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Service Manual - How To Motorcycle Repair

1. N Fastener E Remarks ji N m kgfm ft lb 1 Engine Mounting Nuts 44 4 5 33 Engine Mounting Bracket Nut Engine Side AA 45 33 2 10 mm KX125 250 M2 49 5 0 36 3 Engine Mounting Bracket Nuts Frame Side 29 3 0 22 8 mm 4 Swing Arm Pivot Shaft Nut 98 5 Frame 6 Engine Mounting Bracket 7 Pivot Shaft 8 Swingarm G Apply grease 7 4 ENGINE REMOVAL INSTALLATION Special Tool Jack 57001 1238 o e a E Ei N ba e H Di ENGINE REMOVAL INSTALLATION 7 5 Engine Removal Installation Engine Removal e Drain the transmission oil see Engine Bottom End Trans mission chapter e Drain the coolant see Cooling System chapter e Remove Radiator Shrouds Side Covers Seat Fuel Tank Cooling Hoses Radiators Expansion Chamber Ignition Coil KX250 Spark Plug Cap Carburetor with Cables and Hoses Clutch Cable Lower End Drive Chain Engine Sprocket Shift Pedal Brake Pedal e Disconnect the magneto output lead and free the leads from the clamp at the left side of the cylinder e Unbolt the mounting bolts A and remove the engine mounting brackets B e Place a jack A under the frame to lift the motorcycle off the ground and put blocks under the front and rear tires to steady the motorcycle WARNING The swingarm pivot shaft also serves as the en gine mounting bolt Take precautions to insure the frame is well supported and that the motorcycle will not
2. Radiator Installation Radiator Inspection Cap Inspection Filler Neck Inspection Cooling Hoses Breather Hose Inspection Cooling Hoses Breather Hose Installation g System of Contents 4 2 4 6 4 7 4 8 4 8 4 8 4 8 4 8 4 8 4 8 4 9 4 10 4 11 4 11 4 11 4 11 4 11 4 12 4 12 4 12 4 12 4 13 4 14 4 14 4 14 4 14 4 15 4 15 4 15 4 15 4 2 COOLING SYSTEM Exploded View KX125 COOLING SYSTEM 4 3 Exploded View Torque No Fast R k o astener Nem kgfm Pe emarks 1 Water Pump Cover Bolts 8 8 0 9 78 in lb 2 Coolant Drain Plug 8 8 0 9 78 in lb 3 Water Pump Impeller Bolt 6 9 0 7 61 in lb 4 Right Engine Cover Bolts 8 8 0 9 78 in lb 5 Cooling Hose Clamp Screws 1 5 0 15 13 in lb 6 Radiator 7 Radiator Cap 8 Water Pump Cover 9 Impeller 10 Oil Seal Short 11 Oil Seal Long Bearing Water Pump Gear Right Engine Cover Cylinder Head Cylinder Apply grease Apply molybdenum disulfide grease 4 4 COOLING SYSTEM Exploded View KX250 6D02008BN5 COOLING SYSTEM 4 5 Exploded View No Fastener E Remarks N m kgf m ft Ib 1 Water Pump Cover Bolts 8 8 0 9 78 in lb 2 Water Pump Cover Fitting Bolts 5 9 0 6 52 in lb 3 Coolant Drain Plug 8 8 0 9 78 in lb 4 Water Pump Impeller Bolt 6 9
3. 6D06001BS1 Water Pump Cover Installation e Replace the pump cover gasket with a new one e Tighten the water pump cover bolts and clamps Torque Water Pump Cover Bolts 8 8 N m 0 9 kgf m 78 in Ib Cooling Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in lb e Fill the cooling system see Coolant Filling e Bleed the air from the cooling system Impeller Removal e Drain the coolant see Coolant Draining e Remove the cover bolts and take out the water pump cover from the right engine cover with the cooling hoses attached e Remove the impeller bolt A and take out the impeller B and washer 6D06002BS1 Impeller Installation e Tighten the impeller bolt Torque Impeller Bolt 6 9 N m 0 7 kgf m 61 in Ib 4 12 COOLING SYSTEM Water Pump Impeller Inspection e Visually check the impeller A x If the surface is corroded or if the blades B are dam aged replace the impeller Water Pump Shaft Removal e Remove Right Engine Cover see Engine Right Side chapter e Pull out the water pump shaft A toward inside of the right engine cover Water Pump Shaft Installation e To prevent the oil seal lips from peeling apply a molybde num disulfide grease A to the water pump shaft B and insert it into the oil seals C from the inside of the right engine cover D CAUTION Be sure to apply a molybdenum disulfide grease to the water pump shaft when installing If it is
4. FREQUENCY After Every Every Every each 3 races 5 races 10 Asre See OPERATION race or or 7 5 or 12 5 races quired Page 2 5 hr hr hr or25hr Front fork inspect and clean e 2 37 Front fork oil change 1st time after 2 races then every 5 races 2 38 Rear shock oil replace 1st time after 2 races then every 5 races 2 40 C Fuel system clean 2 15 H Fuel hose replace Every 4 years 2 13 A Fuel hose connections inspect t e 2 13 S Steering play inspect t e 2 41 S Steering stem bearing grease 2 43 Swing arm and Uni Trak linkage pivots 2 40 grease s Swing arm and Uni Trak linkage pivots An EE 2 40 inspect t Nuts bolts fasteners inspect t General lubrication perform 2 44 T Replace add adjust clean or torque if necessary R Replace PERIODIC MAINTENANCE 2 5 Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench If insufficiently tightened a bolt or nut may become damaged strip an internal thread or break and then fall out The following table lists the tightening toque for the major bolts and nuts and the parts requiring use of a non permanent locking agent or liquid gasket When checking the tightening toque of the bolts and nuts first loosen the bolt or nut by half a turn and then tighten to specified torque Letters used in the Remarks column mean L Apply a non permanent locking a
5. A WARNING 6c060184S1 If dirt or dust is allowed to pass through into the carburetor the throttle may become stuck possibly causing an accident CAUTION If dirt gets through into the engine excessive en gine wear and possibly engine damage will occur FUEL SYSTEM 3 15 Carburetor Carburetor Installation e For KX250 lifting up the link shaft end A of the throttle sensor install the throttle valve assembly e Being careful not to bend or otherwise damage the jet needle Check to see that the throttle valve B goes all the way down into the carburetor body and slides smoothly e Tighten Torque Carburetor Top Cover Screws 3 0 N m 0 3 kgf m 26 in Ib KX125 Carburetor Top Cover Allen Bolts 3 9 N m 0 4 kgf m 35 in Ib KX250 e When installing the carburetor into the carburetor holder align the center A of the carburetor with the groove B on the holder e Tighten the clamps securely Torque Carburetor Holding Clamp Screw 1 4 N m 0 14 kgf m 12 in lb e Route the air vent and overflow hoses properly see Ap pendix chapter CAUTION Always keep the hoses free of obstruction and make sure they do not get pinched by the chain or shock absorber e For KX250 connect the carburetor lead connector e After installing the carburetor do the following OTurn the fuel tap to the ON position and check for fuel leakage from the carburetor A WARNING Fuel s
6. e Check and Adjust Steering Front Brake Clutch Cable Throttle Cable GNO05010481 13 8 STEERING Steering Maintenance Stem Bearing Lubrication e Refer to the Stem Bearing Lubrication in the Periodic Maintenance chapter Stem Bearing Wear Damage e Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer rase and the rollers Replace the bearing assembly if it show damage Stem Warp e Whenever the steering stem is removed or ifthe steering cannot be adjusted for smooth action check the steering stem for straightness x lf the steering stem shaft is bent A replace the steering stem GNO401038S1 STEERING 13 9 Handlebar Handlebar Removal e Disconnect the engine stop switch connector e Remove Band A Clutch Lever Holder B Throttle Grip Assembly C Master Cylinder D Handlebar Clamp El Handlebar Installation e Apply adhesive cement to the inside of the left handlebar grip e Install the left handlebar grip so that the arrow A on the grip point to the punch mark B on the handlebar e Install the clutch holder sot that the parting line C of the holder with punch mark D on the handlebar e Apply grease to the throttle cable upper end and clutch cable upper end e
7. 6B06066Bw1 A Previous Carburetor B New Carburetor C Jet Needle D Air Baffle E Main Air F Needle Jet G Engine Intake H Semi Air Bleed Hole Air Screen GENERAL INFORMATION 1 21 Unit Conversion Table Prefixes for Units Units of Length km x 0 6214 mile Prefix Symbol Power m x 3 281 ft mega M x 1000 000 mm x 0 03937 in kilo k x 1 000 centi c x 0 01 milli m x 0 001 Units of Torque micro H x 0 000001 N m x 0 1020 kgf m N m x 0 7376 ft lb N m x 8 851 in Ib kgf m x 9 807 N m Units of Mass kgf m x 7 233 ft lb kg x 2 205 Ib kgf m x 86 80 in Ib g x 0 03527 OZ Units of Pressure Units of Volume kPa x 0 01020 kgf cm L x 0 2642 gal US kPa x 0 1450 psi L x 0 2200 gal imp kPa x 0 7501 cm Hg L x 1 057 qt US kgf cm x 98 07 kPa L x 0 8799 qt imp kgf cm x 14 22 psi L x 2 113 pint US cmHg x 1 333 kPa L x 1 816 pint imp mL x 0 03381 oz US mL x 0 02816 oz imp Units of Speed mL x 0 06102 cu in km h x 0 6214 mph Units of Force Units of Power N x 0 1020 kgf kW x 1 360 PS N x 0 2248 Ib kW x 1 341 HP kof x 9 807 N PS x 0 7355 kW kof x 2 205 Ib PS x 0 9863 HP Units of Temperature i a 40 Sreto NEE F F 4 32 68 176 212 248 284 40 20 0 20 40 60 104 80 100 120 140 160 180 200 220 240 260 280 300 320 40 20 oi 17 8 4 4 C 20 i 26 7
8. Torque Steering Stem Head Nut 78 N m 8 0 kgf m 58 ft lb Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 14 5 ft lb Lower 20 N m 2 0 kgf m 14 5 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Check the steering again x lf the steering is too tight or too loose repeat the adjust ment as mentioned above PERIODIC MAINTENANCE 2 43 Periodic Maintenance Procedures e Install the handlebar clamp A together with the handle bar so that the cut side B on the clamp points at the front e Tighten the handlebar clamp bolts C Torque Handlebar Clamp Bolts 25 N m 2 5 kgf m 18 ft lb OTighten the clamp bolts rear first and then the front If the handlebar clamp is correctly installed there will be no gap at the rear and a gap at the front after tightening e Install the number plate Stem Bearing Lubrication e Remove the steering stem see Steering Stem Removal in Steering chapter e Using a high flash point solvent wash the upper and lower tapered rollers in the cages and wipe the upper and lower outer races which are press fitted into the frame head pipe clean off grease and dirt e Visually check the outer races and the rollers Replace the bearing assemblies if they show wear or damage e Pack the upper and lower tapered roller bearings A in the cages with grease and apply a light coat of grease to the upper and lower outer races e In
9. Torque Throttle Sensor bolt 20 N m 0 2 kgf m 17 in lb 60606011852 C Gco060190S1 FUEL SYSTEM 3 19 Carburetor Carburetor Cleaning WARNING Clean the carburetor in a well ventilated area and take care that there is no spark or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or low flash point solvent to clean the carburetor e Make sure the fuel tap is in the OFF position e Remove the carburetor e Drain the fuel in the carburetor e Disassemble the carburetor CAUTION Do not use compressed air on an assembled carbu retor the float may be deformed by the pressure Remove as many rubber or plastic parts from the carburetor as possible before cleaning the carbu retor with a cleaning solution This will prevent damage or deterioration of the parts Do not use a strong carburetor cleaning solution which could attack the plastic parts instead use a mild high flash point cleaning solution safe for plastic parts Do not use wire or any other hard instrument to clean carburetor parts especially jets as they may be damaged e Immerse all the metal parts in a carburetor cleaning solu tion e Rinse the parts in water e Afterthe parts are cleaned dry them with compressed air e Blow through the air and fuel passages with compressed air e Assemble t
10. 9 10 Rim Runout Inspection artearen na e a aaa 9 10 Axle Inspection serai re adi 9 10 AA A EE 9 11 Air Pressure Inspection Adjustment ss 9 11 Tires INSPectiON aiii clicar tee le Ee 9 11 Tire Removal cion iaa ri dante EEN nadia dass 9 12 Installation iii AA Reena tee a ete hea 9 13 PII DSB GANG EE 9 15 H b Bearing REMOVAL oo uereg Leta OM tae ee Ree EE 9 15 H b Bearing REES 9 15 H b Bearing TASB SCUOM EE 9 15 9 2 WHEELS TIRES Exploded View 6J02036BW5 WHEELS TIRES 9 3 Exploded View Torque N m kgf m ft Ib Spoke Nipple 2 2 0 22 19 in lb Front Axle 78 8 0 58 Front Axle Clamp Bolts 20 2 0 14 5 Rear Axle Nut 110 11 0 80 Spoke Front Tire Rim Front Axle Swingarm Rear Tire Rear Axle KX125 250 M1 model KX125 250 M2 model Apply grease Apply soap and water solution or rubber lubricant z 9 Fastener Remarks AIOINJ gt a CH 7 69 91091 Ou gt 9 4 WHEELS TIRES Specifications Item Standard Service Limit Wheels Rims Rim Runout 2 mm 0 079 in Axial 1 0 mm 0 039 in or less 2 mm 0 079 in Radial 1 0 mm 0 039 in or less Axle Runout 100 mm 0 1 mm 0 004 in 0 2 mm 0 008 in Tires Air Pressure Front and Rear Tires Standard Tire KX125 Front Size Make Type KX125 M3 Rear Size Make Type KX125 M3 KX250 Front Size Make Type Rear S
11. Cable Inspection e With the throttle cable disconnected at both ends the ca ble should move freely A within the cable housing x If cable movement is not free after lubricating if the cable is frayed or if the housing is kinked replace the cable 6004040251 FUEL SYSTEM 3 11 Carburetor Since the carburetor regulates and mixes the fuel and air going to the engine there are two general types of carbure tor trouble too rich a mixture too much fuel and too lean a mixture too little fuel Such trouble can be caused by dirt wear maladjustment or improper fuel level in the float chamber A dirty or damaged air cleaner can also alter the fuel to air ratio Idle Speed Inspection e Refer to the Idle Speed Inspection in the Periodic Main tenance chapter Idle Speed Adjustment e Refer to the Idle Speed Adjustment in the Periodic Main tenance chapter Service Fuel Level Inspection Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position e Remove the fuel tank e Remove the carburetor and hold it in true vertical position on a stand The fuel hose and carburetor cable do not have to be removed to inspect the fuel level A e Put the fuel tank on a b
12. Fastener Torque Remarks N m kgf m ft Ib Main Lever Mounting Allen Bolt 3 9 0 4 35 in lb L Governor Shaft Lever Mounting Bolt KX125 6 9 0 7s 61 in lb Exhaust Valve Retaining Bolts KX125 5 9 0 6 52 in lb Main Shaft Stopper Pin Plug KX125 0 8 0 08 6 9 in lb Main Valve Retaining Bolts KX250 5 9 0 6 52 in lb Operating Rod Retaining Screw KX250 5 4 0 55 48 in lb Operating Rod Left Side Plug KX250 22 2 2 16 Main Valve Rod Cover Screw KX250 5 9 0 6 52 in lb Silencer Inner Pipe Bolts 8 8 0 9 78 in lb L Silencer Pipe Mounting Bolts 8 8 0 9 78 in lb L Engine Right Side Oil Filler Cap 1 5 0 15 13 in lb External Shift Mechanism Return Spring Pin KX250 42 4 3 31 L Clutch Spring Bolts 8 8 0 9 78 in lb Clutch Hub Nut 98 10 72 Exhaust Valve Advancer Lever Mounting Allen Bolts 3 9 0 4 35 in lb L Governor Shaft Lever Positioning Plug 0 6 0 06 5 in lb Gear Set Lever Nut 8 8 0 9 78 in lb Gear Set Lever Pivot Stud L Planted Side Ratchet Plate Mounting Bolts 8 8 0 9 78 in lb Water Pump Impeller Bolt 6 9 0 7 61 in lb Kick Ratchet Guide Bolt 8 8 0 9 78 in lb Kick Pedal Bolt KX125 12 1 2 8 7 KX250 25 2 5 18 Primary Gear Nut KX125 59 6 0 43 Clutch Cover Bolts 8 8 0 9 78 in lb Right Engine Cover Bolts 8 8 0 9 78 in lb Engine Removal Installation Engine Mounting Nuts 44 4 5 33 Engine Mounting Bracket Nuts Engine Side 10 mm KX125 250 M1 44 4 5 33 Engine Side 10 mm KX125 250 M2 49 5 0 36 Frame Side 8 mm 29 3 0 22 Swing Arm Pivot Shaft
13. Flywheel Magneto Removal e Remove the magneto cover e Hold the flywheel steady with the flywheel holder A and remove the flywheel bolt KX125 or nut KX250 B Special Tool Flywheel amp Pulley Holder 57001 1605 e Remove the flywheel holder e Screw the flywheel puller A into the flywheel by turning it counterclockwise left hand thread e Remove the flywheel from the crankshaft by turning in the puller center bolt and tapping the head of the bolt lightly with a hammer while holding the puller body steady There is a woodruff key in the crankshaft tapered portion Special Tool Flywheel Puller M12 x 1 75 57001 252 CAUTION Never strike the grab bar or the flywheel itself Strik ing the bar can bend it If the flywheel is strike the magnets may lose their magnetism e Unscrew the mounting screws A and remove the stator plate B and the wiring grommet C e Remove the band KX125 e Remove the number plate e Disconnect the magneto lead connector A from the CD unit ELECTRICAL SYSTEM 14 13 Flywheel Magneto KX250 e Remove the left radiator shroud e Disconnect the magneto lead connector A from the main harness Flywheel Magneto Installation e Using a high flash point solvent clean off any oil or dirt that may be on the crankshaft taper A or in the hole B in the flywheel Dry them with a clean cloth e Fit the woodruff key A secu
14. GC060185S1 6006017751 GC060186S1 FUEL SYSTEM 3 17 Carburetor For KX250 e Remove the fuel cut valve A from the carburetor For KX250 e Remove the throttle sensor mounting bolt A e Before removing the throttle sensor B mark C the car buretor body and sensor so that it can be installed later in the same position For KX250 e Remove the throttle sensor link assembly screws A e Remove the link assembly B KX125 e Remove the following parts from the carburetor body A Idle Adjusting Screw B Nut C Air Screw D Spring E Slow Jet F Main Jet G Float Valve Needle H Float Pin Screw J O ring K Float Bowl L Needle Jet M Main Jet Holder N Float Plate 6C06061BS2 C 3 18 FUEL SYSTEM Carburetor KX250 e Remove the following parts from the carburetor body A Idle Adjusting Screw B Spring C Air Screw D Spring E Slow Jet F Main Jet G Float Valve Needle H Float l Pin J O ring K Float Bowl L Power Jet Carburetor Assembly e Clean the disassembly parts before assembling e Replace the O rings with a new one if it is deteriorated or damaged e Turn in the air screw A fully but not tightly and then back it out the specified number of turns see Specifications of this chapter e For KX250 install the throttle sensor so that the marks aligns and check it position see Electrical System chap ter
15. e Start the engine e Thoroughly warm up the engine so that the engine oil be tween the piston and cylinder wall will help seal compres sion as it does during normal running e Stop the engine e Remove the fuel tank see Fuel System chapter e Remove the spark plug and screw a compression gauge firmly into the spark plug hole Special Tools Compression Gauge 20 kgf cm 57001 221 A Compression Gauge Adapter M14 x 1 25 57001 1159 e With the throttle fully open turn the engine over sharply with the kickstarter several times until the compression gauge stops riding the compression is the highest read ing obtainable Cylinder Compression Usable Range KX125 890 1 370 kPa 9 1 14 0 kgf cm 129 199 psi KX250 825 1 275 kPa 8 4 13 0 kgf cm 119 185 psi Alf cylinder compression is higher than the usable range check the following 1 Carbon build up on the piston head and cylinder head clean off any carbon on the piston head 2 Cylinder head gasket cylinder base gasket use only the proper gaskets for the cylinder head and base The use of gasket of the incorrect thickness will change the compression Alf cylinder compression is lower than the usable range check the following 1 Piston cylinder clearance piston seizure 2 Gas leakage around the cylinder head replace the damaged gasket and check the cylinder head for warp ing 3 Piston ring piston ring groove Cylinder Head Remov
16. 1 2 165 mm 85 2 in 840 mm 33 1 in 1 265 mm 49 8 in 1 470 mm 57 9 in lt 940 mm 37 0 in lt 1 1 1 1 1 1 11 1 1 EU 10 9 1 8 5 1 EU 8 3 1 30 2 KW 41 0 PS 11 500 r min rpm 26 5 Nm 2 70 kgfm 19 5 ft lb 10 500 r min rpm lt 13 BTDC 9 710 r min rpm NGK R6918B 9 lt 1 1 1 1 1 1 8 GENERAL INFORMATION General Specifications Items KX125 M1 KX125 M2 Drive Train Primary Reduction System Type Gear Reduction Ratio 3 200 64 20 Clutch Type Wet multi disc Transmission Type 6 speed constant mesh return Eo shift Gear Ratios 1st 2 384 31 13 2nd 1 857 26 14 3rd 1 529 26 17 4th 1 294 22 17 5th 1 125 27 24 6th 1 000 25 25 Final Drive System Type Chain drive E Reduction Ratio 3 923 51 13 Overall Drive Ratio 12 553 Top gear Transmission Oil Type API SE SF or SG E API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 0 7 L 0 74 US qt Frame Type Tubular semi double cradle E Steering Angle 45 to either side 42 to either side Caster rake angle 27 5 27 Trail Front Tire Size Make Type Rear Tire Size Make Type Front Suspension Type Wheel Travel Rear Suspension Type Wheel Travel Brake Type Front and Rear 100 mm 3 9 in 80 100 21 51M DUNLOP Tube type 100 90 19 57M DUNLOP Tube type Telescopic fork up
17. 46 9 53 9 mm 1 85 2 12 in KX125 M1 49 0 55 6 mm 1 93 2 19 in KX125 M2 Alf the lever position is not within the standard select the correct thickness of adjusting washer s B according to the tables shown tr id Adjusting Washers Thickness Part NUMBER 1 5 mm 0 06 in 92200 1548 1 0 mm 0 04 in 92200 0045 GRO5030BS2 C Release Shaft Lever Position and Adjusting Washer Se lection KX125 M1 Position Distance Washer Thickness Qty 46 9 mm to 53 9 mm 1 85 2 12 in Standard More than 53 9 mm 2 12 in 1 0 mm 0 04 in 1 Less than 46 9 mm 1 85 in 1 0 mm 0 04 in 2 1 5 mm 0 06 in 1 KX125 M2 Position Distance Washer Thickness Qty 49 0 mm to 55 6 mm 1 93 2 19 in Standard 1 5mm 0 06 in 1 More than 55 6 mm 2 19 in 1 0 mm 0 04 in 1 Less than 49 0 mm 1 93 in 1 0 mm 0 04 in 2 Remove the push rod holder assembly as necessary and reinstall the clutch Olnstall the magneto cover Friction and Steel Plates Wear Damage Inspection e Refer to the Friction and Steel Plates Wear Damage In spection in the Periodic Maintenance chapter Friction and Steel Plate Warp Inspection e Refer to the Friction and Steel Plate Wrap Inspection in the Periodic Maintenance chapter 6 18 ENGINE RIGHT SIDE Clutch Spring Free Length Measurement e Since the spring A becomes shorter as
18. KX125 250 6P02176BW5 ELECTRICAL SYSTEM 14 5 Exploded View Torque No Fastener Nan kgf m ftlb Remarks 1 Flywheel Bolt KX125 22 2 2 16 0 2 Flywheel Nut KX250 78 8 0 58 3 Stator Plate Mounting Screw 4 4 0 45 39 in lb 4 Spark Plug 26 5 2 75 19 5 5 Magneto Cover Bolts 4 9 0 5 43 in lb Magneto Cover Bolts KX125 250 M2 3 9 0 4 35 in lb Magneto Cover Flywheel Magneto Stator Ignition Coil C D I Unit Spark Plug Cap Main Harness KX250 Regulator Rectifier KX250 Throttle Sensor KX250 Apply Silicon Sealant KX125 250 M2 Model KX125 M1 M2 Model 6 7 8 9 10 11 12 13 14 Fuel Cut Valve KX250 15 SS A B C KX125 M3 Model 14 6 ELECTRICAL SYSTEM Specifications Item Standard Magneto Crankshaft Sensor Air Gap 0 63 0 67 mm 0 025 0 026 in Crankshaft Sensor Resistance 180 280 O Magneto Output Voltage in the text Magneto Coil Resistance in the text Regulator Rectifier KX250 Internal Resistance in the text Out Put Voltage 14 7 40 5 V Ignition System Ignition Timing KX125 13 BTDC 10 010 r min rpm KX250 14 BTDC 7 740 r min rpm Disconnect the throttle sensor lead Ignition Coil 3 Needle Arcing Distance 7 mm 0 26 in or more Primary Winding Resistance KX125 0 24 0 04 Q at 20 C KX250 0 53 0 08 Q at 20 C Secondary Winding Resistance KX125 8 3 1 2 kQ at 2
19. OTake the reed valve A out of the cylinder 6012002BS1 Reed Valve Installation e For KX125 install the reed valve A as shown Upward B 3 26 FUEL SYSTEM Reed Valve e For KX250 install the reed valve A so that the t marked side B faces upward e Tighten the carburetor holder mounting bolts Torque Carburetor Holder Mounting Bolts 8 8 N m 0 9 kgf m 78 in lb Reed Valve Inspection e Refer to the Reed Valve Inspection in the Periodic Main tenance chapter 6012004BS1 COOLING SYSTEM 4 1 Coolin Table Exploded View Specifications iernii arai Special Tools Colin a hear Coolant Level Inspection Coolant Deterioration Inspection Coolant Draining sentida Coolant Filling EE Air Bleeding BEES Cooling System Pressure Testing Cooling System Flushing Disassembly and Assembly Precautions Water Pump teaei iaeei eiiiai taa E i iKi Water Pump Cover Removal Water Pump Cover Installation Impeller Hemoval Impeller Installation Impeller Inspection nssneeeeeeeeeeeeeeeeeee en Water Pump Shaft Removal Water Pump Shaft Installation Oil Seal Hemoval Oil Seal Installation Radiator sieste iras Radiator Removal
20. Transmission Shift Fork Gear Groove Wear e Measure the thickness of the shift fork ears A and mea sure the width B of the shift fork grooves in the transmis sion gears Alf the thickness of a shift fork ear is less than the service limit the shift fork must be replaced Shift Fork Ear Thickness Standard KX125 4 9 5 0 mm 0 1768 0 1969 in KX250 4 4 4 5 mm 0 1732 0 1772 in Service Limit KX125 4 8 mm 0 189 in KX250 4 3 mm 0 169 in Alf a gear shift fork groove is worn over the service limit the gear must be replaced Shift Fork Groove Width Standard KX125 5 05 5 15 mm 0 1988 0 2028 in KX250 4 55 4 65 mm 0 1791 0 1830 in Service Limit KX125 5 25 mm 0 207 in KX250 4 75 mm 0 187 in Shift Fork Guide Pin Shift Drum Groove Wear e Measure the diameter A of each shift fork guide pin and measure the width B of each shift drum groove Alf the guide pin on any shift fork is less than the service limit the fork must be replaced Shift Fork Guide Pin Diameter Standard 5 90 6 00 mm 0 2323 0 2362 in Service Limit 5 80 mm 0 228 in Alf any shift drum groove is worn over the service limit the drum must be replaced Shift Drum Groove Width Standard 6 05 6 20 mm 0 2382 0 2440 in Service Limit 6 25 mm 0 246 in Gear Damage e Visually inspect the gear teeth on the transmission gears x Repair lightly damaged gear teeth with an oilstone The gear must
21. Water and coolant mixture ratio 1 1 water 50 Coolant 50 Total amount KX125 0 97 L 1 02 US qt KX250 1 20 L 1 27 US qt Coolant Deterioration Inspection e Visually inspect the coolant x If whitish cotton like wafts are observed aluminum parts in the cooling system are corroded If the coolant is brown iron or steel parts are rusting In either case flush the cooling system Alf the coolant gives off an abnormal smell check for a cooling system leak It may be caused by exhaust gas leaking into the cooling system Coolant Draining The coolant should be changed periodically to ensure long engine life A WARNING To avoid burns do not remove the radiator cap or try to change the coolant when the engine is still hot Wait until it cools down Coolant on tires will make them slippery and can cause an accident and injury Immediately wipe up or wash away any coolant that spills on the frame engine or other painted parts Since coolant is harmful to the human body do not use for drinking 2 18 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Remove the radiator cap NOTE ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap e Place a container under the coolant drain plug KX125 A or plugs KX250 B and drain the coolant fr
22. 0 049 0 079 mm 0 0019 0 0031 in 0 025 0 06 mm 0 00098 0 00236 in 1 01 1 03 mm 0 0398 0 0406 in 0 970 0 985 mm 0 0382 0 0388 in 0 25 0 45 mm 0 0098 0 0177 in 17 995 18 000 mm 0 7085 0 7087 in 0 03 mm 0 0012 in 54 10 mm 2 130 in 53 81 mm 2 118 in 0 15 mm 0 006 in 1 11 mm 0 044 in 0 91 mm 0 036 in 0 85 mm 0 033 in e an 14 96 mm 0 589 in 15 08 mm 0 594 in 19 05 mm 0 750 in 66 46 mm 2 617 in 66 19 mm 2 6059 in 0 16 mm 0 006 in 1 11 mm 0 044 in 0 90 mm 0 035 in 0 75 mm 0 030 in 17 96 mm 0 707 in 2 10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit Piston Pin Hole Diameter Small End Inside Diameter 18 001 18 011 mm 0 7087 0 7091 in 22 003 22 012 mm 0 8663 0 8666 in 18 08 mm 0 712 in 22 05 mm 0 868 in Engine Right Side Clutch Lever Free Play Friction Plate Thickness KX125 KX250 Steel Plate Thickness KX125 KX250 Friction Plate Warp Steel Plate Warp 2 3 mm 0 08 0 12 in 2 72 2 88 mm 0 107 0 113 in 2 92 3 08 mm 0 115 0 121 in 1 5 1 7 mm 0 059 0 067 in 1 46 1 74 mm 0 057 0 069 in Not more than 0 15 mm 0 006 in Not more than 0 2 mm 0 008 in 2 6 mm 0 102 in 2 8 mm 0 110 in 1 4 mm 0 055 in 1 36 mm 0 054 in 0 3 mm 0 012 in 0 3 mm 0 012 in Engine Bottom End Tra
23. 70 120 mm 2 76 4 72 in elf no oil is drawn out there is insufficient oil in the outer tube Pour in enough oil then drawn out the excess oil e Install the parts removed see Front Fork Assembly in Suspension chapter Rear Shock Absorber Oil Change e Refer to the Rear Suspension Uni Trak section in the Suspension chapter for Rear Shock Absorber Disassem bly Oil Change and Assembly Uni Trak Linkage Inspection e Check the uni trak component parts for wear periodically or whenever excessive play is suspected e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Push and pull on the swingarm A up and down to check for wear A small amount of play on the swingarm is normal and no corrective action is needed However if excessive play is felt remove the uni trak parts from the frame and check for wear GM040110S1 GM04011282 C 6S14015BS1 PERIODIC MAINTENANCE 2 41 Periodic Maintenance Procedures Chain Guide Wear Inspection e Visually inspect the drive chain guide A and replace it if excessively worn or damaged Chain Slipper Wear Inspection e Visually inspect the upper and lower chain slippers A on the swingarm B and replace them if worn or damaged Steering Steering Inspection e Using the jack raise the front wheel off the ground Special Tool Jack 57001 1238 e With the fr
24. B to the hose joint opening A WARNING To avoid serious injury never place your fingers or palm inside the caliper opening If you apply com pressed air into the caliper the piston s may crush your hand or fingers NOTE Olf the caliper is to be disassembled after removal and compressed air is not available remove the piston s using the following three steps before disconnecting the brake hose from the caliper OPrepare a container for brake fluid and perform the work above it ORemove the pads and spring see Pad Removal OPump the brake lever or pedal to remove the caliper piston s e Remove the dust seal s and fluid seal s e Remove the bleed valve and rubber cap GLO506068S1 BRAKES 11 15 Caliper Caliper Assembly e Clean the caliper parts except for the pads CAUTION For cleaning the parts use only disc brake fluid isopropyl alcohol or ethyl alcohol e Tighten the bleed valve with rubber cap Torque Caliper Bleed Valve 7 8 N m 0 8 kgf m 69 in Ib e Replace the fluid seals which are removed with new ones OApply brake fluid to the fluid seals A and install them into the cylinders by hand e Replace the dust seals with new ones if they are dam aged OApply brake fluid to the dust seals B and install them into the cylinders by hand e Apply brake fluid to the outside of the pistons C and push them into each cylinder by hand e Install the anti
25. GE05008BS1 ENGINE TOP END 5 11 Cylinder Cylinder Removal e Drain the coolant see Cooling System chapter OFor KX250 be sure to remove the cylinder drain plug e Remove the cylinder head see this chapter e Remove the cooling hoses e Remove the KIPS cover A at the cylinder e Remove the governor shaft lever in accordance with the following procedure KX125 ORemove the bolt A and pull out the governor shaft lever B from the main shaft KX250 OLoosen the clamps and pull the carburetor out of the holder and the air cleaner duct ORemove the E clip A from the operating rod OPut a 9 mm 0 35 in spanner wrench A on the governor shaft lever upper end OTurn the governor shaft lever B counterclockwise with the wrench and take off the operating rod collar C by pushing the operating rod into the cylinder OBefore pulling the governor shaft lever A free turn the remaining E clip B to a suitable position as shown in the figure to prevent the governor shaft lever boss C and the E clip from hitting 6E06002BS1 5 12 ENGINE TOP END Cylinder e For KX250 remove the magneto lead and the clutch ca ble from clamp e Remove the cylinder nuts A e Lift offthe cylinder and remove the cylinder base gasket If necessary tap lightly around the base of the cylinder with a plastic mallet A taking care not to damage the cylinder e Remove the exhaust
26. e Apply a soap and water solution or rubber lubricant to the rim flange and tire beads 6J05053BS1 9 14 WHEELS TIRES Tires e Position the tire on the rim so that the valve A is at the tire balance mark B the chalk mark made during removal or the yellow paint mark on a new tire see Removal e Insert the valve stem into the rim and screw the nut on loosely e Fit the rim protectors and use tire irons to install the tire bead NOTE OTo prevent rim damage be sure to place the rim protec tors at any place the tire irons are applied e Pry one side of the tire back onto the rim Fit the bead protector into the tire e Pry the other side of the tire onto the rim starting at the side opposite the valve OTake care not to insert the tire irons so deeply that the tube is damaged e Install the other side of the tire bead onto the rim in the same manner e Check that the tube is not pinched between the tire and rim e Tighten the bead protector nut and valve stem nut and put on the valve cap e Check and adjust the air pressure after installing 605060451 WHEELS TIRES 9 15 Hub Bearings Hub Bearing Removal e Remove the wheel see Wheel Removal CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Remove the oil seals and circlips e
27. shift drum cam J shift drum The gear is shifted into 1st position continues to operate in the same way as Shift Up 6B06071BS1 6B06072BS1 6B06075BS1 GENERAL INFORMATION 1 15 Technical Information Chrome Composite Plating Cylinder KX250M KX125M OThis new cylinder bore A has Kawasaki s compos ite cylinder plating which is used for the first time on two stroke engines The composite plating includes a nickel phosphorous alloy inorganic materials like ce ramic silicone carbide and some organic materials 6B06059BS1 OThe treatment improves heat transfer of the cylinder for consistent power output allows closer piston to cylinder clearances for more horsepower OThe treatment is porous so it holds lubrication well and hard so it resists abrasion and seizure OThis plating gets on well even the chamfered edge of the cylinder top or port OThis improves the surface of the chamber at the top of the cylinder preventing hot spots resultant pre ignition LD and other abnormal combustion in the chamber Previous Cylinder A New Cylinder B Exhaust Port C Cylinder Top D 6B06060BS1 OThis enables the top end of the exhaust port from round KX250 to straight in order to make gas flow smooth and improve gt mid high performance and extending piston ring life Ser Yo Previous Cylinder A New Cylinder B E
28. to the tester B and measure the arcing distance To avoid extremely high voltage shocks do not touch the coil or lead x If the distance reading is less than the specified value the ignition coil or spark plug cap is defective 3 Needle Arcing Distance Standard 7 mm 0 26 in or more e To determine which part is defective measure the arcing distance again with the spark plug cap removed from the ignition coil lead x If the arcing distance is subnormal as before the trouble is with the ignition coil itself If the arcing distance is now normal the trouble is with the spark plug cap E 6P10045BS1 ELECTRICAL SYSTEM 14 19 Ignition System Measuring Coil Resistance If the arcing tester is not available the coil can be checked for a broken or badly shorted winding with an ohmmeter However an ohmmeter cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage e Remove the ignition coil e Measure the primary winding resistance A OComnect an ohmmeter between the coil terminals OSet the meter to the x 1 Q range and read the meter e Measure the secondary winding resistance B OPull the spark plug cap off the lead OComnect an ohmmeter between the spark plug lead and the ground lead terminal OSet the meter to the x 1 KQ range and read the meter Alf the meter does not read as specified replace the coil Alf the meter reads as spe
29. 31 Rear Suspension Uni Trak Rear Shock Absorber The rear suspension system of this motorcycle is Uni trak It consists of a rear shock absorber swing arm tie rod and rocker arm To suit to various riding conditions the spring preload of the shock absorber can be adjusted or the spring can be replaced with an optional one Also the damping force can be adjusted easily so changing oil viscosity unnecessary Rebound Damping Adjustment e Turn the rebound damping adjuster A on the rear shock absorber lower end with the blade of a screwdriver until you feel a click x If the damper setting feels too soft or too stiff adjust it in accordance with the following table e For KX125 250 M2 model as shown in the figure A Rebound Damping Adjuster Seated position adjuster turned fully clockwise A Rebound Damping Adjuster Setting Standard KX125 M1 12 clicks KX125 M2 11 clicks KX250 10 clicks NOTE OAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force Always make any damping adjustments in small steps and test their effects before using them in com petition Counterclockwise Clockwise Softer lt _ Harder 125 250 STD STD 161514131211109 8 7 6 5 4 3 2 bel Se i KX125 250 M1 Models A 6M05053BS1 12 32 SUSPENSION Rear Suspension Uni Trak Compression Damping Adjustment e
30. 48 9 80 100 120 i 440 71 1 93 3 116 138 160 C PERIODIC MAINTENANCE 2 1 Periodic Maintenance Table of Contents Periodic Maintenance Chart 2 3 Torque anid LO KING Ee EE 2 5 eene te TEE 2 9 Special IOOIS EE 2 12 Periodic Maintenance Procedures 2 13 F el Soleado estress tear detal lu 2 13 Fuel Hose and Connection Check 2 13 Throttle Grip Free Play Inspection 2 13 Throttle Grip Free Play Adjustment ss 2 13 Idle Speed Inpec cinc SEAN 2 14 Idle Speed AdJUSIMEN eee RRA iia 2 14 Air Cleaner Element Cleaning and Inspection 2 14 Fuel Tank and Tap Cleaning nai al riada 2 15 Evel Tap Inspection ian a AAA a AL A Neve E 2 16 Reed Valve Inspection ss 2 16 Beeler EE 2 16 Coolant Level Inspechon 2 17 Coolant Deterioration Inspechon 2 17 Cool nt Draining EE EE 2 17 Cola AI EE 2 18 O A EE 2 19 Cooling Hoses and Connections Inspection 2 19 Engine Top End KE 2 19 Cylinder Head Warp Inspection ccccccccceecccccceececeeeeeeeceeceeeeeceeeeeeeseceeeeeeeeeeseeeeeeeeeeess 2 19 Cylinder Wear Ins POCHOM EE 2 20 Piston Diameter Measurement oooccccnnncnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnneninens 2 21 Piston Cylinder ClearanCe EE 2 21 Piston Ring Piston Ring Groove Inspection 2 22 Piston Ring End Gap Inspection 2 23 Pis
31. 5 DIV CAM iii dani ER 10 6 Drive Chain Slack Inspection 10 6 Drive Chain Slack Ee LE 10 6 Wheel Alignment Inspection assises 10 6 Wheel Alignment Adjustment teens 10 6 Drive Chain Wear Inspection ooccccccccccncccnccnnnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnniss 10 6 Drive Ghain Bee ET 10 6 Drive Chain HRemoval EEEE EEEE EEEE EE EEE 10 6 Drive Chain Installation ia aa E EER 10 6 leie TEE 10 7 Engine sprocket e EE 10 7 Engine Sprocket Installation seine EES ita E ad id 10 7 Rear Sprocket Removal snra neaei a ra aaa iaaa aa a etai 10 7 Rear Sprocket Installation 10 7 Sprocket Wear Inspechon ss 10 7 Rear Sprocket Warp Inspection 10 7 10 2 FINAL DRIVE Exploded View 6Kk02068BW5 FINAL DRIVE 10 3 Exploded View z 9 Fastener Torque N m kgf m Remarks ft lb Rear Axle Nut 110 11 0 80 Rear Sprocket Nuts 34 3 5 25 Engine Sprocket Cover Bolts 4 9 0 5 43 in lb ODNOOA C AIN Engine Sprocket Output Shaft Chain Slipper Swingarm Chain Guide Locknut Adjusting Bolt Chain Adjuster Drive Chain Rear Sprocket Rear Axle KX125 M1 M2 Model Apply grease Apply oil 10 4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Chain Slack Chain 20
32. 6 19 Clutch Release Shaft Installation e Apply high temperature grease to the oil seal lips e Apply engine oil to the bearing in the hole of the crankcase e Insert the release shaft straight in to the hole of the crankcase e Install the clutch see Clutch Installation OFor KX125 install the magneto cover 6 20 ENGINE RIGHT SIDE External Shift Mechanism External Shift Mechanism Removal e Remove Shift Pedal Right Engine Cover Clutch Housing e Pull out the external shift mechanism A e Remove the bolts B and take off the shift ratchet assem bly C with collar e Remove the nut D and take off the gear set lever E GRO7003BS1 External Shift Mechanism Installation e Before installing the shift shaft apply high temperature grease to the oil seal lips and shift shaft splines e Install the gear set lever ODo not forget to install the color e Tighten the gear set lever nut Torque Gear Set Lever Nut 8 8 N m 0 9 kgf m 78 in Ib e Set up the shift ratchet assembly as shown in the figure Ratchet A Pawls B Pins C Springs D e Then install the ratchet assembly A to the ratchet plat B as shown in the figure e Install the ratchet assembly to the shift drum e Tighten Torque Ratchet Plat Mounting Bolts 8 8 N m 0 9 kgf m 78 in Ib ODo not forget to install the collar A e Instal the removal parts ENGINE RIGHT SIDE 6 21 External
