm Piston / Cylinder Clearance Pilton/Cylinder Claaranet Stllnderd : 0 , 100 - 0. 130 mm Engine Right Side Exploded Viow Specifications ...
... . ....... . .... . .. . .. . ......... . ..... . .............................. . .... .. . R ight Eng i ne Cover Exhaust Advancer Assembly Disassembly / Assembly Notes e The exhaus t advancer assembly consists of the fol- lowing parts. 1 . P ins 2.
16 Engine Bottom End / Transmission ..... ..... . .. .. .... .. .. .. . ............. . ... ... .. ... ........ . . ... . . ... .. .. . .. . Crankcase Splitting Crankcase Assembly _I nstall the bearing for the drive shaft Into the left crankcase half 50 that stepped side faces inside .
Wheels / Tires Exploded View Specifications ltom Tires: Front : Size Make , type Rear : Size Make , type IE) : European mode l IU): U.K. model Stondard 80 / 100-2151M T1 : 64 N-m (5,5 kg-m, 40 ft-Ib) T2: 29 N'm 13.
18 Wheels ............................................................................ Front Wheel Removal eR eplace a stand or block under the motorcycle SO that the front wheel is raised off the gr o und. - Loosen the right axle clamp nuts. -Un screw the axle .
_ Check the fr o nt brake fo r weak braking power and brake drag. AWARNING Do not attempt to drive the motorcycle until a full brake lever I, obtained by pumping th e brake levar until the PMis ere againtt the disc.. The brake will not function on tha fint application of tha levar jf thl' i, not done .
20 Drive Chain Drive Chain Slack Adjustment - Pull o ut th e cotte r pin, and l oose n the axle nut. A . Cotter Pin D. Locknut B . Axle Nut E . M arks C. Adjusting Bolt F. N o tch _ After adju s tment , insert a new cotter pin thr o u gh the axl e nut an d ax l e, and spread its ends.
Brakes Exploded View T2 Specifications Disc Brake : Item Brake Pads: Pad lini ng thickness: Brake Disc: Disc thic k ness : T1 ~ .. o f Front Rear Front Rear Standard 4.5mm 4 . 7 mm T1 : 5. 9 N'm (0 .8 kg-m . 52 in-Ib) T2 : 26 Nom (2 .5 k9"m.
22 Disc Brakes Caliper" Caliper Removal eR emove the disc cover. A. Di sc Cover B . Mounting Bolts -L oose n the brake pad bo l ts before th e caliper remova l if t he caliper i s to be disassembled.
Brake Pads : Pad Removal • Loosen the brake pad bolts bef o re the calipe r rem oval. A. Brake Pad Bolts Pad Ins tallation eTi ghten the brake pad bolts to the specified torque. Spe ci fied Torque 18 N·m (1.8 kg-m. 13 . 0 ft · lbl Pad Inspect io n _ Check the lin ing thickness and condition of the pads in eac h ca l iper.
24 Suspension ... .. .. . ... . .. ..... ...... . ... . ... . ............ .......... .......... ..... ... . .. Exploded View L : Apply. noo-permanent locking agent to the threads . T1 : 21 Nom (2. 1 kg.m, 16 .0 ft · lb) T2: 20 N' m (2 .0 kg.m, 14 .
25 Specifications It em Standard Service Limit Front Fork : Air pressure Atmospheric pressure - - - Rebound damping ad ju stment (Adjustable range) (turn the adjuster counterclockwise) : KX500 - E2 10 c lick s, (0) 8 clicks 16 clicks E 3 - E5 9 clicks, (0) 10 clicks 16 c li cks E6.
Item Standard Service limit Rear Shock Absorbers : Gas pressure 1 000 k Pa (10 kg / cm 2 , 14 2 psi) --- Spring preload (adjusting nut position from th e cen t er (ad ju s table range) of the upper mounting hole) : KX500 - E2 - E5 122 . 5 mm , (0) 123 .
Front Fori< ( KXSOO - E2 - E7 ) Rebound Damp in g Adjustment " , 16 o----@ Soher H,rd,r (COUIHerClock w i 5e ) (Ctoc kw in) Number of turns countercl o ckw i se usable range-16 clicks A. Seated position wit h adjuster turned fuJly c l ockwise .
26 Special Tool s Fork SpJirti Holder : 67001-1286 Fork Push Rod Puller : 57001 · 1289 Oil Syringe : 57001 · 1290 Fork Oil Seal Driver : 57001-1340 Fork Cylinder Holder: 67001 · 1287 Jack : 57001-1.
.... . ........ . ...... . ............ . .......... . .. . ....... . .... ... ..... . ...... . Front Fork ... ... ............ . .....................