33. 6 ft lb 7 500 r min rpm Carburetor KEIHIN PWK38S Primary kick CDI 14 BTDC 7 740 r min rpm NGK BR8EIX Full open 57 6 BBDC 57 6 ABDC 78 1 BBDC low speed 91 4 BBDC high speed 78 1 ABDC low speed 91 4 ABDC high speed Petrol mix 32 1 KX250 M2 SH 840 mm 33 1 in 1 265 mm 49 8 in lt 340 mm 13 4 in lt t t 1 1 1 1 10 5 1 8 8 1 41 6 KW 56 5 PS 9 000 r min rpm 49 0 N m 5 0 kgf m 36 2 ft lb 8 000 r min rpm lt 1171 59 3 BBDC 59 37 ABDC 78 4 BBDC 92 2 BBDC 78 4 ABDC 92 2 ABDC low speed high speed low speed high speed AS AA TD A GENERAL INFORMATION 1 11 General Specifications Items KX250 M1 KX250 M2 Drive Train Primary Reduction System Type Gear Reduction ratio 3 000 63 21 Clutch Type Wet multi disc Transmission Type 5 speed constant mesh return shift Gear Ratios 1st 1 800 27 15 2nd 1 437 23 16 3rd 1 176 20 17 4th 1 000 21 21 5th 0 869 20 23 Final Drive System Type Chain drive E Reduction Ratio 3 769 49 13 Overall Drive Ratio 9 832 Top gear Transmission Oil Type API SE SF or SG amp API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 0 85 L 0 90 US qt Frame Type Tubular semi double cradle E Steering Angle 45 to either side 42 to either side Cast
34. A from the lower end B of the rear shock body A GMO5068BS2 C e Insert the piston end A of the piston rod assembly into the rear shock body C slowly Do not insert the seal assembly B yet Pump the piston rod until all the air is forced out of the rear shock body A GMO5067BS1 SUSPENSION 12 39 Rear Suspension Uni Trak e Push the seal assembly into the rear shock body until it just clears the circlip groove e Check the circlip x If it is deformed or damaged replace it with a new one e Fit the circlip A into the groove in the rear shock body B CAUTION If the circlip is not a certain fit in the groove in the rear shock body the piston rod assembly may come out of the shock absorber when injecting the nitro gen gas or riding the motorcycle e Pull up the piston rod assembly C against the circlip e Force the stop D into the rear shock body by lightly tap ping around the edge of the stop with a mallet e Fully extend the piston rod assembly e For KX125 250 M2 model note the following OHold the lower end of the push rod assembly with a vise OPump the rear shock up and down several times and then leave it in the fully extend position for about three minutes ORemove the air bleeder bolt from the upper part of the rear shock body x If oil comes out of the air bleeder bolt hole let it overflow until it stops Olnstall t
35. Apply a engine oil to the throttle grip inner wall e Install the throttle grip assembly so that the grip A is in as far as it will go OPosition the throttle grip assembly so that the horizontal parting line B of the throttle case is aligned with punch mark C on the handlebar Olnstall the master cylinder so that the vertical parting line D of the front master cylinder clamps with punch mark E on the handlebar e Install the handlebar clamp see Steering Adjustment in Periodic Maintenance chapter Torque Handlebar Clamp Bolts 25 N m 2 5 kgf m 18 ft Ib GNOGOO4BS1 GNOGOO5BS1 ELECTRICAL SYSTEM 14 1 Electrical System Table of Contents MINO DAA EE 14 2 Exploded Vie Wi at A a A eae da T co 14 4 Si OT 14 6 Special TOONS ii A A A de ad A A 14 7 A A A a iaaa SAREM AAR ne dat eme tes pe ee 14 8 Electrical Wiring Sui 14 9 tele ee EE 14 9 ignition TIMINO dias 14 10 A a en de 14 10 Flywheel Magneto E 14 12 Flywheel Magneto REMOVAL Eeer eegen 14 12 Flywheel Magneto Instala EE 14 13 Flywheel Magneto Inspection sico iii cad aii cba 14 14 Regulator Rectifier Removal bh X2b0 nn nccnnnnnn 14 16 Regulator Rectifier Output Voltage Inspection KX250 eee eeeeeneeeee eee eeeeentaeeeeeeeeeeee 14 16 Regulator Rectifier Inspection KX250 UUUUU no nnnnnnnnnnnns 14 17 NOA STE A A A A AA AAA A A it 14 18 Safety INSTUCUONS stes atado 14 18 Ignition Coil R
36. Banjo Bolts 25 N m 2 5 kgf m 18 5 ft Ib e Bleed the brake line after installing the brake hose see Bleeding the Brake Line Brake Hose Inspection e Refer to the Brake Hose and Connection Check in the Periodic Maintenance chapter SUSPENSION 12 1 Suspension Table of Contents Exploded View 12 2 Rear Shock Absorber Removal Specifications 12 10 Rear Shock Absorber Installation Special Tools 12 14 Spring Replacement Front EE 12 16 Rear Shock Absorber Air Pressure 12 16 Disassembly Oil Change Rebound Damping Adjustment 12 16 Rear Shock Absorber Assembly Compression Damping Rear Shock Absorber Scrapping Adjustment 12 17 SII A Mirian as i Fork Oil Level Adjustment Swingarm Removal SIMPY ica nta 12 17 Swingarm Installation Oil Change Oil Level Adjustment Swingarm Bearing Removal each fork leg 12 21 Swingarm Bearing Installation Front Fork Removal 12 21 Drive Chain Guide Chain Slipper Front Fork Installation 12 21 VWear n eeii eet Front Fork Disassembly each Tie Rod Rocker Am fork leg E 12 22 Tie Rod Removal Front Fork Assemblv 12 26 Tie Rod Installation Inner Tube Inspection 12 29 Rocker Arm Removal Guide Bush Insp
37. Crankshaft Connecting Rod Crankshaft Alignment e In the case of horizontal misalignment which is the most common strike the projecting rim of the flywheel with a plastic soft lead or brass hammer as indicated in the figure e Recheck the runout with a dial gauge repeating the process until the runout falls within the service limit OVertical misalignment is corrected either by driving a wedge in between the flywheels or by squeezing the flywheel rims in a vise depending on the nature of the E misalignment In cases of both horizontal and vertical misalignment correct the horizontal misalignment first CAUTION Don t hammer the flywheel at point A x If flywheel misalignment cannot be corrected by the above method replace the crankpin or the crankshaft itself 6105008BS2 C 8 16 ENGINE BOTTOM END TRANSMISSION Transmission Shaft Removal e Split the crankcase see Crankcase Splitting e Pull off the shift rods A and disengage the shift fork guide pins from the shift drum grooves e Remove the shift drum B e Remove the shift forks C from the transmission gears e Take out the drive shaft D and output shaft E together with their gears meshed Shaft Installation e Hold the drive shaft A and output shaft B together with their gears meshed and fit them into the right crankcase half e To install the shift forks and shift drum see Shift Drum and Fork Ins
38. DOT4 Rear DOT4 NOTE OThe procedure to change the front brake fluid Chang ing the rear brake fluid is the same as for the front brake e Level the brake fluid reservoir e Remove the reservoir cap e Remove the rubber cap A on the bleed valve B e Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a con tainer e For KX125 250 M2 model as shown in the figure GLOSO16BS1 6S13035BS1 2 36 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Change the brake fluid as follows ORepeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes 1 Open the bleed valve A 2 Apply the brake and hold it B 3 Close the bleed valve C 4 Release the brake D OFill the reservoir with fresh specified brake fluid NOTE OThe fluid level must be checked often during the chang ing operation and replenished with fresh brake fluid If the fluid in the reservoir runs out any time during the changing operation the brakes will need to be bled since air will have entered the brake line e Remove the clear plastic hose e Tighten the bleed valves and install the rubber caps Torque Caliper Bleed Valve 7 8 N m 0 8 kgf m 69 in Ib e After changing the fluid check the brake for good braking power no brake drag and no fluid leakage x If necessary bleed the air from the lines WAR
39. El Le E 13 5 Steering Bn Ee e WEE 13 5 Steering A A de testes decade deni dau nd A Sanaa ai inaasa taia 13 5 Steering Stem Stem Bearing Removal ooccccccccnnnnnncnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnininnnss 13 5 Steering Stem Stem Bearing Installation 13 6 Steering Maintenance sidad dd 13 8 A nn ne eo ass canes handy thane hes auton n de 13 8 stem Bearing Wear DAaMage ueno 13 8 Stem ME ee EE iaa 13 8 A O 13 9 Handlebar Removal oia A A AA ee A 13 9 Handlebar Installations a a CERS dee e 13 9 13 2 STEERING Exploded View GNG2014B 5 STEERING 13 3 Exploded View Torque No Fastener Nem korn ft lb Remarks Handlebar Clamp Bolts 25 2 5 18 0 Steering Stem Head Nut 78 8 0 58 Steering Stem Locknut 4 9 0 5 43 in lb T Front Fork Clamp Bolts Upper Lower 20 2 0 14 5 1 2 3 4 5 Handlebar Clamp 6 Handlebar 7 Handlebar Holder 8 9 10 11 12 Steering Stem Head Bracket Tapered Roller Bearing Head Pipe Tapered Roller Bearing Steering Stem AD Apply adhesive cement G Apply grease O Apply 2 Stroke Oil T Tighten all snugly then loosen retighten to 4 9 N m 0 5 kgf m 43 in Ib 13 4 STEERING Special Tools Steering Stem Bearing Driver 57001 137 ST5701378T Steering Stem Bearing Driver Adapter 634 5 57001 1074 O ST5710748T Head Pipe Outer Race Press Shaft 57001 1075 ST5710758T Head Pipe
40. If the piston pin diameter is less than the service limit at any point replace the piston pin e Using a cylinder gauge measure the diameter of both of piston pin holes C in the piston and the inside diameter of the connecting rod small end x If either piston pin hole diameter exceeds the service limit replace the piston lf the connecting rod small end inside diameter exceeds the service limit replace the crankshaft assembly e Check the needle bearing D OThe rollers in a needle bearing normally wear very little and wear is difficult to measure Instead of measuring in spect the bearing for abrasion color change other dam age x If there is any doubt as to the condition of a needle bear ing replace the bearing and piston pin Piston Pin Diameter KX125 Standard eg 15 000 mm 0 5904 0 5906 Service Limit 14 96 mm 0 589 in KX250 Standard 17 995 18 000 mm 0 7085 0 7087 in Service Limit 17 96 mm 0 707 in Piston Pin Hole Diameter KX125 15 001 15 011 mm 0 5906 Salary 0 5910 in Service Limit 15 08 mm 0 594 in KX250 Standard 18 001 18 011 mm 0 7087 0 7091 in Service Limit 18 08 mm 0 712 in Small End Inside Diameter KX125 Standard Keen 19 014 mm 0 7481 0 7486 Service Limit 19 05 mm 0 750 in KX250 Standard 22 003 22 012 mm 0 8663 0 8666 in Service Limit 22 05 mm 0 868 in 6E06010582 C PERIODIC MAINTENANCE 2 25 Period
41. Kickstarter Assembly Disassembly Assembly AA Idle Gear Removal Idle Gear Installation 6 2 6 6 6 7 6 8 6 8 6 8 6 9 6 9 6 10 6 10 6 11 6 12 6 13 6 13 6 15 6 15 6 16 6 17 6 17 6 18 6 18 6 18 6 18 6 19 6 20 6 20 6 20 6 21 6 22 6 22 6 22 6 23 6 23 6 23 6 24 6 24 6 2 ENGINE RIGHT SIDE Exploded View KX125 GRO2002B 5 ENGINE RIGHT SIDE 6 3 Exploded View No Fastener Torque Remarks N m kgf m ft Ib 1 Clutch Hub Nut 98 10 0 72 2 Clutch Spring Bolts 8 8 0 9 78 in lb 3 Clutch Cover Bolts 8 8 0 9 78 in lb 4 Governor Shaft Lever Positioning Plug 0 6 0 06 5 in lb 5 Oil Filler Cap 1 5 0 15 13 in lb 6 Right Engine Cover Bolts 8 8 0 78 in lb 00 _ alo wo Governor Shaft Lever Mounting Bolt Exhaust Valve Advancer Lever Mounting Allen Bolt Primary Gear Nut Gear Set Lever Nut Ratchet Plate Mounting Bolts Clutch Lever 6 9 61 mb 3 9 35 mb O 0 L 50 0 d 0 Tt O o 9 7 4 4 8 8 9 78 in lb 8 8 9 78 in lb 9 8 12 Kick Ratchet Guide Bolt 8 8 0 78 in lb i 12 Kick Pedal Bok 14 Clutch Cable Clutch Cover Right Engine Cover Governor Shaft Lever Primary Gear Exhaust Advancer Assembly Gear Set Lever Ratchet Assembly Shift Shaft Kickstarter Idle Gear Ratchet Gear Kick Gear Kick Shaft Clutch Hub Release Lever Shaft Push
42. PERIODIC MAINTENANCE Special Tools Steering Stem Nut Wrench Fork Piston Rod Puller M12 x 1 25 57001 1100 57001 1289 Jack Fork Oil Level Gauge 57001 1238 57001 1290 ST5712388ST ST5712908T PERIODIC MAINTENANCE 2 13 Periodic Maintenance Procedures Fuel System Fuel Hose and Connection Check OThe fuel hoses are designed to be used throughout the motorcycle s life without any maintenance however if the motorcycle is not properly handled the inside the fuel line can cause fuel to leak A or the hose to burst Remove the fuel tank and check the fuel hose x Replace the fuel hose if any fraying cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps d are tightened correctly e When installing route the hoses according to Cable Wire and Hose Routing section in the Appendix chapter e When installing the fuel hoses avoid sharp bending kink ing flattening or twisting and route the fuel hoses with a minimum of bending so that the fuel flow will not be ob structed Replace the hose if it has been sharply bent or kinked GSO5009BS1 Throttle Grip Free Play Inspection e Check throttle grip free play B by lightly turning the throt tle grip A back and forth x lf the free play is improper adjust the throttle cable Throttle Grip Free Play Standard 2 3 mm 0 08 0 12 in e Check that the throttle grip moves smoothly from
43. Pour in the type and amount of fork oil specified and adjust the oil level see Oil Level Adjustment e Screw the fork piston rod puller A onto the end of the push rod Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 e Pull the push rod up with the special tool for the next pro cedures OPull up the push rod slowly so as not to spill the fork oil out of the fork tube 6M04022BS1 e Install the fork spring A e Pull the fork spring away a little and slip the fork spring holder in on top of the spring seat and under the push rod nut EAS GE 6M04101BS1 SUSPENSION 12 29 Front Fork e Remove the fork piston rod puller e Check the O ring A on the top plug and replace it with a new one if damaged e Unscrew the rebound damping adjuster fully then screw the front fork top plug onto the push rod e Holding the top plug B with a wrench tighten the push rod nut C against the top plug Torque Push Rod Nut 28 N m 2 85 kgf m 20 6 ft lb e For KX125 250 M2 model as shown in the figure 6M04155BS1 e Pull out the fork spring holder raise the outer tube and screw the top plug into it e After installing the front fork tighten the top plug Torque Fork Top Plug 29 N m 3 0 kgf m 22 ft lb Inner Tube Inspection e Visually inspect the inner tube A repair any damage e Nick or rust damage can sometimes be repaired by usin
44. Remove the hub bearing by tapping evenly around the bearing inner race as shown A Bar B Distance Collar C Hub Bearing 6J06013BS1 Hub Bearing Installation e Before installing the wheel bearings blow any dirt or for eign particles out of the hub B with compressed air to prevent contamination of the bearings e Replace the bearings with new ones e Lubricate them and install them using the bearing driver set A so that the marked or shielded sides face out OPress in the bearings until they are bottomed Special Tool Bearing Driver Set 57001 1129 6J06009BS1 e Replace the circlips and oil seals with new ones e Press in the oil seals A so that the seal surface is flush B with the end of the hole e Apply high temperature grease to the oil seal lips Special Tool Bearing Driver set 57001 1129 6J06008BS1 Hub Bearing Inspection NOTE Olt is not necessary to remove any bearings for inspec tion If any bearings are removed they will need to be replaced with new ones e Spin A it by hand to check its condition x If it is noisy does not spin smoothly or has any rough spots it must be replaced e Examine the bearing seal B for tears or leakage x If the seal is torn or is leaking replace the bearing 6J06002BS1 FINAL DRIVE 10 1 Final Drive Table of Contents Exploded VIS Wii AA Rte Re ad clea saat er eed tt 10 2 eet e le EE 10 4 Special TOS io 10
45. Reservoir Compression Damping Adjustment from the seated position adjuster turned fully clockwise KX125 13 clicks counterclockwise 16 clicks KX250 12 clicks counterclockwise Adjustable Range Gas Pressure 980 kPa 10 kgf cm 142 psi SUSPENSION 12 11 Specifications Item Standard Service Limit Tie Rod Rocker Arm Sleeve Outside Diameter 19 987 20 000 mm 0 7869 Large 0 7874 in 19 85 mm 0 781 in 15 987 16 000 mm 0 6294 Small 0 6299 in 15 85 mm 0 624 in Rocker Arm Mounting Bolt Runout under 0 1 mm 0 004 in 0 2 mm 0 008 in 12 12 SUSPENSION Specifications KX125 250 M2 Standard Service Limit Front Fork Air Pressure Atmospheric pressure EE Rebound Damping Adjustment Adjustable Range itor Ie Sealed position adjuster 14 clicks counterclockwise 16 clicks turned fully clockwise Compression Damping Adjustment from the seated position adjuster turned fully clockwise AdjustapIs Range KX125 10 clicks counterclockwise 16 clicks KX250 10 clicks counterclockwise Oil Viscosity KAYABA 01 or SAE OW EE Oil Capacity KX125 565 4 mL 19 10 0 14 US oz KX250 578 4 mL 19 54 0 14 US oz Oil Level fully compressed spring Adjustable Range removed KX125 105 2 mm 4 13 0 08 in 70 120 mm from top of outer tube 2 76 4 72 in KX250 88 2 mm 3 46 0 08 in from top of outer tube Fork Spring Free Length 460 mm 18 11 in 450 mm 1
46. Rod Steel Plate Friction Plate Sleeve Clutch Housing Push Rod Holder Clutch Pressure Plate Apply a non permanent locking agent to the threads Apply molybdenum disulfide grease Apply high temperature grease Apply oil Apply transmission oil 6 4 ENGINE RIGHT SIDE Exploded View KX250 6RO2003BW5 ENGINE RIGHT SIDE 6 5 Exploded View Torque No Fastener Nem kgf m ftIb Remarks 1 Clutch Cover Bolts 8 8 0 9 78 in lb 2 Right Engine Cover Bolts 8 8 0 9 78 in lb 3 Oil Filler Cap 1 5 0 15 13 in lb 4 Governor Shaft Lever Positioning Plug 0 6 0 06 5 in lb 5 ona Advancer Lever Mounting 3 9 04 35 in lb L BEM Gear Set Lever Nut cen in lb O Ratchet Plate Mounting Bolts Exhaust Shift Mechanism Return Spring Pin RE CI ofr loo Spring Bos 88 09 en nu Kick Ratchet Guide Bot 88 09 en az kek Pesis s 25 1 _ 3 Clutch Lever Clutch Cable 15 Clutch Cover 16 Right Engine Cover 17 Governor Shaft Lever 18 Exhaust Advancer Assembly 19 Water Pump Driver Gear 20 Primary Gear 21 Gear Set Lever 22 Ratchet Assembly 23 Shift Shaft 24 Ratchet Gear 25 Kickstarter Idle Gear 26 Kick Gear 27 Kick Shaft 28 Clutch Hub 29 Steel Plate 30 Friction Plate 31 Push Rod Holder 32 Clutch Pressure Plate 33 Clutch Housing 34 Sleeve 35 Push Rod 36 Release Lever Shaft M Apply molybdenum disulfide grease G Apply high temper
47. and Cable If the throttle grip has excessive free play due to cable stretch or misadjustment there will be a delay in throttle re sponse Also the throttle valve may not open fully at full throttle On the other hana if the throttle grip has no play the throttle will be hard to control and the idle speed will be erratic Check the throttle grip play periodically in accor dance with the Periodic Maintenance Chart and adjust the play if necessary The throttle cable routing is shown in Cable Harness Hose Routing in the Appendix chapter Free Play Inspection e Refer to the Throttle Grip Free Play Inspection in the Pe riodic Maintenance chapter Free Play Adjustment e Refer to the Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter Throttle Cable Installation e Install the throttle cable in accordance with the Cable Harness Hose Routing section in the Appendix chapter e After the installation adjust each cable properly A WARNING Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding con dition Cable Lubrication e Whenever the throttle cable is removed or in accordance with the Periodic Maintenance Chart lubricate the these cables Refer to General Lubrication in the Periodic Main tenance chapter OApply a thin coating of grease to the cable upper or lower ends OUse a commercially available pressure cable lubricator to lubricate these cables
48. bad worn weak broken or sticking Piston ring and clearance excessive Cylinder head gasket damaged Cylinder head warped Cylinder base gasket damaged Reed valve damaged Cylinder nut loose Engine rpm will not rise properly Starter plunger stuck open Float level too high or too low Main jet clogged Throttle valve does not fully open Air cleaner clogged Muffler clogged Water or foreign matter in fuel Cylinder exhaust port clogged Brake dragging Clutch slipping Overheating Transmission oil level too high Transmission oil viscosity too high Crankshaft bearing worn or damaged KIPS ports stuck closed KIPS ports stuck closed KIPS exhaust valves stuck closed valve seizure or carbon accumulation KIPS exhaust valves assembled incorrectly KIPS ports clogged carbon accumulation Exhaust valve operating rod seizure Rod for KIPS seized in cylinder Knocking Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect C D I Unit trouble Overheating Firing incorrect Spark plug dirty broken or maladjusted Spark plug incorrect C D I Unit trouble Fuel air mixture incorrect Main jet clogged or wrong size Fuel level in carburetor float bowl too low Fuel cut valve won t fully open Carburetor holder loose Air cleaner poorly sealed or missing Air cleaner duct poorly sealed Air cleaner clogged Compression high Carbon built up in combustion chamber Engine load faulty Brake dragging Clut
49. both ends the cable should move freely within the cable housing see Appen dix chapter GFO4002BS1 6004011481 ENGINE RIGHT SIDE 6 9 Clutch Cover Clutch Cover Removal e Drain the transmission oil see Engine Bottom End Trans mission chapter e Remove the brake pedal see Brake chapter e Unbolt the clutch cover bolts A and take off the clutch cover B 6R12000BS1 Clutch Cover Installation e There are two knock pins of the mating surfaces of right engine cover and clutch cover e Replace the clutch cover gasket with a new one e Tighten the clutch cover bolts Torque Clutch Cover Bolts 8 8 N m 0 9 kgf m 78 in Ib e Install the brake pedal see Brake chapter 6 10 ENGINE RIGHT SIDE Right Engine Cover Right Engine Cover Removal e Removal Transmission Oil drain see Engine Bottom End Trans mission chapter Coolant drain see Cooling System chapter Cooling Hose Lower end Kick Pedal Brake Pedal Muffler e Unscrew the KIPS cover bolt A and remove the KIPS cover B from the right side of the cylinder e Remove the governor shaft lever in accordance with the following procedure KX125 ORemove the bolt A and pull out the governor shaft lever B from the main shaft KX250 ORemove the E clip A from the operating rod OPut a 9 mm 0 35 in spanner wrench A on the governor shaft lever upper end OTurn the governor shaft lever B
50. can be reinstalled in the same position e Take out the valve core B to let out the air e Remove the valve stem nut C OWhen handling the rim be careful not to damage the rim flanges e Loosen the bead protector nut e Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant This helps the tire beads slip off the rim flanges CAUTION Never lubricate with mineral oil engine oil or gaso line because they will cause deterioration of the tire SCH ne ae 6J05002BS1 6y050401S1 WHEELS TIRES 9 13 Tires e Break the beads away from both sides of the rim with the bead breaker A Special Tool Bead Breaker Assembly 57001 1072 605060351 e Step on the side of the tire opposite valve stem pry the tire off the rim with the tire iron A of the bead breaker protecting the rim with rim protectors B Special Tools Rim Protector 57001 1063 Bead Breaker Assembly 57001 1072 CAUTION Take care not to inset the tire irons so deeply that the tube gets damaged GJ05016451 e Remove the tube when one side of the tire is pried off e Pry the tire off the rim Installation NOTE OThe tires should be installed so that the year and week of manufacture A or the ID serial faces to left side De Siy e Inspect the rim and tire and replace them if necessary e Install the tube
51. condition Idle Speed Inspection e Start the engine and warm it up thoroughly e With the engine idling turn the handlebar to both sides If handlebar movement changes the idle speed the throt tle cable may be improperly adjusted or incorrectly routed or it may be damaged Be sure to correct any of these conditions before riding see Cable Harness Hose Rout ing in the Appendix chapter A WARNING Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding condition e Check idle speed Adjust it as needed Idle Speed Adjustment e First turn in the air screw A until it seats lightly and back it out the specified number of turns see specifications in the Fuel System chapter e Start the engine and warm it up thoroughly e Turn the idle adjusting screw B to obtain desired idle speed If no idle is preferred turn out the screw until the engine stops e Open and close the throttle a few times to make sure that the idle speed is as desired Readjust if necessary Air Cleaner Element Cleaning and Inspection NOTE Oln dusty areas the element should be cleaned more frequently than recommended interval OAfter riding through rain or on muddy roads the element should be cleaned immediately OSince repeated cleaning opens the pores of the ele ment replace it with a new one in accordance with the Periodic Maintenance Chart Also if there is a break in
52. counterclockwise with the wrench and take off the operating rod collar C by pushing the operating rod into the cylinder OBefore pulling the governor shaft lever A free turn the remaining E clip B to a suitable position as shown in the figure to prevent the governor shaft lever boss C and the E clip from hitting 6E06002BS1 ENGINE RIGHT SIDE 6 11 Right Engine Cover ORemove the cover bolts A and take off the right engine cover B and gasket Right Engine Cover Installation e There are two knock pins of the mating surfaces of the crankcase and right engine cover e In case the exhaust advancer assembly has been re moved install it and turn the gear so as to level the gear drive pin A CAUTION If the gear drive pin is not positioned level it may fall out when installing the right engine cover e Apply a high temperature grease to the kick pedal oil seal lips and kick shaft spline e Tighten the right engine cover bolts and kick shaft mount ing bolt Torque Right Engine Cover Bolts 8 8 N m 0 9 kgf m 78 in Ib Kick Pedal Mounting Bolt KX125 12 N m 1 2 kgf m 8 7 ft lb KX250 25 N m 2 5 kgf m 18 ft lb KX125 e Using the 14 mm 0 56 in spanner wrench A install the governor shaft lever B as shown e Tighten Torque Governor Shaft Lever Mounting Bolt C 6 9 N m 0 7 kgf m 61 in Ib e Install the KIPS cover e Tighten Torque KIPS Cover Bolts 4 9 N m
53. cylin der B e Install the main valve retaining bolts C securely and tighten them Torque Main Valve Retaining Bolts 5 9 N m 0 6 kgf m 52 in Ib e Check the main exhaust valve assembly slide smoothly e Fit the spring A to the main lever B aomis P e Install the main lever A with spring to the slide valve pin B e Install the main valve rod C in the cylinder so that the grooved side D faces outward and the gear teeth face down e Insert the main shaft A into the hole of the left upper end at the cylinder and through the hole in the main lever B and spring C Then put the main shaft into the cylinder hole 5 22 ENGINE TOP END Exhaust Valve KIPS e Align the punch mark A on the main shaft gear with the groove B on the main valve rod e Turn the cylinder upside down e Push A the main valve rod in until it is fully seated into the cylinder e Insert the sub exhaust valves partially into the cylinder so that the operating rod can pass underneath the gears The right sub exhaust valve A is smaller than the left sub exhaust valve e Insert the operating rod until it is fully seated against the plug on the opposite side of the cylinder and push the oil seal assembly into the cylinder e Align the punch mark B marked with red paint on the exhaust valve rods A with the grooves C in the operat ing rod NOTE OThe marked tooth A is identified by its shape also B Pu
54. e Turn the fuel tap to the OFF position e Pull the fuel hose off the fuel tap e Remove the fuel tank mounting bolt A and band B e Remove the fuel tank C e Drain the fuel tank Fuel Tank Installation e Check the rubber dampers A on the frame Alf the dampers are damaged or deteriorated replace them e Be sure the fuel hose is clamped to the fuel tap to prevent leaks e Insert the fuel tank breather hose outlet end into the steer ing stem hole see Appendix chapter Fuel Tap Removal e Remove the fuel tank and drain it e Remove the mounting bolts A and take out the fuel tap B 6C009028BS1 Fuel Tap Installation e Be sure the O ring is in good condition to prevent leaks e Be sure to clamp the fuel hose to the tap to prevent leaks 3 24 FUEL SYSTEM Fuel Tank Fuel Tap Inspection e Refer to the in the Periodic Maintenance chapter Fuel Tank and Tap Cleaning e Refer to the Fuel Tank and Tap Cleaning in the Periodic Maintenance chapter FUEL SYSTEM 3 25 Reed Valve Reed Valve Removal e Remove the reed valve in accordance with the following procedure KX125 ORemove the carburetor holder mounting bolts and car buretor holder ORemove the reed valve A out of the crankcase KX250 ODrain the coolant ORemove the carburetor and coolant hose A ORemove the holder mounting bolts B and take off the carburetor holder C NIN K K ER
55. eg Removal EE 5 25 Muffler Instala a 5 25 Silencer Packing Change EE 5 25 5 2 ENGINE TOP END Exploded View KX125 ENGINE TOP END 5 3 Exploded View Fastener Torque No ES kgfm ftlb Remarks 1 Mam Valve Cover Bolts 5 9 0 6 52 in lb 2 Cylinder Head Nuts 25 2 5 18 3 Spark Plug 26 5 2 75 19 5 4 Engine Mounting Bracket Nut Engine Side 5 10 mm Engine Mounting Bracket Nuts Frame Side 8 mm KIPS Cover Bolts d KX125 M2 8 8 Cylinder Nuts 25 2 5 44 4 5 29 3 0 4 9 0 5 43 in lb 0 9 78 in lb 33 Main Shaft Stopper Pin Plug 0 8 0 08 6 9 in lb Main Lever Mounting Allen Bolt 3 9 04 35 in lb L 1 1 1 1 1 Main Valve Cover Cylinder Head Engine Mounting Brackets KIPS Cover Piston Ring Piston R Mark Alphabet Mark Piston Pin Cylinder Main Shaft Main Lever Spring Exhaust Valve Retaining Plate Governor Shaft Lever Exhaust Valve Right Identification Slot Exhaust Valve Left Expansion Chamber KX125 M1 model Expansion Chamber KX125 M2 model Rubber Seals Silencer Apply grease Apply a non permanent locking agent Apply 2 stroke engine oil Apply molybdenum disulfide grease Apply silicone sealant 6 7 eet 9 1 1 Exhaust Valve Retaining Bolts 5 9 0 6 52 in lb 0 1 6 5 4 ENGINE TOP END Exploded View KX250 E
56. fall over when the pivot shaft is removed Special Tool Jack 57001 1238 e Remove the engine mounting bolts B e Pull out the swing arm pivot shaft C e Lift the engine out to the right 7 6 ENGINE REMOVAL INSTALLATION Engine Removal Installation Engine Installation e Tighten the following nuts Torque Engine Mounting Nuts 44 N m 4 5 kgf m 33 ft Ib 49 N m 5 0 kgf m 36 ft lb KX125 250 M2 Engine Mounting Bracket Nuts 10 mm 44 N m 4 5 kgf m 33 ft lb 10 mm 49 N m 5 0 kgf m 36 ft Ib KX125 250 M2 8 mm 29 N m 3 0 kgf m 22 ft lb Pivot Shaft Nut 98 N m 10 0 kgf m 72 ft Ib e To route the leads cables and hoses refer to the Appen dix chapter e To install parts removed refer to the appropriate chapters e Fill the cooling system with coolant see Cooling System chapter e Fill the engine with transmission oil see Engine Bottom End Transmission chapter e Agjust Throttle Cable Clutch Cable Drive Chain Rear Brake ENGINE BOTTOM END TRANSMISSION 8 1 Engine Bottom End Transmission Exploded View Specifications Special Tools Transmission Oil Table of Contents Oil Level Inspection cc ccccddevsccasscdeseechscensteavisazcteaa ddeaucoasescnadguscedheccinestccstencseahtachdeavetas Oil Change Crankcase Crankcase Splittihg EE Crankcase DIS le TE Crankcase Assembly sisi Rea Crankshaft Connecting E
57. full open to close and the throttle closes quickly and completely in all steering positions by the return spring x If the throttle grip does not return properly check the throt tle cable routing grip free play and cable damage Then lubricate the throttle cable e Run the engine at the idle speed and turn the handlebar all the way to the right and left to ensure that the idle speed does not change x lf the idle speed increase check the throttle cable free play and the cable routing 6004060181 Throttle Grip Free Play Adjustment e Loosen the locknut A at the upper end of the throttle cable e Turn the adjuster B until the proper amount of throttle grip free play is obtained e Tighten the locknut el 6004060281 2 14 PERIODIC MAINTENANCE Periodic Maintenance Procedures lf the throttle grip free play cannot be adjusted with the adjuster at the upper end of the throttle cable use the cable adjuster A at the carburetor e Free the fuel cut valve connector from the frame e Pull the boot off of the carburetor top Make the necessary free play adjustment at the lower cable adjuster tighten the locknut B and install the boot e Turn the handlebar from side to side while idling the en gine If idle speed varies the throttle cable may be poorly routed or it may be damaged Operation with an improperly adjusted incorrectly routed or damaged cable could result in an unsafe riding
58. groove clearance excessive Cylinder head gasket damaged Cylinder head warped Cylinder base gasket damaged Reed valve damaged Cylinder nut loose Kips ports stuck open KIPS exhaust valve stuck open valve seizure or carbon accumulation KIPS exhaust valves assembled incorrectly Exhaust advancer spring damaged Exhaust valve operating rod seizure Rod for KIPS seized in cylinder Other C D I Unit trouble Transmission oil viscosity too high Brake dragging APPENDIX 15 3 Troubleshooting Guide Poor Running or No Power at High Speed Firing incorrect Spark plug dirty damaged or maladjusted Spark plug cap or high tension wiring dam aged Spark plug cap shorted or not in good con tact Spark plug incorrect C D I Unit trouble Ignition coil trouble Flywheel magneto damaged Ignition coil lead or C D I Unit lead not in good contact Fuel air mixture incorrect Main jet clogged or wrong size Jet needle or needle jet worn Jet needle clip in wrong position Float level too high or too low Fuel cut valve won t fully open Air jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter plunger stuck open Fuel to carburetor insufficient Water or foreign matter in fuel Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Fuel tap clogged Fuel line clogged Compression low Spark plug loose Cylinder head not sufficiently tightened down Cylinder piston worn Piston ring
59. in stalled dry the seals may wear excessively e Instal the impeller and check to see that the impeller turn freely Oil Seal Removal e Remove Right Engine Cover see Engine Right Side chapter Water Pump Shaft e Insert a bar A into the water pump shaft hole from the outside of the right engine cover and remove the ball bearing B by tapping C evenly around the bearing in ner race 6D06003BS1 6D06008BS1 6D060105S1 6D060106S1 COOLING SYSTEM 4 13 Water Pump e Insert a bar A into the water pump shaft hole from the inside of the right engine cover and remove the oil seal B by tapping C evenly around the seal lips 6D060107S1 Oil Seal Installation CAUTION If the oil seal or ball bearing is removed replace all of them with new ones at the same time e Be sure to replace the oil seals e Apply plenty of high temperature grease to the oil seal lips A e Press the oil seals B into the hole from the outside of the right engine cover Special Tool Bearing Driver Set 57001 1129 e Set the oil seal thick so that dual lips side face outward and set the oil seal thin so that a lip faces outward as shown NOTE OUse a bearing driver larger in diameter than the oil seal and press the oil seal into the hole until the edge of the oil seal located 0 1 0 5 mm 0 0039 0 0197 in D deep from the surface of the
60. it weakens check its free length to determine its condition x If any of the springs is shorter than the service limit it must be replaced Clutch Spring Free Length KX125 Standard 46 8 mm 1 843 in Service Limit 44 9 mm 1 768 in KX250 Standard 35 mm 1 378 in Service Limit 33 6 mm 1 323 in Friction Plate Clutch Housing Clearance e Measure the clearance between the tangs A on the fric tion plate and the fingers B of the clutch housing x lf this clearance is excessive the clutch will be noisy x If the clearance exceeds the service limit replace the fric tion plates Friction Plate Clutch Housing Clearance KX125 Standard 0 04 0 55 mm 0 0016 0 0217 in Service Limit 0 9 mm 0 0354 in KX250 Standard 0 15 0 45 mm 0 0059 0 0177 in Service Limit 0 8 mm 0 0315 in Clutch Hub Spline Inspection e Visually inspect where the teeth on the steel plates wear against the splines A of the clutch hub x If there are notches worn into the splines replace the clutch hub Also replace the clutch plates if their teeth are damaged Release Shift Removal e Remove the clutch see Clutch Removal e Remove the clutch cable upper end see Clutch Cable Removal OFor KX125 remove the magneto cover e Remove the tips A of the clutch cable e Pull the lever and shaft assembly B out of the crankcase GRO5010481 GRO50105S1 ENGINE RIGHT SIDE
61. line can cause fluid to leak A or the hose to burst if the line is not properly main tained Bend and twist the rubber hose while examining it x Replace the hose if any cracks B or bulges C are no ticed Tighten any loose fittings Suspension Front Fork Oil Leak Inspection e Visually inspect the front fork for oil leakage scoring or scratches on the outer surface of the inner tube A Alf necessary repair any damage e Nick or rust damage can sometimes be repaired by using a wet stone to remove sharp edges or raised areas which cause seal damage x lf the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired or replaced e Temporarily assemble the inner and outer tubes and pump them back and forth manually to check for smooth operation CAUTION If the inner tube is badly bent or creased replace it Excessive bending followed by subsequent straightening can weaken the inner tube e For KX125 250 M2 model as shown in the figure GL1001018S1 2 38 PERIODIC MAINTENANCE Periodic Maintenance Procedures Front Fork Oil Change Oil Level Adjustment each fork leg e Loosen the front fork upper clamp bolts e Place the handlebar on one side and loosen the fork top plug e Remove the front fork e Hold the inner tube lower end in a vise e Disassemble the top plug fr
62. maintenance and repair satisfactorily When ever the owner has insufficient experience or doubts as to his ability to do the work all ad justments maintenance and repair should be carried out only by qualified mechanics In order to perform the work efficiently and to avoid costly mistakes read the text thor oughly familiarize yourself with the procedures before starting work and then do the work care fully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substitute tools may ad versely affect safe operation To get the longest life out of your motorcycle e Follow the Periodic Maintenance Chart in the Service Manual e Be alert for problems and non scheduled maintenance e Use proper tools and genuine Kawasaki mo torcycle parts Special tools gauges and testers that are necessary when servicing Kawasaki Motorcycles are introduced by the Special Tool Manual Genuine parts provided as spare parts are listed in the Parts Catalog e Follow the procedures in this manual care fully Don t take shortcuts e Remember to keep complete records of main tenance and repair with dates and any new parts installed How to Use this Manual In this manual the product is divided into its major systems and these systems make up the manual s chapters The Quick Reference Guide shows
63. mm 2 85 3 15 mm Rear 3 85 4 15 mm 0 152 0 163 in Service Limit Front 2 5 mm 0 10 in Rear 3 5 mm 0 14 in e Place a jack under the motorcycle so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 e Set up a dial gauge against the disc A as illustrated OFor the front disc turn the handlebar fully to one side e Measure the disc runout while rotating the wheel slowly B x If the runout exceeds the service limit replace the disc Runout Standard Not more than 0 25 mm 0 098 in Service Limit 0 3 mm 0 01 in GLO80101S1 GLO8060481 11 22 BRAKES Brake Hose Brake Hose Removal Installation CAUTION fluid quickly ruins painted or plastic surfaces any spilled fluid should be completely wiped up imme diately with watered cloth e When removing the brake hose take care not to spill the brake fluid on the painted or plastic parts e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e There are washers on each side of the brake hose fitting Replace them with new ones when installing e When installing the hoses avoid sharp bending kinking flattening or twisting and route the hoses according to the Cable Harness Hose Routing section in the General Information chapter e Torque the banjo bolts at the hose fittings Torque Brake Hose
64. one machine to another BE amp Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Products amp Machinery Company Part No 99924 1298 04 Printed in Japan
65. plates with vernier calipers x If they have worn past the service limit replace them with new ones GRO5010281 PERIODIC MAINTENANCE 2 27 Periodic Maintenance Procedures Friction Plate Thickness KX125 Standard 2 72 2 88 mm 0 107 0 113 in Service Limit 2 6 mm 0 102 in KX250 Standard 2 92 3 08 mm 0 115 0 121 in Service Limit 2 8 mm 0 110 in Steel Plate Thickness KX125 Standard 1 5 1 7 mm 0 059 0 067 in Service Limit 1 4 mm 0 055 in KX250 Standard 1 46 1 74 mm 0 057 0 069 in Service Limit 1 36 mm 0 054 in Friction and Steel Plate Warp Inspection e Place each friction plate or steel plate on a surface plate and measure the gap between the surface plate A and each friction plate or steel plate B with a thickness gauge C The gap is the amount of friction or steel plate warp Alf any plate is warped over the service limit replace it with a new one Friction and Steel Plates Warp o_o o e Standard amp F13010781 Friction Plate Not more than 0 15 mm 0 006 in Steel Plate Not more than 0 2 mm 0 008 in Service Limit Friction Plate 0 3 mm 0 012 in Steel Plate 0 3 mm 0 012 in Engine Bottom End Transmission In order for the transmission and clutch to function prop erly always maintain the transmission oil at the proper level and change the oil periodically WARNING Motorcycle operation with insufficien
66. rattle spring A in the caliper as shown e Replace the shaft rubber friction boot A and dust cover B if they are damaged e Apply a thin coat of silicone grease to the caliper holder shafts C and holder holes PBC is a special high tem perature water resistant grease e Install the pads see Pads Installation e Wipe up any spilled brake fluid on the caliper Fluid Seal Damage The fluid seal around the piston maintains the proper pad disc clearance If this seal is not in good condition pad wear will increase and constant pad drag on the disc will raise brake and brake fluid temperature e Replace the fluid seals under any of the following condi tions a fluid leakage around the pad b brakes over heat c there is a large difference in left and right pad wear d the seal is stuck to the piston If the fluid seal is replaced replace the dust seal as well Also replace all seals every other time the pads are changed Dust Seal and Cover Damage e Check that the dust seals and covers are not cracked worn swollen or otherwise damaged Alf they show any damage replace them GLO5004BS1 GLO5006BS1 11 16 BRAKES Caliper Piston Cylinder Damage e Visually inspect the piston and cylinder surfaces Replace the cylinder and piston if they are badly scored or rusty Caliper Holder Shaft Wear The caliper body must slide smoothly on the caliper holder shafts If the bo
67. re moval weakens and deforms them If old ones are reused they could become detached while the motorcycle is driven leading to a major problem 15 Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film During assembly make sure to apply oil to any sliding surface or bearing that has been cleaned Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives therefore make sure to wipe it off and apply fresh grease or oil Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended 16 Direction of Engine Rotation To rotate the crankshaft manually make sure to do so in the direction of positive rotation Pos itive rotation is counterclockwise as viewed from the left side of the engine To carry out proper adjustment it is furthermore necessary to rotate the engine in the direction of positive rotation as well 17 Replacement Parts When there is a replacement instruction replace these parts with new ones every time they are removed Replacement parts will be damaged or lose their original function once they are removed There fore always replace these parts with new ones every time they are removed Although the pre viously mentioned gasket O ring ball bearing needle bearing grease
68. seal oil seal circlip and cotter pin have not been so designated in their respective text they are replacement parts 18 Electrical Wires All the electrical wires are either one color or two color A two color wire is identified first by the primary color and then the stripe color For example a yellow wire with thin red stripes is referred to as a yellow red wire it would be a red yellow wire if the colors were reversed Unless in structed otherwise electrical wires must be connected to wires of the same color Two Color Electrical Wire cross section Color Indicated on the Wire Color Indicated on the Wiring Diagram Red Wire Strands Yellow Red Y Rass Yellow Red 6B020601w1 1 4 GENERAL INFORMATION Before Servicing 19 Inspection When parts have been disassembled visually inspect these parts for the following conditions or other damage If there is any doubt as to the condition of them replace them with new ones Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure 20 Specifications Specification terms are defined as follows Standards show dimensions or performances which brand new parts or systems have Service Limits indicate the usable limits If the measurement shows excessive wear or dete riorated performance replace the damaged parts GENERAL INFORMATION 1 5 Model Identification KX125 M1 Left Side View KX125 M1
69. the drive chain Install the master link clip A so that the closed end of the U B points in the direction of chain rotation C 6K04002BS1 e Check the drive chain slack see Final Drive chapter e Tighten the axle nut Torque Rear Axle Nut 110 N m 11 kgf m 80 ft lb e Install the new cotter pin A and spread its end GKO4001BS1 NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise A up to next alignment Olt should be within 30 degree OLoosen once tighten again when the slot goes past the nearest hole 6y04034BS1 e Install disc cover e Check the rear brake for good braking power and no brake drag WARNING Do not attempt to drive the motorcycle until a full brake pedal is obtained by pumping the brake pedal until the pads are against the disc The brake will not function on the first application of the pedal if this is not done 9 10 WHEELS TIRES Wheels Rims Wheels Inspection e Place the jack under the frame so that the front rear wheel is raised off the ground Special Tool Jack 57001 1238 e Spin the wheel lightly and check for roughness or binding x If roughness or binding is found replace the hub bearings e Visually inspect the front and rear axles for damage x If axle is damaged or bent replace it Spoke Tightness Inspection e Refer t
70. the element material or any other damage to the ele ment replace the element with a new one d GCO4003BS1 6006017851 PERIODIC MAINTENANCE 2 15 Periodic Maintenance Procedures WARNING Clean the element in a well ventilated area and take care that there are no sparks or flame anywhere near the working area this includes any appliance with a pilot light Because of the danger of highly flammable liquids do not use gasoline or a low flash point solvent to clean the element e Remove the air cleaner element and separate the ele ment A from the frame B e Clean the element in a bath of a high flash point solvent using a soft bristle brush Squeeze it dry in a clean towel Do not wring the element or blow it dry the element can be damaged e Check all the parts of the element for visible damage Alf any of the parts of the element are damaged replace them e After cleaning saturate the element with a high quality foam air filter oil squeeze out the excess then wrap it in a clean rag and squeeze it as dry as possible Be careful not to tear the sponge filter e Assemble the element e Remove the towel from the carburetor e Install the element Fuel Tank and Tap Cleaning A WARNING Clean the fuel tank in a well ventilated area and take care that there is no sparks or flame anywhere near the working area Because of the danger of highly flammable liqui
71. the lower surface of the head at several different points and measure warp by inserting a thickness gauge B between the straightedge and the head Alf warp exceeds the service limit repair the mating sur face Replace the cylinder head if the mating surface is badly damaged Cylinder Head Warp Service Limit 0 03 mm 0 0012 in B 6D030001S1 6S06004BS1 6E0506018S1 2 20 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cylinder Wear Inspection NOTE OMeasure the cylinder inside diameter when the cylinder is cold room or ambient temperature e Visually Inspect the inside of the cylinder for scratches and abnormal wear x If the cylinder is damaged or badly worn replace it with a new one e Since there is a difference in cylinder wear in different di rections take a side to side and a front to back measure ment shown in the figure x lf any of the cylinder inside diameter measurements ex ceeds the service limit the cylinder must be replaced with a new one since the PLATING cylinder cannot be bored or honed A KX125 15 mm 0 6 in KX250 30 mm 1 2 in Cylinder Inside Diameter KX125 Standard 54 010 54 025 mm 2 1264 2 1270 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 54 10 mm 2 130 in or more than 0 05 mm 0 020 in difference between any two measurements
72. to the terminals of the magneto lead connector B Special Tool Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connection Adapter Positive Green White Lead C Adapter Negative White Yellow Lead D OCrank the engine by kicking the pedal several times to measure the peak voltage of the crankshaft sensor Peak Voltage 2 4 V or above KX125 1 6 V or above KX250 A WARNING Do not touch the metal portion of the probe in case of measuring the voltage or you may receive a se rious electric shock x If the voltage is less than the specified check the crank shaft sensor 6P10042BS1 ELECTRICAL SYSTEM 14 23 Ignition System Exciter Coil Peak Voltage Check e Disconnect the connector of the magneto lead connec tor from the C D I unit KX125 or the main harness KX250 e To check the peak voltage do the following procedures NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head OThe correct value may not be obtained if disconnected OConnect the peak voltage adapter A of the tester to the terminals of the magneto lead connector B Special Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connection Adapter Positive White Lead C Adapter Negat
73. you all of the product s system and assists in locating their chapters Each chapter in turn has its own comprehensive Ta ble of Contents For example if you want ignition coil informa tion use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chap ter to find the Ignition Coil section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices WARNING This warning symbol identifies special instructions or procedures which if not correctly followed could result in per sonal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in dam age to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of informa tion NOTE OThis note symbol indicates points of par ticular interest for more efficient and con venient operation e Indicates a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a NOTE x Indicates a conditional step or what action to take based on the results of the test or inspec tion in the procedural step or sub step it fol lows In most chapters an e
74. 0 C KX250 12 6 1 9 kQ at 20 C Spark Plug Type KX125 M1 NGK BR9EIX KX125 M2 NGK R6918B 9 KX250 NGK BR8EIX Gap 0 7 0 8 mm 0 026 0 031 in C D I Unit in the text Noise Suppressor Resistance 3 75 6 250 Throttle Sensor KX250 Input Voltage around 5 V Output Voltage when the throttle valve completely closed when the throttle fully opened 3 5 3 7 V 0 4 0 6 V Fuel Cut Valve KX250 Resistance 49 7 56 2 Q Protrusion When Battery is Disconnected 19 4 19 6 mm 0 76 0 77 in When Battery is Connected 21 3 21 7 mm 0 84 0 85 in ELECTRICAL SYSTEM 14 7 Special Tools Spark Plug Wrench Hex 21 Flywheel amp Pulley Holder 57001 110 57001 1605 O ST5716058T Flywheel Puller M12 x 1 75 Hand Tester 57001 252 57001 1394 T5702528T T5713948T Peak Voltage Adapter 57001 1415 ST5714158T 14 8 ELECTRICAL SYSTEM Precautions There are numbers of important precautions that are musts when servicing electrical systems Learn and ob serve all the rules below OThe electrical parts should never be struck sharply as with a hammer or allowed to fall on a hard surface Such a shock to the parts can damage them OTroubles may involve one or in some cases all items Never replace a defective part without determining what CAUSED the failure If the failure was caused by some other item or items they too must be repaired or replaced or the n
75. 0 0386 0 0392 in Service Limit 0 91 mm 0 036 in KX250 Standard 0 970 0 985 mm 0 0382 0 0388 in Service Limit 0 90 mm 0 035 in Piston Ring Groove Width KX125 Standard 1 01 1 03 mm 0 0398 0 0406 in Service Limit 1 11 mm 0 044 in KX250 Standard 1 01 1 03 mm 0 0398 0 0406 in Service Limit 1 11 mm 0 044 in GE16020881 PERIODIC MAINTENANCE 2 23 Periodic Maintenance Procedures Piston Ring End Gap Inspection i e Place the piston ring A inside the cylinder B using the E piston to locate the ring squarely in place e Set it close to the bottom of the cylinder where cylinder wear is low e Measure the gap between the ends ofthe ring with a thick ness gauge C Alf the gap is wider than the service limit the ring is over worn and must be replaced GEO60106S1 Piston Ring End Gap KX125 Standard 0 35 0 55 mm 0 0138 0 0217 in Service Limit 0 85 mm 0 033 in KX250 Standard 0 25 0 45 mm 0 0098 0 0177 in Service Limit 0 75 mm 0 030 in 2 24 PERIODIC MAINTENANCE Periodic Maintenance Procedures Piston Piston Pin Connecting Rod Wear Inspection e Visually inspect the snap ring A still fitted in place lf the ring shows weakness or deformation replace the ring Also if the pin hole groove shows excessive wear replace the piston e Measure the diameter of the piston pin B with a microm eter x
76. 0 5 kgf m 43 in Ib KX125 M2 8 8 N m 0 9 kgf m 78 in Ib KX250 e Put a 9 mm 0 35 in spanner wrench A on the governor shaft lever upper end e Turn the governor shaft lever counterclockwise with the wrench and fit the groove of the operating rod collar B to the boss of the governor shaft lever and install the collar on the operating rod while turning the governor shaft lever clockwise 6E06011BS1 6 12 ENGINE RIGHT SIDE Right Engine Cover e After installing the collar install the E clip A on the oper ating rod B e Tighten the KIPS cover bolts Torque KIPS Cover Bolts 2 5 N m 0 25 kgf m 22 in Ib e Apply grease to the inside of the brake pedal boss e Tighten the brake pedal mounting bolt Torque Brake Pedal Mounting Bolt 25 N m 2 5 kgf m 18 in Ib e Fill the cooling system with coolant see Cooling System chapter e Fill the transmission with oil see Engine Bottom End Transmission chapter e Check the rear brake Right Engine Cover Disassembly e Remove the right engine cover e Turn the governor shaft lever A to the left and remove the exhaust advancer assembly B e Remove the Allen bolts C and take off the advancer lever e Pull the dust cover D ENGINE RIGHT SIDE 6 13 Right Engine Cover e Remove the plug screw A and take out the governor shaft lever positioning pin e Pull the governor shaft lever B out of the right engine c
77. 0 7 61 in lb 5 Cooling Hose Clamp Screws 1 5 0 15 13 in lb 6 Cylinder Drain Plug 8 8 0 9 78 in lb 7 Cooling Hose Elbow Fitting Bolts 8 8 0 9 78 in lb 8 Right Engine Cover Bolts 8 8 0 9 78 in lb 9 Radiator 10 Radiator Cap 11 Water Pump Cover 12 Impeller 13 Oil Seal Short Oil Seal Long Bearing Water Pump Gear Right Engine Cover Cylinder Head Cylinder Elbow Fitting Apply grease Apply molybdenum disulfide grease 4 6 COOLING SYSTEM Specifications Item Service Limit Coolant Type Permanent type antifreeze for aluminum engines and radiators Color Green Mixed Ratio Soft water 50 antifreeze 50 Total Amount KX125 0 97 L 1 02 US at KX250 1 20 L 1 27 US qt Radiator Cap Relief Pressure 93 123 kPa 0 95 1 25 kgf cm 13 18 psi COOLING SYSTEM 4 7 Special Tools Bearing Driver Set 57001 1129 ST5711298T 4 8 COOLING SYSTEM Coolant Check the coolant level each day before riding the motor cycle and replenish coolant if the level is low Change the coolant in accordance with the Periodic Maintenance Chart see Periodic Maintenance chapter A WARNING To avoid burns do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot Wait until it cools down Coolant Level Inspection e Referto the Coolant Level Inspection in the Periodic Main tenance chapter Coolant De
78. 1 18 Rear Master Cylinder Removal ss 11 18 Rear Master Cylinder Installation ss 11 19 Front Master ureegen cio 11 19 Rear Master Cylinder Disassembly ss 11 19 Master ele E ue 11 20 Master Cylinder Inspection Visual Inspechon 11 20 eer DISK as E Rs etal Ee 11 21 Brake Disc INSpectiON Sienne 11 21 Brake MOSS ann A ee Re Me ee den isd 11 22 Brake Hose Removal Installation su 11 22 Brake HOSe Inspeccion 11 22 11 2 BRAKES Exploded View BRAKES 11 3 Exploded View z 9 Fastener Torque N m kgf m ft lb Remarks Front Master Cylinder Clamp Bolts 8 8 0 9 78 in lb Brake Hose Banjo Bolts 25 2 5 18 Brake Pad Bolt 18 1 8 13 Caliper Bleed Valve 7 8 0 8 69 in lb Caliper Mounting Bolts 25 2 5 18 Brake Disc Mounting Bolts 9 8 1 0 87 in lb L Front Brake Reservoir Brake Lever Brake Lever Adjuster Locknut Brake Hose Clamps Front Caliper Brake Pad Piston Front Disc KX125 250 M1 model KX125 250 M2 model Apply Silicone grease Replacement Parts 11 4 BRAKES Exploded View GLO2035B 5 BRAKES 11 5 Exploded View No Fastener Torque Remarks i N m kgf m ft Ib 1 Brake Hose Banjo Bolts 25 2 5 18 2
79. 1109 wN o toa a w le li Compression Damping Adjuster Setting ot Standard GMO4096BS1 C KX125 M2 10 clicks KX250 M1 13 clicks KX250 M2 10 clicks Fork Oil Level Adjustment Simplify e Raise the front wheel off the ground using a jack Special Tool Jack 57001 1238 e Remove Front Fender Brake Hose Guard A Brake Hose Clamps B Fork Protectors C Number Plate Handlebar e For KX125 250 M2 model note the following ORaise the front wheel off the ground using a jack Special Tool Jack 57001 1238 ORemove Front Fender Brake Hose Clamps A Fork Protectors B and Protector Guides Number Plate z S A Handlebar EM04143BS1 12 18 SUSPENSION Front Fork e Loosen the upper fork clamp bolts e Disassemble the front fork top plugs from the outer tube e Slowly compress the front fork fully by pushing up the inner tubes A until they are stepped portion contacts the dust seals B on the lower end of the outer tubes C e For KX125 250 M2 model as shown in the figure e Place a stand or other suitable support A under the front wheel e For KX125 250 M2 model as shown in the figure e While holding the push rod nut with a 17 mm 0 67 in wrench A loosen the front fork top plug B from the top of the push rod e Remove the fork top plug with the fork spring seat C and fork spring D e Remove the other fork spring in the same way as de scrib
80. 22 mb Brake Pedal Mounting Bolt 25 2 5 18 Suspension Front Fork Clamp Bolts Upper Lower 20 2 0 14 5 Front Fork Cylinder Valve Assembly 54 5 5 40 L Front Fork Top Plug 29 3 0 22 Push Rod Nut 28 2 85 20 6 Swingarm Pivot Shaft Nut 98 10 0 72 2 8 PERIODIC MAINTENANCE Torque and Locking Agent Fastener Torque Remarks N m kgf m ft Ib Rear Shock Absorber Mounting Nuts Upper 39 4 0 29 Lower 34 3 5 25 Tie Rod Mounting Nut Front Rear 83 8 5 61 Rocker Arm Pivot Nut 83 8 5 61 Steering Steering Stem Head Nut 78 8 0 58 Steering Stem Locknut 4 9 0 5 43 in lb Handlebar Clamp Bolts 25 2 5 18 Front Fork Clamp Bolts Upper Lower 20 2 0 14 5 Electrical System Flywheel Bolt 22 2 2 16 Flywheel Nut 78 8 0 58 Stator Plate Mounting Screws 4 4 0 45 39 in lb Spark Plug 26 5 2 75 19 5 Magneto Cover Bolts KX125 250 M1 4 9 0 5 43 in lb Magneto Cover Bolts KX125 250 M2 3 9 0 4 35 in lb Basic Torque for General Fasteners Threads dia Torque mm N m kgf m ft Ib 5 3 4 4 9 0 35 0 50 30 43 in lb 6 5 9 7 8 0 60 0 80 52 69 in lb 8 14 19 1 4 19 10 0 13 5 10 25 34 2 6 3 5 19 0 25 12 44 61 4 5 6 2 33 45 14 73 98 7 4 10 0 54 72 16 115 155 11 5 16 0 83 115 18 165 225 17 0 23 0 125 165 20 225 325 23 33 165 240 PERIODIC MAINTENANCE 2 9 Specifications Item Standard Service Limit Fuel System Throttle Grip Free Play Air Cle
81. 37 5 R42 Fork Oil Level Gauge 57001 1101 57001 1290 ST571101ST ST571290ST Bearing Driver Set Fork Cylinder Holder 57001 1129 57001 1413 ST5711298T Fork Outer Tube Weight Fork Oil Seal Driver 48 57001 1218 57001 1509 ST5712188ST ST571509 S SUSPENSION 12 15 Special Tools Fork Cylinder Holder Bearing Remover Shaft 9 57001 1573 57001 1265 D ST5715738T ST5712658T Bearing Remover Head 415 x 17 57001 1267 amp 12 16 SUSPENSION Front Fork Air Pressure The standard air pressure in the front fork legs is atmo spheric pressure Air pressure in the fork legs increase with normal use so the fork action stiffens during opera tion Release air pressure form the fork legs prior to each race through the pressure relief screw located in each front fork cap e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e Remove the screws A at the top of the front fork top plugs to let the air pressure equalize NOTE ODO not use the side stand when adjusting the air pres sure OAdjust the air pressure when the front forks are cold e Check the O ring of the screw Replace the O ring with a new one if damage e Install the screw Rebound Damping Adjustment e Place the jack under the frame so that the front wheel off the ground Special Tool Jack 57001 1238 e To adjust rebound damping turn the ad
82. 4 kgf m 35 in Ib e Fit the advancer lever pin B into the groove C on the exhaust advancer assembly D and install the assembly in the engine cover while turning the governor shaft lever to the left ENGINE RIGHT SIDE 6 15 Clutch Clutch Removal e Remove the clutch cover see Clutch Cover Removal e Remove the clutch spring bolts A spring and clutch pressure plate B c e Remove the push rod holder assembly A friction plates steel plates and push rod B e For KX125 Remove steel boll C 1 e Remove the clutch hub nut A and washer NOTE OUse the clutch holder B to prevent the clutch hub from rotating Special Tool Clutch Holder 57001 1243 e Remove the clutch hub and housing needle bearing A and sleeve B GRO5022BS1 6 16 ENGINE RIGHT SIDE Clutch Clutch Installation e Apply molybdenum disulfide grease to the outside of the sleeve e Apply transmission oil to the inside of the clutch housing gear and kickstarter driven gear e Install the sleeve needle bearing clutch hub and hous ing ODo not forget to install the thrust washer A before in stalling the clutch hub B e Tighten the clutch hub nut A Torque Clutch Hub Nut 98 N m 10 kgf m 72 ft lb NOTE OUse the clutch holder B to prevent the clutch hub from rotating Special Tool Clutch Holder 57001 1243 e For KX250 stake the clutch hub nut A in th
83. 5 250 M2 model note the following OAdjust the gas reservoir damping adjusters A to the soft est position ORemove the air bleeder bolt B and pump the rear shock to drain the oil out of the rear shock body Olnstall the air bleeder bolt e Using the suitable tool A and press push the reservoir cap B in 10 mm 0 39 in e Remove the circlip C from the gas reservoir e Pull the gas reservoir cap B out of the gas reservoir using the pliers A e Pry or tap A at the gaps B in the stop C with suitable tools to free the stop from the rear shock body D e Slide the stop up the top of the piston rod then lightly tap around the seal with a suitable rod and mallet and push the seal assembly 10 mm 0 39 in down e Remove the circlip A e Lightly move the piston rod back and forth and pull out the piston rod assembly e Pour the oil out of the rear shock body 6M05104BS1 GMO5065BS1 SUSPENSION 12 37 Rear Suspension Uni Trak Rear Shock Absorber Assembly e Pour KYB K2 C SAE 5W or Bel Ray SE2 40 oil into the gas reservoir to 60 70 mm 2 63 2 76 in A from the gas reservoir upper end GM05010481 e Check that the bladder A on the gas reservoir cap is not partially collapsed x If it is push down the valve core with a screwdriver e Check the bladder for sign of damage or crack Alf necessary replace it with a new one CAUTION Do
84. 5 mm 0 750 in ENGINE TOP END 5 7 Specifications KX250 Standard Cylinder Head Cylinder Compression Cylinder Head Warp Usable range 825 1 275 kPa 8 4 13 0 kgf cm 119 185 psi Service Limit 0 03 mm 0 0012 in Cylinder Piston Cylinder Inside Diameter 30 mm 1 18 in below of the cylinder head Piston Diameter Piston Cylinder Clearance Piston Ring Groove Clearance Piston Ring Groove Width Piston Ring Thickness Piston Ring End Gap Piston Pin Diameter Piston Pin Hole Diameter Small End Inside Diameter 66 400 66 415 mm 2 6142 2 6148 in 66 336 66 351 mm 2 6116 2 6122 in 0 049 0 079 mm 0 0019 0 0031 in 0 025 0 06 mm 0 00098 0 00236 in 1 01 1 03 mm 0 0398 0 0406 in 0 970 0 985 mm 0 0382 0 0388 in 0 25 0 45 mm 0 0098 0 0177 in 17 995 18 000 mm 0 7085 0 7087 in 18 001 18 011 mm 0 7087 0 7091 in 22 003 22 012 mm 0 8663 0 8666 in 66 46 mm 2 617 in 66 19 mm 2 6059 in 0 16 mm 0 006 in 1 11 mm 0 044 In 0 90 mm 0 035 in 0 75 mm 0 030 in 17 96 mm 0 707 in 18 08 mm 0 712 in 22 05 mm 0 868 in 5 8 ENGINE TOP END Special Tool Compression Gauge 20 kgf cm Piston Pin Puller Assembly 57001 221 57001 910 T5702218T g ST5709108ST Compression Gauge Adapter M14 x 1 25 57001 1159 ENGINE TOP END 5 9 Cylinder Head Cylinder Compression Measurement
85. 7 72 in Rear Suspension Uni Trak Rear Shock Absorber Rebound Damping Adjustment from the seated position adjuster fully clockwise Turned KX125 11 clicks counterclockwise 16 clicks KX250 10 clicks counterclockwise Spring Preload Adjustment Adjusting nut position from the center of the mounting hole upper Adjustable Range Adjustable Range KX125 111 mm 4 37 in 109 127 5 mm 4 29 5 02 in KX250 112 mm 4 41 in 109 129 5 mm 4 29 5 10 in Rear Shock Spring Free Length 260 mm 10 24 in 255 mm 10 04 in Gas Reservoir Compression Damping Adjustment from the seated position adjuster turned fully clockwise KX125 13 clicks counterclockwise 16 clicks KX250 10 clicks counterclockwise Adjustable Range Gas Pressure 980 kPa 10 kgf cm 142 psi SUSPENSION 12 13 Specifications Item Standard Service Limit Tie Rod Rocker Arm Sleeve Outside Diameter 19 987 20 000 mm 0 7869 Large 0 7874 in 19 85 mm 0 781 in 15 987 16 000 mm 0 6294 Small 0 6299 in 15 85 mm 0 624 in Rocker Arm Mounting Bolt Runout under 0 1 mm 0 004 in 0 2 mm 0 008 in 12 14 SUSPENSION Special Tools Oil Seal amp Bearing Remover Jack 57001 1058 57001 1238 ST5710588T ES ST5712388ST Steering Stem Nut Wrench Fork Piston Rod Puller M12 x 1 25 57001 1100 57001 1289 e O DS ST571100ST ST571289ST Hook Wrench R
86. BA Kawasaki KX250 Motorcycle Service Manual This quick reference guide will assist you in locating a desired topic or pro cedure Bend the pages back to match the black tab of the desired chapter num ber with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the spe cific topic required Quick Reference Guide General Information Periodic Maintenance Fuel System Cooling System Engine Top End Engine Right Side Engine Removal Installation Engine Bottom End Transmission 8 Wheels Tires Final Drive Brakes Suspension Electrical System 01 A N O 0O NO IG AIIIN Appendix KX125 Kawasaki KX250 Motorcycle Service Manual All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products amp Machinery Company Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactur
87. Circlip 6113011181 e The output shaft gears can be identified by size the largest diameter gear is 1st gear and the smallest is 5th KX250 or 6th KX125 Be sure that all parts are put back in the correct sequence and facing the proper direction and that all circlips are properly in place KX125 A 2nd gear 26T dog recesses face right B 6th gear C 3rd gear D 4th gear E 5th gear F 1st gear G Circlip KX250 A 2nd gear B 4th gear C 3rd gear D 5th gear E 1st gear 25T fork groove goes to the right side of the gear teeth 26T dog recesses face left 22T dog recesses face right 27T fork groove goes to the left side of the gear teeth 31T plain side faces right 23T dog recesses face right 21T fork groove goes to the right side of the gear teeth 20T dog recesses face left 20T fork groove goes to the left side of the gear teeth 27T dog recesses face left F Circlip G Collar e Check that each gear spins or slides freely on the trans mission shaft without binding after assembly Shift Drum and Fork Installation e Apply a little transmission oil to the shift fork A ears and fit the shift forks into the gear grooves 6113007BS1 8 18 ENGINE BOTTOM END TRANSMISSION Transmission Shift Fork Identification KX125 Drive shaft 3rd gear and 4th gear shift fork A ears ar
88. DEE Grankshal ne EE CGr nkshaft Installations nee egen A ee eevee Crankshaft Disassembly E Grankshaft EI Connecting Rod Big End Radial Clearance ooooooocccccccccccnonoconcncncccnnnnnnnannnnnnnnnnncnnnnnnannnnno Connecting Rod Big End Seizure iii o Connecting Rod Big End Side Clearance us Crankshaft RUMOUL tua ged vaca nakua eeka aaan EES EES eekleg aae aio Neo E eE aena Transmission Shaft Removal Shaft Installation Dhan DiSASSEMOLY EE Shaft Assembly Shift Drum and Fork Installatton iiiiiieeeeeeceeeceeeneseeeeeeeeesee Shift Fork Bending Shift Fork Gear Groove Wear nero neronernnernnannnennncnnncinnes Shift Fork Guide P Gear Damage in Shift Drum Groove Wear ccoocccncccnccnnccnncnnncnoncnnncnnncnnncnncnonanoncnanecinens Gear Dog Gear Dog Hole Damage nnnnnnssesrrrrrrrrrrrrrrrrrrrrrrrrtrttrrrtttttrttttnttttettrtttnnnnn Ball Bearing Wear 8 2 8 6 8 7 8 8 8 8 8 8 8 9 8 10 8 10 8 13 8 13 8 13 8 13 8 13 8 14 8 14 8 14 8 14 8 15 8 16 8 16 8 16 8 16 8 16 8 17 8 18 8 19 8 19 8 19 8 20 8 20 8 2 ENGINE BOTTOM END TRANSMISSION Exploded View KX125 aos ea 6102032BW5 ENGINE BOTTOM END TRANSMISSION 8 3 Exploded View Torque No Fast R k o astener Nm karm itib emarks 4 Output Shaft Bearing Retaining 54 0 55 48 in Ib L Screws gt Shift Drum Bearing Retaining Screws Es S A 56 in lb L Bolis Mo
89. E Olf a sprocket requires replacement the chain is proba bly worn also When replacing a sprocket inspect the chain GKO040606S1 6K04030351 6k050611S1 PERIODIC MAINTENANCE 2 33 Periodic Maintenance Procedures Rear Sprocket Warp Inspection e Using the jack raise the rear wheel off the ground Special Tool Jack 57001 1238 e Set a dial gauge A against the rear sprocket B near the teeth as shown and rotate C the rear wheel to measure the sprocket runout warp The difference between the highest and lowest dial gauge readings is the amount of runout warp Alf the runout exceeds the service limit replace the rear sprocket 6ko050111S1 Rear Sprocket Warp Standard Under 0 4 mm 0 016 in Service Limit 0 5 mm 0 020 in Brakes Brake Lever Play Adjustment e Adjust the front brake lever A to suit you e Slide the brake lever dust cover B out of place e Loosen the adjuster locknut C and turn the adjuster D to either side e After adjustment tighten the locknut 6L04004BS1 WARNING Always maintain proper brake adjustment If ad justment is improper the brake could drag and overheat This could damage the brake assembly and possibly lock the wheel resulting in loss of control 2 34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Level Inspection In accordance with the Period
90. E TOP END Cylinder e When installing the piston ring on the piston note the fol lowing OFor KX250 the top A and second B rings are identical OFirst fit one end of the piston ring against the pin in the ring groove spread the ring opening with the other hand and then slip the ring into the groove OFor KX125 the piston ring have a R mark A on it upper surface Olnstall the ring so that the pin A in the piston ring groove is between the ends of the piston ring e Apply 2 stroke engine oil to the connecting rod needle bearing and the piston pin eFor KX125 install the piston so that the Alphabet marked side A faces the front side Exhaust side of the engine e For KX250 install the piston so that the IN marked side A faces the back side of the engine e When installing a piston pin snap ring A 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 e Fit a new piston pin snap ring into the side of the piston so that the ring opening B does not coincide with the notch C in the edge of the piston pin hole Cylinder Wear Inspection e Refer to the Cylinder Wear Inspection in the Periodic Maintenance chapter Ke KX125 GE060102 1 6E060101S1 GE060602 1 ENGINE TOP END 5 15 Cylinder Pi
91. ION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Remove the rear shock absorber lower mounting bolt B e For KX125 250 M2 model note the following ORemove the tie rod rear mounting bolt A ORemove the rear shock absorber lower mounting bolt B e Remove the rear shock absorber upper mounting bolt A nut and pull out the rear shock absorber B down and out Rear Shock Absorber Installation e Pack the rocker arm needle bearings with grease e Tighten the following Torque Rear Shock Absorber Upper Mounting Nut 39 N m 4 0 kgf m 29 ft lb Rear Shock Absorber Lower Mounting Nut 34 N m 3 5 kgf m 24 ft lb Tie Rod Mounting Nut 83 N m 8 5 kgf m 61 ft lb Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib Spring Replacement In addition to the standard spring heavy and light springs are available If the standard spring is improper for your purpose select a proper one according to the rider s weight or course conditions e Remove Side Covers Seat Silencer Rear Frame with Air Cleaner Housing e Remove the rear shock absorber e Clean the threaded portion on the upper of the rear shock absorber e Hold the lower of the rear shock absorber with a vise GMO5061BS1 SUSPENSION 12 35 Rear Suspension Uni Trak e Using the hook wrenches C loosen the locknut B and turn the a
92. KX250 Standard 66 400 66 415 mm 2 6142 2 6148 in and less than 0 01 mm 0 0004 in difference between any two measurements Service Limit 66 46 mm 2 617 in or more than 0 05 mm 0 020 in difference between any two measurements 6E060104S1 PERIODIC MAINTENANCE 2 21 Periodic Maintenance Procedures Piston Diameter Measurement e Measure the outside diameter of the piston 15 0 mm 0 59 in KX125 or 20 5 mm 0 81 in KX250 A up from the bottom of the piston at a right angle to the direction of the piston pin Q x If the measurement is under the service limit replace the piston A A KX125 15 0 mm 0 59 in KX250 20 5 mm 0 81 in 6E06010351 Piston Diameter KX125 Standard 53 955 53 970 mm 2 1242 2 1248 in Service Limit 53 81 mm 2 118 in KX250 Standard 66 336 66 351 mm 2 6116 2 6122 in Service Limit 66 19 mm 2 606 in Piston Cylinder Clearance The piston to cylinder clearance is measured whenever a piston or cylinder is replaced with a new one The standard piston to cylinder clearance must be adhered to whenever the cylinder is replaced If only a piston is replaced the clearance may exceed the standard slightly But it must not be less than the minimum in order to avoid piston seizure The most accurate way to find the piston clearance is by making separate piston and cylinder diameter measure ments and then computing
93. Maintenance Procedures Clutch Lever Free Play Check e Slide the clutch lever dust cover A out of place e Check that the clutch cable upper end is fully seated in the adjuster B e Check that the clutch lever C has 2 3 mm 0 08 0 12 in of play D x lf it does not adjust the lever play 6R110601S1 Clutch Lever Free Play Adjustment e Slide the clutch lever dust cover out of place e Loosen the knurled locknut A e Turn the adjuster B so that the clutch lever will have 2 3 mm 0 08 0 12 in of play C NOTE OBe sure that the outer cable end at the clutch lever is fully seated in the adjuster at the clutch lever or it could slip into the place later creating enough cable play to prevent clutch disengagement GR11060281 e Tighten the locknut e f it cannot be done loosen the locknut A at the lower of the clutch cable and turn the adjusting nut B so that clutch lever has 2 3 mm 0 08 0 12 in of play e After the adjustment is made tighten the locknut and start the engine and check that the clutch does not slip and that it release properly 6R11002BS1 Friction and Steel Plates Wear Damage Inspection e Visually inspect the friction and steel plates to see if they show any signs of seizure or uneven wear x If any plates show signs of damage replace the friction plates and steel plates as a set e Measure the thickness A of the friction plates B and steel
94. NGINE TOP END 5 5 Exploded View No Fastener Torque E N m kgf m ft lb marks 1 Cylinder Head Nuts 25 2 5 18 2 Spark Plug 26 5 2 75 19 5 3 Main Valve Cover Bolts 5 9 0 6 52 in lb 4 Main Valve Retaining Bolts 5 9 0 6 52 in lb 5 Main Valve Rod Cover Screw 5 9 0 6 52 in lb 6 Main Lever Mounting Allen Bolt 3 9 0 4 35 in lb L 7 Operating Rod Retaining Screw 5 4 0 55 48 in lb 8 Cylinder Drain Plug 8 8 0 9 78 in lb 9 Cylinder Nuts 34 3 5 25 10 Operating Rod Left Side Plug 22 2 2 16 11 Cylinder Left Cover Bolts 5 9 0 6 52 in lb 12 KIPS Cover Bolts 2 9 0 3 26 in lb Engine Mounting Bracket Nuts Frame Side 8 mm Engine Mounting Bracket Nuts Engine Side 10 mm Silencer Inner Pipe Bolts 78 in lb 16 Silencer Pipe Mounting Bolts 8 8 0 9 78 in lb L 17 Muffler Damper Mounting Bolts 8 8 0 9 78 in lb 18 Expansion Chamber Mounting Bolt 12 1 2 8 7 19 Cylinder Head 38 Guide 20 Engine Mounting Brackets 39 Piston Ring 21 Governor Shaft Lever 40 Piston 22 KIPS Cover 41 IN Mark 23 Operating Rod 42 Piston Pin 24 Main Valve Cover 43 Reed Valve 25 Main Lever 44a Expansion Chamber 26 Spring KX250 M1 model 27a Main Exhaust Valve Assembly KX250 M1 model 44b Expansion Chamber 27b Main Exhaust Valve Assembly KX250 M2 model KX250 M2 model 28 Main Valve Rod Cover 45 Rubber Seals 29 Main Valve Rod 46 Gasket 30 Main Shaft 47 Silencer 31 C
95. NING Do not mix two brands of fluid Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified Brake Pad Wear Inspection e Remove the brake pad see Brake Pad Removal in Brakes chapter e Check the lining thickness and condition of the pads in each caliper x If either pad is damaged replace both pads in the caliper as a set x lf the lining thickness A of either pad is less than the service limit B replace both pads in the caliper as a set Lining Thickness Standard Front 3 8 mm 0 150 in Rear 6 4 mm 0 252 in Service Limit Front 1 mm 0 04 in Rear 1 mm 0 04 in e Install the brake pad see Brake Pad Installation in Brakes chapter e Tighten Torque Brake Pad Bolt 18 N m 1 8 kgf m 13 ft lb Brake Master Cylinder Cup and Dust Seal Replacement e Refer to the Master Cylinder section in the Brakes chapter for Brake Master Cylinder Seal Replacement GLO9060482 C 6L06002BS1 PERIODIC MAINTENANCE 2 37 Periodic Maintenance Procedures Caliper Piston Seal and Dust Seal Replacement e Refer to the Calipers section in the Brakes chapter for Caliper Piston Dust Seal Replacement Brake Hose and Connection Check e Inspect the brake hose and fittings for deterioration cracks and signs of leakage OThe high pressure inside the brake
96. No good Replace Replace No good Voltage is less than the specified value Voltage is specified Voltage is none or almost but faulty ignition none Defective Ignition coil Inspect 1 Adapter connection is incorrect or adapter is 2 Engine stop switch 3 Capacitor Replace the 4 Regulator Rectifier malfunctioned 5 Crankshaft sensor no good part peak voltage 6 Exciter coil peak voltage All good Inspect 1 Speed of cranking engine is slow Increase force of kicking engine 2 Lower resistance in the tester Use KAWASAKI Hand Tester 3 Lacking of sampling Sampling few times 4 Capacitor 5 Crankshaft sensor peak voltage 6 Exciter coil peak voltage All good C D I Unit is defective Replace the malfunctioned part or inspect in proper way 14 22 ELECTRICAL SYSTEM Ignition System Crankshaft Sensor Peak Voltage Check e To check the peak voltage do the following procedures ODisconnect the connector of the magneto lead connec tor from the C D I unit KX125 or the main harness KX250 NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug installed to the cylinder head OThe correct value may not be obtained if disconnected OComnect the peak voltage adapter A of the tester