28 Compre u ion Damp i ng Ad ju l tment _ Clean the bottom of the OlJter tubes. • Remove the caps on t h e bottom of the outer tubes . e To adj u st compression damping. turn the adj u ster on the fro n t fork cylinder valve with the blade of a screw- driver until you feel a click.
A. Rebound Damping Adjuster Rod (short) B . Push Rod B Hoid the fork tube upside down over a clean containe r and pump it to drain the oil. Remove the r ebound damping adjuster rod (long) fr o m the push rod . A . Push Rod B. Rebound Damping Adjuster Rod (long) NOTE o To discharge the fork oil, pump the push rod up and down um tirmn.
30 - After purging the air from the assembly. let it sit for about five minutes so that any suspended air bubbles can surface. Adjusting Oil LweI e Set the oil syringe (special tool), stopper so that its lower side shows the oil level distance specified.
Front Fork Removal (Each Fork Tube) Front Fork Remonl - Using the jack (spec ia l tool ) under the frame, stabilize the motorcycle. e Place a stand or block under the engine so that the front wheel is raised off t h e ground.
32 _ Pull the fork spring away from the top plug a little and slip the fork spring holder (special tool) in on top of the spring seat and under the rod nut . A. Fork Spring B. P ush Rod Nut C. Fork Spring Holder : 57001·1286 - Use wrenches on the rod nut and the top plug to loosen the push rod nUL A.
3 1. Fork Cylinder Holder : 57001-1287 2. Cylinder Unit 3. Cylinder Valve Assembly A. l nnerTube C. O-ring B. Cylinder Valve Assembly D. Gasket NOTE 0 00 not remove the inner tube from the outer tube. A. Pu s h Rod C. Inn er Tube B. Inn er Cylinder _U nscrew the guide stay nu t from the piston holder, and remove the split ring keepers.
34 o Remove the retaining ring from the outer tube . A. Retaining Ring o Grasp the in ner tube and stroke the outer tube up and down several times. Th e sh ock to th e fork seal sep- arates the outer tube from th e in ner tube . e Rem ov e the guide bus h ings, washer, all se al , r etai n ing r in & dust seal from the inner tube .
Inner Cylinder Auembly _ Install the oil lock piston on the piston holder so that the grooves face down. OFirst, insert the push rod into the cartridF, then, install the anti-bottoming piston . The hardened steel keepers that hold the anti-bottoming p isto n to the push rod can cause severe damage to the forlc if not in- stalled sec ur ely.
36 _ Screw on the push rod nut so that the chamfered side is down. o Position the push rod nut at 18.5 rnm or more from the top of the push rod. }@) n 1.18.5 mm 2. Push Rod Nut 3. CoUar (82 Mode l only) 4. Chamfered Side S. Spring Guide e lnsert the rebound damping adjuster rod (long) into the push rod.
I n ner T ube I nspection e Visuall y inspect the inner tube, repair any damage. e Nicks or rust damage can sometimes be repaired by using a wet-stone to remove sharp edges or raised areas which cause seal damage. * If the damage is not repa i rable, replace the inner tube.
38 ........ . ..... ... .. . ... . ................ .. .. " ...... . ... . .............. . ... . . .. Rsar Suspension (Un i· Trak) .... . ......
Electrical System ...... . ..... .... ... ....... . . ...... . .. ... . .... ... ... ... .. ............. .... ... Exploded View ........... ..... . . . .. ... . .. . . ... .......... ... .... . . . .. . .. .. .. . .. . ... .. ...... .. ... ....... ..
40 ... ... . . ....... . ............................... . ........ . ................ . .. Specifications ............................. ..... .... ... ........................ . ....... ... Item Standard I SJlition System : Ignition timing : 19 ' BTDC @6 000 r / min (rpm) Ignition Coil : Primary winding resistance 0.
SUPPLEMENT - 2000 - 2004 MODELS 1·1 Supplement - 2000 - 2004 Models Table of Contents Foreword ............................................................ ..................................................................... 1-2 General I nformation .
1 -2 SUPPLEMENT - 2000 - 2004 MODELS Foreword How to Us e thi s Manual This " Supp l ement 2000 - 2004 Mode ls" designed to be used in conjunction with the front part of this manual (up to P.40) andior Base Manual ' SS KX12SIKX2S0IKXSOO Service Manual - Part No .
General Information Model Identificat i on KX50o-E12 Left Si de Vi ew : KX50o-E12 Right Side View : SUPPLEMENT - 2000 - 2004 MODELS 1-3.
1-4 SUPPLEMENT - 2000 - 2004 MODELS General Information General Specifications Items Dimens i ons : Overall l eng th Overall width Overall height Whee l base Road clearance Seat height Dry weight Curb.