97. Nut 98 10 0 72 Engine Bottom End Transmission Cylinder Stud L Planted Side Crankcase Bolts 8 8 0 9 78 in lb PERIODIC MAINTENANCE 2 7 Torque and Locking Agent Fastener Torque Remarks N m kgf m ft Ib Crankshaft Web Cover Bolts KX125 6 9 0 7 61 in lb L KX250 11 1 1 8 E Transmission Oil Drain Plug 20 2 0 14 5 Output Shaft Bearing Retaining Screws 5 4 0 55 48 in lb L Drive Shaft Bearing Retaining Bolts KX250 8 8 0 9 78 in lb Shift Drum Bearing Retaining Screws KX125 M1 6 4 0 65 56 in lb Shift Drum Bearing Retaining Bolts KX250 KX125 M2 8 8 0 9 78 in lb Shift Drum Operating Cam Bolt 24 2 4 17 L Flywheel Bolt KX125 22 2 2 16 Flywheel Nut KX250 78 8 0 58 Wheels Tires Front Axle 78 8 0 58 Front Axle Clamp Bolts 20 2 0 14 5 Rear Axle Nut 110 11 0 80 Not less Not less Spoke Nipple Not less than than 19 than 2 2 0 22 in lb Final Drive Rear Axle Nut 110 11 0 80 Rear Sprocket Nuts 34 3 5 25 Engine Sprocket Cover Bolts 4 9 0 5 43 in lb Brakes Caliper Mounting Bolts Front 25 2 5 18 Brake Hose Banjo Bolts 25 2 5 18 Front Master Cylinder Clamp Bolts 8 8 0 9 78 in lb S Rear Master Cylinder Mounting Bolts 9 8 1 0 87 in lb Rear Master Cylinder Push Rod Locknut 18 1 8 13 0 Brake Disc Mounting Bolts 9 8 1 0 87 in lb L Front Rear 23 2 3 16 6 L Caliper Bleed Valves Front Rear 7 8 0 8 69 in lb Caliper Holder Bolt 27 2 8 20 Brake Pad Bolt 18 1 8 13 Rear Brake Pad Bolt Plug 2 5 0 25
98. ON Brake fluid quickly ruins painted or plastic sur faces any spilled fluid should be completely wished up immediately Front Master Cylinder Removal e Remove the banjo bolt A to disconnect the upper brake hose from the master cylinder see Brake Hose Re moval Installation e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum e Unscrew the clamp bolts B and take off the master cylin der C as an assembly with the reservoir and brake lever Front Master Cylinder Installation e Position the master cylinder so that the vertical parting line A of the front master cylinder clamps align with the punch mark B on the handlebar e The master cylinder clamp must be installed with the ar row mark A upward OTighten the upper clamp bolt B first and then the lower clamp bolt C There will be a gap at the lower part of the clamp after tightening Torque Master Cylinder Clamp Bolts 8 8 N m 0 9 kgf m 78 in Ib e Replace the washers that are on each side of hose fitting with new ones e Tighten the brake hose banjo bolt Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 0 ft lb e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage Rear Master Cylinder Removal e Remove the cotter pin A e Pull off the joint pin B with washer NOTE OPull o
99. Outer Race Driver 51 5 57001 1076 Head Pipe Outer Race Driver 54 5 57001 1077 Steering Stem Nut Wrench 57001 1100 ST571077ST ST5711008T Head Pipe Outer Race Remover ID gt 37 mm 57001 1107 Jack 57001 1238 ST571107ST ST5712388ST STEERING 13 5 Steering Steering Inspection e Refer to the Steering Inspection in the Periodic Mainte nance chapter Steering Adjustment e Refer to the Steering Adjustment in the Periodic Mainte nance chapter Steering Stem Stem Bearing Removal e Remove Front Wheel see Wheels Tires chapter Brake Hose Clamp see brake System chapter Caliper Mounting Bolts see Brake System chapter Master Cylinder Clamp see Brake System chapter Front Fender Handlebar see Handlebar Removal Front Fork see Suspension chapter e Remove the steering stem head nut and washer e Remove the steering stem head e Pushing up on the stem base A and remove the steering stem locknut B with the steering stem nut wrench C then remove the steering stem D and stem base Special Tool Steering Stem Nut Wrench 57001 1100 e Take off the upper stem bearing inner race tapered roller bearing A e Drive out the bearing outer races from the head pipe ORemove the outer races pressed into the head pipe using the head pipe outer race remover A and hammer the head pipe outer race remover to drive it out Special Tool Head Pipe O
100. Periodic Maintenance Chart A WARNING To avoid a serious burn never touch the hot engine or exhaust chamber during clutch adjustment Clutch Lever Free Play Check e Refer to the Clutch Lever Free Play Check in the Periodic Maintenance chapter Free Play Adjustment e Refer to the Clutch Lever Free Play Adjustment in the Periodic Maintenance chapter Clutch Cable Removal e Slide the dust cover out of place e Loosen the locknut at the upper of the cable and turn the adjusting nut to give the cable plenty of play e Loosen the knurled locknut A at the clutch lever and screw in the adjuster B e Line up the slots C in the clutch lever knurled locknut and adjuster and then free the cable from the clutch lever OFor KX125 remove the magneto cover see Release Shaft Removal e Free the clutch inner cable tip from the clutch release lever CAUTION Do not remove the clutch release shaft unless it is absolutely necessary If removed release shaft oil seal must be replaced with a new one e Pull the clutch cable out of the frame Clutch Cable Installation e Run the clutch cable according to the Cable Harness Hose Routing section of the Appendix chapter e Adjust the clutch cable see Free Play Adjustment Clutch Cable Lubrication and Inspection e Lubricate the clutch cable using the pressure cable luber in accordance with the Periodic Maintenance Chart e With the cable disconnected at
101. Pivot Nut 83 N m 8 5 kgf m 61 ft Ib Rear Shock Absorber Lower Mounting Nut 34 N m 3 5 kgf m 25 ft lb Tie Rod Mounting Nut 83 N m 8 5 kgf m 61 ft Ib Swingarm Pivot Shaft Nut 98 N m 10 0 kgf m 72 ft Ib Tie Rod and Rocker Arm Bearing Removal e Remove Tie Rod see Tie Rod Removal Rocker Arm see Rocker Arm Removal Washers A E Sleeves B Bs Q Oil Seal C BRO Grease Seals D D e Remove the needle bearings E using the bearing re mover head and bearing remover shaft e Remove the needle bearing F using the oil seal amp bear ing remover 6M07014BS1 SUSPENSION 12 45 Tie Rod Rocker Arm Special Tool Bearing Remover Head 15 x 417 57001 1267 Bearing Remover Shaft 69 57001 1265 Oil Seal amp Bearing Remover 57001 1058 e For KX125 250 M2 as shown in the figure GMO7011BS2 C Tie Rod and Rocker Arm Bearing Installation e Replace the needle bearing grease seals and oil seals with new ones e Apply plenty of grease to the oil seal and needle bearings NOTE Olnstall the grease seals so that the deep groove side of the rip out ward e Install the needle bearing A B grease seals C and oil seals D position as shown e Tighten the following Torque Rocker Srm Pivot Nut 83 N m 8 5 kgf m 61 ft lb Rear Shock Absorber Lower Mounting Nut 34 N m 3 5 kgf m 25 ft lb Tie Rod Mounting Nut 83 N m 8 5 kgf m 61 ft lb Swingarm Pivot Shaft N
102. Rear Master Cylinder Mounting Bolts 9 8 1 0 87 in lb 3 Rear Master Cylinder Push Rod 18 18 13 Locknut 4 Caliper Bleed Valve 7 8 0 8 69 in lb 5 Brake Pad Bolt 18 1 8 13 6 Rear Brake Pad Bolt Plug 2 5 0 25 22 in lb 7 Caliper Holder Shaft 27 2 8 20 8 Brake Pedal Mounting Bolt 25 2 5 18 9 Brake Disc Mounting Bolts 23 2 3 16 6 L 10 Brake Hose 11 Rear Master Cylinder 12 Brake Pedal 13 Rear Caliper Cover 14 Rear Caliper 15 Piston 16 Brake Pad 17 Rear Disc G Apply high temperature grease H Apply Silicone grease Replacement Parts A 11 6 BRAKES Specifications Item Standard Service Limit Brake Adjustment Lever Play Adjustable to suit rider Brake Fluid Recommended Disc Brake Fluid Type Front DOT3 or DOT4 Rear DOT4 Brake Pads Lining Thickness Front 3 8 mm 0 150 in 1 mm 0 04 in Rear 6 4 mm 0 252 in 1 mm 0 04 in Brake Disc Thickness Front 2 85 3 15 mm 0 112 0 124 in 2 5 mm 0 10 in Rear 3 85 4 15 mm 0 152 0 163 in 3 5 mm 0 14 in Runout Not more than 0 25 mm 0 098 in 0 3 mm 0 01 in BRAKES 11 7 Special Tools Inside Circlip Pliers Jack 57001 143 57001 1238 ST5701438T ST5712388ST 11 8 BRAKES Brake Lever Brake Pedal Brake Lever Play Adjustment e Refer to the Brake Lever Play Adjustment in the Periodic Maintenance chapter Brake Pedal Position Pedal Play Adjustment The brake pedal positi
103. Right Side View 68038052 P 1 6 GENERAL INFORMATION Model Identification KX250 M1 Left Side View 68038053 P KX250 M1 Right Side View 63038054 P GENERAL INFORMATION 1 7 General Specifications Items KX125 M1 KX125 M2 Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass Curb Mass Front Rear Fuel Tank Capacity Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Low Speed Low Speed Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Ignition Timing Spark Plug Port Timing Inlet Open Close Scavenging Open Close Exhaust Open Close Lubrication System Gasoline Oil 2 155 mm 84 8 in 825 mm 32 5 in 1 200 mm 47 2 in 1 455 mm 57 3 in 340 mm 13 4 in 930 mm 36 6 in 87 kg 192 Ib 45 kg 99 Ib 47 kg 104 Ib 8 2 L 2 2 US gal 2 stroke single cylinder crankcase reed valve Liquid cooled 54 0 x 54 5 mm 2 13 x 2 15 in 124 mL 7 6 cu in 10 6 1 8 1 1 29 8 kW 40 5 PS 11 500 r min rpm 26 0 N m 2 65 kgf m 19 2 ft lb 10 500 r min rpm Carburetor MIKUNI TMX38x Primary kick CDI 13 BTDC 10 010 r min rpm NGK BR9EIX Full open 64 9 BBDC 64 9 ABDC 73 8 BBDC low speed 95 4 BBDC high speed 73 8 ABDC low speed 95 4 ABDC high speed Petrol mix 32
104. Screw 5 4 N m 0 55 kgf m 48 in 1b e Install the main valve cover main valve rod cover and cylinder left cover on the cylinder Torque Main Valve Cover Bolts 5 9 N m 0 6 kgf m 52 in 1b Main Valve Rod Cover Screw 5 9 N m 0 6 kgf m 52 in lb e Install the removed parts ENGINE TOP END 5 25 Muffler Expansion Chamber Silencer Muffler Removal e Remove Right Radiator Shroud Right Side Cover e Remove the mounting bolts A and pull the silencer B off toward the rear e Remove the exhaust pipe holding springs A e Remove the muffler damper mounting bolts A and pull off the expansion chamber to the front ward e Remove the O rings from the expansion chamber OFor KX250 be sure to remove exhaust gasket e For KX125 250 M2 model as shown in the figure Muffler Installation e Scrape any carbon out of the expansion chamber e Check the exhaust O rings for signs of damage Alf necessary replace them with new ones Silencer Packing Change e Refer to the Exhaust System in the Periodic Maintenance chapter ENGINE RIGHT SIDE 6 1 Engine Right Side Exploded View Specifications Special Tools Clutch Cable Table of Contents Clutch Lever Free Play Check di tege Gegner dde etienne Free Play AUS MON ooo it A RA Clutch Cable Hemoval a a Clutch Cable Installation cccccccccccecccccceeceececeeceeeeceeeeeecceeceec
105. Shift Mechanism External Shift Mechanism Inspection e Check the shift shaft A for bending or damage to the splines Alf the shaft is bent straighten or replace it If the splines are damaged replace the shift mechanism e Check the return spring B for cracks or distortion Alf the spring is damaged in any way replace it e Check the shift mechanism arm C for distortion Alf the shift mechanism arm is damaged in any way re place the shift mechanism e Check the collar D for damage Alf the collar is damaged in any way replace it e Check the ratchet assembly for damage Alf ratchet pawls pins or springs are damaged in any way replace them e For KX250 Check that the return spring pin A is not loose x lf it is loose unscrew it apply a non permanent locking agent to the threads and tighten it Torque Return Spring Pin 42 N m 4 3 kgf m 31 ft lb e Check the gear set lever and its spring for cracks or dis tortion x If the lever or spring is damaged in any way replace them e Visually inspect the shift drum cam xf it is badly worn or if it shows any damage replace it GRO7O04BS1 GRO7OO5BS1 6 22 ENGINE RIGHT SIDE Primary Gear Primary Gear Removal e Remove the right engine cover see Right Engine Cover Removal e Remove the clutch see Clutch Removal eFor KX125 remove the primary gear nut A spring washer woodruff key primary gear B and O
106. Turn the compression damping adjuster A on the rear shock absorber gas reservoir with a flat bead screwdriver x If the damping feels too soft or too stiff adjust it in accor dance with the following table Seated position adjuster turned fully clockwise A Compression Damping Standard KX125 13 clicks KX250 M1 12 clicks KX250 M2 10 clicks NOTE OAdjustment of the rebound damping adjuster for the rear suspension will slightly affect the compression damping force Always make any damping adjustments in small steps and test their effects before using them in com petition Spring Preload Adjustment e Remove Seat Side Covers Silencer Rear Frame Mounting Bolts A Rear Frame B with Air Cleaner Housing e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Using the hook wrenches A loosen the locknut B on the rear shock absorber Special Tool Hook Wrench R37 5 R42 57001 1101 Counterclockwise Softer 50 TD ON 161514131211109 8 7 6 5 4 HA 6M05054BS1 Clockwise Harder ov N pel GMO5070BS1 GMO5058BS1 SUSPENSION 12 33 Rear Suspension Uni Trak e Using the stem nut wrench A turn the adjusting nut B as required Turning the adjusting nut downward marks the spring action harder and upward softer Special Tool Steering Stem Nut Wrench 57001 1100 Spring Preload Adju
107. US oz NOTE E iT SALW Keser NF OWhile doing this take care to keep the oil level topped off so that it stays above the two large holes A near the top of the inner tube B SS NS Bilberry KSSSSSSSSSSSSSSSSSSSS GM040109S1 e Screw the fork piston rod puller A onto the end of the push rod Special Tool Fork Piston Rod Puller M12 x 1 25 57001 1289 e Purge the air from the fork cylinder by gently moving the piston rod puller up and down five times e Remove the fork piston rod puller 6M04022BS1 2 40 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Purge the air from between the inner and outer tubes by pumping the outer tube A up and down e After purging the air from the assembly let it sit for about five minutes so that any suspended air bubbles can sur face e Install the spring guide e Screw the push rod nut e Adjust the oil level OWith the fork fully compressed put the oil level gauge A and the stopper B and inspect the distance from the top of the inner tube to the oil Special Tool Fork Oil Level Gauge 57001 1290 Oil Level fully compressed without spring Standard KX125 M1 133 137 mm 5 24 5 39 in KX125 M2 103 107 mm 4 06 4 21 in KX250 M1 123 127 mm 4 84 5 00 in KX250 M2 86 90 mm 3 39 3 54 in Adjustable Range KX125 250 M1 100 145 mm 3 94 5 71 in KX125 250 M2
108. a new one e After the oil has completely drained out install the drain plug with the gasket and tighten it Torque Transmission Oil Drain Plug 20 N m 2 0 kgf m 14 5 ft lb e Fill the engine with a good quality motor oil specified be low e Check the oil level Recommended Transmission Oil Type API SE SF or SG SRE ZOW API SH or SJ with JASO MA SAE 2089 40 Viscosity SAE10W 40 SAE 10W 50 Capacity KX125 0 7 L 0 74 US qt KX250 0 85 L 0 90 US qt SAE 10W 30 I I I NOTE OAlthough 10W 40 engine oil is the recommended oil for most conditions the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area 10 20 3 l 1 0 L 40 C J 50 68 8 6 104 F GSO9010BS1 PERIODIC MAINTENANCE 2 29 Periodic Maintenance Procedures Wheel Tires Spoke Tightness Inspection e Check that all the spokes are tightened evenly Alf spoke tightness is uneven or loose tighten the spoke nipples evenly Torque Spoke Nipples 2 2 N m 0 22 kgf m 19 in Ib e Check the rim runout A WARNING If any spoke breaks it should be replaced immedi ately A missing spoke places an additional load on the other spokes which will eventually cause other spokes to break Rim Runout Inspection e Place the jack under the frame so that the front rear wheel off the ground Special Tool Jack 57001 1238 e Inspect the rim for small crac
109. aged Carburetor Removal WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Turn the fuel tap to the OFF position and pull the fuel hose off the tap 3 14 FUEL SYSTEM Carburetor e For KX250 disconnect the carburetor lead connector e Loosen the clamps A and remove the carburetor from the end of the air cleaner duct and then pull it out of the carburetor holder 6c060180S1 x If necessary do the following procedure ORemove Seat Right Side Cover Silencer Rear Frame Bolt A OLoosen the rear frame bolts B pull up the rear frame C with the air cleaner housing and remove the carburetor e Drain the fuel from the float bowl by removing the drain plug After draining install the drain plug securely e Unscrew the carburetor cap screws KX125 or bolts KX250 A e Pull out the throttle valve assembly A CAUTION If the throttle valve is not removed from the cable wrap it in a clean cloth to avoid damage O K iraia a h ARKAAN DE d N SY KE 7 E e After removing the carburetor push a clean lint free towel into the carburetor holder and the air cleaner duct to keep dirt or other foreign material from entering
110. al e Drain the coolant see Cooling System chapter e Remove Radiator Shrouds Seat Side Covers Fuel Tank see Fuel System chapter Muffler see this chapter Radiators see Cooling System chapter Cooling Hose A Spark Plug B Bolts amp Nuts C Engine Mounting Brackets D 6E05004BS1 GE05005BS1 5 10 ENGINE TOP END Cylinder Head e Remove the cylinder head nuts A and take off the cylinder head B and the O rings KX125 or the gasket KX250 Cylinder Head Installation e Replace the O rings or the head gasket with a new one e Scrape out any carbon and clean the head with a high flash point solvent e Check for a crust of minerals and rust in the head water jacket and remove them if necessary e For KX125 install new O rings to the grooves of the cylin der securely e For KX250 install a new cylinder head gasket with the EX marked side A forward e Tighten the head nuts diagonally Torque Cylinder Head Nuts 25 N m 2 5 kgf m 18 ft Ib e Tighten the engine mounting bracket nuts Torque Cylinder Head Nuts 25 N m 2 5 kgf m 18 ft Ib Torque Engine Mounting Bracket Nuts 10 mm 44 N m 4 5 kgf m 33 ft lb 8 mm 29 N m 3 0 kgf m 22 ft Ib e Tighten the spark plug Torque Spark Plug 26 5 N m 2 75 kgf m 19 5 ft Ib Cylinder Head Warp Inspection e Refer to the Cylinder Head Warp Inspection in the Peri odic Maintenance chapter 6E05007BS1
111. aliper on some kind of stand so that it doesn t dangle e For KX125 250 M2 model note the following ORemove the fork protectors A ORemove the front brake hose clamps B ORemove the front wheel see Wheels Tires chapter ORemove the caliper C from the fork leg to be removed and rest the caliper on some kind of stand so that it doesn t dangle e Remove the number plate e Loosen the upper and lower fork clamp bolts A e With a twisting motion work the fork leg down and out Front Fork Installation e If the fork leg was disassembled check the fork oil level e Install the fork so that the distance B between the top end A of the outer tube and the upper surface C of the steering stem head is specified dimension B 15 mm 0 59 in e Route the cables and hose according to the Cable Har ness Hose Routing section in the Appendix chapter e Install the front wheel see Wheels Tires chapter e Tighten the fork clamp bolts Torque Fork Clamp Bolts Upper Lower 20 N m 2 0 kgf m 14 5 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Tighten Torque Front Caliper Mounting Bolts 25 N m 2 5 kgf m 18 ft lb e Check the front brake operation after installation 6M04106BS1 12 22 SUSPENSION Front Fork Front Fork Disassembly each fork leg Spring Guide Removal e Place the handlebar on one side and loosen t
112. aner Element Oil Read Valve Warp 2 3 mm 0 08 0 12 in High quality foam air filter oil Cooling System Coolant Type recommended Color Mixed Ratio Freezing Point Total Amount KX125 KX250 Permanent type antifreeze Green Soft water 50 and coolant 50 35 C 31 F 0 97 L 1 02 US at 1 20 L 1 27 US qt Engine Top End Cylinder Head Warp Cylinder Piston KX125 Cylinder Inside Diameter 15 mm 0 59 in below of the cylinder head Piston Diameter Piston Cylinder Clearance Piston Ring Groove clearance Piston Ring Groove Width Piston Ring Thickness Piston Ring End Gap Piston Pin Diameter Piston Pin Hole Diameter Small End Inside Diameter Cylinder Piston KX250 Cylinder Inside Diameter 30 mm 1 18 in below of the cylinder Head Piston Diameter Piston Cylinder Clearance Piston Ring Groove Clearance Piston Ring Groove Width Piston Ring Thickness Piston Ring End Gap Piston Pin Diameter 54 010 54 025 mm 2 1264 2 1270 in 53 955 53 970 mm 2 1242 2 1480 in 0 040 0 070 mm 0 0016 0 0028 in 0 015 0 050 mm 0 0006 0 0020 in 1 01 1 03 mm 0 0398 0 0406 in 0 980 0 995 mm 0 0386 0 0392 in 0 35 0 55 mm 0 0138 0 0217 in 14 995 15 000 mm 0 5904 0 5906 in 15 001 15 011 mm 0 5906 0 5910 in 19 003 19 014 mm 0 7481 0 7486 in 66 400 66 415 mm 2 6142 2 6148 in 66 336 66 351 mm 2 6116 2 6122 in
113. assembly Since assembly of the crankshaft demands exacting tol erances the disassembly and reassembly of the crankshaft can only be done by a shop having the necessary tools and equipment e If it should be necessary to disassemble the crankshaft use a press to remove the crankpin Crankshaft Assembly Since the assembly of the crankshaft demands exacting tolerances the disassembly and reassembly of the crank shaft can only be done by a shop having the necessary tools and equipment e Reassemble the crankshaft according to the standard tol erances in Specifications OConnecting rod bend twist OConnecting rod big end radial clearance OCold fitting tolerance between crankpin and flywheels OSide clearance between the connecting rod big end and one of flywheels OCrankshaft runout 8 14 ENGINE BOTTOM END TRANSMISSION Crankshaft Connecting Rod Connecting Rod Big End Radial Clearance e Set the crankshaft in a flywheel alignment jig or on V blocks and place a dial gauge against the connecting rod big end e Push the connecting rod first towards the gauge and then in the opposite direction The difference between the two gauge readings is the radial clearance le 7 6105005BS1 Connecting Rod Big End Radial Clearance Standard KX125 0 036 0 047 mm 0 0014 0 0019 in KX250 0 037 0 049 mm 0 0015 0 0019 in Service Limit KX125 0 10 mm 0 004 in KX250 0 10 mm 0 004 in x If the radial clearanc
114. ature grease O Apply oil TO Apply transmission oil L Apply a non permanent locking agent to the threads 6 6 ENGINE RIGHT SIDE Specifications Item Standard Service Limit Clutch Lever Free Play Friction Plate Thickness KX125 KX250 Steel Plate Thickness KX125 KX250 Friction Plate Warp Steel Plate Warp Clutch Spring Free Length KX125 KX250 Friction Plate Clutch Housing Clearance KX125 KX250 2 3 mm 0 08 0 12 in 2 72 2 88 mm 0 107 0 113 in 2 92 3 08 mm 0 115 0 121 in 1 5 1 7 mm 0 059 0 067 in 1 46 1 74 mm 0 057 0 069 in Not more than 0 15 mm 0 006 in Not more than 0 2 mm 0 008 in 46 8 mm 1 843 in 35 0 mm 1 378 in 0 04 0 55 mm 0 0016 0 0217 in 0 15 0 45 mm 0 0059 0 0177 in 2 6 mm 0 102 in 2 8 mm 0 110 in 1 4 mm 0 055 in 1 36 mm 0 054 in 0 3 mm 0 119 in 0 3 mm 0 119 in 44 9 mm 1 768 in 33 6 mm 1 323 in 0 9 mm 0 0354 in 0 8 mm 0 0315 in ENGINE RIGHT SIDE 6 7 Special Tools Drum Pusher 24 Flywheel Holder 57001 1440 57001 1313 wy ST571440ST ST571313ST Clutch Holder Flywheel amp Pulley Holder 57001 1243 57001 1605 C ST5712438ST ST5716058T 6 8 ENGINE RIGHT SIDE Clutch 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
115. be replaced if the teeth are badly damaged When gear is repaired or replaced the driving gear should also be inspected and repaired or replaced if necessary QG 6113010781 6113004BS1 8 20 ENGINE BOTTOM END TRANSMISSION Transmission Gear Dog Gear Dog Hole Damage e Visually inspect the gear dogs A and gear dog holes B Replace any damaged gears or gears with excessively worn dogs or dog holes 6113014BS1 Ball Bearing Wear e Check the ball bearing on the crankcase x Since the ball bearings are made to extremely close toler ances the wear must be judged by feel rather than mea surement Clean each bearing in a high flash point sol vent dry it do not spin the bearing while it is dry and oil it with transmission oil OSpin the bearing by hand to check its condition x If the bearing is noisy does not spin smoothly or has any rough spots replace it WHEELS TIRES 9 1 Wheels Tires Table of Contents Exploded Views ds 9 2 elen e le TEE 9 4 Special Tolva A A E EEdEEEA AE ee Ee 9 5 Wheels RIAS nt ti UE 9 6 Front Wheel Removal ss 9 6 Front Wheel Installation ss 9 7 Rear Wheel Removal ss 9 8 Rear Wheel Installation 0 2 0 0 ccc ccccceecceecccee an a e a o ar eaa a ni 9 8 Wheels Inspection a e a a a a a ae aae aenea 9 10 Spoke Tightness Inspection
116. ch slipping Transmission oil level too high Transmission oil viscosity too high Lubrication inadequate Transmission oil level too low Transmission oil poor quality or incorrect Coolant incorrect Coolant level too low Coolant deteriorated Cooling system component incorrect Radiator clogged Radiator cap trouble Water pump not rotating Clutch Operation Faulty Clutch slipping No clutch lever play Clutch cable maladjusted Clutch inner cable catching Friction plate worn or warped Steel plate worn or warped Clutch spring broken or weak Clutch release mechanism trouble Clutch hub or housing unevenly worn 15 4 APPENDIX Troubleshooting Guide Clutch not disengaging properly Clutch lever play excessive Clutch plate warped or too rough Clutch spring tension uneven Transmission oil deteriorated Transmission viscosity too high Transmission oil level too high Clutch housing frozen on drive shaft Clutch release mechanism trouble Gear Shifting Faulty Doesn t into gear shift pedal doesn t return Clutch not disengaging Shift fork bent or seized Gear stuck on the shaft Gear positioning lever binding Shift return spring weak or broken Shift return spring pin loose Shift mechanism arm spring broken Shift mechanism arm broken Shift drum broken Jumps out of gear Shift fork worn Gear groove worn Gear dogs and or dog holes worn Shift drum groove worn Gear positioning lever spring weak or bro ken Shift fork guide pin worn Driv
117. chamber A by remov ing the spring B because the sealed air into the cylinder unit may be leaked 6M04151BS1 e Pull the push rod assembly out the bottom of the cylinder unit Inner Tube Removal e Separate the inner tube A from the outer tube B as follows OSlide up the spring band C pS OSlide up the dust seal D 6M040614S1 ORemove the retaining ring A from the outer tube OGrasp the outer tube and stroke the inner tube up and down several times The shock to fork seal separates the inner tube from the outer tube x lf the tubes are tight use a fork outer tube weight A Special Tool Fork Outer Tube Weight 57001 1218 GM0406228S1 12 26 SUSPENSION Front Fork e Remove the guide bushes A washer B oil seal C retaining ring D and dust seal E from the inner tube GM040615S1 e For KX125 250 M2 model remove the guide bushes A collar B oil seal C retaining ring D and dust seal E from the inner tube Front Fork Assembly Inner to Outer Tube Assembly ES O e Replace the following with new ones Dust Seal A e Retaining Ring B Oil Seal C Guide Bushes D e Place an oil coated plastic bag E over the end of the inner tube to protect the oil seals OThe inner tube guide bush groove has a sharp edge F that can out the sealing lip of the seals as they are pushed down over the inner tube e Ins
118. cified the ignition coil windings are probably good However if the ignition system still does not perform as it should after all other components have been checked test replace the coil with one known to be good Ignition Coil Winding Resistance Primary windings KX125 0 24 0 04 Q at 20 C KX250 0 53 0 08 Q at 20 C Secondary windings KX125 8 3 1 2 kQ at 20 C KX250 12 6 1 9 kQ at 20 C e Check the spark plug lead for visible damage Alf the spark plug lead is damaged replace the coil Spark Plug Cleaning and Inspection e Refer to the Spark Plug Cleaning and Inspection in the Periodic Maintenance chapter Spark Plug Gap Inspection e Refer to the Spark Plug Gap Inspection in the Periodic Maintenance chapter C D I Unit Removal e Remove the number plate e Disconnect the magneto lead connector A KX125 or main harness connector KX250 e Unscrew the mounting bolt B and remove the C D I Unit C 6P10046BS1 14 20 ELECTRICAL SYSTEM Ignition System C D I Unit Inspection CAUTION When inspecting the C D I unit observe the follow ing to avoid damage to the C D I unit Do not disconnect the C D I unit while the engine is running This may damage the C D I unit Ignition Coil Primary Peak Voltage Check e Disconnect the spark plug cap from mounting the spark plug e Connect the good spark plug A to the spark plug cap then touch the engine with th
119. cket B Rear Sprocket Installation e Install the rear sprocket A so that the marked side B faces out e Install the rear sprocket bolts and tighten the nuts Torque Rear Sprocket Nuts 34 N m 3 5 kgf m 25 ft lb Sprocket Wear Inspection e Refer to the Sprocket Wear Inspection in the Periodic Maintenance chapter Rear Sprocket Warp Inspection e Refer to the Rear Sprocket Warp Inspection in the Peri odic Maintenance chapter GKO5002BS1 nc GKO5004BS1 BRAKES 11 1 Brakes Table of Contents Exploded MIS Wii AA AAA Re A tnt 11 2 A le EE 11 6 Special TOONS EE 11 7 Brake Lever Brake Pedaloc coi lla EE et EE EEN 11 8 Brake Lever Play AUS Meninas o 11 8 Brake Pedal Position Pedal Play Adjustment AAA 11 8 Brake Pedal Removal siens 11 8 Brake Pedal Installatidn 00 la is 11 9 Brake FlUid cuidada dada 11 10 Fluid Level INSPOCUON EE 11 10 Fluid CAMS E 11 10 Bleeding the Brake ie ori A A ct 11 11 IR lee 11 13 RE leen e EEN 11 13 Caliper EE Le E 11 14 Caliper RE EE 11 14 A NT Fluid Seal Damage Dust Seal and Cover Damage Piston Cylinder Damage ivi is 11 16 Caliper Holder Shaft Wear ss 11 16 Brake Pad Removal escocia 11 16 Brake Pad TiS Allons ne etileno Nala ne de 11 17 Brake Pad Inspection 11 17 Master Cylindet siaren Sette A Na O is 11 18 Front Master Cylinder Removal catas MO A rend torrent ae ee tardo as 11 18 Front Master Cylinder Installation ccoo annees 1
120. d connector e Using an auxiliary leads connect the regulator rectifier connector A and main harness connector B e Connect the hand tester C as shown in the table e Start the engine and note the voltage readings at vari ous engine speeds The readings should show under the specified voltage when the engine speed is low and as the engine speed rises the readings should also rise 6P21005BS1 ELECTRICAL SYSTEM 14 17 Flywheel Magneto Regulator Rectifier Output Voltage Tester Range Reading Tester Tester to 25 V DC Red White Black Yellow 14 2 15 2 V e Push off the stop switch to stop the engine and discon nect the hand tester x If the regulator rectifier output voltage is kept between the values given in the table the charging system is consid ered to be working normally x If the output voltage is much higher than the values spec ified in the table the regulator rectifier is defective or the regulator rectifier leads are loose or open x lf the output voltage does not rise as the engine speed increases then the regulator rectifier is defective or the magneto output is insufficient for the loads Check the magneto and regulator rectifier to determine which part is defective Regulator Rectifier Inspection KX250 e Remove the regulator rectifier e Set the hand tester x 100 Q range measure the internal resistance in both directions between the terminals Special T
121. djusting nut A all way up Special Tool Hook Wrench R37 5 R42 57001 1101 e Remove the rear shock absorber from the vise e Slide down the rubber bumper A e Remove the spring guide B from the shock absorber and lift off the spring C e Exchange the spring for an optional part Install the spring so that closed coil large diameter end A faces upward e Install the spring guide e Adjust the spring preload see Spring Preload Adjust ment e Install the rear shock absorber e Install the parts removed Rear Shock Absorber Disassembly Oil Change The oil should be changed in the rear shock absorber at least once per racing season The frequency for best per formance must be based upon riding conditions and rider ability e Remove the rear shock absorber from the frame see Rear Shock Absorber Removal e Remove the shock absorber spring see Spring Replace ment e Pointthe valve A away from you slowly release nitrogen gas pressure by pushing down the valve core with a screw driver Do not to point the reservoir valve toward your face or body when releasing nitrogen gas pressure An oil mist is often released with the nitrogen Always release nitrogen gas pressure before disassem bling the rear shock absorber to prevent explosive separation of parts GMO5006BS1 6M05062BS1 GMO5056BS1 12 36 SUSPENSION Rear Suspension Uni Trak e For KX12
122. drive chain from the chassis Drive Chain Installation e Fit the drive chain back onto the sprockets with the ends at the rear sprocket e Install the master link from the frame side e Install the clip A so that the closed end of the U B pointed in the direction of chain rotation C e Adjust the drive chain slack see Drive Chain Slack Ad justment e Check the rear brake see the Brakes chapter LO 6K04031BS1 C 6K04003BS1 6K04002BS1 FINAL DRIVE 10 7 Sprockets Engine Sprocket Removal e Remove Engine Sprocket Cover A Drive Chain B free of engine sprocket e Remove the circlip C and pull off the engine sprocket D Special Tool Outside Circlip Pliers 57001 144 Engine Sprocket Installation e Replace the circlip with a new one e Install the circlip so that the tooth is aligned with a spline groove Special Tool Outside Circlip Pliers 57001 144 e For KX250 clamp the air vent hoses with clamps which are installed together with engine sprocket cover Torque Engine Sprocket Cover Bolts 4 9 N m 0 5 kgf m 43 in lb Rear Sprocket Removal e Remove the rear wheel see Wheels Tires chapter CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so that the disc does not touch the ground e Unscrew the rear sprocket bolts A and remove the rear spro
123. drive shaft bearing retaining bolts screws securely Torque Bearing Retaining Bolts 8 8 N m 0 9 kgf m 78 in lb Bearing Retaining Screws 5 4 N m 0 55 kgf m 48 in lb ENGINE BOTTOM END TRANSMISSION 8 11 Crankcase OFor KX125M install the release shaft needle bearing as shown A Oil Seal B Needle Bearing C Needle Bearing Position KX125 M1 M2 3 5 0 2 mm 0 138 0 008 in KX125 M3 3 3 0 2 mm 0 130 0 008 in Olf the crankshaft bearings stay on the crankshaft when splitting the crankcase remove the bearings from the crankshaft and reinstall them in the crankcase and then assemble the crankcase see Crankshaft Removal and Installation e Turn the crankshaft A to BDC and install the crankshaft jig C between the flywheels opposite the connecting rod B big end to protect flywheel alignment as shown Olf the crankshaft has been removed from the crankcase install the jig between the crankshaft flywheels before pressing the crankshaft into the right crankcase half Special Tool Crankshaft Jig 57001 1174 e Install the transmission shaft as a set see this chapter e Install the shift fork shift drum and shift rod e Check to see that the crankcase knock pins A and O ring B KX125 are in place on the right crankcase half If any of them has been removed replace it with a new one 6104009BS1 8 12 ENGINE BOTTOM END TRANSMISSION Crankcase e Apply
124. ds do not use gasoline or low flash point solvent to clean the tank e Remove the fuel tank and drain it e Pour some high flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits e Pour the solvent out of the tank e Remove the fuel tap from the tank by taking out the bolts e Clean the fuel tap filter screen in a high flash point sol vent e Pour high flash point solvent through the tap in all lever positions e Dry the tank and tap with compressed air e Install the tap in the fuel tank e Install the fuel tank 2 16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel Tap Inspection e Remove the fuel tap e Check the fuel tap filter screen A for any breaks or dete rioration x If the fuel tap screen have any breaks or is deteriorated it may allow dirt to reach the carburetor causing poor run ning Replace the fuel tap x If the fuel tap leaks or allows fuel to flow when it is at OFF position replace the damaged O ring B Reed Valve Inspection e Inspect the reeds for cracks folds or other visible dam age x lf there is any doubt as to the condition of a reed replace the reed valve part with a new one x If a reed becomes wavy replace the valve part with a new one even if its warp is less than the service limit e Measure the clearance between the reed A and holder B and check the reed warp as shown lf any one of the clearance measurements excee
125. ds the service limit replace the damaged valve parts with a new one Reed Warp Service Limit 0 5 mm 0 020 in Cooling System Check the coolant level each day before riding the motor cycle and replenish coolant if the level is low Change the coolant in accordance with the Periodic Maintenance Chart WARNING To avoid burns do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot Wait until it cools down GCO9029BS1 GC12000BS1 C PERIODIC MAINTENANCE 2 17 Periodic Maintenance Procedures Coolant Level Inspection NOTE OCheck the level when the engine is cold room or ambi ent temperature e Situate the motorcycle so that it is perpendicular to the ground e Remove the radiator cap A NOTE ORemove the radiator cap in two steps First turn the cap counterclockwise to the first stop and wait there for a few seconds Then push down and turn it further in the same direction and remove the cap B e Check the coolant level The coolant level A should be at the bottom of the filler neck B Alf the coolant level is low add coolant through the filler opening to the bottom of the filler neck Install the cap Recommended coolant Permanent type of antifreeze soft water and posooo1si ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators
126. dy does not slide smoothly one pad will wear more than the other pad wear will increase and con stant drag on the disc will raise brake and brake fluid tem perature e Check too see if the caliper holder shafts are not badly worn or stepped or the rubber friction boot is not dam aged x If the shafts or rubber friction boot are damaged replace the shafts rubber friction boot and the caliper holder Brake Pad Removal e Remove the plug and the pad bolt A e Take the piston side pad B e Push the caliper holder toward the piston and then re move another pad C from the caliper holder e For KX125 250 M2 model as shown in the figure 6L06000BS1 6L06001BS1 BRAKES 11 17 Caliper Brake Pad Installation e Push the caliper pistons in by hand as far as they will go e Install the piston side pad first and then another pad e Tighten the brake pad bolt Torque Brake Pad Bolt 18 N m 1 8 kgf m 13 ft lb e Check the brake for good braking power no brake drag and no fluid leakage Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brake will not function on the first appli cation of the lever or pedal if this is not done Brake Pad Inspection e Refer to the Brake Pad Wear Inspection in the Periodic Maintenance chapter 11 18 BRAKES Master Cylinder CAUTI
127. e Manual use them Either too little or too much torque may lead to serious damage Use a good quality reliable torque wrench Force Common sense should dictate how much force is necessary in assembly and disassembly If a part seems especially difficult to remove or install stop and examine what may be causing the problem Whenever tapping is necessary tap lightly using a wooden or plastic faced mallet Use an impact driver for screws particularly for the removing screws held by non permanent locking agent in order to avoid damaging the screw heads Edges Watch for sharp edges as they could cause injury through careless handling especially during major engine disassembly and assembly Use a clean piece of thick cloth when lifting the engine or turning it over High Flash Point Solvent A high flash point solvent is recommended to reduce fire danger A commercial solvent com monly available in North America is standard solvent generic name Always follow manufacturer and container directions regarding the use of any solvent Gasket O ring Replace a gasket or an O ring with a new part when disassembling Remove any foreign matter from the mating surface of the gasket or O ring to ensure a perfectly smooth surface to prevent oil or compression leaks 10 Liquid Gasket Locking Agent Clean and prepare surfaces where liquid gasket or non permanent locking agent will be used Apply them sparingly Excessive amount may block engine oil passa
128. e bearings using the oil seal amp bearing remove El Special Tool Oil Seal 8 Bearing Remover 57001 1058 e For KX125 250 M2 model as shown in the figure Swingarm Bearing Installation e Replace the needle bearings grease seals and oil seals with new ones e Apply plenty of grease to the grease seals oil seals and needle bearings NOTE Olnstall the needle bearings so that the manufacturer s marks face out Olnstall the grease seals so that the deep groove side of the rip in ward Special Tool Bearing Driver Set 57001 1129 e Install the needle bearings A grease seals B and oil seals C position as shown OThe installation procedure is the same as the counter side e For KX125 250 M2 model h in the fi f l or model as shown in the figure Right Side 6M06025BS1 Drive Chain Guide Chain Slipper Wear e Refer to the Chain Guide and Chain Slipper Wear Inspec tion in the Periodic Maintenance chapter SUSPENSION 12 43 Tie Rod Rocker Arm Tie Rod Removal e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Remove the tie rod front mounting bolt A CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Remove the tie rod rear mounting bolt B and then take out the tie rods C e F
129. e exceeds the service limit the crank shaft should be either replaced or disassembled and the crankpin needle bearing and connecting rod big end ex amined for wear Connecting Rod Big End Seizure ln case of serious seizure with damaged flywheels the crankshaft must be replaced ln case of less serious damage disassemble the crank shaft and replace the crankpin needle bearing side washers and connecting rod Connecting Rod Big End Side Clearance e Measure the side clearance A of the connecting rod with a thickness gauge Connecting Rod Big End Side Clearance Standard Soi CET KX125 0 40 0 50 mm 0 0157 0 0197 in KX250 0 45 0 55 mm 0 0177 0 0217 in Service Limit 0 70 mm 0 028 in x If the clearance exceeds the service limit replace the crankshaft 6105006BS1 Crankshaft Runout e Set the crankshaft in a flywheel alignment jig or on V blocks and place a dial gauge against the points indi cated e Turn the crankshaft slowly The maximum difference in gauge readings is the crankshaft runout A KX125 8 0 mm 0 315 in KX250 8 5 mm 0 335 in 6105010751 Crankshaft Runout Standard Not more than 0 03 mm 0 0012 in Service Limit 0 05 mm 0 002 in x If the runout at either point exceeds the service limit align the flywheels so that the runout falls within the service limit ENGINE BOTTOM END TRANSMISSION 8 15
130. e groove of the operating rod collar B to the boss of the governor shaft lever and install the collar on the operating rod while holding the governor shaft lever clockwise e After installing the collar install the E clip A on the oper ating rod B e Install the KIPS cover Torque KIPS Cover Bolts 2 5 N m 0 25 kgf m 22 in Ib Piston Removal e Remove the cylinder e Stuff a clean cloth into the crankcase opening around the connecting rod so that no parts will fall into the crankcase e Remove one of the piston pin snap rings with needle nose pliers e Remove the piston by pushing the piston pin out the side from which the snap ring was removed Use a piston pin puller assembly A if the pin is tight Special Tool Piston Pin Puller Assembly 57001 910 e Remove the piston ring s OCarefully spread the ring A opening with your thumbs and then push up on the opposite side of the ring to re move it Piston Installation e Stuff a clean cloth into the crankcase opening around the connecting rod so that no parts will fall into the crankcase e Scrape off any carbon of the piston then lightly polish the piston with fine emery cloth e Clean carbon and dirt out of the piston ring groove using a suitable tool CAUTION Carbon particles can be very abrasive to piston ring Don t allow such particles to fall onto the cylinder walls 6E06011BS1 GE1606068S1 5 14 ENGIN
131. e shaft output shaft and or gear splines worn Overshifts Gear positioning lever spring weak or bro ken Shift mechanism arm spring broken Abnormal Engine Noise Knocking C D I Unit trouble Carbon built up in combustion chamber Fuel poor quality or incorrect Spark plug incorrect Overheating Piston slap Cylinder piston clearance excessive Cylinder piston worn Connecting rod bent Piston pin piston pin hole worn Other noise Connecting rod small end clearance exces sive Connecting rod big end clearance exces sive Piston ring worn broken or stuck Piston seizure or damaged Cylinder head gasket leaking Exhaust pipe leaking at cylinder head con nection Crankshaft runout excessive Engine mounts loose Crankshaft bearing worn Primary gear worn or chipped Abnormal Drive Train Noise Clutch noise Clutch housing friction plate clearance ex cessive Clutch housing gear primary gear backlash excessive Metal chip jammed in clutch housing gear teeth Transmission noise Crankcase bearing worn or damaged Transmission gear worn or chipped Metal chip jammed in gear teeth Transmission oil insufficient or too thin Kick ratchet gear not properly disengaging from kick gear Output shaft idle gear worn or chipped Drive chain noise Drive chain adjusted improperly Chain worn Rear and or engine sprocket s worn Chain lubrication insufficient Rear wheel misaligned Abnormal Frame Noise Front fork noise Oil insufficient or t
132. e shorter than those of the other two shift forks Output shaft 5th gear shift fork B guide pin goes to left side of the ears Output shaft 6th gear shift fork C guide pin goes to right side of the ears KX250 Drive shaft 3rd gear and 4th ears are shorter than those of the gear shift fork A other two shift forks Output shaft 4th gear shift guide pin goes to center side of fork B the ears Output shaft 5th gear shift guide pin goes to left side of the fork C ears e Tighten the shift drum bearing retaining screws or bolts Torque Shift Drum Bearing Retaining Screws 6 4 N m 0 65 kgf m 56 in Ib KX125 M1 Shift Drum Bearing Retaining bolts 8 8 N m 0 9 kgf m 78 in Ib KX250 KX125 M2 e Install the shift dram A e Fit the shift fork guide pins into the corresponding shift drum grooves e Apply a little transmission oil to the shift rods A and slide amp 113029B51 them into the shift forks B e Holding the shift drum with the suitable too and tighten the shift drum operating plate bolt Torque Shift Drum Operating Cam Bolt 24 N m 2 4 kgf m 17 0 ft lb Shift Fork Bending e Visually inspect the shift forks and replace any fork that is bent A bent fork could cause difficulty in shifting or allow the transmission to jump out of gear when under power A 90 A 6113014581 ENGINE BOTTOM END TRANSMISSION 8 19
133. e spark plug NOTE OMeasure the voltage with each lead connected cor rectly The correct value may not be obtained if disconnected OMaintain the correct value of compression pressure for the cylinder Be sure to measure the voltage with the spark plug install to the cylinder head OThe correct value may not be obtained if disconnected e Connect the peak voltage adapter B between the termi nal of primary lead orange and ground connection of the unit with the lead of the ignition coil C connected Special Tool Peak Voltage Adapter 57001 1415 Type KEK 54 9 B Connection Tester Positive Ground Lead D Tester Negative Orange Lead E C D I Unit F e Shift the gear to the neutral position then free the engine stop switch e Crank the engine by kicking the pedal several times to measure the peak voltage of the primary ignition coil Peak Voltage 200 V or above KX125 150 V or above KX250 WARNING Do not touch the metal portion of the probe in case of measuring the voltage or you may receive a se rious electric shock x If the voltage is less than the specified value see the next page 6P10040BS1 ELECTRICAL SYSTEM 14 21 Ignition System Troubleshooting Faulty ignition Malfunctioned engine Wiring and connect portion of the ignition system inspection Spark plug inspection Noise suppressor inspection Ignition coil primary peak voltage inspection
134. ection 12 30 Rocker Arm Installation Dust Seal Oil Seal Inspection 12 30 Tie Rod and Rocker Arm Bearing Spring Tension 12 30 Removal Rear Suspension Uni Trak 12 31 Tie Rod and Rocker Arm Bearing Rear Shock Absorber 12 31 Installation Rebound Damping Adjustment 12 31 Needle Bearing Inspection Compression Damping Uni Trak Maintenance Adjustment arenero tops 12 32 Uni Trak Linkage Inspection Spring Preload Adjustment 12 32 Rocker Arm Sleeve Wear Spring Tension 12 33 Rocker Arm Mounting Bolt Bend 12 33 12 34 12 34 12 35 12 37 12 40 12 41 12 41 12 41 12 42 12 42 12 42 12 43 12 43 12 43 12 43 28 12 44 12 45 12 45 12 46 12 46 12 46 12 46 12 2 SUSPENSION Exploded View KX125 250 M1 0 IP OI DE 6M02031BW5 SUSPENSION 12 3 Exploded View z 9 Torque Fast astener Nom kgf m ft lb Remarks Front Fork Top Plug 29 3 0 22 Front Fork Clamp Bolts Upper Lower 20 2 0 14 5 Steering Stem Head Nut 78 8 0 58 Push Rod Nut 28 2 85 20 6 Front Axle Clump Bolts 20 2 0 14 5 Front Fork Cylinder Valve Assembly 54 5 5 40 Ooan P aAlAlwlrm Screw O Ring Damper Washer Spr
135. ed above 6M04097BS1 SUSPENSION 12 19 Front Fork e For KX125 250 M2 model note the following OWhile holding the push rod nut with a 19 mm 0 75 in wrench A loosen the front fork top plug B from the top of the push rod ORemove the fork top plug with the fork spring seat C and fork spring D ORemove the other fork spring in the same way as de scribed above 6M04047BS1 e Use the oil level gauge to measure the fork oil level OWith the fork fully compressed put the oil level gauge A and the stopper B and adjust the distance from the top of the inner tube to oil Special Tool Fork Oil Level Gauge 57001 1290 Front Fork Oil Level fully compressed without spring Standard KX125 M1 133 137 mm 5 24 5 39 in E KX125 M2 103 107 mm 4 00 4 21 in KX250 M1 123 127 mm 4 84 5 00 in KX250 M2 86 90 mm 3 39 3 54 in Adjustable Range KX125 250 M1 100 145 mm 3 94 5 71 in KX125 250 M2 70 120 mm 2 76 4 72 in If no oil is drawn out there is insufficient oil in the fork tube Pour in enough oil then pump out the excess oil Recommended Fork Oil KAYABA 01 or SAE 5W 20 e Install the push rod puller A onto the push rod B e Slowly pull up the push rod e Let the fork oil overflow through the hole in the push rod until it stops e Insert the fork spring A into the fork tube e Remove the p
136. ed previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts 2002 Kawasaki Heavy Industries Ltd Fourth Edition 1 Jun 1 2004 K LIST OF ABBREVIATIONS A ampere s Ib pound s ABDC after bottom dead center m meter s AC alternating current min minute s ATDC after top dead center N newton s BBDC before bottom dead center Pa pascal s BDC bottom dead center PS horsepower BTDC before top dead center psi pound s per square inch C degree s Celsius r revolution DC direct current rpm revolution s perminute F farad s TDC top dead center F degree s Fahrenheit TIR total indicator reading ft foot feet V volt s g gram s W watt s h hour s Q ohm s L liter s Read OWNER S MANUAL before operating Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop However it contains enough detail and basic in formation to make it useful to the owner who de sires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop proce dures must be understood in order to carry out
137. ee Wheel Alignment Inspec tion in the Final Drive chapter and adjust it if necessary see Wheel Alignment Adjustment in the Final Drive chap ter NOTE OClean the drive chain if it is dirty and lubricate it if it appears dry e Rotate the rear wheel to find the position where the chain is tightest e Measure the space chain slack A between the chain and the swing arm at the rear of the chain slipper as shown x If the drive chain slack exceeds the standard adjust it Chain Slack Standard 52 62 mm 2 05 2 44 in Drive Chain Slack Adjustment e Loosen the left and right chain adjuster locknuts A e Remove the cotter pin B and loosen the axle nut C x lf the chain is too tight back out the left and right chain adjusting bolts D evenly and push the wheel forward until the chain is too loose x lf the chain is too loose turn both chain adjusting bolts evenly until the drive chain has the correct amount of slack To keep the chain and wheel properly aligned the rear end of the left chain adjuster should align with the same swingarm mark E as the right chain adjuster rear end F e Check the wheel alignment e Tighten both chain adjuster locknuts securely e Tighten the axle nut Torque Rear Axle Nut 110 N m 11 0 kgf m 80 ft lb e Rotate the wheel measure the chain slack again at the tightest position and readjust if necessary e Install a new cotter pin A through the axle nut and axle and
138. eeeceneeeeeeeeeeeeeceeeeeeeeeaeesaeeates Brake Master Cylinder Cup and Dust Seal Henlacement nennen Caliper Piston Seal and Dust Seal Replacement snssseseseeeseeerrrerrrrrrrrrrrrrrrrrrrrrrrrrrne Brake Hose and Connection Check Suspension Front Fork Oil Leak A i geben fie Ge ROSE Geh eg bes TE Paaa RAE Front Fork Oil Change Oil Level Adjustment each fork Teo Rear Shock Absorber Oil Change siens Uni Trak Linkage Inspection ssp llo ere ee Chain Guide Wear Inspection ococccccnccnnccnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnneninenos Chain Slipper Wear Inspection sise Steering eren Steering Inspection Steering Adjustment Stem Bearing Lubric Electrical System Spark Plug Cleaning atio pce MSA AR A TG e en O nt orne de and Inspechon oooconcccnicnnnnncicnoncnoncno nono E nan rra EEKE EEEa EEE Eaa Eai Spark Hlug Gap Inspection ista cia en General Lubrication Lubrication Nut Bolt and Fastener Tightness nennsesnrrnttrntttttttntttnttrttttntttn ttnn rEAEEEEAEEEnEEEnE EEEE EEEE EEEE Tightness Inspection 2 30 2 30 2 31 2 32 2 32 2 33 2 33 2 33 2 34 2 35 2 36 2 36 2 37 2 37 2 37 2 37 2 38 2 40 2 40 2 41 2 41 2 41 2 41 2 41 2 43 2 43 2 43 2 43 2 44 2 44 2 46 2 46 PERIODIC MAINTENANCE 2 3 Periodic Maintenance Chart The maintenance must be done in accordance with this chartto keep the motorcycle in good r
139. eeeeeeeeeeseeeeeceseeeeseeeeeeeeeness Clutch Cable Lubrication and Inspection cccccccccccccceccceceeeeeeeceeeecaeseaeceaeeeaeesaeeeeenees Clutch Cover Clutch Cover REMOWal iii dE DEER EE Glutch Gover Installation n Right Engine Cover Right Engine Cover Removal uo siii dd a eae Right Engine Cover Installation td A ede te Right Engine Cover Disassembly us Exhaust Advancer Assembly Disassembly ASSEMDIY A Right Engine eege A Clutch Removal Clutch Installation Friction and Steel Plates Wear Damage Inspechon sees tees eeeeeeeeeeeeeeeees Friction and Steel Plate Warp Inspection Spring Free Length Measurement vivio ri cies Friction Plate Clutch Housing Clearance 2 ccceesceseccceeeeeeeseseeeeseeeeeeeestsesseeeeeeeeeeenees Clutch Hub Spline Inspechon ss Release Shift Removal ccccccccccesseceecceeececseaeeeseceeeeseseeasescececeeseesseeaeseseeeeesesseaeseseeees Release Shaft Installation siens External Shift Mechanlsm iii External Shift Mechanism Removal External Shift Mechanism Installation ccccccccccccccceccecceseesceeeeeeseecaeeeeseceeeessesseaeaseeeeees External Shift Mechanism Inspection sree ent Primary Gear Primary Gear Removal eso Primary Gear Instala escasa decian tes ee E Kickstarter Kickshaft Removal
140. em base e Install the stem head and washer and tighten the stem head nut lightly e Settle the bearing in place as follows OTighten the stem locknut to 39 N m 4 0 kgf m 29 ft lb of torque To tighten the steering stem locknut to the specified torque hook the wrench A on the stem locknut and pull the wrench at the hole by 22 2 kg force B in the direction shown Special Tool Steering Stem Nut Wrench 57001 1100 OCheck that there is no play and the steering stem turns smoothly without rattles If not the steering stem bearings may be damaged OAgain back out the stem locknut a fraction of a turn until it turns lightly OTurn the stem locknut lightly clockwise until it just be comes hard to turn Do not overtighten or the steering will be too tight Torque Steering Stem Locknut 4 9 N m 0 5 kgf m 43 in Ib e Install the front fork see the Suspension chapter NOTE OTighten the fork upper clamp bolts first next the stem head nut last the fork lower clamp bolt Torque Steering Stem Head Nut 78 N m 8 0 kgf m 58 ft Ib Front Fork Clamp Bolts Upper 20 N m 2 0 kgf m 14 5 ft lb Lower 20 N m 2 0 kgf m 14 5 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Install the parts removed see the appropriate chapter A WARNING Do not impede the handlebar turning by routing the cables wires and hoses improperly see the Gen eral Information chapter
141. emoval iaa 14 18 ignition Coil MSpeEctiON WEE 14 18 Spark Plug Cleaning and Inspection 14 19 Spark Plug Gap Inspection ica mire Le Lie nette SEA dues 14 19 C D I Unit Removal Crankshaft Sensor Air Gap Adjustment 14 25 Throttle EE 14 26 Throttle Sensor Inspection KX250 siccoiicomsnicias rot a EEN EES EEGEN 14 26 Throttle Sensor Position Adjustment KX250 oooonoocooccccccccccncnononnnononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 14 26 Fuel Cut Valve oi AT 14 27 Fuel Cut Valve Removal KX250 inside aiii 14 27 Fuel Cut Valve Installation KX250 4e 14 27 Fuel Cut Valve Inspection KX250 est det Eet eege 14 27 14 2 ELECTRICAL SYSTEM Wiring Diagram KX125M Magneto W Engine R kx125 M1 M2 790 SOP G W m y Crankshaft Sensor KX125 M1 M2 Engine Stop Button o Hoi Noise Ignition i le GG Suppressor Coil Spark Plug BK Black BR Brown C6 Green 0 orange R Red W White GPO5041B 3 ELECTRICAL SYSTEM 14 3 Wiring Diagram KX250M Regulator Rectifier Throttle Sensor 3 Fuel Cut Valve Crankshaft Sensor A BK O oO BK 1 gt _ 8K W Engine Stop Button 0 Sl Noise ee i gen tien i Suppressor Spark Plug Red White Yellow 98052 0003A W2 0003AW3 14 4 ELECTRICAL SYSTEM Exploded View
142. ench and connect the fuel tap to the carburetor using a suitable hose e Remove the drain plug from the bottom of the float bowl and screw a fuel level gauge B into the plug hole Special Tools Fuel Level Gauge 57001 1577 KX125 Fuel Level Gauge M18 x 1 0 57001 122 KX250 6006061652 C 3 12 FUEL SYSTEM Carburetor e Hold the gauge vertically against the side of the carbure tor body so that the Zero line C is several millimeters higher than the bottom edge D of the carburetor body e Turn the fuel tap to the ON position to feed fuel to the carburetor e Wait until the fuel level in the gauge settles e Keeping the gauge vertical slowly lower the gauge until the zero line is even with the bottom edge of the carbu retor body NOTE ODO not lower the zero line below the bottom edge of the carburetor body If the gauge is lowered and then raised again the fuel level measure shows somewhat higher than the actual fuel level Ifthe gauge is lowered too far dump the fuel out of it into a suitable container and start the procedure over again e Read the fuel level in the gauge and compare it to the specification Service Fuel Level above the bottom edge of the carb body Standard 10 1 mm 0 394 0 039 in KX125 10 5 1 mm 0 413 0 039 in KX250 x If the fuel level is incorrect adjust it e Turn the fuel tap to the OFF position and remove the fuel level gauge e In
143. er of the 21st pin Since the chain may wear unevenly take measurements at several places Chain 20 link Length Standard 317 5 318 2 mm 12 50 12 53 in Service Limit 323 mm 12 72 in x If any measurements exceed the service limit replace the chain Also replace the front and rear sprockets when the drive chain is replaced A WARNING If the drive chain wear exceeds the service limit re place the chain or an unsafe riding condition may result A chain that breaks or jumps off the sprock ets could snag on the engine sprocket or lock the rear wheel severely damaging the motorcycle and causing it to go out of control Standard Chain Make DAIDO Type D I D 520DMA2 Link KX125 112 Links KX250 114 Links Drive Chain Lubrication elt the chain appears especially dirty it should be cleaned before lubrication with high flash point solvent elt a special lubricant is not available a heavy oil such as SAE90 is preferred to a lighter oil because it will stay on the chain longer and provide better lubrication e Apply oil to the sides of the rollers so that oil will penetrate to the rollers and bushings e Wipe off any excess oil Oil applied area A Sprocket Wear Inspection e Visually inspect the front and rear sprocket teeth for wear and damage lf they are worn as illustrated or damaged replace the sprocket A Worn Tooth Engine Sprocket B Worn Tooth Rear Sprocket C Direction of Rotation NOT
144. er rake angle 27 Trail 97 mm 3 8 in 112 mm 4 4 in Front Tire Size Make Type Rear Tire Size Make Type Front Suspension Type Wheel Travel Rear Suspension Type Wheel Travel Brake Type Front and Rear 80 100 21 51M BRIDGESTONE Tube type EUR DUNLOP Tube type 110 90 19 62M BRIDGESTONE Tube type EUR DUNLOP Tube type Telescopic fork up side down 300 mm 11 8 in Swingarm Uni trak 310 mm 12 2 in Single disc 1 1 1 1 1 1 1 1 Swingarm New Uni trak lt 1 12 GENERAL INFORMATION General Specifications Items KX250 M1 KX250 M2 Effective Disc Diameter Front 220 mm 8 7 in 225 mm 8 9 in Rear 200 mm 7 9 in 215 mm 8 5 in Specifications are subject to change without notice and may not apply to every country EUR Europe Model GENERAL INFORMATION 1 13 Technical Information Ratchet Type Shift Mechanism KX250M KX125M OThe shift mechanism of the KX250M 5 speed is shown in the following figure OThis mechanism is stronger and simpler than the usual slide type and enables light and positive shifting When the shift pedal D is applied its turning force is transmitted almost directly to the shift drum E OThe mechanism has shorter length between the shift drum and the drive shaft compared with the previous model for example from 67 mm to 43 2 mm for KX125 OThe shift force is transmitted as follows Shift Peda
145. ert the exhaust valves A so that their spherical parts B shall direct to downward NOTE OThere are left and right sides for the exhaust valves ORight exhaust valve has a identification slot C so that it shall be installed upward e Install the retaining plate D and tighten exhaust valve retaining bolts E Torque Exhaust Valve Retaining Bolts 5 9 N m 0 6 kgf m 52 in Ib e Check that the exhaust valves slide smoothly 6E07000BS2 C ENGINE TOP END 5 19 Exhaust Valve KIPS e Fit the spring A to the main lever B e Insert the main shaft A in the hole of the cylinder and through the holes in the main lever B with spring C e Install the stopper pin A e Tighten Torque Stopper Pin Plug 0 8 N m 0 08 kgf m 69 in Ib e Apply a non permanent locking agent to the Allen bolt B e Fix the main lever to the main shaft with the Allen bolt e Tighten Torque Main Lever Allen Bolt 3 9 N m 0 4 kgf m 35 in Ib e Install the main valve cover e Tighten Torque Main Valve Cover Bolts 5 9 N m 0 6 kgf m 52 in Ib NOTE OWhen main shaft A turns clockwise and with the ex haust valves B fully opened position check the end of exhaust valves and the exhaust ports C are aligned with om P 6E07001BS1 5 20 ENGINE TOP END Exhaust Valve KIPS e Install the cylinder see Cylinder Installation Torque Cylinder Nuts 25 N m 2 5 kgf m 18 f
146. ew replacement will soon fail again OMake sure all connectors in the circuit are clean and tight and examine wires for signs of burning fraying etc Poor wires and bad connections will affect electrical system op eration OMeasure coil and winding resistance when the part is cold at room temperature OElectrical Connectors A Female Connectors B Male Connectors Safety Instructions A WARNING The ignition system produces extremely high volt age Do not touch the spark plug high tension coil or spark plug lead while the engine is running or you could receive a severe electrical shock GPO60101S1 6P0601028S1 ELECTRICAL SYSTEM 14 9 Electrical Wiring Wiring Inspection e Visually inspect the wiring for signs of burning fraying etc Alf any wiring is poor replace the damaged wiring e Pull each connector A apart and inspect it for corrosion dirt and damage x If the connector is corroded or dirty clean it carefully If it is damaged replace it e Check the wiring for continuity OUse the wiring diagram to find the ends of the lead which is suspected of being a problem OConnect an ohmmeter between the ends of the leads OSet the meter to the x 1 Q range and lead the meter Alf the meter does not read 0 Q the lead is defective Re place the lead or the wiring harness if necessary GPO70103S1 14 10 ELECTRICAL SYSTEM Ignition Timing I
147. ff the joint pin while pressing down the brake pedal e Unscrew the master cylinder mounting bolts C and re move the master cylinder e Unscrew the brake hose banjo bolt D see Brake Hose Removal Installation e When removing the brake hose temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum 6L07018BS1 GLO7060281 6L07019BS1 BRAKES 11 19 Master Cylinder Rear Master Cylinder Installation e Replace the cotter pin with a new one e Replace the washers are on each side of hose fitting with new ones e Tighten the following Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 0 ft lb Rear Master Cylinder Mounting Bolts 9 8 N m 1 0 kgf m 87 in 1b e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage e Check the brake pedal position master cylinder push rod length Front Master Cylinder Disassembly e Remove the front master cylinder e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Unscrew the locknut and pivot bolt and remove the brake lever e Push the dust cover A out of place and remove the cir clip B Special Tool Inside Circlip Pliers 57001 143 e Remove the washer C pull out the piston D secondary cup E primary cup F and return spring G CAUTION Do not re
148. flash point solvent Do not use one which will leave an oily residue Replace the pads with new ones if they cannot be cleaned satisfacto rily 8 Brake fluid quickly ruins painted surfaces any spilled fluid should be completely wiped up imme diately 9 If any of the brake line fittings or the bleed valve is opened at any time the AIR MUST BE BLED FROM THE BRAKE LINE Fluid Level Inspection e Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter Fluid Change e Refer to the Brake Fluid Change in the Periodic Mainte nance chapter BRAKES 11 11 Brake Fluid Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action Air however is easily compressed When air enters the brake lines brake lever or pedal movement will be partially used in compressing the air This will make the lever or pedal feel spongy and there will be a loss in braking power A WARNING Be sure to bleed the air from the brake whenever brake lever or pedal action feels soft or spongy af ter the brake fluid is changed or whenever a brake line fitting has been loosened for any reason NOTE OThe procedure to bleed the front brake line is as follows Bleeding the rear brake line is the same as for the front brake e Remove the reservoir cap and check that there is plenty of fl
149. ft Connecting Rod Crankshaft Removal e Split the crankcase see Crankcase Splitting e Remove the transmission shafts see Transmission Shaft Removal e Using a press remove the crankshaft from the right crankcase Olf the bearings stay on the crankshaft when splitting the crankcase or removing the crankshaft from the right crankcase remove the bearings from the crankshaft with a bearing puller A and adapter B Special Tools Bearing Puller 57001 158 Bearing Puller Adapter 57001 136 6104016BS1 Crankshaft Installation e When installing the crankshaft bearings B apply high temperature grease to the outer sides of the bearings and then press them into the crankcase using the bearing driver A until the bearing bottoms against the step OPosition the crankcase half so that the main bearing hous ing is seated on a suitable press fixture Olnstall the crankshaft bearing so that the mark side faces out Special Tool Bearing Driver Set 57001 1129 6104104BS1 e Insert the crankshaft jig C between the crankshaft fly wheels opposite the connecting rod B big end to protect flywheel alignment as shown and press the crankshaft A into the right crankcase OWhen pressing position the jig in the crankcase opening so the jig does not hit the crankcase Special Tool Crankshaft Jig 57001 1174 e Apply 2 stroke oil to the connecting rod big end bearing Crankshaft Dis
150. g a wet stone to remove sharp edges or raised areas which OT cause seal damage sl the damage is not repairable replace the inner tube Since damage to the inner tube damages the oil seal replace the oil seal whenever the inner tube is repaired o or replaced e Temporarily assemble the inner and outer tubes and pump them back and forth manually to check for smooth operation CAUTION If the inner tube is badly bent or creased replace GM040118S1 it Excessive bending followed by subsequent straightening can weaken the inner tube 12 30 SUSPENSION Front Fork Guide Bush Inspection e Visually inspect the guide bushes A and replace them if necessary 6M040119S1 Dust Seal Oil Seal Inspection e Inspect the dust seal A for any signs of deterioration or damage Replace it if necessary e Replace the oil seal B with a new one whenever it has been removed Spring Tension e Since a spring becomes shorter as it weakens check its free length A to determine its condition lf the spring of either fork leg is shorter than the service limit it must be replaced If the length of a replacement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the fork legs balanced from motorcycle stability Fork Spring Free Length GM04011651 Standard 460 mm 18 11 in Service Limit 450 mm 17 72 in SUSPENSION 12
151. gent to the threads LG Apply liquid gasket to the threads S Tighten the fasteners following the specified sequence Fuel System Carburetor Top Cover Screws KX125 3 0 0 3 26 in lb Carburetor Top Cover Allen Bolts KX250 3 9 0 4 35 in lb Throttle Sensor Bolt KX250 2 0 0 2 17 in lb Rear Frame Mounting Bolts 34 3 5 25 Carburetor Holding Clamp Screws 1 4 0 14 12 in lb Carburetor Holder Mounting Bolts 8 8 0 9 78 in lb Reed Valve Screws 1 0 0 1 8 8 in lb Fuel Tap Plate Mounting Screws 0 8 0 08 7 in lb Cooling System Cooling Hose Elbow Fitting Bolts Cylinder KX250 8 8 0 9 78 in lb Water Pump Cover Bolts 8 8 0 9 78 in lb Water Pump Impeller Bolt 6 9 0 7 61 in lb Cooling Hose Clamp Screws 1 5 0 15 13 in lb Coolant Drain Plug Water Pump Cover 8 8 0 9 78 in lb Coolant Drain Plug Cylinder KX250 8 8 0 9 78 in lb Water Pump Cover Fitting Bolts KX250 5 9 0 6 52 in lb Engine Top End Cylinder Head Nuts 25 2 5 18 Cylinder Head Cover Stud o Spark Plug 26 5 2 75 19 5 Coolant Drain Plug Cylinder KX250 8 8 0 9 78 in lb Cylinder Nuts KX125 25 2 5 18 0 KX250 34 3 5 25 Engine Mounting Bracket Nuts Engine Side 10 mm KX125 250 M1 44 4 5 33 Engine Side 10 mm KX125 250 M2 49 5 0 36 Frame Side 8 m 29 3 0 22 KIPS Cover Bolts KX125 M1 4 9 0 5 43 in lb KX125 M2 8 8 0 9 78 in lb KX250 2 9 0 3 26 in lb Main Valve Cover Bolts 5 9 0 6 52 in lb 2 6 PERIODIC MAINTENANCE Torque and Locking Agent
152. ges and cause serious dam age GENERAL INFORMATION 1 3 Before Servicing 11 Press When using a press or driver to install a part such as a wheel bearing apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit 12 Ball Bearing and Needle Bearing Do not remove a ball bearing or a needle bearing unless itis absolutely necessary Replace any ball or needle bearings that were removed with new ones Install bearings with the manufacturer and size marks facing out applying pressure evenly with a suitable driver Apply force only to the end of the race that contacts the press fit portion and press it evenly over the base component 13 0il Seal and Grease Seal Replace any oil or grease seals that were removed with new ones as removal generally dam ages seals Oil or grease seals should be pressed into place using a suitable driver applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole unless instructed otherwise When pressing in an oil or grease seal which has manufacturer s marks press it in with the marks facing out 14 Circlip Retaining Ring and Cotter Pin When installing circlips and retaining rings take care to compress or expand them only enough to install them and no more Install the circlip with its chamfered side facing load side as well Replace any circlips retaining rings and cotter pins that were removed with new ones as
153. gnition Timing Adjustment e Remove the magneto cover e Check to see if the center mark of the three marks A on the magneto stator is aligned with the mark B on the crankcase lf the marks are not aligned loosen the magneto stator screws C and turn the magneto stator D e Tighten the screws securely Torque Stator Plate Mounting Screws 4 4 N m 0 45 kgf m 39 in Ib e Install the magneto cover Torque Magneto Cover Bolts 4 9 N m 0 5 kgf m 43 in Ib Magneto Cover Bolts KX125 250 M2 3 5 N m 0 4 kgf m 35 in Ib The ignition timing can be adjusted for different power band to suit to rider s preference ability e Remove the magneto cover e Loosen the stator screws e Adjust the timing by shifting the stator position within the three lines A GP22010581 ELECTRICAL SYSTEM 14 11 Ignition Timing NOTE OFor best engine performance it is very important to ad just the ignition timing within the adjustable range just explained A Crankshaft Rotation B Stator Movement C Retard D Advance e Tighten the stator screws securely see Igniting Timing Adjustment e Install the magneto cover see Ignition Timing Adjust ment Torque Magneto Cover Bolts 4 9 N m 0 5 kgf m 43 in Ib Magneto Cover Bolts KX125 250 M2 3 5 N m 0 4 kgf m 35 in Ib e Test ride the motorcycle and readjust the ignition timing if necessary 14 12 ELECTRICAL SYSTEM Flywheel Magneto
154. guide pins from the shift drum 2 grooves e Take off the shift drum B e Remove the shift forks C from the transmission gears e Take out the drive shaft D and output shaft E together with their gear meshed e Remove the crankshaft from the right crankcase half us ing a press 6104008BS1 Crankcase Disassembly CAUTION Do not remove the bearings and the oil seals unless it is necessary Removal may damage them Crankcase Assembly e Before fitting the left case on the right case note the fol lowing OChip off the old gasket from the mating surfaces of the crankcase halves and clean off the crankcase with a high flash point solvent After cleaning apply transmission oil to the transmission gears shift drum shift forks and so on OBe sure to replace any oil seal removed with a new one Press in the new oil seal using a press and suitable tools so that the seal surface is flush with the surface of the crankcase OApply high temperature grease to the oil seal lips OPress in the ball bearings using the bearing driver set until the bearing is bottomed Special Tool Bearing Driver Set 57001 1129 Olnstall the bearing for the output shaft into the left crankcase half so that stepped side faces A inside CAUTION Install the bearings for the crankshaft in the right and left crankcase so that their sealed sides face toward the oil seal side 6104010651 OTighten the output and
155. he carburetor and install it on the motorcycle Carburetor Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light 3 20 FUEL SYSTEM Carburetor e Remove the carburetor e Before disassembling the carburetor check the fuel level see Fuel Level Inspection x If the fuel level is incorrect inspect the rest of the carbu retor before correcting it e Pull the carburetor cable to check that the throttle valve A moves smoothly and returns by spring pressure x If the throttle valve does not move smoothly Replace the carburetor e Disassemble the carburetor e Clean the carburetor e Check the O rings on the float bowl pilot screw and throt tle sensor are in good condition lf any of the O rings are not in good condition replace them e Check the tapered portion A of the pilot screw B for wear or damage x If the pilot screw is worn or damaged on the tapered por tion it will prevent the engine from idling smoothly Re place it e Remove the float valve needle e Check the plastic tip A of the float valve needle B for wear x If the needle is worn as shown right C replace the valve needle e Push the rod D in the valve needle then release it x lf the rod does no
156. he core fin direction A MAM GD070603S1 COOLING SYSTEM 4 15 Radiator Cap Inspection e Check the condition of the valve spring B and the top and bottom valve seals A of the radiator cap Alf any one of them shows visible damage replace the cap e Wet the top and bottom valve seals with water or coolant to prevent pressure leaks e Install the cap A on a cooling system pressure tester B e Watching the pressure gauge slowly pump the pressure tester to build up the pressure The gauge hand must remain within the relief pressure range in the table below at least 6 seconds Continue to pump the tester until the relief valve opens indicated by the gauge hand flicking downward The relief valve must open within the specified range Radiator Cap Relief Pressure Standard 93 123 kPa 0 95 1 25 kgf cm 13 18 psi x If the cap cannot hold the pressure or if the relief pressure is too high or too low replace the cap with a new one Filler Neck Inspection e Check the radiator filler neck for signs of damage e Check the condition of the top and bottom sealing seats A in the filler neck They must be smooth and clean for the radiator cap to function properly Cooling Hoses Breather Hose Inspection e Refer to the Cooling Hoses and Connections Inspection in the Periodic Maintenance chapter Cooling Hoses Breather Hose Installation e Install the cooling hoses or brea
157. he each fork top plug e Remove the front fork e Hold the inner tube lower end in a vise e Disassemble the top plug from the outer tube e Push the outer tube all the way down away from the top plug and hold it there through out the following procedure OFor KX125 250 M1 model pull the fork spring A away from the top plug a little and sip the spanner wrench B in on top of the spring seat and under the push rod nut C 6M04100BS1 e Use wrenches on the rod nut and top plug A loosen the push rod nut e Remove the top plug from the push rod e Lift the fork spring B and its top spring seat C out of the outer tube e For KX125 250 M2 model as shown in the figure 6M04148BS1 e Take the rebound damping adjuster rod A out of the push rod 6M04109BS1 SUSPENSION 12 23 Front Fork e Hold the fork tube A upside down over a clean container B and pump it to drain the oil NOTE OTo discharge the fork oil pump the push rod up C and down ten times 6M04015BS1 e Remove the push rod nut A and the spring guide B 6M04023BS1 o Cylinder Unit Removal KX125 250 M1 e Clean the bottom of the inner tube e Remove the cap on the bottom of the inner tube e Hold the front fork horizontally in a vise e Stop the cylinder unit A from turning by using the fork cylinder holder B Unscrew the cylinder valve assembly C and take the cyli
158. he pedal with return spring onto the frame Torque Brake Pedal Mounting Bolt 25 N m 2 5 kgf m 18 ft Ib e Check the brake pedal position e Install the joint pin washer and a new cotter pin 11 10 BRAKES Brake Fluid A WARNING When working with the disc brake observe the pre cautions listed below 1 Never reuse old brake fluid 2 Do not use fluid from a container that has been left unsealed or that has been open for a long time 3 Do not mix two types and brands of fluid for use in the brake This lowers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate 4 Don t leave the reservoir cap off for any length of time to avoid moisture contamination of the fluid 5 Don t change the fluid in the rain or when a strong wind is blowing 6 Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning of the brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterio ration of the rubber parts Oil spilled on any part will be difficult to wash off completely and will eventually deteriorate the rubber used in the disc brake 7 When handling the disc pads or disc be careful that no disc brake fluid or any oil gets on them Clean off any fluid or oil that inadvertently gets on the pads or disc with a high