General Information Items Transmission : Type Gear ratios : Final dri ve system 1 sl 2nd 3rd 41h 51h SUPPLEMENT - 2000 - 2004 MODELS 1-5 KX500-E12 I KE500-E13 -E 16 S-speed , constant mesh , retum shift 2.000 (32116) 1.444 (26 / 18) 1 . 181 (26 / 22) 0.
1-6 SUPPLEMENT - 2000 - 2004 MODELS General Information Torque and Locking Agent Tighren all boits and nuts to the proper torque using an accurate wrench. If insufficiently tightened , a bolt or nut may become damaged or fall off, possibly resulting in damage to the motorcycle and injury to th e rider .
Fuel System Exploded View T1 : 34 N·m (3.5 kgf ·m , 25 ft · lb) T2 : 34 N· m (3.5 kgf·m , 25 ft · lb) Specifications I te m Ca rbur e tor Specific a tion s: Make / type Main jet Throttle valve cutaway Jet needle Jet needle clip position Slow iet Air screw Service f uel l eve l SUPPLEMENT - 2000 - 2004 MODELS 1·7 • I COI .
1-8 SUPPLEMENT - 2000 - 2004 MODELS Engine Removal/Installation T1 : 44 N ·m (4 . 5 kg f· m, 32.5 ft·lb) T2 : 29 N ·m (3 .0 kg f ·m , 21.5 ft · lb ) IH~IO!II ' ! C.
SUPPLEMENT - 2000 - 2004 MODELS 1-9 Engine Bottom EndlTransmission Specifications Item Standard Transmission Oil : T ype AP I S E , S F or SG AP I SH or SJ with JASO MA Viscosity SAE 10W-40 Capacily 0 .
1-10 SUPPLEMENT - 2000 - 2004 MODELS WheelslTires Exploded View T1: 79 N · m (8.0 kgf·m , 58 ft ·l b) T2 : 34 N·m (3 .5 kgf·m , 25 ft · lb) T3 : 110 N·m (1 1 kgf·m , 81 ft · lb) Specification.
Final Drive Exploded View T1 : 34 N·m (3.5 kgf·m, 25 ft · l b) T 2: 110 N · m (1 1 kgf .m , 8 1 ft · lb ) T 3: 79 N·m (8 . 0 kgf ·m , 58 ft · l b) SUPPLEMENT - 2000 - 2004 MODELS 1·11 nOll l .
1-12 SUPPLEMENT - 2000 - 2004 MODELS Brakes Exploded View A : KX500-E12 - E15 Models S: KX500-E16 Model - T1 : 5 .9 N·m (0.6 kgf·m , 52 in·lb) T2 : 25 N·m (2 . 5 kgf ·m . 18.0 ft · lb) T3 : 8.8 N ·m (0.9 kgf·m, 78 in·lb) T4 : 7 . 8 N · m (0 .
Suspension Exploded View o o o ~ 8 T1 : 20 N·m (2 . 0 kgf · m , 14 .5 ft · lb) T2 : 30 N · m (3 . 0 kgf ·m , 22 ft·lb ) T3 : 28 N · m (2 . 9 kgf ·m , 21 ft ·l b) T4 : 8 . 9 N ·m (0 . 90 kgf · m , 78 in · lb) T5 : 54 N · m (5 . 5 kgf ·m , 40 ft · lb ) T6 : 83 N · m (8 .
1-14 SUPPLEMENT - 2000 - 2004 MODELS Suspension Rear Suspension (Uni-Trak) Rear Shock Absorber : The rear su s upension system of this motorcycle is Uni ~ t rak.
Steering Exploded View T1 : 25 N ·m (2 . 5 kgf ·m , 1 8 ft · lb) T 2 : 4 4 N ·m (4 . 5 kgf·m , 33 ft · lb ) T 3 : 4.9 N· m (0 .5 kg ·m , 43 in ·lb) T4 : 20 N ·m (2.
MOD EL APPLI C ATION Year M:>del Beginning Frame No . 1990 KX500-E2 JKAKXVE10LAOO2001 or KXSOOE-002001 1991 KX500-E3 JKAKXVE10MAD04001 or KX500E-004001 1992 KX500-E4 JKAKXVE10NAOO7001 or KXSOOE - 0.
An important point after buying a device Kawasaki KX125 (2004) (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Kawasaki KX125 (2004) yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Kawasaki KX125 (2004) - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kawasaki KX125 (2004) you will learn all the available features of the product, as well as information on its operation. The information that you get Kawasaki KX125 (2004) will certainly help you make a decision on the purchase.
If you already are a holder of Kawasaki KX125 (2004), but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Kawasaki KX125 (2004).
However, one of the most important roles played by the user manual is to help in solving problems with Kawasaki KX125 (2004). Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kawasaki KX125 (2004) along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