159. he radiator filler neck B with coolant A and install the cap turning it clockwise about 1 4 turn NOTE OPour in the coolant slowly so that it can expel the air from the engine and radiator The radiator cap must be installed in two steps First turn the cap clockwise to the first stop Then push down on it and turn it the rest of the way e Check the cooling system for leaks Air Bleeding Before putting the motorcycle into operation any air trapped in the cooling system must be removed as follows e Start the engine warm up the engine thoroughly and then stop the engine Wait until the engine cools down e Remove the radiator cap e Check the coolant level x If the coolant level is low add coolant up to the bottom of the filler neck e Install the radiator cap e Check the cooling system for leaks Cooling Hoses and Connections Inspection OThe high pressure inside the cooling hose can cause coolant to leak A or the hose to burst if the line is not properly maintained Visually inspect the hoses for signs of deterioration Squeeze the hoses A hose should not be hard and brittle nor should it be soft or swollen x Replace the hose if any fraying cracks B or bulges C are noticed e Check that the hoses are securely connected and clamps are tightened correctly Torque Cooling Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in lb Engine Top End Cylinder Head Warp Inspection e Lay a straightedge A across
160. he suitable oil cup A to the air bleeder bolt hole and fill the specified oil into the cup OPurge the air from between the gas reservoir B and rear shock body C by slowly pumping the piston rod D in and out Olnstall the air bleeder bolt securely OFully extend the piston rod assembly e Inject nitrogen gas to a pressure of 50 kPa 0 5 kgf cm 7 psi through the valve on the gas reservoir e Check the rear shock body and gas reservoir for oil and gas leaks x If there are no leaks inject the nitrogen gas up to the 980 kPa 10 kgf cm 142 psi pressure WARNING Pressurize the gas reservoir with nitrogen gas only Do not use air or other gases since they may cause premature wear rust fire hazard or substandard performance High pressure gas is dangerous Have a qualified mechanic perform this procedure e Install the spring and spring guide e Adjust spring preload Reinstall the rear shock absorber e Install the parts removed GMO5069BS1 6M05105BS1 12 40 SUSPENSION Rear Suspension Uni Trak Rear Shock Absorber Scrapping WARNING Since the reservoir tank of the rear shock absorber contains nitrogen gas do not incinerate the reser voir tank without first releasing the gas or it may explode e Remove the shock absorber see Rear Shock Absorber Removal e Remove the valve cap A and release the nitrogen gas completely from the gas reservo
161. hole GDO60108S1 e Press the ball bearing into the hole until the bearing is bottomed against the step E Special Tool Bearing Driver Set 57001 1129 4 14 COOLING SYSTEM Radiator Radiator Removal 4 a e Drain the coolant see Coolant Draining e Remove Radiator Shrouds Fuel Tank see Fuel System chapter e Unscrew the clamps A and the bolts B e Remove the radiator screens C e Unscrew the bolts A e Remove Radiator Brackets B Radiator C with the cooling hoses OFor KX125 be sure to remove the magneto lead harness from left radiator Radiator Installation e Radiator installation is the reverse of removal e Route the cooling and breather hoses correctly Radiator Inspection e Check the radiator core x If there are obstructions to air flow remove them lf the corrugated fins are deformed carefully straighten them with the thin blade of a screwdriver A CAUTION Do not tear the radiator tubes while straightening S d the fins j x If the air passages of the radiator core are blocked more than 20 by unremovable obstructions or irreparably de formed fins replace the radiator with a new one CAUTION When cleaning the radiator with steam cleaner be careful of the following to prevent radiator damage Keep the steam gun C away more than 0 5 m 1 64 ft B from the radiator core Hold the steam gun perpendicular to the core surface Run the steam gun following t
162. hrottle Sensor Throttle Sensor Inspection KX250 NOTE Olf the variable rheostat is not available refer to throttle sensor output input voltage check in the C D I Unit in spection OWhen inspecting the throttle sensor the throttle valve of the carburetor shall be completely closed and remain the throttle cable connected e Remove the carburetor see Fuel System chapter e Connect the carburetor lead connector A with the battery B variable rheostat C and hand testers D as shown Variable Rheostat R G Lead Terminal E Hand Tester W BK Lead terminal F Hand Tester BK G Lead terminal G e Check the sensor input voltage Throttle Sensor Input Voltage Standard around 5 V e Check the sensor output voltage with the throttle valve is completely closed Throttle Sensor Output Voltage 0 4 0 6 V when the throttle valve Standard completely closed x lf it is not within the specified voltage adjust the throt tle sensor position see Throttle Sensor Position Adjust ment x If it is within specified voltage go to next test e Check the sensor output voltage with the throttle fully opened Throttle sensor Output Voltage Standard 3 5 3 7 V When throttle fully opened x If it is not within the specified voltage replace the sensor Throttle Sensor Position Adjustment KX250 e Remove the carburetor e Check the throttle valve is completely closed e Loosen the throttle sensor moun
163. ic Maintenance Chart in spect the brake fluid level in the front or rear brake fluid reservoirs e Check the brake fluid level in the front or rear brake reser voir A NOTE OHold the reservoir horizontal when checking brake fluid level OThe front or rear reservoir must be kept above the lower level line B If the fluid level in front or rear reservoir is lower than the lower level line fill the reservoir to the upper level line Inside the reservoir is stopped end showing the upper level line C 6S13011BS1 PERIODIC MAINTENANCE 2 35 Periodic Maintenance Procedures Brake Fluid Change In accordance with the Periodic Maintenance Chart change the brake fluid The brake fluid should also be changed if it becomes contaminated with dirt or water Furthermore the brake fluid should be changed to bleed the air quickly and completely whenever the brake line parts are removed WARNING Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that already is in the reser voir are unidentified After changing the fluid use only the same type and brand of fluid thereafter Mixing different types and brand of brake fluid low ers the brake fluid boiling point and could cause the brake to be ineffective It may also cause the rubber brake parts to deteriorate Recommended Disc Brake Fluid Type Front DOT3 or
164. ic Maintenance Procedures Exhaust Valve Clean and Inspect e Refer to the Exhaust Valve KIPS section in the Engine Top End chapter Exhaust System e The exhaust system in particular the silencer is designed to reduce exhaust noise and conduct the exhaust gases away from the rider while minimizing power loss If car bon has built up inside the silencer exhaust efficiency is reduced causing engine performance to drop elf the silencer is badly damaged dented cracked or rusted replace it Replace the silencer packing if the exhaust noise becomes too loud or engine performance drops Silencer Packing Change e Remove the silencer e Remove the inner pipe mounting bolts A and pull the inner pipe B from the silencer body e Unscrew the silencer pipe mounting bolts A e Pull the silencer pipe B from the silencer body e Pull off the old silencer packing and install the new si lencer packing A into the silencer e Apply silicone sealant to the circumference B of the si lencer pipe and inner pipe e Apply a non permanent locking agent to the pipe mount ing bolts e Install the silencer Torque Silencer Inner Pipe Bolts 8 8 N m 0 9 kgf m 78 in Ib Silencer Pipe Bolts 8 8 N m 0 9 kgf m 78 in lb GEO80101S1 Engine Right Side A WARNING To avoid a serious burn never touch the hot engine or exhaust chamber during clutch adjustment 2 26 PERIODIC MAINTENANCE Periodic
165. ift Shaft Apply molybdenum disulfide grease Apply 2 stroke engine oil Apply transmission oil to the transmission gears and shift forks etc Apply high temperature grease Apply a non permanent locking agent Apply liquid gasket to the left and right case mating surface Replacement parts 8 6 ENGINE BOTTOM END TRANSMISSION Specifications Item Standard KX125 250 M1 Service Limit Transmission Oil Type Viscosity Capacity KX125 KX250 Crankshaft Connecting Rod Connecting Rod Bend Connecting Rod Big End Radial Clearance KX125 KX250 Connecting Rod Big End Side Clearance KX125 KX250 Crankshaft Runout API SE SF or SG API SH or SJ with JASO MA SAE 10W 40 0 7 L 0 74 US at 0 85 L 0 90 US at Not more than 0 03 mm 0 0012 in 100 mm 3 937 in 0 036 0 047 mm 0 0014 0 0019 in 0 037 0 049 mm 0 0015 0 0019 in 0 40 0 50 mm 0 0157 0 0197 in 0 45 0 55 mm 0 0177 0 0217 in Not more than 0 03 mm 0 0012 in 0 2 mm 0 008 in 100 mm 3 937 in 0 10 mm 0 004 in 0 10 mm 0 004 in 0 70 mm 0 028 in 0 70 mm 0 028 in 0 05 mm 0 002 in Transmission Gear Backlash Shift Fork Ear Thickness KX125 KX250 Gear Shift Fork Groove Width KX125 KX250 Shift Fork Guide Pin Diameter Shift Drum Groove Width 0 02 0 20 mm 0 0008 0 0078 in 4 90 5 00 mm 0 1768 0 1969 in 4 40 4 50 mm 0 1732 0 1772
166. igh Tire air pressure too high Rear shock absorber maladjusted Too soft Front fork oil insufficient and or leaking Front fork oil viscosity too low Front fork rear shock absorber spring weak Rear shock absorber gas leaking Rear shock absorber maladjusted Brake Doesn t Hold Disc brake Air in the brake line Pad or disc worn Brake fluid leak Disc warped Contaminated pads Brake fluid deteriorated Primary or secondary cup damaged Master cylinder scratched inside Brake maladjustment lever or pedal play excessive 15 6 APPENDIX Cable Wire and Hose Routing KX125 Left Radiator Inside View GBC9600B 5 APPENDIX 15 7 Cable Wire and Hose Routing J O O1 PB amp ND Throttle Cable Clutch Cable Engine Stop Switch Lead Band Radiator Overflow Tube Right Screen Run the overflow tube backward of the down tube Run the tube outside of the engine mount bracket Run the tube forward of the radiator connection hose Left Screen Frame C D I Unit Run the throttle cable left side of the stop switch lead Clamp the magneto lead harness and stop switch lead connector Do not clamp the throttle cable Run the magneto lead Harness thought the frame and radiator Magneto Lead Harness Band Clamp the magneto lead and air vent tube Magneto Ignition Coil Ignition Coil Primary Winding Lead Tighten together with ignition c
167. in 5 05 5 15 mm 0 1988 0 2028 in 4 55 4 65 mm 0 1791 0 1830 in 5 90 6 00 mm 0 2323 0 2362 in 6 05 6 20 mm 0 2382 0 2440 in 0 30 mm 0 012 in 4 80 mm 0 189 in 4 30 mm 0 169 in 5 25 mm 0 207 in 4 75 mm 0 187 in 5 80 mm 0 228 in 6 25 mm 0 246 in ENGINE BOTTOM END TRANSMISSION 8 7 Special Tools Bearing Puller Adapter Bearing Driver Set 57001 136 57001 1129 ST5701368T ST5711298T Outside Circlip Pliers Crankshaft Jig 57001 144 57001 1174 ST5701448T ST5711748T Bearing Puller Kawasaki Bond Liquid Gasket Silver 57001 158 92104 002 ST5701588T ST9200028T Crankcase Splitting Tool Assembly 57001 1098 8 8 ENGINE BOTTOM END TRANSMISSION Transmission Oil In order for the transmission and clutch to function prop erly always maintain the transmission oil at the proper level and change the oil periodically WARNING Motorcycle operation with insufficient deteri orated or contaminated transmission oil will accelerated wear and may result in transmission seizure and injury Oil Level Inspection e Refer to the Transmission Oil Level Inspection in the Pe riodic Maintenance chapter Oil Change e Refer to the Transmission Oil Change in the Periodic Maintenance chapter ENGINE BOTTOM END TRANSMISSION 8 9 Crankcase Crankcase Splitting e Remove the engine see the Engine Removal In
168. inder valve assembly and screw the valve assem bly into the bottom of the inner tube e Hold the cylinder unit with the fork cylinder holder and tighten the cylinder valve assembly Special Tool Fork Cylinder Holder 57001 1573 Torque Cylinder Valve Assembly 54 N m 5 5 kgf m 40 ft Ib e Check the O ring A on the guide stay nut and replace it with a new one if damaged e Install the inner cylinder unit e Install the piston holder A into the push rod assembly B then the oil rock piston C so that its notch side down ward to the piston holder e Install the split ring keeper D in the groove of the push rod assembly e Fastening the top end of the piston holder to the split ring keeper and tighten the guide stay nut E to the piston holder Torque Guide Stay Nut 27 N m 2 8 kgf m 20 ft Ib NOTE OBe sure to install securely a snap ring to fasten the oil rock piston on the push rod Olf it is not securely installed the fork may be damaged 6M04025BS1 6M04153BS1 6M04024BS1 A 8 IVI 6M04160BS1 12 28 SUSPENSION Front Fork e Install the spring guide A so that the thinner portion end B is down e Screw on the push rod nut C fully 6M04108BS1 e For KX125 250 M2 as shown in the figure 6M04154BS1 e Insert the rebound damping adjuster rod A into the push rod 6M04109BS1 e
169. ing Seat Spring Rebound Damping Adjuster Rod Spring Guide Push Rod Fork Cylinder Outer Tube Guide Bush Washer Oil Seal Retaining Ring Dust Seal Inner Tube Gasket Cap Steering Stem Head Steering Stem Fork Guide Fork Protector Apply a non permanent locking agent to the threads 12 4 SUSPENSION Exploded View KX125 250 M2 O IDO l LU 40a x LT TI 0006032 bs 6M02074BW5 SUSPENSION 12 5 Exploded View No Fastener Torque Remarks N m kgf m ft lb 1 Front Fork Top Plug 29 3 0 22 2 Front Fork Clamp Bolts Upper Lower 20 2 0 14 5 3 Steering Stem Head Nut 78 8 0 58 4 Push Rod Nut 28 2 85 20 6 5 Front Axle Clump Bolts 20 2 0 14 5 6 Front Fork Cylinder Valve Assembly 54 5 5 40 L 7 Screw 8 O ring 9 Damper 10 Washer 11 Spring Seat 12 Spring 13 Rebound Damping Adjuster Rod 14 Spring Guide 15 Push Rod 16 Fork Cylinder 17 Outer Tube 18 Guide Bush 19 Washer 20 Oil Seal 21 Retaining Ring 22 Dust Seal 23 Inner Tube 24 Gasket 25 Cap 26 Steering Stem Head 27 Steering Stem 28 Fork Guide 29 Fork Protector L Apply a non permanent locking agent to the threads 12 6 SUSPENSION Exploded View KX125 250 M1 S 2 6M02075BW5 SUSPENSION 12 7 Exploded View Torque No Fastener Nm kgfm Pe Remarks Swingarm Piv
170. ins are damaged replace them with new ones Nut Bolt and Fastener to be checked Wheels Spoke Nipples Front Axle Nut Rear Axle Nut Cotter Pin Rear Axle Nut Final Drive Chain Adjuster Locknuts Rear Sprocket Nuts Brakes Front Master Cylinder Clamp Bolts Caliper Mounting Bolts Front Rear Master Cylinder Mounting Bolts Rear Master Cylinder Joint Cotter Pin Brake Lever Pivot Nut Brake Pedal Bolt Suspension Front Fork Clamp Bolts Front Fender Mounting Bolt Rear Shock Absorber Mounting Nuts Swingarm Pivot Shaft Nut Swingarm Pivot Shaft Locknut Uni Trak Link Nuts Steering Stem Head Nut Handlebar Clamp Bolts Engine Engine Mounting Nuts Engine Bracket Nuts Cylinder Head Nuts Shift Pedal Bolt Exhaust Pipe Holder Nuts Muffler Bolt and Nut Kick Pedal Bolt Others Rear Frame Mounting Bolts FUEL SYSTEM 3 1 Fuel System Table of Contents EXPO WAT Specifications cit ti Mee De elle EUR Kee Throttle Elle Ee e EE Free Play NS eNO E Free Play AUS MOL aa Throttle Cable Installation ss Cable Lubricante Gable Inspection sin hhasttens drames anna fete alice Gar 010 112110 PR RE ai Idle Speed INP miii A en nn Lanai pl ira idle Sp ed ENT EE Service Fuel Level Inspection Service Fuel Level Adjustment su Carburetor Removals iani leal dl ait aiii Carburetor Jnstallaton Fuel Inspection iii A A a A EA La ddr ae Carburetor DiSasSemblY carmona aan Carburetor Assembly soii daa Carburetor Cleanings rs lr A Nine te Carb
171. ir e Remove the valve GMO5056BS1 Since the high pressure gas is dangerous do not point the valve toward your face or body SUSPENSION 12 41 Swingarm Swingarm Removal e Place the jack under the frame so that the rear wheel is off the ground Special Tool Jack 57001 1238 e Remove Rear Wheel see Wheels Tires chapter Clamps A Brake Pedal B Tie rod Rear Mounting Bolt C Rear Shock Absorber D see Rear Shock Absorber Re moval e For KX125 250 M2 model note the following ORemove Rear Wheel see Wheels Tires chapter Rear Flap A Clamps B Brake Pedal C Plug and Rocker Arm Pivot Nut D CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on a bolt could damage the bolt sleeve and bearing e Pull out the swing arm pivot shaft E and remove the swing arm F e Separate the chain guide and chain slipper from the swing arm Swingarm Installation e Apply plenty of grease to the inside of the needle bear ings sleeves and oil seals e Tighten the following Torque Swingarm Pivot Shaft Nut 98 N m 10 0 kgf m 72 ft lb Tie Rod Mounting Nut 83 N m 8 5 kgf m 61 ft lb e Refer to the Wheels Tires Final Drive and Brakes chap ters for wheel installing 12 42 SUSPENSION Swingarm Swingarm Bearing Removal e Remove Swingarm Collars A Grease Seals B Sleeves C Needle Bearings D e Remove the needl
172. ir Cleaner Housing Rear Frame Apply grease High quality foam air filter oil Replacement Part Remarks Xian DOQDNADCOANODGA O N 3 8 FUEL SYSTEM Specifications KX125 Item andara Service Limit KX125 M1 KX125 M2 KX125 M3 Carburetor Make Type MIKUNI TMX38x Main Jet 420 SE Throttle Valve Cutaway 5 75 Jet Needle 6CHJ 11 82 6CHJ 10 82 Jet Needle Clip Position 3rd groove from the top Slow Jet Pilot Jet 40 Air Screw Turns out 2 1 2 1 1 2 Service Fuel Level above the bottom edge of the carb body Float Height KX250 Item 10 1 mm 0 394 0 039 in 9 5 1 mm 0 374 0 039 in Standard KX250 M1 KX250 M2 Service Limit Carburetor Make Type Main Jet Power Jet Throttle Valve Cutaway Jet Needle Jet Needle Clip Position Slow Jet Pilot Jet Air Screw Turns out Service Fuel Level above the bottom edge of the carb body Float Height Fuel Cut Valve Throttle Sensor KEIHIN PWK38S 165 50 8 NAFH NALF 2nd groove from the top 52 2 1 1 2 10 5 1 mm 0 413 0 039 in 6 5 1 mm 0 256 0 039 in see Electrical System chapter see Electrical System chapter FUEL SYSTEM 3 9 Special Tools Fuel Level Gauge 57001 1577 ST571577ST Fuel Level Gauge M18 x 1 0 57001 122 3 10 FUEL SYSTEM Throttle Grip
173. ive Red Lead D OCrank the engine by kicking the pedal several times to measure the peak voltage of the exciter coil Peak Voltage 32 V or Above KX250 16 V or above KX250 x If the voltage is less than the specified check the exciter coil Fuel Cut Valve Operation Check KX250 e Disconnect the carburetor lead connector A e Set the tester to the DC25V range and connect it to the carburetor lead of the main harness side Connections Tester Positive Red White Lead B Tester Negative Brown Lead C e Start the engine e Run it at the rpm given below Fuel Cut Valve Operate Revolutions Standard 8 100 rpm e Read the tester running the engine at the specified revo lution Fuel Cut Valve Operation Voltage When engine is specified revolutions or above DC 12V When engine is less than specified revolutions ON Alf the tester does not read as specified check the mag neto Alf the magneto has normal functions replace the C D I Unit 6P10043BS1 6P10044BS1 14 24 ELECTRICAL SYSTEM Ignition System Throttle Sensor Output Input Voltage Check KX250 NOTE Olf the variable rheostat is available refer to throttle sen sor inspection e Remove the carburetor lead connector e Connect the auxiliary leads A between carburetor lead connector B and main harness connector C e Set the tester to the DC 10V range and connect it to the auxiliary leads Hand Te
174. ize Make Type EUR Europe Model 100 kPa 1 0 kgf cm 14 psi 80 100 21 51M DUNLOP D739FA Tube EUR D755F J Tube D742F Tube other than EUR 100 90 19 57M DUNLOP D739 Tube EUR D755G Tube D756 Tube other than EUR 80 100 21 51M BRIDGESTONE EUR DUNLOP M601 Tube EUR D755FJ Tube 110 90 19 62M BRIDGESTONE EUR DUNLOP M602 Tube EUR D755J Tube WHEELS TIRES 9 5 Special Tool Inside Circlip Pliers Bearing Driver Set 57001 143 57001 1129 e i LA Rim Protector 57001 1063 57001 1238 Bead Breaker Assembly 57001 1072 9 6 WHEELS TIRES Wheels Rims Front Wheel Removal e Using the jack A under the frame and stabilize the mo torcycle Special Tool Jack 57001 1238 e Place a jack under the engine to raise the front wheel off the ground e For KX125 250 M1 model unscrew the guard screw A and remove the guard B e Unscrew the axle nut A e Loosen the left axle clamp bolts B e For KX125 250 M2 model as shown in the figure e Loosen the right axle clamp bolts A remove the axle B and pull out the wheel Take off the collar C and cap D from each side of the front hub CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so the disc does not touch the ground Y ELA Rf a o
175. juster A on the front fork top plugs with the blade of a screwdriver until you feel a click Adjust the rebound damping to suit you preference under special condition NOTE OThe left and right fork legs must have the same shock damping Seated positions adjuster turned fully clockwise A Rebound Damping Adjuster Setting Standard KX125 M1 13 clicks KX125 M2 14 clicks KX250 M1 13 clicks KX250 M2 14 clicks 6M04093BS1 6M04094BS1 Counterclockwise Clockwise Softer lt _ Harder 125 250 STD 16151413121110 9 wN toa a w Gef KX125 250 M1 Models 6M04095BS1 SUSPENSION 12 17 Front Fork Compression Damping Adjustment e Place the jack under the frame so that the front wheel off the ground A Special Tool Jack 57001 1238 e Clean the bottom of the fork tubes e Remove the caps on the bottom of the fork tubes e To adjust compression damping turn the adjuster A on the front fork cylinder valve with the blade of a screwdriver until you feel a click Adjust the compression damping to suit your preference under special condition da e 6M04008BS1 NOTE Counterclockwise Clockwise OThe left and right fork legs must have the same shock Softer Harder damping STD STD Seated positions adjuster turned fully clockwise A y e Put the caps into the bottom of the fork tubes 1615141312 1
176. ks dents bending or warp ing Alf there is any damage to the rim it must be replaced e Set a dial gauge against the side of the rim and rotate the rim to measure the axial runout A The difference be Dosen e tween the highest and lowest dial readings is the amount of runout e Set a dial gauge against the outer circumference of the rim and rotate the rim to measure radial runout B The difference between the highest and lowest dial readings is the amount of runout x If rim runout exceeds the service limit check the wheel bearings first Replace them if they are damaged If the problem is not due to the bearings correct the rim warp runout A certain amount of rim warp can be corrected by recentering the rim Loosen some spokes and tighten others within the standard torque to change the position of different parts of the rim If the rim is badly bent however it must be replaced Rim Runout with tire installed Standard Axial under 1 0 mm 0 04 in Radial under 1 0 mm 0 04 in Service Limit Axial 2 mm 0 08 in Radial 2 mm 0 08 in Wheel Bearing Inspection e Refer to the Hub Bearing Inspection in the Wheels Tires chapter 2 30 PERIODIC MAINTENANCE Periodic Maintenance Procedures Final Drive Drive Chain Slack Inspection e Raise the rear wheel off the ground rotate the rear wheel to find the place where the chain is tightest because it wears unevenly e Check the wheel alignment s
177. l Shift Shaft F Shift Mechanism Arm G gt Ratchet H Pawls I M in Ratchet Shift Drum Cam J Shift Forks Gears GBO6058B 3 A Top View F Top View K Gear Set Lever B Front G Shift Mechanism Arm L Return Spring Pin C Ratchet Plate H Ratchet M Lower Pawl D Shift Pedal Upper Pawls N Neutral Detent E Shift Drum J Shift Drum Cam O Return Spring 1 14 GENERAL INFORMATION Technical Information OThis mechanism operates as follows 1 Suppose the 1st gear position is set as shown Neutral Detent N 2 Shift Up for example shift from 1st to 2nd gt transmitting of shift force The shift pedal is lifted The arm G turns counter clockwise until it stops at pin L ratchet H lower pawl M shift drum cam J shift drum The gear is shifted in 2nd position 3 Ratchet Returns The arm G returns by force of spring O The ratchet H disengages to be free by itself The set lever K holds the shift drum cam J The ratchet H returns turns clockwise 4 The 2nd Gear Position settles The upper and lower pawls I M catch the next teeth inside the shift drum cam J The ratchet H settles in position The 2nd gear position settles 5 Shift Down for example shift from 2nd to 1st The shift pedal is depressed The arm G turns clock wise until it stops at the pin L ratchet H upper pawl I
178. lean lint free towel into the carburetor so no dirt is allowed to enter the carburetor e Wipe out the inside of the air cleaner housing with a clean damp towel CAUTION Check inside of the inlet tract and carburetor for dirt If dirt is present clean the intake tract and car buretor thoroughly You may also need to replace the element and seal the housing and inlet tract Element Installation e When installing the element coat the lip of the element with a thick layer of all purpose grease A to assure a complete seal against the air cleaner element base Also coat the base where the lip of the element fits e Apply grease to all connections and screw holes in the air cleaner housing and intake tract e Take out the towel from the carburetor securely 6007010351 C 3 22 FUEL SYSTEM Air Cleaner e Install the element so that its tab A faces upward and fit the element projections B to the holes of the housing C Element Cleaning and Inspection e Refer to the Air Cleaner Element Cleaning and Inspection in the Periodic Maintenance chapter FUEL SYSTEM 3 23 Fuel Tank Fuel Tank Removal Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove Radiator Shrouds Seat
179. link Length Standard Chain 52 62 mm 2 05 2 44 in 317 5 318 2 mm 12 50 12 53 in 323 mm 12 72 in Make DAIDO PTE Type D I D 520DMA2 se Length KX125 112 Links DAS KX250 114 Links ne Sprocket Rear Sprocket Warp Under 0 4 mm 0 016 in 0 5 mm 0 020 in FINAL DRIVE 10 5 Special Tools Outside Circlip Pliers Jack 57001 144 57001 1238 ST5701448T ST5712388ST 10 6 FINAL DRIVE Drive Chain Drive Chain Slack Inspection e Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter Drive Chain Slack Adjustment e Refer to the Drive Chain Slack Adjustment in the Periodic maintenance chapter Wheel Alignment Inspection e Check that the rear end A of the left chain adjuster aligns with the same swing arm mark B as the right chain ad juster A WARNING Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Wheel Alignment Adjustment This procedure is the same as Drive Chain Slack Adjust ment Drive Chain Wear Inspection e Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter Drive Chain Lubrication e Refer to the Drive Chain Lubrication in the Periodic Main tenance chapter Drive Chain Removal e Remove the engine sprocket cover e Remove the clip A from the master link using pliers and free the drive chain from the rear sprocket e Remove the
180. liquid gasket to the mating surface A of the crankcase half Sealant Kawasaki Bond Liquid Gasket Silver 92104 002 KX125 6104040BS1 6104042BS1 e Using a suitable tool on the left crankcase to press A around the hole for the crankshaft fit the crankcase halves together with a press on the tool NOTE OConstantly check the alignment of the two crankcase halves and the position of the transmission shafts and shift drum The front and rear of the crankcase must be pushed together evenly e Remove the crankshaft jig from the flywheels e Tighten the crankcase bolts starting with the ones around the crankshaft and then the farther ones OAt this time tighten the crankcase bolt A and clamp B for the breather hoses together Torque Crankcase Bolts 8 8 N m 0 9 kgf m 78 in lb e Check to see that the crankshaft drive shaft and output shaft all turn freely in the neutral position lf the crankshaft will not turn probably the crankshaft is not centered tap the appropriate end of the crankshaft with a mallet to reposition it e Spinning the output shaft shift the transmission through all the gears to make certain there is no binding and that all the gears shift properly e Install the parts removed in the reverse order of removal and refer to the appropriate chapters OReplace the O ring on the output shaft with a new one ENGINE BOTTOM END TRANSMISSION 8 13 Cranksha
181. moval Installation CAUTION Immediately wipe up any brake fluid that is spilled c 6L05002BS1 11 14 BRAKES Caliper Caliper Installation e Tighten the brake pad bolts if it was removed Torque Brake Pad Bolts 18 N m 1 8 kgf m 13 ft Ib Front Brake e Install the caliper and tighten the bolts Torque Caliper Mounting Bolts 25 N m 2 5 kgf m 18 0 ft lb Rear Brake e Before install the caliper install the rear wheel see Wheels Tires chapter e Install the brake hose lower end OReplace the washers that are on each side of hose fitting with new ones Torque Brake Hose Banjo Bolt 25 N m 2 5 kgf m 18 0 ft lb e Bleed the brake line see Bleeding the Brake Line e Check the brake for good braking power no brake drag and no fluid leakage A WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brakes will not function on the first appli cation of the lever or pedal if this is not done Caliper Disassembly e Remove the front rear caliper see Caliper removal e Remove the pads and spring see Pad Removal e Remove the caliper holder shaft rubber friction boot and cover e Using compressed air remove the piston s OCover the caliper opening with a clean heavy cloth A ORemove the piston s by lightly applying compressed air
182. move the secondary cup from the piston since removal will damage it Rear Master Cylinder Disassembly e Remove the rear master cylinder e Remove the reservoir cap and diaphragm and pour the brake fluid into a container e Slide the dust cover A on the push rod B out of place and remove the retainer C Special Tool Inside Circlip Pliers 57001 143 e Pull out the push rod with the piston stop D e Take off the piston E secondary cup F primary cup G and return spring H CAUTION Do not remove the secondary cup from the piston since removal will damage it GLO7010281 GLO7020BS2 C 11 20 BRAKES Master Cylinder Master Cylinder Assembly e Before assembly clean all parts including the master cylinder with brake fluid or alcohol e Apply brake fluid to the removed parts and to the inner wall of the cylinder CAUTION Except for the disc pads and disc use only disc brake fluid isopropyl alcohol or ethyl alcohol for cleaning brake parts Do not use any other fluid for cleaning these parts Gasoline engine oil or any other petroleum distillate will cause deterioration of the rubber parts Oil spilled on any part will be diffi cult to the wash off completely and will eventually deteriorate the rubber used in the disc brake e Take care not to scratch the piston or the inner wall of the cylinder e Tighten the brake lever pivot bolt and the locknut sec
183. n of the lever if this is not done 6J04049BS1 6y040101S1 6J04050BS1 9 8 WHEELS TIRES Wheels Rims Rear Wheel Removal e Using the jack under the frame so that the rear wheel is raised off the ground Special Tool Jack 57001 1238 e Remove the clip A from the master link using pliers and free the drive chain B from the rear sprocket e Remove Disc Cover A Cotter Pin B Axle Nut C e Pull out the axle D e Move the rear wheel back with the rear caliper installed e Take off the collar and cap from the each side of the rear hub CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so the disc does not touch the ground e Insert a wood wedge between the brake pads This pre vents them from being moved out of their proper position should the brake pedal be squeezed accidentally Rear Wheel Installation e Fit the brake holder stop A with the stop grooves B against the swingarm stop space C with the stop pro jection D Dy Geh Can PRIX IN NX Les 2 leet E LA Z de 6J04006BS1 6J04035BS1 WHEELS TIRES 9 9 Wheels Rims e Fit the projection on the cap to the groove on the collar e Install the collars A on the left and right side of the hub 6J04008BS1 e Install
184. nch Mark Red Panjab 6E07005BS1 6E07006BS1 ENGINE TOP END 5 23 Exhaust Valve KIPS e Insert the idle gear e Apply high temperature grease to the O ring e Mount the valve guides B D on the sub exhaust valves A and idle gear C e Apply a non permanent locking agent to the Allen bolt e Fix the main lever A to the main shaft B with the Allen bolt C e Tighten Torque Main Lever Mounting Allen Bolt 3 9 N m 0 4 kgf m 35 in Ib eCheck that the main exhaust valve assembly slide smoothly NOTE OWhen tighten the main lever mounting Allen bolt A main exhaust valve assembly B should be in fully closed position as shown 6E07004BS1 e For KX250 M2 model as shown in the figure e There are three checks to ensure the sub exhaust valves are in the correct position OWith the sub exhaust valves in the fully closed position the hole leading to the left side KIPS chamber is only partially open A 5 24 ENGINE TOP END Exhaust Valve KIPS OThe distance from the top of the operating rod collar to the cylinder should be 14 5 15 5 mm 0 57 0 61 in A Oln the fully open position with the main valve rod flush with the cylinder A the sub exhaust valves will be aligned B with the sub exhaust ports e Check that the sub exhaust valves operate smoothly e Install the operating rod retaining screw securely Torque Operating Rod
185. nder e Remove the E clip A and operating rod collar B from the operating rod e Remove the cylinder see Cylinder Removal e Turn the cylinder up side down e Remove the plug A and the gasket B at the left side of the cylinder e Pull out the operating rod A as far as it goes e Remove the operating rod retaining screw B e Remove the idle gear A e Lift up the exhaust valves B and remove the valve guides C e Lift up the exhaust valves and pull out the operating rod D Then take out the exhaust valves e Remove the main valve cover A main valve rod cover B and cylinder left cover C from the cylinder 5 18 ENGINE TOP END Exhaust Valve KIPS e Unscrew the Allen bolt A from the main lever B e Position the main exhaust valve full open and pull out the main shaft C e Set the main exhaust valve full closed position and re move the main lever with spring D e Pull out the main valve rod E from the cylinder e Unscrew the two main valve retaining bolts A and take out the main exhaust valve assembly B from the cylinder Exhaust Valve Installation KX125 Model e Scrape out any carbon and clean the valves with a high flash point solvent e Check the following for signs of damage Exhaust Valves Oil Seal Gaskets x If necessary replace them with new ones e Apply a 2 stroke engine oil to the operation parts e Apply a high temperature grease to the oil seal lip e Ins
186. nder valve assembly and gasket out of the bottom of the inner tube Special Tool Fork Cylinder Holder 57001 1413 GM04011381 o A Inner Tube B Cylinder Valve Assembly C O ring D Gasket 6M04021BS1 e Pull the cylinder unit A out the top of the inner tube NOTE ODo not disassembly the cylinder unit as the push rod and cylinder are consisted of as the single assembly 6M04107BS1 12 24 SUSPENSION Front Fork Cylinder Unit Removal KX125 250 M2 e Using the spanner wrench A loosen the guide stay nut B 6M04157BS1 EE 6M04158BS1 e Remove the split ring keeper A e Remove the guide stay nut B the guide stay nut C the oil lock piston D and the piston holder E e Clean the bottom of the inner tube e Remove the cap on the bottom of the inner tube e Hold he front fork horizontally in a vise e Stop the cylinder unit A from turning by using the fork cylinder holder B Unscrew the cylinder valve assembly C and take the cylinder valve assembly and gasket out of the bottom of the inner tube Special Tool Fork Cylinder Holder 57001 1573 6M04162BS1 A Inner Tube B Cylinder Valve Assembly C O ring D Gasket 6M04150BS1 e Pull the cylinder unit A out the top of the inner tube B 6M04161BS1 C SUSPENSION 12 25 Front Fork CAUTION Do not disassemble the air
187. ng the main air flow stable 6B06067Bw1 A Previous Carburetor B New Carburetor C Jet Needle D Air Baffle E Main Air F Needle Jet G Engine Intake Carburetor KX125M OThe 38 mm 1 496 in Mikuni TMX 38 27 carburetor helps boost mid range and top end power OThe arched slide A improves throttle response in the very low and low ranges OLarge bores in the front and back of the carburetor and a smoother shape 38 to 40 mm tapered bore B boost mixture flow for more mid range and top end power OThe semi air bleed needle jet C improves throttle re sponse in the low range and provides proper mixture from the low to top range Front D 6B06064BS2 C Oln low range fuel drops in the fuel air mixture is larger and tends to stick to the carburetor wall The arched slide deflects fuel air mixture flow from the wall to the middle of the carburetor for better atomization and better throttle response 1 20 GENERAL INFORMATION Technical Information GB06079B 1 A Previous Carburetor B New Carburetor C Flat Slide piston valve D Arched Shape Slide piston valve E Engine Intake OThe semi air bleed hole is positioned at the side of the needle jet where fuel mixes with air well due to enough fuel and faster air flow than in main bore resulting in better atomizing The air screen suppresses dynamic pressure around the main air inlet eege ISS NS
188. not use a damaged or partially collapsed blad der because it may burst gently reducing rear shock performance GMO5066BS1 e Apply grease to the lip B of the bladder and install the reservoir cap C e Push the bladder into the gas reservoir slowly until it just clears the circlip groove Wipe out any spilled oil CAUTION Ensure that no air remains in the system e Check the circlip for weakening deformity and flaws Alf necessary replace it with a new one CAUTION If weakened deformed or flawed circlip 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 e Mount the circlip A in the groove in the gas reservoir GMO5057BS1 12 38 SUSPENSION Rear Suspension Uni Trak e Pull up the gas reservoir cap A against the circlip The end of the gas reservoir cap must align C with the end of the gas reservoir B WARNING If the end of the gas reservoir cap and the end of the gas reservoir are not aligned the circlip is not correctly fitting in the groove in the gas reservoir or is deformed In this case the oil and internal parts could explode out of the reservoir when injecting the nitrogen gas or while riding the motorcycle GMO5011BS1 e Pour KYB K2 C SAE 5W or Bel Ray SE2 40 oil into the O rear shock body to 55 mm 1 77 in
189. ns on the motorcycle This prevents the engine from accidentally turning over while work is being carried out sparks from being generated while disconnecting the wires from electrical parts as well as damage to the electrical parts themselves For reinstallation first connect the positive wire to the positive terminal of the battery Installation Assembly Generally installation or assembly is the reverse of removal or disassembly However if instal lation or assembly sequence is given in this Service Manual follow it Note parts locations and cable wire and hose routing during removal or disassembly so they can be installed or assem bled in the same way It is preferable to mark and record the locations and routing whenever possible Tightening Sequence When installing bolts nuts or screws for which a tightening sequence is given in this Service Manual make sure to follow the sequence When installing a part with several bolts nuts or screws start them all in their holes and tighten them to a snug fit thus ensuring that the part has been installed in its proper location Then tighten them to the specified torque in the tightening sequence and method indicated If tightening sequence instructions are not given tighten them evenly in a cross pattern Conversely to remove a part first loosen all the bolts nuts or screws that are retaining the part a 1 4 turn before removing them Torque When torque values are given in this Servic
190. nsmission Transmission Oil Type API SE SF or SG API SH or SJ with JASO MA Viscosity SAE 10W 40 Capacity 0 7 L 0 74 US qt KX125 KX250 0 85 L 0 90 US qt EE Wheels Tires Rim Runout Axial Under 1 0 mm 0 04 in 2 mm 0 08 in Radial Under 1 0 mm 0 04 in 2 mm 0 08 in Final Drive Drive Chain Slack Drive Chain 20 Link Length 52 62 mm 2 05 2 44 in 317 5 318 2 mm 12 50 12 53 in 323 mm 12 72 in Rear Sprocket Warp Under 0 4 mm 0 016 in 0 5 mm 0 020 in Brakes Brake Lever Free Play Adjustable to suit rider Brake Fluid Type Front DOT3 or DOT4 Rear DOT4 Brake Pad Lining Thickness Front 3 8 mm 0 150 in 1 mm 0 04 in Rear 6 4 mm 0 252 in 1 mm 0 04 in Suspension Fork Oil Oil Viscosity KAYABA 01 or SAE OW Oil Capacity par unit KX125 M1 652 4 mL 22 04 0 14 US oz EE PERIODIC MAINTENANCE 2 11 Specifications Item Standard Service Limit KX250 M1 664 4 mL 22 45 0 14 US oz KX125 M2 565 4 mL 19 10 0 14 US oz KX250 M2 578 4 mL 19 54 0 14 US oz Oil Level fully compressed spring removed KX125 M1 KX250 M1 KX125 M2 KX250 M2 Electrical System Spark Plug Gap 135 2 mm 5 31 0 08 in 125 2 mm 4 92 0 08 in 105 2 mm 4 13 0 08 in 88 2 mm 3 46 0 08 in Adjustable range 100 145 mm 3 94 5 71 in 70 120 mm 2 76 4 72 in 0 7 0 8 mm 0 028 0 031 in 2 12
191. o the Spoke Tightness Inspection in the Periodic Maintenance chapter Rim Runout Inspection e Refer to the Rim Runout Inspection in the Periodic Main tenance chapter Axle Inspection e Visually inspect the front and rear axle for damages x lf the axle is damaged or bent replace it e Place the axle in V blocks that are 100 mm 3 937 in A apart and set a dial gauge on the axle at a point halfway between the blocks Turn the axle to measure the runout The difference between the highest and lowest dial read ings is the amount of runout Axle Runout 100 mm 3 937 in Standard Under 0 1 mm 0 004 in Service Limit 0 2 mm 0 008 in x If runout exceeds the service limit replace the axle 604010251 WHEELS TIRES 9 11 Tires Air Pressure Inspection Adjustment e Using tire air pressure gauge A measure the tire pres sure when the tires are cold Adjust the tire air pressure to suit track conditions and rider preference but do not stray too far from the recom mended pressure Track Condition Tire Pressure When the track is wet muddy sandy 80 kPa 0 8 kgf em or slippery reduce the tire pressure 11 psi to increase the tire tread surface on psi the ground T When the track is pebbly or hard increase the tire pressure to prevent 2 damage or punctures though the BEE kavom 14 psi tires will skid more easily Tires Inspection As the tire tread wears do
192. oil ground lead and magneto lead harness ground as figure Ignition Coil Ground Lead Air Vent Hose Clamp the clutch cable To the C D I Unit Clamps Install the magneto lead from this side To the Ignition coil To the Magneto Mating section on the clamp at outside KX125 M2 KX125 M3 Model 15 8 APPENDIX Cable Wire and Hose Routing KX250 Left Radiator Inside View 6B09337B 5 APPENDIX 15 9 Cable Wire and Hose Routing J O O1 P ND A Throttle Cable Clutch Cable Engine Stop Switch Lead Band Radiator Overflow Tube Right Screen Run the tube backward of the down tube Run the tube outside of the engine mount bracket Run the tube forward of the radiator connection pipe Left Screen Frame C D I Unit Run the throttle cable leftside of main harness Clamp the main harness and stop switch lead connector Regulator Rectifier Do not clamp the throttle cable Bands Main Harness Magneto Lead Connector Ignition Coil Ignition Coil Primary Winding Lead Ignition Coil Ground Lead Tighten together with the ignition coil lead ground and main harness ground Carburetor Lead Connector Carburetor Magneto Clamp the clutch cable Clamp the magneto lead Install the spark plug cap so that the high tension cable and spark plug cap do not touch the cooling hose Run the clutch cable
193. om the radiator and engine by removing the drain plug on the water pump cover and the cylinder KX250 Immediately wipe or wash out any coolant that spills on the frame engine or wheel e Inspect the old coolant for visual evidence of corrosion and abnormal smell see Coolant Deterioration Inspec tion Coolant Filling CAUTION Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufac ture s Soft or distilled water must be used with the antifreeze see below for antifreeze in the cooling system If hard water is used in the system it causes scale accumulation in the water passages and considerably reduces the efficiency of the cooling system Recommended Coolant Type Permanent type antifreeze soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators Color Green Mixed ratio Soft water 50 Coolant 50 Freezing 35 C 31 F point Total amount KX125 0 97 L 1 02 US qt KX250 1 20 L 1 27 US qt e Install the drain plug OReplace the gasket with a new one Torque Coolant Drain Plug on Water Pump Cover 8 8 N m 0 9 kgf m 78 in lb Coolant Drain Plug on Cylinder KX250 8 8 N m 0 9 kgf m 78 ft lb 6D05007BS1 6D05003BS1 PERIODIC MAINTENANCE 2 19 Periodic Maintenance Procedures e Fill the radiator up to the bottom of t
194. om the outer tube e Push the outer tube all the way down away from the top plug and hold it there throughout the following procedure OFor KX125 250 M1 model pull the fork spring A away from the top plug a little and slip the spanner wrench B in on top of the spring seat and under the push rod nut C e Use wrenches on the rod nut and the top plug A to loosen the push rod nut e Remove the top plug from the push rod e Lift the fork spring B and its top spring seat C out of the outer tube e For KX125 250 M2 model as shown in the figure e Take the rebound damping adjuster rod A out of the push rod 6M04100BS1 6M04148BS1 6M04109BS1 PERIODIC MAINTENANCE 2 39 Periodic Maintenance Procedures e Hold the fork tube A upside down over a clean container B and pump it to drain the oil NOTE OTo discharge the fork oil pump the push rod up C and down ten times 6M04015BS1 e Hold the fork tube upright press the outer tube and the push rod all the way down e Insertthe rebound damping adjuster rod into the push rod NOTE OThe spring should not be installed e Fill the specified oil to the outer tube Recommended Oil KAYABA 01 or SAE 5W 20 Front Fork Oil Capacity KX125 M1 652 4 mL 22 04 0 14 US oz KX125 M2 565 4 mL 19 10 0 14 US oz KX250 M1 664 4 mL 22 45 0 14 US oz KX250 M2 578 4 mL 19 54 0 14
195. on and pedal play should not be adjusted There is no pedal position adjustment device as such The only adjustment is master cylinder push rod length NOTE OUsually t is not necessary to adjust the push rod length but always adjust it when the rear master cylinder A is disassembled OWhen the brake pedal is in its rest position measure the length B indicated in the figure 6L04005BS1 B 79 3 mm 3 12 in 67 3 mm 2 65 in KX125 250 M2 C Push Rod Locknut x If the length is not within the specified length adjust the clevis A as follows OLoosen the push rod locknut B OPull out the cotter pin C and the joint pin D OTurn the clevis to obtain the specified length OTighten the locknut Torque Push Rod Locknut 18 N m 1 8 kgf m 13 0 ft lb Olnstall the joint pin and new cotter pin O NOTE 6L04060251 C Olf the pedal position is incorrect after adjusting the mas ter cylinder push rod the brake pedal may be deformed or incorrectly installed Brake Pedal Removal e Remove Cotter Pin A Joint Pin B Washer GLO4000BS1 BRAKES 11 9 Brake Lever Brake Pedal e Remove the mounting bolt A and take off the brake pedal and return spring B Brake Pedal Installation e Check the pedal O ring for signs of damage If necessary replace them with new one e Apply high temperature grease to the shaft portion of the brake pedal and install t
196. ont wheel pointing straight ahead alternately nudge each end of the handlebar The front wheel should swing fully left and right from the force of gravity until the fork hits the stop x If the steering binds or catches before the stop check the routing of the cables hoses and harnesses x lf the steering feels tight adjust or lubricate the steering e Feel for steering looseness by pushing and pulling the forks x If you feel looseness adjust the steering GNO4007BS1 e For KX125 250 M2 model as shown in the figure 6S15008BS1 Steering Adjustment e Using the jack raise the front wheel off the ground Special Tool Jack 57001 1238 2 42 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Loosen the front fork lower clamp bolts A e Remove Handlebar Clamp Bolts A Handlebar Clamp B Handle Bar C GNO4008BS1 e Loosen the front fork upper clamp bolts A and remove the steering stem head nut B and steering stem head C e Turn the steering stem locknut A with the steering stem nut wrench B to obtain the proper adjustment x If the steering is too tight loosen the stem locknut a frac tion of a turn if the steering is too loose tighten the lock nut a fraction of a turn Special Tool Steering Stem Nut Wrench 57001 1100 NOTE OTurn the locknut 1 8 turn at a time maximum e Install the steering stem head e Tighten the following
197. oo thin Spring weak or broken Front fork air pressure high Rear shock absorber noise Shock absorber damaged Disc brake noise Pad installed incorrectly Pad surface glazed Disc warped Caliper trouble Cylinder damaged Other noise Bracket nut bolt etc mounted or tightened not properly Exhaust Smoke Excessive white smoke Throttle cable maladjusted Brownish smoke Air cleaner clogged Main jet too large of fallen out Starter plunger stuck open Float level too high APPENDIX 15 5 Troubleshooting Guide Handling and or Stability Right left front fork oil level uneven Unsatisfactory Shock absorption unsatisfactory Handlebar hard to turn Too hard Control Cable routing incorrect Wiring routing incorrect Steering stem locknut too tight Bearing ball damaged Bearing race dented or worn Steering stem bearing lubrication inade quate Steering stem bent Tire air pressure too low Handlebar shakes or excessively vibrates Tire worn Swingarm sleeve or needle bearing dam aged Rim warped or not balanced Front rear axle runout excessive Wheel bearing worn Handlebar clamp loose Steering stem head nut loose Handlebar pulls to one side Frame bent Wheel misalignment Swingarm bent or twisted Swingarm pivot shaft runout excessive Steering maladjusted Steering stem bent Front fork leg bent Front fork oil excessive Front fork oil viscosity too high Front fork leg bent Front fork air pressure h
198. ool Hand Tester 57001 1394 x lf the reading is not specified value replace the regula tor rectifier Internal Resistance Unit O Tester Lead Terminal BK Y 500 5K 300 3K 500 50K 500 5K 500 5K 500 50K 500 5K BK Y 300 3K 200 20K 200 20K Tester Lead Connection CAUTION Use only Hand Tester 57001 1394 for this test An ohmmeter other than the Hand Tester may show different readings If a megger or a meter with a large capacity battery is used the regulator will be damaged 6P09037BS1 14 18 ELECTRICAL SYSTEM Ignition System Safety Instructions WARNING The ignition system produces extremely high volt age Do not touch the spark plug high tension coil or spark plug lead while the engine is running or you could receive a severe electrical shock Ignition Coil Removal e Remove Seat Radiator Shrouds Fuel Tank e Disconnect the ignition coil primary lead A e Pull the plug cap B off the spark plug e Unscrew the mounting bolts C and remove the ignition coil D Ignition Coil Inspection Measuring arcing distance The most accurate test for determining the condition of the ignition coil is made by measuring arcing distance using the coil tester for the 3 needle method e Remove the ignition coil e Connect the ignition coil with the spark plug cap left in stalled on the spark plug lead A
199. or KX125 250 M2 model note the following ORemove the tie rod rear mounting bolt A ORemove the tie rod front mounting bolt B and then take out tie rod C Tie Rod Installation e Apply plenty of grease to the inside of the needle bearings and oil seals e Be sure seated the washers to the rocker arm mating sur faces e Tighten the tie rod front and rear mounting nuts Torque Tie Rod Mounting Nuts 83 N m 8 5 kgf m 61 ft lb Rocker Arm Removal e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 e Loosen the swingarm pivot shaft nut e Remove the tie rod front mounting bolt A CAUTION When pulling out the mounting bolts lift the rear wheel slightly Forcing or tapping on bolt could damage the bolt sleeve and bearing e Remove the rear shock absorber lower mounting bolt B e Remove the rocker arm pivot shaft C e Remove the rocker arm D 12 44 SUSPENSION Tie Rod Rocker Arm e For KX125 250 M2 model note the following ORemove the tie rod rear mounting bolt A ORemove the rear shock absorber lower mounting bolt B ORemove the rocker arm pivot shaft C and then remove rocker arm D Rocker Arm Installation e Apply plenty of grease to the inside of the rocker arm holes needle bearings oil seals and grease seals out side of the sleeve e Be sure seated washers e Tighten the following Torque Rocker Arm
200. ot Shaft Nut 98 10 0 72 Rocker Arm Pivot Nut 83 8 5 61 Tie Rod Mounting Nut Front Rear 83 8 5 61 Rear Shock Absorber Mounting Nut Upper 5 Rear Shock Absorber Mounting Nut Lower 6 Pivot Shaft 7 Swingarm 8 Rocker Arm 9 Tie Rod 10 Rear Shock Absorber Cylinder 11 Bladder 12 Cap 13 Circlip 14 15 16 17 18 19 JO N 39 4 0 29 34 3 5 25 Valve Cap Locknut Adjusting Nut Spring Spring Guide Circlip 20 Piston Rod Assembly 21 Piston 22 O ring 23 Oil Seal 24 Stopper 25 Rear Shock Absorber G Apply grease 12 8 SUSPENSION Exploded View Wa ES e a KX125 250 M2 GMO2076BW5 SUSPENSION 12 9 Exploded View Torque No Fastener Nm kgfm Pe Remarks Swingarm Pivot Shaft Nut 98 10 0 72 Tie Rod Mounting Nut Front Rear 83 8 5 61 Rocker Arm Pivot Nut 83 8 5 61 Rear Shock Absorber Mounting Nut Upper 5 Rear Shock Absorber Mounting Nut Lower 6 Pivot Shaft 7 Swingarm 8 Rocker Arm 9 Tie Rod 10 Rear Shock Absorber Cylinder 11 Air Bleeder Bolt 12 O ring 13 Bladder 14 15 16 17 18 19 A JO N 39 4 0 29 34 3 5 25 Cap Circlip Valve Cap Locknut Adjusting Nut Spring 20 Spring Guide 21 Circlip 22 Piston Rod Assembly 23 Piston 24 O ring 25 Oil Seal 26 Stopper 27 Rear Shock Absorber G Apply grease L Apply a non permanen
201. over e Pull off the water pump shaft see Cooling System chap ter Exhaust Advancer Assembly Disassembly Assembly e The exhaust advancer assembly A consists of the fol lowing parts A Pins B Rod C Guide D O ring E Steel Balls F Holder G Needle Bearing H Spacer Collar J Spring K Gear e Check the exhaust advancer assembly parts for damage Any damaged parts should be replaced with new ones e When assembling apply molybdenum disulfide grease between the rod and inside outside diameter parts of the holder needle bearing and spacer Right Engine Cover Assembly e Apply high temperature grease to the oil seal lips before inserting the governor shaft lever e Apply molybdenum disulfide grease to the surface of the lever shaft and insert the governor shaft lever A into the right engine cover hole e Insert the positioning pin B into the hole then fit it to the grove C of the shaft e Tighten the governor shaft lever positioning plug screw D securely Torque Governor Shaft Lever Positioning Plug 0 6 N m 0 06 kgf m 5 in Ib e Install the dust cover GRO4005BS1 SS GRO4010181 GRO4006BS1 6 14 ENGINE RIGHT SIDE Right Engine Cover e Apply a non permanent locking agent to the threads of the advancer mounting Allen bolts e Tighten the advancer lever mounting Allen bolts A Torque Advancer Lever Mounting Allen Bolts 3 9 N m 0
202. pilled from the carburetor is hazardous OAdjust the following items if necessary Throttle Cable Idle Speed Fuel Inspection A WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light Kann Y SX A XXX 77 NE LULA GC060183S1 3 16 FUEL SYSTEM Carburetor e Turn the fuel tap to the OFF position e Remove the carburetor e Place a suitable container beneath the carburetor e Remove the drain plug A from the bottom of the float bowl and check for water or dirt in the fuel lf any water or dirt comes out clean the carburetor fuel tap and fuel tank see this chapter e Install the drain plug on the float bowl and tighten it se curely e Install the carburetor Carburetor Disassembly e Remove the carburetor e Unscrew the carburetor top cap screws KX125 or bolts KX250 A e Pull out the throttle valve assembly e Remove the throttle valve assembly A spring B re tainer C and carburetor cap from the carburetor cable lower end e Disassemble the throttle valve assembly connector A jet needle with circlip B and throttle valve C e Remove the choke knob starter plunger assembly A from the carburetor 6006017651 6006054BS1
203. raking power no brake drag and no fluid leakage A WARNING Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc The brake will not function on the first appli cation of the lever or pedal if this in not done BRAKES 11 13 Caliper Caliper Removal Front Brake e Loosen the banjo bolt A so as not to spill brake fluid e Remove the caliper mounting bolts B e Remove the banjo bolt and take off the brake hose from the caliper C e f the caliper is to be disassembled after removal and if compressed air is not available remove the piston using the following steps before disconnecting the brake hose from the caliper ORemove the pads OPump the brake lever to remove the piston e For KX125 250 M2 model as shown in the figure Rear Brake e Unbolt the guard bolts A and remove the rear caliper guard B e Loosen the banjo bolt C so as not to spill brake fluid e Loosen the brake pad bolt A and caliper holder shaft B before the caliper removal if the caliper is to be disassem bled NOTE Olf the caliper is to be disassembled after removal and compressed airis not available disassemble the caliper before brake hose removal see Caliper Disassembly e Remove the rear wheel see Wheels Tires chapter e Unscrew the banjo bolt and remove the brake hose C from the caliper see Brake Hose Re
204. ran M2 a 78 in Ib 7 Left Crankcase 8 Right Crankcase 9 Crankshaft Assembly 10 Flywheel Magneto 11 Stator 12 Drive Shaft 13 Output Shaft 14 Engine Sprocket 15 Shift Fork 16 Shift Rod 17 Shift Drum 18 Shift Drum Operating Cam 19 Shift Pedal 20 Shift Shaft M Apply molybdenum disulfide grease O Apply 2 stroke engine oil TO Apply transmission oil to the transmission gears and shift forks etc G Apply high temperature grease L Apply a non permanent locking agent LG Apply liquid gasket to the left and right case mating surface R Replacement parts 8 4 ENGINE BOTTOM END TRANSMISSION Exploded View KX250 6102033BW5 ENGINE BOTTOM END TRANSMISSION 8 5 Exploded View z 9 Torque Fast Remarks SE N m kgfm ft lb Crankcase Bolts 8 8 0 9 78 in lb Output Shaft Bearing Retaining Screws 5 4 0 55 48 in lb L Shift Drum Bearing Retaining Bolts 8 8 0 9 78 in lb Transmission Oil Drain Plug 20 2 0 14 5 Drive Shaft Bearing Retaining Bolts 8 8 0 9 78 in lb Flywheel Nut 78 8 0 58 Shift Drum Operating Cam Bolt 24 2 4 17 L ol 10 BR IN T NN aa 2 A 2 DOFOOOZX 2000X00Rhu0NnN O0o Left Crankcase Right Crankcase Crankshaft Assembly Stator Flywheel Magneto Drive Shaft Output Shaft Engine Sprocket Shift Fork Shift Rod Shift Drum Operating Cam Shift Drum Shift Pedal Sh
205. ree points B to the spline grooves to secure it in place CAUTION When staking the nut be careful not to apply shock to the shaft and bearings Such a shock could dam age the shaft and or bearings e Install the friction plates and steel plates starting with a friction plate and alternating them Finishing with a friction plate CAUTION If dry steel plates and friction plates are installed apply transmission oil to the surfaces of each plate to avoid clutch plate seizure e For KX125 the grooves A on the friction plate surfaces are cut tangentially and radially install the first and last friction plates B so that the grooves run toward the cen ter in the direction of the clutch housing rotation counter clockwise viewed from the engine right side e Apply molybdenum disulfide grease to the rubbing portion of the push rod holder e Tighten the clutch spring bolts fixing the flywheel with the special tool Torque Clutch Spring Bolts 8 8 N m 0 9 kgf m 78 in Ib Special Tool Flywheel Holder 57001 1313 GRO5010181 GRO5014BS1 ENGINE RIGHT SIDE 6 17 Clutch e For KX125 check the release shaft lever positions A ORemove the magneto cover OPushing the release shaft lever C lightly upward mea sure the distance between the release shaft lever and clutch cable set position of crankcase D View E Release Shaft Lever Position Standard
206. rely in the slot in the crank shaft before installing the stator plate e Apply silicone sealant around the circumference of the wiring grommet e Set the stator wiring grommet A securely in the notch B in the left crankshaft half and route the wires according to the Cable Harness Hose Routing section in the Ap pendix chapter e Install the stator plate and tighten it Torque Stator Plate Mounting Screws 4 4 N m 0 45 kgf m 39 in Ib e Holding the flywheel steady with the flywheel holder and tighten the flywheel bolt KX125 or nut KX250 Special Tool Flywheel amp Pulley Holder 57001 1605 Torque Flywheel Bolt KX125 22 N m 2 2 kgf m 16 ft lb Flywheel Nut KX250 78 N m 8 0 kgf m 58 ft lb 14 14 ELECTRICAL SYSTEM Flywheel Magneto e Measure the crankshaft sensor air gap A Clearance be tween the flywheel and the crankshaft sensor B core Crankshaft Sensor Air Gap Standard 0 63 0 67 mm 0 025 0 026 in x lf the gap is incorrect adjust it see this chapter e Replace the gasket with a new one e Connect the magneto lead connector to the C D I unit KX125 or main harness KX250 Flywheel Magneto Inspection e There are three types of magneto problems short open wire burned out or loss in flywheel magnetism A short or open in one of the coil wires will result in either a low output or no output at all A loss in flywheel magnetism which may be caused by d
207. ring NOTE OUse the flywheel amp pulley holder to prevent the crank shaft from the rotating Special Tool Flywheel amp Pulley Holder 57001 1605 e For KX250 remove the circlip A and take off the water pump drive gear B and primary gear C Special Toos Outside Circlip Pliers 57001 144 Primary Gear Installation KX125 e Instal the O ring e Fit the woodruff key B on the crankshaft groove e Install the spring washer so that concave side faces A inward e Tighten the primary gear nut Torque Primary Gear Nut 59 N m 6 0 kgf m 43 ft Ib NOTE OUse the flywheel amp pulley holder to prevent the crank shaft from the rotating Special Toos Flywheel amp Pulley Holder 57001 1605 KX250 e Install the primary gear A so that chamfered side B faces outward e Install the water pump drive gear C so that the cham fered side D faces outward e Replace the old circlip with a new one Special Toos Outside Circlip Pliers 57001 144 GROGOO2BS1 D Te GROGOO3BS1 GROGOO4BS1 ENGINE RIGHT SIDE 6 23 Kickstarter Kickshaft Removal e Remove Right Engine Cover Clutch Housing e Pull the end of the kick spring A out of the hole in the crankcase e Remove the kickstarter assembly B e Remove the bolts A take off the ratchet guide B Kickstarter Assembly Disassembly Assembly e The kickstarter assembly consists of the following par
208. ropping or hitting the flywheel by leaving it near an electromagnetic field or just by ag ing will result in low output e Check the magneto output voltage do the following pro cedures ODisconnect the magneto lead connector A MET P710003 P ELECTRICAL SYSTEM 14 15 Flywheel Magneto OComnect the auxiliary leads between the C D I unit A KX125 or main harness connector A KX250 and the magneto lead connector B OConnect the hand tester as shown in the table 1 OStart the engine ORun it at the rpm given in the table 1 ONote the voltage readings total 2 measurements Table 1 Magneto Output Voltage 1 KX125 Range Tester to Tester to 4 000 rpm 6P21004BS1 250 V AC White lead Red lead 80 V or more 2 KX250 Tester Connections Reading Range Tester to Tester to 4 000 rpm 250V AC White lead Red lead 59 V or more 50 V AC Moss Yellow lead 16 V or more dE x If the output voltage shows the value in the table the mag neto operates properly x If the output voltage shows a much higher than the value in the table the regulator rectifier is damaged A much lower reading than that given in the table indicates that the magneto is defective e To check the stator coil resistance as follows OStop the engine ODisconnect the auxiliary leads OComnect the hand tester as shown in the table 2 ONote the readings
209. sh the cool ing system If this accumulation is not removed it will clog up the water passages and considerably reduce the effi ciency of the cooling system e Drain the cooling system e Fill the cooling system with fresh water mixed with a flush ing compound CAUTION Avoid the use of a flushing compound which is harmful to the aluminum engine and radiator Carefully follow the instructions supplied by the manufacture of the cleaning product e Warm up the engine and run it at normal operating tem perature for about ten minutes e Stop the engine and drain the cooling system after the coolant cools down e Fill the system with fresh water e Warm up the engine and drain the system after the coolant cools down e Repeat the previous two steps once more e Fill the system with a permanent type coolant and bleed the air from the system see Air Bleeding 4 10 COOLING SYSTEM Disassembly and Assembly Precautions e Prior to disassembly of cooling system parts radiator pump etc wait until the coolant cools down and then drain the coolant e After assembling and filling the system with coolant bleed any air from the system COOLING SYSTEM 4 11 Water Pump Water Pump Cover Removal e Drain the coolant see Coolant Draining e Loosen the cooling hose clamps A and disconnect the cooling hoses on the water pump cover B e Unscrew the cover bolts C and remove the water pump cover
210. short the valve is defective and must be replaced Testing Fuel Cut Valve Standard Protrusion When battery is disconnected 19 4 19 6 mm 0 76 0 77 in When battery is connected 21 3 21 7 mm 0 84 0 85 in GP14005BS2 C APPENDIX 15 1 Appendix Table of Contents Troubleshooting Guide E ib 15 2 Cable Wire and Hose Routing ccccceecceeeeeeee ence cece ee ee ence rn rr rn 15 6 15 2 APPENDIX Troubleshooting Guide NOTE OThis is not an exhaustive list giving every possible cause for each problem listed It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties Engine Doesn t Start Starting Difficulty Engine won t turn over Cylinder piston seizure Crankshaft seizure Connecting rod small end seizure Connecting rod big end seizure Transmission gear or bearing seizure Kick shaft return spring broken Kick ratchet gear not engaging No fuel flow No fuel in tank Fuel tap turned off Tank cap air vent obstructed Fuel tap clogged Fuel line clogged Float valve clogged Fuel cut valve left close Engine flooded Float level too high Float valve worn or stuck open Starting technique faulty when flooded kick with the throttle fully open to allow more air to reach the engine No spark spark weak Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trou ble Spark plug cap not in good con
211. side down 300 mm 11 8 in Swingarm Uni trak 310 mm 12 2 in Single disc 113 mm 4 4 in 1 1 1 1 1 1 Swingarm New Uni trak lt GENERAL INFORMATION 1 9 General Specifications Items KX125 M1 KX125 M2 Effective Disc Diameter Front 220 mm 8 7 in 225 mm 8 9 in Rear 200 mm 7 9 in 215 mm 8 5 in Specifications are subject to change without notice and may not apply to every country EUR Europe Model 1 10 GENERAL INFORMATION General Specifications Items Dimensions Overall Length Overall Width Overall Height Wheelbase Road Clearance Seat Height Dry Mass Curb Mass Front Rear Fuel tank Capacity Engine Type Cooling System Bore and Stroke Displacement Compression Ratio Low Speed High Speed Maximum Horsepower Maximum Torque Carburetion System Starting System Ignition System Ignition Timing Spark Plug Port Timing Inlet Open Close Scavenging Open Close Exhaust Open Close Lubrication System Gasoline Oil KX250 M1 2 175 mm 85 6 in 825 mm 32 5 in 1 205 mm 47 4 in 1 480 mm 58 3 in 355 mm 14 0 in 945 mm 37 2 in 97 kg 214 lb 50 kg 110 Ib 51 kg 112 lb 8 2 L 2 2 US gal 2 stroke single cylinder piston reed valve Liquid cooled 66 4 x 72 0 mm 2 61 x 2 85 in 249 mL 15 25 cu in 10 1 1 8 6 1 41 1 KW 56 5 PS 8 500 r min rpm 51 0 N m 5 2 kgf m 37
212. sition D Low Speed Position E Straightened Exhaust Passage OThe KX250 s governor inside is changed from straight to concave in order to move the balls smoothly Previous Governor A New Governor B operate over a wider rpm range to improve low and mid OThe KIPS governor is modified so that the exhaust valves range power and smooth the power delivery Carburetor KX250M OThe 38 7 mm 1 524 in Keihin PWK 38S carburetor helps boost mid range and top end power 1 18 GENERAL INFORMATION Technical Information OThe crescent shaped slide A enables the needle to sit closer to the intake ports for quicker throttle response OLarge bores in the front and back of the carburetor and a smoother shape 38 to 40 mm tapered bore B boost mixture flow for more mid range and top end power OThe semi air bleed needle jet C improves throttle re sponse in the very low and low range Front D 6B06063BS2 C OThe air baffle forms vacuum the stop narrows the outlet and speeds up outflow from the needle jet improving atomization ZN 6B06068BW2 Fuel Droplets Eos Fuel Mist A Previous Carburetor B New Carburetor C Jet Needle D Air Baffle E Needle Jet F Stop G Engine Intake GENERAL INFORMATION 1 19 Technical Information H Main Air OThe new main air inlet tends to take in static pressure and to exclude dynamic pressure and vor texes maki
213. spread its ends GKO4010BS1 GKO4030BS1 GKO4001BS1 PERIODIC MAINTENANCE 2 31 Periodic Maintenance Procedures NOTE OWhen inserting the cotter pin if the slots in the nut do not align with the cotter pin hole in the axle shaft tighten the nut clockwise A up to next alignment Olt should be within 30 degree OLoosen once tighten again when the slot goes past the nearest hole GJ04034BS1 A WARNING If the axle nut is not securely tightened or the cotter pin is not installed an unsafe riding condition may result e Check the rear brake see Brakes chapter NOTE Oln wet and muddy conditions mud sticks to the chain and sprockets resulting in an overly tight chain and the chain may break To prevent this adjust the chain to 62 72 mm 2 44 2 83 in of slack whenever necessary Drive Chain Wear Inspection e Rotate the rear wheel to inspect the drive chain for dam aged rollers and loose pins and links x If there is any irregularity replace the drive chain A Lubricate the drive chain if it appears dry A Bushing B Roller C Pin D Pin Link E Roller Link SE 2 32 PERIODIC MAINTENANCE Periodic Maintenance Procedures e Stretch the chain taut by hanging a 98 N 10 kgf 20 Ib weight A on the chain e Measure the length of 20 links B on the straight part C of the chain from the pin center ofthe 1st pin to the pin cent
214. stall the drain plug on the bottom of the float bowl Service Fuel Level Adjustment WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Always stop the engine and do not smoke Make sure the area is well ventilated and free from any source of flame or sparks this includes any appliance with a pilot light e Remove the carburetor and drain the fuel into a suitable container e Remove the float bowl KX125 e Unscrew the pivot pin screw A and remove the float B GC060191S1 FUEL SYSTEM 3 13 Carburetor KX250 e Drive out the pivot pin A and remove the float B yer GC060179S1 e Bend the tang A on the float arm very slightly to change the float height Increasing the float height lowers the fuel level and decreasing the float height raises the fuel level Float Height Standard 9 5 1 mm 0 374 0 039 in KX125 6 5 1 mm 0 256 0 039 in KX250 6006017551 NOTE OFloat height A is the distance from the float bowl mat ing surface B of the carburetor body with the gasket removed to the top of the float C Measure the height with the carburetor upside down ODo not push the needle rod D in during the float height measurement 6C06056BS1 e Assemble the carburetor and recheck the fuel level Alf the fuel level cannot be adjusted by this method the float or the float valve is dam
215. stall the steering stem and adjust the steering see Steering Stem Stem Bearing Installation Steering Ad justment in Steering chapter Electrical System Spark Plug Cleaning and Inspection e Remove the spark plug and visually inspect it e Clean the spark plug preferably in a sandblasting device and then clean off any abrasive particles The plug may also be cleaned using a high flash point solvent and a wire brush or other suitable tool x lf the spark plug electrodes are corroded or damaged or if the insulator is cracked replace the plug Use the standard spark plug Spark Plug Gap Inspection e Measure the gap A with a wire type thickness gauge x lf the gap is incorrect carefully bend the side electrode B with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 7 0 8 mm 0 028 0 031 in GNO4009BS1 GNO4004BS1 DEER Mii ERRATA DSS Y N LL SIS GP100108S1 2 44 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication Lubrication e Before lubricating each part clean off any rusty spots with rust remover and wipe off any grease oil dirt or grime e Lubricate the points listed below with indicated lubricant NOTE OWhenever the vehicle has been operated under wet or rainy conditions or especially after using a high pressure water spray perform the general lubri cation Pivo
216. stallation chapter e Set the engine on a clean surface while parts are being removed e Remove Magneto Cover Cylinder Head see Engine Top End chapter Cylinder see Engine Top End chapter Piston see Engine Top End chapter Right Engine Cover see Engine Right Side chapter Clutch see Engine Right Side chapter Primary Gear see Engine Right Side chapter Kickstarter Assembly see Engine Right Side chapter Kickstarter Idle Gear see Engine Right Side chapter External Shift Mechanism see Engine Right Side chap ter Shift Ratchet Assembly see Engine Right Side chapter Gear Set Lever A Shift Drum Operating Cam B Output Shaft Sleeve C and O ring D KX250 O rings Flywheel Magneto and Stator see Electrical System chapter Reed Valve KX125 see Fuel System chapter 6104015BS1 e Remove the crankcase bolts A e Install the crankcase splitting tool A and bearing puller adapter B into the left side of the crankcase Be certain to screw the tool in all the way Special Tools Crankcase Splitting Tool Assembly 57001 1098 Bearing Puller Adapter 57001 136 e Tighten the bolt on the crankcase splitting tool to split the crankcase halves e Once the crankcase is split remove the crankcase split ting tool and lift off the left crankcase half 6104060281 8 10 ENGINE BOTTOM END TRANSMISSION Crankcase e Pull out the shift rods A 3 e Disengage the shift fork
217. ster Red Green Lead Hand Tester Black Green Lead e Start the engine e Check the sensor input voltage with the engine running Throttle Sensor Input Voltage Standard 4 V or above x lf it is not within the specified voltage range check the magneto output voltage If it has normal functions re place the C D I Unit e To check the output voltage do the following procedures OUsing the auxiliary leads A connect the hand tester B as follows Hand Tester White Black Lead Hand Tester Black Green Lead ORemove the spark plug OCrank the engine by kicking the pedal several times to measure the throttle sensor output voltage with the throt tle valve completely closed Throttle Sensor Output Voltage 0 4 0 6 V when throttle valve is Standard completely closed x lf it is not within the specified voltage range adjust the throttle sensor position see Throttle Sensor Position Ad justment x If it is within specified voltage go to next test OCrank the engine by kicking the pedal several times to measure the throttle sensor output voltage with the throt tle fully opened Throttle Sensor Output Voltage when the throttle fully opened Standard 3 5 3 7 V x If it is not within the specified voltage replace the throttle sensor ELECTRICAL SYSTEM 14 25 Ignition System Engine Stop Switch Electric Current Check e Disconnect the engine stop switch lead e S
218. stment Adjusting nut position A from the center of the mounting hole Standard KX125 M1 112 mm 4 41 in KX125 M2 111 mm 4 37 in KX250 M1 117 mm 4 61 in KX250 M2 112 mm 4 41 in Adjustable Range KX125 109 127 5 mm 4 29 5 02 in KX250 109 129 5 mm 4 29 5 10 in e Tighten the locknut securely e After adjusting move the spring up and down to make sure that the spring is seated e Install the parts removed e Tighten the rear frame mounting bolts Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib GMO5060BS1 Spring Tension e Since the spring becomes shorter as it weakens check its free length A to determine its condition Alf the spring of either rear shock absorber is shorter than the service limit it must be replaced If the length of re placement spring and that of the remaining spring vary greatly the remaining spring should also be replaced in order to keep the rear shock absorbers balanced of mo torcycle stability GM040116S1 Shock Absorber Spring Free Length Standard 260 mm 10 24 in Service Limit 255 mm 10 04 in Rear Shock Absorber Removal e Remove Seat Side Covers Silencer Rear Frame with Air Cleaner Housing e Using the jack under the frame raise the rear wheel off the ground Special Tool Jack 57001 1238 12 34 SUSPENSION Rear Suspension Uni Trak e Remove the tie rod front mounting bolt A CAUT
219. ston Diameter Measurement e Referto the Piston Diameter Measurement in the Periodic Maintenance chapter Piston Cylinder Clearance e Refer to the Piston Cylinder Clearance in the Periodic Maintenance chapter Piston Ring Piston Ring Groove Inspection e Refer to the Piston Ring Piston Ring Groove Inspection in the Periodic Maintenance chapter Piston Ring End Gap Inspection e Refer to the Piston Ring End Gap Inspection in the Peri odic Maintenance chapter Piston Piston Pin Connecting Rod Wear Inspection e Refer to the Piston Piston Pin Connecting Rod Wear Inspection in the Periodic Maintenance chapter 5 16 ENGINE TOP END Exhaust Valve KIPS Exhaust Valve Removal KX125 Model e Drain the coolant e Remove Radiator see Cooling System chapter Muffler see Muffler Removal KIPS Cover see Engine Right Side chapter Bolt A Governor Shaft Lever B 6E06002BS1 e Remove Cylinder see Cylinder Removal Main Valve Cover Bolts A Main Valve Cover B Stopper Pin Screw A and Stopper Pin B Allen Bolt C e Pull out the main exhaust valve shaft A and remove the main lever B with spring C e Remove the exhaust valve retaining bolts A e Pull out the exhaust valves B ENGINE TOP END 5 17 Exhaust Valve KIPS Exhaust Valve Removal KX250 Model e Remove Carburetor see Fuel System chapter Cylinder Head see Cylinder Head Removal e Remove the KIPS cover at the cyli
220. t 6J04037BS1 GJ04064BS1 WHEELS TIRES 9 7 Wheels Rims e For KX125 250 M2 model as shown in the figure e Insert a wood wedge between the disc brake pads this prevents them from being moved out of their proper posi tion should the brake lever be squeezed accidentally Front Wheel Installation e Apply grease to the seals e Fit the projection on the cap to the groove on the collar e Install the caps B collars A on the left longer collar and right shorter collar side of the hub e Insert the axle C from right side e Unbolt the right axle clamp bolts D temporally e Tighten the axle nut E Torque Front Axle 78 N m 8 0 kgf m 58 ft Ib e Remove the jack Push and release the handlebars five times or more apply the front brake to move the front forks so that the axle shaft has a snug fit with the axle holder e Tighten the left axle clamp bolts F first and tighten the right axle clamp bolts Torque Front Axle Clamp Bolts 20 N m 2 0 kgf m 14 5 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e For KX125 250 M2 model as shown in the figure e Check the front brake for good braking power and no brake drag A WARNING Do not attempt to drive the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc The brake will not function on the first applicatio
221. t deteri orated or contaminated transmission oil will accelerated wear and may result in transmission seizure and injury 2 28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Transmission Oil Level Inspection e Situate the motorcycle so that it is perpendicular to the ground e f the motorcycle has just been used wait several minutes until the oil settles e Check that the oil level comes up between the upper level A and lower level B through the oil level gauge C on the clutch cover x If the oil level is too high remove the excess oil through the oil filler opening using a syringe or some other suitable device x lf the oil level is too low add the correct amount of oil Use the same type and make of oil that is already in the engine 6117000BS1 NOTE Olf the transmission oil type and make are unknown use any brand of the specified oil to top up the level in pref erence to running the engine with the oil level low Then at your earliest convenience change the oil completely Transmission Oil Change e Warm up the engine thoroughly so that the oil will pick up any sediment and drain easily Then stop the engine e Place an oil pan beneath the engine e Remove the transmission oil drain plug A on the bottom of the engine and let the oil drain completely NOTE OHold the motorcycle upright so that the oil may drain completely e Replace the gasket at the drain plug with
222. t come out fully by spring tension re place the valve needle Push and release E e Remove the slow jet e Check the slow jet for any damage x If the slow jet is damaged replace it with a new one e Remove the throttle valve and jet needle e Inspect the outside of the throttle valve for scratches and abnormal wear x If it is badly scratched or worn replace the throttle valve e Inspect the inside of the carburetor body for these same faults x lf it is badly scratched or worn replace the entire carbu retor e Check the jet needle for wear Xx A worn jet needle should be replaced e Clean the fuel and air passages with a high flash point solvent and compressed air 0 To aN i REMERA E wg KANSAS N Ciy LJ ae oy O 6c060184S1 GC060119S1 C 6006014351 C FUEL SYSTEM 3 21 Air Cleaner Housing Removal e Remove Side Covers Seat Silencer see Engine Top End chapter Bolts and Rear Fender A Screws and Rear Flap B Rear Frame Bolts C e Loosen the air cleaner duct clamp D e Remove the air cleaner housing E Air Cleaner Housing Installation e Installation is the reverse of the removal e Tighten the rear frame mounting bolts A Torque Rear Frame Mounting Bolts 34 N m 3 5 kgf m 25 ft Ib Element Removal e Remove the seat e Remove the wing bolt A and pull out the element B e Stuff a c
223. t lb e Using the 14 mm 0 56 in spanner wrench A install the governor shaft lever B as shown e Tighten Torque Governor Shaft Lever Mounting Bolt C 6 9 N m 0 7 kgf m 61 in Ib e Install the KIPS cover e Tighten Torque KIPS Cover Bolts 4 9 N m 0 5 kgf m 43 in Ib KX125 M2 8 8 N m 0 9 kgf m 78 in Ib e Install the removal parts Exhaust Valve Installation KX250 Model e Remove any carbon and clean the valves with a high flash point solvent e Check the following for signs of damage Exhaust Valves Valve Operating Rod Oil Seal on Rod Seal Plug O rings Gaskets lf necessary replace damaged or worn items with new ones e Check the gasket on the left plug for signs of damage x If necessary replace it with new one e Install the operating rod left side plug on the cylinder Torque Operating Rod Left Side Plug 22 N m 2 2 kgf m 16 0 ft Ib e Apply a 2 stroke engine oil to the following Valve Guides inside Valve Operating Rod Journals Valve Operating Rod Rack Main Exhaust Valve Parts e Apply a high temperature grease to the oil seal lip on the operating rod e Set up the main exhaust valve assembly as shown Slide Valve A Valve Holder B e Check the slide valve move smoothly ENGINE TOP END 5 21 Exhaust Valve KIPS e For KX250 M2 model note the following OApply a 2 stroke engine oil to the main exhaust valve A e Insert the main exhaust valve assembly A into the
224. t locking agent to the threads 12 10 SUSPENSION Specifications KX125 250 M1 em Standard Service Limit Front Fork Air Pressure Atmospheric pressure Rebound Damping Adjustment Adjustable Range from the seated position adjuster turned fully clockwise Compression Damping Adjustment from the seated position adjuster turned fully clockwise 13 clicks counterclockwise 16 clicks Adjustable Range KX125 14 clicks counterclockwise 16 clicks KX250 13 clicks counterclockwise Oil Viscosity KAYABA 01 or SAE 5W 20 Oil Capacity KX125 652 4 mL 22 04 0 14 US oz KX250 664 4 mL 22 45 0 14 US oz Oil Level fully compressed spring Adjustable Range removed KX125 135 2 mm 5 31 0 08 in 100 145 mm from top of outer tube 3 94 5 71 in KX250 125 2 mm 4 92 0 08 in from top of outer tube Fork Spring Free Length 460 mm 18 11 in 450 mm 17 72 in Rear Suspension Uni Trak Rear Shock Absorber Rebound Damping Adjustment from the seated position adjuster fully clockwise Turned KX125 12 clicks counterclockwise 16 clicks KX250 10 clicks counterclockwise Spring Preload Adjustment Adjusting nut position from the center of the mounting hole upper Adjustable Range Adjustable Range KX125 112 mm 4 41 in 109 127 5 mm 4 29 5 02 in KX250 117 mm 4 61 in 109 129 5 mm 4 29 5 10 in Rear Shock Spring Free Length 260 mm 10 24 in 255 mm 10 04 in Gas
225. tact Spark plug incorrect C D I Unit trouble Ignition coil trouble Ignition coil resistor open Flywheel magneto damaged Wiring shorted or open Fuel air mixture incorrect Idle adjusting screw maladjusted Slow jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter jet clogged Compression Low Spark plug loose Cylinder head not sufficiently tightened down Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring groove clearance excessive Cylinder head gasket damaged Cylinder head warped Cylinder base gasket damaged Read valve damaged Cylinder nut loose Poor Running at Low Speed Spark weak Spark plug dirty broken or maladjusted Spark plug cap or high tension wiring trou ble Spark plug cap shorted or not in good con tact Spark plug incorrect C D I Unit trouble Ignition coil trouble Flywheel magneto damaged Ignition coil lead or C D I Unit lead not in good contact Fuel air mixture incorrect Idle adjusting screw maladjusted Slow jet or air passage clogged Air cleaner clogged poorly sealed or miss ing Starter plunger stuck open Float level too high or too low Fuel tank air vent obstructed Fuel cut valve won t fully open Carburetor holder loose Air cleaner duct loose Compression Low Spark plug loose Cylinder head not sufficiently tightened down Cylinder piston worn Piston ring bad worn weak broken or sticking Piston ring
226. tall in order these parts on the inner tube GM040115S1 e When assembling the new outer tube guide bush A hold the washer against the new one and tap the washer with the fork oil seal driver B until it stops Special Tool Fork Oil Seal Driver 648 57001 1509 e After installing the washer install the oil seal by using the fork oil seal driver Special Tool Fork Oil Seal Driver 648 57001 1509 e Install the retaining ring to the outer tube e Push the dust seal into the outer tube and put the spring band on the dust seal GM040420S1 SUSPENSION 12 27 Front Fork Install Inner Cylinder KX125 250 M1 e Install the cylinder unit e Check the O ring A on the cylinder valve assembly B and replace it with a new one e Replace the gasket C with a new one e Apply a non permanent locking agent to the threads D of the cylinder valve assembly and screw the valve assem bly into the bottom of the inner tube e Hold the cylinder unit with the fork cylinder holder and tighten the cylinder valve assembly Special Tool Fork Cylinder Holder 57001 1413 Torque Cylinder Valve Assembly 54 N m 5 5 kgf m 40 ft lb Install Inner Cylinder KX125 250 M2 e Install the cylinder unit e Check the O ring A on the cylinder valve assembly B and replace it with a new one e Replace the gasket C with a new one e Apply a non permanent locking agent to the threads D of the cyl
227. tallation 6113006BS1 Shaft Disassembly e Remove the transmission shafts see Shaft Removal e Using circlip pliers to remove the circlips disassemble the transmission shaft Special Tool Outside Circlip Pliers 57001 144 Shaft Assembly e Apply transmission oil liberally to the transmission shaft gears and bearings e Replace any circlips that were removed with new ones OAlways install circlips A so that the opening B is aligned with a spline groove C Special Tool Outside Circlip Pliers 57001 144 6113011351 e The drive shaft gears can be identified by size the smallest diameter gear is 1st gear and the largest is 5th KX250 or 6th KX125 Be sure that all parts are put back in the correct sequence and facing the proper di rection and that all circlips and the washers are properly in place KX125 A 1st gear 13T part of drive shaft B 5th gear 24T plain side faces right EEN C 3rd 4th gear 17T 17T larger gear faces right D 6th gear 25T plain side faces left E 2nd gear 14T stepped side faces left F Circlip ENGINE BOTTOM END TRANSMISSION 8 17 Transmission KX250 KX250 A 1st gear 15T part of drive shaft a0 B 5th gear 23T dog recesses face left C 3rd gear 17T fork groove goes to the left side of the gear teeth D 4th gear 21T dog recesses face right E 2nd gear 16T chamfered side faces right F
228. tart the engine e Ground the stop switch lead of the main harness side while the engine is running x If does not stop the engine replace the C D I Unit Crankshaft Sensor Inspection e Remove Magneto Lead Connector see Flywheel Magneto In spection e Set the hand tester A to the x 1000 range and connect it to the Green White B and White Yellow C Leads in the connector Special Tool Hand Tester 57001 1394 Alf there is more resistance than the specified value the coil has an open lead and must be replaced Much less than this resistance means the coil is shorted and must be replaced Crankshaft Sensor Resistance 180 280 Q e Using the highest resistance range of the tester measure the resistance between the crankshaft sensor leads and chassis ground A Any tester reading less than infinity indicates a short necessities replacement of the crankshaft sensor assem bly Crankshaft Sensor Air Gap Adjustment e Loosen the crankshaft sensor screws A e Insert a 0 65 mm 0 026 in thickness gauge B between the crankshaft sensor core and the timing plat e While pressing the crankshaft sensor toward the magneto flywheel tighten the coil screws and remove the thickness gauge e Check the air gap see Flywheel Magneto Installation x lf the air gap is not within the specified range readjust the gap GP10011481 O ZN 010181 14 26 ELECTRICAL SYSTEM T
229. terioration Inspection e Refer to the Coolant Deterioration Inspection in the Peri odic Maintenance chapter Coolant Draining e Refer to the Coolant Draining in the Periodic Maintenance chapter Coolant Filling e Refer to the Coolant Filling in the Periodic Maintenance chapter Air Bleeding e Refer to the Air Bleeding in the Periodic Maintenance chapter Cooling System Pressure Testing CAUTION During pressure testing do not exceed the pres sure for which the system is designed to work The maximum pressure is 123 kPa 1 25 kgf cm 18 psi e Remove the radiator cap and install a cooling system pressure tester A and adapter B on the radiator filler neck C NOTE OWet the adapter cap sealing surfaces with water or coolant to prevent pressure leaks e Build up pressure in the system carefully until the pres sure reaches 123 kPa 1 25 kgf cm 18 psi e Watch the gauge for at least 6 seconds If the pressure holds steady the cooling system is all right e Remove the pressure tester replenish the coolant and install the radiator cap x lf the pressure drops and no external source is found check for internal leaks Check the cylinder head gasket for leaks GD05060281 COOLING SYSTEM 4 9 Coolant Cooling System Flushing Over a period of time the cooling system accumulates rust scale and lime in the water jacket and radiator When this accumulation is suspected or observed flu
230. the difference between the two values Measure the piston diameter as just described and measure the cylinder diameter at the very bottom of the cylinder Piston Cylinder Clearance Standard KX125 0 040 0 070 mm 0 0016 0 0028 in KX250 0 049 0 079 mm 0 0023 0 0031 in 2 22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Piston Ring Piston Ring Groove Inspection e Visually inspect the piston rings and the piston ring grooves x If the rings are worn unevenly or damaged they must be replaced x If the piston ring grooves are worn unevenly or damaged the piston must be replaced and fitted with new rings e Check for uneven groove wear by inspecting the ring seat ing e The rings should fit perfectly parallel to the groove sur faces If not the piston must be replaced e With the piston ring in its groove make several mea surements with a thickness gauge A to determine piston ring groove clearance x lf the clearance exceeds the service limit measure the thickness of the piston ring x If the ring has worn down to less than the service limit replace the ring if the groove width exceeds the service limit replace the piston Piston Ring Groove Clearance KX125 Standard Ka 0 050 mm 0 0006 0 0020 Service Limit 0 15 mm 0 0059 in KX250 Standard 0 025 0 060 mm 0 0010 0 0024 in Service Limit 0 16 mm 0 006 in Piston Ring Thickness KX125 Standard 0 980 0 995 mm
231. ther hose being careful to follow the performed bends see Appendix chapter Avoid sharp bending kinking flattening or twisting e Tighten the hose clamps securely Torque Cooling Hose Clamp Screws 1 5 N m 0 15 kgf m 13 in lb 6D07000BS1 6D07001BS1 GD07060281 ENGINE TOP END 5 1 Engine Top End Table of Contents Exploded VIS Wii A A M En A 5 2 SPECITICATIONS viii a a ideas 5 6 Special NL EE 5 8 A EE 5 9 Cylinder Compression Measurement 5 9 Cylinder Head Removal ui la illa 5 9 Cylinder Head InstallatiON vecindad ro 5 10 Cylinder Head Warp Inspection cccccccccceccceecceeeeceeceeeeceeeceececeeeceeeseceeeseeeeeeeseeeeeeeeeess 5 10 A ON 5 11 Cyinder Removal A A A A Aa 5 11 Cylinder Een EE 5 12 PISTON ReMOVAl a A A A AAA 5 13 Piston Nee EE 5 13 Cylinder Wear Inspection ccoo ios 5 14 Pist n Diameter Measurement Mis 5 15 Piston Cylinder Clearance viciado s 5 15 Piston Ring Piston Ring Groove Inspection 4 5 15 Piston Ring End Gap Inspection 5 15 Piston Piston Pin Connecting Rod Wear Inspection 5 15 Ex haustVale KIPS ea ne D EE 5 16 Exhaust Valve Removal KX125 Model 5 16 Exhaust Valve Removal KX250 Model 5 17 Exhaust Valve Installation KX125 Model 5 18 Exhaust Valve Installation KX250 Model 5 20 Muffler Expansion Chamber Silencer sn 5 25
232. through the clamps Mating section on the clamp at outside KX250 M2 15 10 APPENDIX Cable Wire and Hose Routing KX125 O D NO Es A NES nN Gs LE AE NN CH SS Clamps Left Radiator Right Radiator To the steering stem hole Air Vent Hose To the fuel tank cap Radiator Overflow Tube Run the radiator over flow tube outside of the engine mount bracket Carburetor Clamp 6B09602BW4 Run the air vent hoses and overflow tube through the clamp Air Vent Hoses Over Flow Tube Cooling Hose Install the fuel hose between the vent hoses Run the radiator over flow tube between frame and right radiator Pay attention to inflection of the radiator over flow tube APPENDIX 15 11 Cable Wire and Hose Routing KX250 CH saan l 3 the engine mount bracket Carburetor lt gt O SE e DIT GB09604BW4 1 Clamps 11 Clamp the air vent hoses with clamps 2 Left Radiator which are installed together with engine 3 Right Radiator sprocket cover and run them along with 4 To the steering stem hole the engine sprocket cover 5 Air Vent Hose 12 Clamps 6 To the fuel tank cap 13 Air Vent Hoses 7 Band 14 Run the radiator over flow tube between 8 Carburetor Lead Connector frame and right radiator 9 Run the radiator overflow tube outside of 15 Pay attention to inflaction of the radiator over flo
233. ting bolt A e Connect the carburetor lead connector with the battery variable rheostat and handtesters in the same manner as specified in the throttle sensor Inspection e Adjust the position of the sensor until the output voltage is within the specified voltage range Throttle Sensor Output Voltage Standard 0 4 0 6 V when throttle valve is completely closed e If it is not within the specified voltage range replace the sensor GP25002BS2 C 6P25001BS1 ELECTRICAL SYSTEM 14 27 Fuel Cut Valve Fuel Cut Valve Removal KX250 WARNING Gasoline is extremely flammable and can be ex plosive under certain conditions Turn 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 6P14004BS1 e Disconnect the carburetor lead connector e Remove the carburetor e Drain the fuel from the float bowl removing the drain plug After draining install the drain plug securely e Loosen the fuel cut valve A and remove it Fuel Cut Valve Installation KX250 e Installation is reverse of removal Fuel Cut Valve Inspection KX250 e Remove the fuel cut valve A 21 3 21 7mm e Connect and disconnect one 12 V battery B to the car buretor lead connector as shown The valve rod moves Alf the protrusion exceeds the standard too long or too
234. ton Piston Pin Connecting Rod Wear Inspection 2 24 Exhaust Valve Clean and Inspect 2 25 EXMAUSE OY Ste E ET E 2 25 Silencer Packing Change EE 2 25 E gine Right Side EE 2 25 Clutch Lever Free Play Check isc its ed dd 2 26 Clutch Lever Free Play Adjustment issus 2 26 Friction and Steel Plates Wear Damage Inspechon cess eeeeeeeeeeeeeeeeeeeeeeeeees 2 26 Friction and Steel Plate Warp Inspection 2 27 Engine Bottom End Transmission seed Eege eene 2 27 Transmission Oil Level Inspection esse 2 28 Transmission Oil Change esse in DM need ire ete tt Nan den sn 2 28 Wheel Ve 2 29 Spoke lightness Inspection its ati its 2 29 Rim Runout Inspection 2 29 Wheel BEarinG INSOSCHOM sas nine re ane adidas ne tn ea entente aTa 2 29 EOI la ia 2 30 2 2 PERIODIC MAINTENANCE Drive Chain Slack In Spettion ea ane steno es esl terete ele eee Drive Chain Slack Adjustment EEN Drive Chain Wear Inspection cooccccccccncccnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnness Drive Chain Lubricat Uta ae AN MAG CR aa and co ea ates Brake Lever Play Adjustment ovio A A tdi dai Brake Fluid Level Inspechon nnen ennn Brake Fluid Change Brake Pad Wear Inspection ccccceccceccceccceeeceeeeeeeeeeeeeeeeeee
235. total 2 measurement 1 KX125 Tester Connections Reading Range Tester to Tester to x 10 White lead Red lead 10 300 2 KX250 Tester Connections Range Tester to Tester to White lead Red lead 10 300 Yellow White lead Yellow White lead Reading Yellow lead 1 40 14 16 ELECTRICAL SYSTEM Flywheel Magneto x If there is more resistance than shown in the table or no hand tester reading infinity the stator has an open lead and must be replaced Much less than this resistance means the stator is shorted and must be replaced e Using the highest resistance range of the hand tester measure the resistance between each leads and chas sis ground Any hand tester reading less than infinity indicates a short necessitating stator replacement x lf the stator coils have normal resistance but the voltage check showed the magneto to be defective then the rotor magnets have probably weakened and the rotor must be replaced Special Tool Hand Tester 57001 1394 Regulator Rectifier Removal KX250 e Remove Left Radiator Shroud Band A e Disconnect the regulator rectifier lead connector B e Unscrew the mounting bolt and remove the regulator rec tifier C Regulator Rectifier Output Voltage Inspection KX250 e Warm up the engine to obtain actual magneto operating conditions e Stop the engine and disconnect the regulator rectifier lea
236. ts e Check the kickstarter assembly parts for damage Any damaged parts should be replaced with new ones A Idle Gear B Circlip C Washer D Spring E Ratchet Gear F Kick Gear GRO80101S1 C G Kick Shaft H Kick Spring l Spring Guide e Apply molybdenum disulfide grease to the inside of the kick gear and ratchet gear e When assembling the ratchet gear A onto the kick shaft B align the punch mark C on the ratchet gear with the punch mark C on the kick shaft e Replace the circlips that were removed with new ones Special Tool Outside Circlip Pliers 57001 144 GROSOOOBS1 6 24 ENGINE RIGHT SIDE Kickstarter Idle Gear Removal e Remove Right Engine Cover see Right Engine Cover Removal Clutch Housing see Clutch Removal e For KX125 pull off the idle gear e For KX250 remove the circlip A and pull off the idle gear B Special Tool Outside Circlip Pliers 57001 144 Idle Gear Installation e Apply molybdenum disulfide grease to the inside of the idle gear e Replace the circlip with a new one Special Tool Outside Circlip Pliers 57001 144 ENGINE REMOVAL INSTALLATION 7 1 Engine Removal Installation Table of Contents Exploded AE 7 2 Special TO EE 7 4 Engine Removal lnstallation EE 7 5 Engine e EE 7 5 Engine Install de EE 7 6 7 2 ENGINE REMOVAL INSTALLATION Exploded View GHO2015BW5 ENGINE REMOVAL INSTALLATION 7 3 Exploded View
237. ts Lubricate with Motor Oil Clutch Lever Brake Lever Kick Pedal Shift Pedal Rear Brake Rod Joint Drive Chain Points Lubricate with Grease Clutch Inner Cable Upper and Lower Ends A Throttle Inner Cable Upper End Swingarm Pivot Tie Rod Pivot Rocker Arm Pivot Steering Stem Bearing Cables Lubricate with Rust Inhibitor Throttle Cable Clutch Cable 6c040101S1 6004011481 PERIODIC MAINTENANCE 2 45 Periodic Maintenance Procedures e With the cable disconnected at the both ends the cable should move freely A within the cable housing Alf cable movement is not free after lubricating if the cable is frayed B or if the cable housing is kinked C replace the cable 6004020152 C 2 46 PERIODIC MAINTENANCE Periodic Maintenance Procedures Nut Bolt and Fastener Tightness Tightness Inspection e Check the tightness of bolts and nuts listed here Also check to see that each cotter pin is in place and in good condition NOTE OFor the engine fasteners check the tightness of them when the engine is cold at room temperature x If there are loose fasteners retorque them to the spec ified torque following the specified tightening sequence Refer to the appropriate chapter for torque specifications If torque specifications are not in the appropriate chapter see the Standard Torque Table For each fastener first loosen it by 1 2 turn then tighten it x If cotter p
238. uid in the reservoir e With the reservoir cap off slowly pump the brake lever several times until no air bubbles can be seen rising up through the fluid from the holes at the bottom of the reser voir OBleed the air completely from the master cylinder by this operation e Install the reservoir cap e Attach a clear plastic hose to the bleed valve on the caliper and run the other end of the hose into a con tainer e Bleed the brake line and the caliper as follows ORepeat this operation until no more air can be seen com ing out into the plastic hose 1 Pump the brake lever until it becomes hard and apply the brake and hold it A 2 Quickly open and close the bleed valve while holding the brake applied B 3 Release the brake C NOTE OThe fluid level must be checked often during the bleed ing operation and replenished with fresh brake fluid as necessary If the fluid in the reservoir runs almost out any time during bleeding operation the bleeding opera tion must be done over again from the beginning since air will have entered the line OTap the brake hose lightly from the caliper to the reser voir for easier bleeding GLO9060582 C 11 12 BRAKES Brake Fluid e Remove the clear plastic hose e Tighten the bleed valves and install the rubber caps Torque Caliper Bleed Valve 7 8 N m 0 8 kgf m 69 in Ib e Check the fluid level e After bleeding is done check the brake for good b
239. unning condition FREQUENCY After each As re See OPERATION race or f z quired Page 2 5 hr Spark plug clean gap t Clutch adjust E Clutch and friction plates inspect t Throttle cable adjust Air cleaner element clean N Air cleaner element replace Carburetor inspect and adjust Transmission oil change G Piston and piston ring clean and inspectt Cylinder head cylinder inspect Small end bearing inspect t Reed valve inspect t Exhaust valve clean and inspect Exhaust pipe O ring replace N Silencer clean and inspectt Silencer packing change Kick pedal and shift pedal clean Engine sprocket inspect t Coolant checkt Cooling hoses and connections inspect t Brake adjustment inspect t Brake pad wear inspect t Brake fluid level inspect t Brake fluid change Every 2 years Brake master cylinder cup and dust seal replace Brake caliper piston seal and dust seal replace Brake hoses and pipe replace Every 4 years Every 2 years Every 2 years Brake hoses connections inspect t Spoke tightness and rim runout inspect t Wheel bearing inspect Drive chain adjust Drive chain lubricate Drive chain wear inspect Chain slipper and guide replace If damaged Rear sprocket inspect t 2 4 PERIODIC MAINTENANCE Periodic Maintenance Chart
240. urely Master Cylinder Inspection Visual Inspection e Disassemble the front and rear master cylinders e Check that there are no scratches rust or pitting on the inner wall of each master cylinder A and on the outside of each piston B If a master cylinder or piston shows any damage replace them e Inspect the primary C and secondary D cups lf a cup is worn damaged softened rotted or swollen the piston assembly should be replace to renew the cups x If fluid leakage is noted at the brake lever the piston as sembly should be replaced to renew the cup 0 e Check the dust covers E for damage x lf they are damaged replace them e Check that the relief F and supply G ports are not plugged x If the small relief port becomes plugged the brake pads will drag on the disc Blow the ports clean with com pressed air e Check the piston return springs H for any damage x lf a spring is damaged replace it K Rear Master Cylinder SSS gt o eel A E ual U e 7 q A 4 q A Ca D GLO7022B BRAKES 11 21 Brake Disk Brake Disc Inspection e Visually inspect the disc A x lf it is scratched or damaged replace the disc e Measure the thickness of each disc at the point B where it has worn the most Replace the disc if it has worn past the service limit Thickness Standard Front 2 85 3 15
241. uretor Inspection ENNEN ENNEN EEN EE entr eebe dates deans ere sn ren le din te eee lef Ge Nun TEE Air Cleaner Housing Installation Element Removal seen Element Installation itet ER entier ls en es Element Cleaning and Inspection Fuel Tank en E EE nm do Fuel Tank Removal ses Fuel Tank Installation ss IWER ue Alivio sn hate aimants Fuel Tap Installation ooooonininnnnnnnnnnnnnnnnnncnnnnncnn nina nc rn nc r nr rn rre Fuel Tap INSPECCIONES Fuel Tank and Tap Cleaning nidad REO VAIVC AO Reed Valve Removal ce endeeegeeegeeaeeeeeeeaeeeaeeeeneeeseeeseeseeeeees Reed Valve Installation ccccceccceccceccceeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeeeeeeeeeeeseeeseeeseseneeeeneeseeeees Reed Valve Inspection seen 3 2 FUEL SYSTEM Exploded View KX125M E TT AIS GCO2095BH5 FUEL SYSTEM 3 3 Exploded View N Fastener E Remarks ig N m kgf m ft lb Carburetor Holder Mounting Bolts 8 8 0 9 78 in lb Carburetor Holding Clamp Screws 1 4 0 14 12 ml Reed Valve Screws 1 0 0 1 8 8 in lb Carburetor Top Cover Screws 3 0 0 3 26 in lb Throttle Cable Throttle Grip Spring Retainer Connector Jet Needle Clip 1 2 3 4 5 6 7 8 9 10 11 Jet Needle 12 Throttle Val
242. ush rod puller Berger GE 6M04101BS1 12 20 SUSPENSION Front Fork e Install the fork spring seat A on the fork spring B e Check both top plug O ring C for damage and replace them if necessary e For KX125 250 M2 model as shown in the figure e While holding the push rod nut A with a 17 mm 0 67 in wrench B tighten the top plug C against the push rod e For KX125 250 M2 model while holding the push rod nut A with a 19 mm 0 75 in wrench B tighten the top plug C against the push rod e Tighten the fork top plug Torque Push Rod Nut 28 N m 2 85 kgf m 20 6 ft lb Front Fork Top Plug 29 N m 3 0 kgf m 22 lb e Assemble the other fork tube in the same way as de scribed above e Tighten the upper fork clamp bolts Torque Front Fork Upper Clamp Blots 20 N m 2 0 kgf m 14 5 ft lb NOTE OTighten the two clamp bolts alternately two times to en sure even tightening torque e Install the parts removed 6M04102BS1 6M04147BS1 SUSPENSION 12 21 Front Fork Oil Change Oil Level Adjustment each fork leg e Refer to the Front Fork Oil Change Oil Level Adjustment in the Periodic Maintenance chapter Front Fork Removal e Remove the fork protectors A and hose guard B e Remove the front brake hose clamps C e Remove the front wheel see Wheels Tires chapter e Remove the caliper D from the fork leg to be removed and rest the c
243. ut 98 N m 10 0 kgf m 72 ft Ib e For KX125 250 M2 model as shown in the figure 6M07010BS1 Needle Bearing Inspection Alf there is any doubt as to the condition of either needle bearing replace the bearing and sleeve as a set 12 46 SUSPENSION Uni Trak Maintenance Uni Trak Linkage Inspection e Refer to the Uni Trak Linkage Inspection in the Periodic Maintenance chapter Rocker Arm Sleeve Wear e Pull out the sleeves A of the rocker arm and measure the outside diameter of the sleeve x If the sleeve is worn past the service limit replace the sleeve Sleeve Outside Diameter Large Standard 19 987 20 000 mm 0 7869 0 7874 in Service Limit 19 85 mm 0 781 in Small Standard 15 987 16 000 mm 0 6294 0 6299 in Service Limit 15 85 mm 0 624 in Rocker Arm Mounting Bolt Bend A bent bolt causes vibration poor handling and instabil ity e To measure the bolt runout remove the bolt place it in V blocks and set a dial gauge to the bolt at a point halfway between the blocks Turn A the bolt to measure the runout The amount of dial variation is the amount of runout x If runout exceeds the service limit replace the bolt Bolt Runout Standard Under 0 1 mm 0 004 in Service Limit 0 2 mm 0 008 in 6M07001BS1 6M07002BS1 STEERING 13 1 Steering Table of Contents EXPO AE 13 2 Special Mt EE 13 4
244. uter Race Remover ID gt 37 mm 57001 1107 NOTE Olf either steering stem bearing is damaged it is recom mended that both the upper and lower bearing includ ing outer races should be replaced with new ones GNO4002BS1 GNO70106S1 13 6 STEERING Steering e Remove the lower stem bearing inner rase tapered roller bearing A with its grease seal from the stem using suit able tools Steering Stem Stem Bearing Installation e Replace the bearing outer race with new ones OApply grease to the outer races and drive them into the head pipe at the same time using the head pipe outer race press shaft A and the drivers Special Tool Head Pipe Outer Race Press Shaft 57001 1075 Head Pipe Outer Race Driver 451 5 57001 1076 B Head Pipe Outer Race Driver 454 5 57001 1077 C e Replace the lower inner races with new ones OApply grease to the lower tapered roller bearing A and drive it onto the stem using the steering stem bearing driver B and adapter C Special Tool Steering Stem Bearing Driver 57001 137 Steering Stem Bearing Driver Adapter 34 5 57001 1074 GNO4010181 GNO05040281 GNO050415S1 STEERING 13 7 Steering e Apply grease to the upper inner race and install it in the head pipe e Install the stem through the head pipe and upper bearing install the stem cap and hand tighten the locknut while pushing up on the st
245. valves from the cylinder see Ex haust Valve Removal Cylinder Installation e Scrape any carbon out of the exhaust port e Check on a crust of minerals and rust in the cylinder water jacket and remove them if necessary e Replace the cylinder base gasket with a new one e Apply engine oil to the piston surface piston rings and cylinder bore e Check to see that the pin A in each piston ring groove is between the ends of the piston ring and fit the base of the cylinder over each ring pressing in on opposite sides of the ring as necessary Be certain that the rings do not slip out of position e Tighten the cylinder nuts diagonally Torque Cylinder Nuts KX125 25 N m 2 5 kgf m 18 ft lb KX250 34 N m 3 5 kgf m 25 ft lb KX125 e Using the 14 mm 0 56 in spanner wrench A turn the governor shaft counterclockwise e Install the governor shaft lever B to the main shaft and tighten the bolt C Torque Governor Shaft Lever Mounting Bolt 6 9 N m 0 7 kgf m 61 in Ib e Install the KIPS cover e Tighten Torque KIPS Cover Bolts 4 9 N m 0 5 kgf m 43 in Ib KX125 M2 8 8 N m 0 9 kgf m 78 in lb ENGINE TOP END 5 13 Cylinder KX250 e Install the governor shaft lever and operating rod collar in accordance with the following procedure OPut a 9 mm 0 35 in spanner A wrench on the governor shaft lever upper end OTurn the governor shaft lever counterclockwise with the wrench and fit th
246. ve 13 14 15 16 17 18 19 Choke Knob Idle Adjusting Screw Air Screw Slow Jet Main Jet Needle Jet Main Jet Holder 20 Float Valve Needle 21 Float 22 Carburetor Holder 23a Reed Valve KX125 M1 Model 23b Reed Valve KX125 M2 Model O Apply oil G Apply grease 3 4 FUEL SYSTEM Exploded View KX250M 6002049BW5 FUEL SYSTEM 3 5 Exploded View T No Fastener oe Remarks N m kgf m ft Ib 1 Carburetor Holder Mounting Bolts 8 8 0 9 78 in lb 2 Carburetor Holding Clamp Screws 1 4 0 14 12 ml 3 Reed Valve Screws 1 0 0 1 8 8 in lb 4 Throttle Sensor Bolt 2 0 0 2 17 in lb 5 Carburetor Top Cover Allen Bolts 3 9 0 4 35 in lb 6 Throttle Cable 7 Throttle Grip 8 Spring 9 Retainer 10 Connector 11 Jet Needle Clip 12 Jet Needle 13 Throttle Valve 14 Choke Knob 15 Idle Adjusting Screw 16 Spring 17 Air Screw 18 Slow Jet 19 Power Jet 20 Main Jet 21 Float Valve Needle 22 Float 23 Throttle Sensor 24 Fuel Cut Valve 25 Carburetor Holder 26 Reed Valve O Apply oil G Apply grease 3 6 FUEL SYSTEM Exploded View FUEL SYSTEM 3 7 Exploded View No Fastener 34 Air Cleaner Duct Clamp Screw 1 4 0 14 12 ml Fuel Tap Plate Mounting Screws 0 8 0 08 7 inlb Fuel Tank Cap Fuel Tank Fuel Tap Element Frame Holder Air Cleaner Duc A
247. w tube 15 12 APPENDIX Cable Wire and Hose Routing KX125 250 M1 Model Front Brake CD of Ar LE J s R N Gi 2 E y Xe hi 9 E je Rear Brake ES EIA mie d gt e if y Ki H BH NO po A SE DO 6B09187BW4 APPENDIX 15 13 Cable Wire and Hose Routing OONOARWN A Front Brake Reservoir Banjo Bolts Clamp Clamp Brackets Hose Guard Front Brake Disc Front Fork Guard Bleed Valves Front Brake Caliper Rear Brake Caliper Caliper Guard Clamps Rear Brake Reservoir Rear Brake Master Cylinder Bend the cotter pin end by along the joint pin Rear Brake Disc Disk Guard 15 14 APPENDIX Cable Wire and Hose Routing KX125 250 M2 Model Front Brake ID of a LY a Jet L AA D ig p E Geer D N K Rear Brake APPENDIX 15 15 Cable Wire and Hose Routing Joo P ND A Front Brake Reservoir Banjo Bolts Clamp Clamp Brackets Front Brake Disc Front Fork Guard Bleed Valves Front Brake Caliper Rear Brake Caliper Caliper Guard Clamps Rear Brake Reservoir Rear Brake Master Cylinder Bend the cotter pin end by along the joint pin Rear Brake Disc Disk Guard MODEL APPLICATION Year Model Beginning Frame No al LSA IE a o mn mmm BE nn mmm HE O This digit in the frame number changes from
248. wn the tire becomes more sus ceptible the puncture and failure e Remove any imbedded stones or other foreign particles from the tread e Visually inspect the tire for cracks and cuts replacing the tire in case of bad damage Swelling or high spots indi cate internal damage requiring tire replacement WARNING To ensure safe handling and stability use only the recommended standard tires for replacement in flated to the standard pressure NOTE OCheck and balance the wheel when a tire is replaced with a new one GJ05010381 9 12 WHEELS TIRES Tires Standard Tire KX125 Front Size 80 100 21 51M Make DUNLOP Type D739FA Tube EUR D755FJ Tube KX125 M3 D742F Tube EUR D755FJ Tube Rear Size 100 90 19 57M Make DUNLOP Type D739 Tube EUR D755G Tube KX125 M3 D756 Tube EUR D755G Tube KX250 Front Size 80 100 21 51M Make BRIDGESTONE EUR DUNLOP Type M601 Tube EUR D755FJ Tube Rear Size 110 90 19 62M Make BRIDGESTONE EUR DUNLOP Type M602 Tube EUR D755J Tube EUR Europe Model Tire Removal CAUTION Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc Place blocks under the wheel so the disc does not touch the ground e Remove the wheel from the motorcycle see Wheels Re moval e To maintain wheel balance mark A the valve stem posi tion on the tire with chalk so that the tire
249. xhaust Port C KX125 A gt Io Dag GBOGO6TBS1 1 16 GENERAL INFORMATION Technical Information KIPS Kawasaki Integrated Power Valve System KX250M KX125M OKIPS varies the exhaust port height to broaden the useful rpm range for low end and mid range without sacrificing the top end power see 95 KDX200H Service Manual for basic information about KIPS OKIPS is 2 stage 3 way type the main exhaust port is opened earlier than the sub exhaust ports 2 stage and they are opened differently in low middle and high rpm 3 way In low rpm resonator open to fully sub exhaust ports and main exhaust port close In middle rpm resonator close main exhaust port open to fully sub exhaust ports open to halfway In high rpm resonator close main exhaust port and sub exhaust ports open fully OThe KIPS valve is now made of aluminum instead of steel to save weight OThe KIPS main valve holder shape is modified to match the straightened exhaust port and timing for the main and sub valves is changed to deliver more power in the low to mid range OThe main valve end is changed from thick end to thin end reducing exhaust pressure on the valve and making valve operation smooth KX250M 6B06069BW2 A Previous KIPS B New KIPS GENERAL INFORMATION 1 17 Technical Information KX125M O of EST EE E ZA IS 6B06070BW2 A Previous KIPS B New Model C Full Opened Po
250. xploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require spec ified tightening torque oil grease or a locking agent during assembly GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing DEE 1 2 M de lidentificatloM se aaae aea e lade abd Msn AR de 1 5 General Specifications 1 7 Technical Informations Maison etant nan dau tn Lin made i rene 1 13 Unit Conv rsion Elei ne ne an 1 21 1 2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera tion on a motorcycle read the precautions given below To facilitate actual operations notes illustra tions photographs cautions and detailed descriptions have been included in each chapter wherever necessary This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts Especially note the following 1 2 8 4 5 8 9 Dirt Before removal and disassembly clean the motorcycle Any dirt entering the engine will shorten the life of the motorcycle For the same reason before installing a new part clean off any dust or metal filings Battery Ground Disconnect the ground wire from the battery before performing any disassembly operatio
251. ylinder Left Cover 48 Vent Hose KX250 M2 model 32 Cylinder G Apply grease 33 Exhaust Valve Left L Apply a non permanent locking agent 34 Exhaust Valve Right M Apply molybdenum disulfide grease 35 Guide O Apply 2 stroke engine oil 36 O ring SS Apply silicone sealant 37 Idle Gear 5 6 ENGINE TOP END Specifications KX125 Rem Standard Cylinder Head Cylinder Compression Cylinder Head Warp Usable range 890 1 370 kPa 9 1 14 0 kgf cm 129 199 psi Service Limit 0 03 mm 0 0012 in Cylinder Piston Cylinder Inside Diameter 15 mm 0 59 in below of the cylinder head Piston Diameter Piston Cylinder Clearance Piston Ring Groove Clearance Piston Ring Groove Width Piston Ring Thickness Piston Ring End Gap Piston Pin Diameter Piston Pin Hole Diameter Small End Inside Diameter 54 010 54 025 mm 2 1264 2 1270 in 53 955 53 970 mm 2 1242 2 1248 in 0 040 0 070 mm 0 0016 0 0028 in 0 015 0 050 mm 0 0006 0 0020 in 1 01 1 03 mm 0 0398 0 0406 in 0 980 0 995 mm 0 0386 0 0392 in 0 35 0 55 mm 0 0138 0 0217 in 14 995 15 000 mm 0 5904 0 5906 in 15 001 15 011 mm 0 5906 0 5910 in 19 003 19 014 mm 0 7481 0 7486 in 54 10 mm 2 130 in 53 81 mm 2 118 in 0 15 mm 0 006 in 1 11 mm 0 044 in 0 91 mm 0 036 in 0 85 mm 0 033 in 14 96 mm 0 589 in 15 08 mm 0 594 in 19 0

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