Mitsubishi Eliminator 125 (2003) manual

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As regras impõem ao revendedor a obrigação de fornecer ao comprador o manual com o produto Mitsubishi Eliminator 125 (2003). A falta de manual ou informações incorretas fornecidas ao consumidor são a base de uma queixa por não conformidade do produto com o contrato. De acordo com a lei, pode anexar o manual em uma outra forma de que em papel, o que é frequentemente utilizado, anexando uma forma gráfica ou manual electrónicoMitsubishi Eliminator 125 (2003) vídeos instrutivos para os usuários. A condição é uma forma legível e compreensível.

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Normalmente, isso é devido à falta de tempo e à certeza quanto à funcionalidade específica do dispositivo adquirido. Infelizmente, a mesma ligação e o arranque Mitsubishi Eliminator 125 (2003) não são suficientes. O manual contém uma série de orientações sobre funcionalidades específicas, a segurança, os métodos de manutenção (mesmo sobre produtos que devem ser usados), possíveis defeitos Mitsubishi Eliminator 125 (2003) e formas de resolver problemas comuns durante o uso. No final, no manual podemos encontrar as coordenadas do serviço Mitsubishi na ausência da eficácia das soluções propostas. Atualmente, muito apreciados são manuais na forma de animações interessantes e vídeos de instrução que de uma forma melhor do que o o folheto falam ao usuário. Este tipo de manual é a chance que o usuário percorrer todo o vídeo instrutivo, sem ignorar especificações e descrições técnicas complicadas Mitsubishi Eliminator 125 (2003), como para a versão papel.

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Primeiro de tudo, contem a resposta sobre a construção, as possibilidades do dispositivo Mitsubishi Eliminator 125 (2003), uso dos acessórios individuais e uma gama de informações para desfrutar plenamente todos os recursos e facilidades.

Após a compra bem sucedida de um equipamento / dispositivo, é bom ter um momento para se familiarizar com cada parte do manual Mitsubishi Eliminator 125 (2003). Atualmente, são cuidadosamente preparados e traduzidos para sejam não só compreensíveis para os usuários, mas para cumprir a sua função básica de informação

Índice do manual

  • Página 1

    ELIMINA T OR 125 Motorcycle Service Manual[...]

  • Página 2

    [...]

  • Página 3

    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 G[...]

  • Página 4

    [...]

  • Página 5

    ELIMINA T OR 125 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawas[...]

  • Página 6

    LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) AT D C after top dead center N newton(s) BBDC before bottom dead center Pa 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 c[...]

  • Página 7

    EMISSION CONTROL INFORMA TION T o protect the environment in which we all live, Kawasaki has incorporated crankcase emis- sion (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. Addi- tionally , Kawasaki has incorporated an e[...]

  • Página 8

    WE RECOMMEN D THA T ALL DE ALERS OBSER VE THESE PROVISIONS OF FEDERAL LA W , THE VIOLA TION OF WHICH IS PUNISHABLE BY CIVIL PENAL TIES NOT EXCEEDING $10,000 PER VIOLA TION. T AMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other tha[...]

  • Página 9

    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[...]

  • Página 10

    [...]

  • Página 11

    GENERAL INFORMA TION 1-1 1 General Information T able of Contents Before Servicing ................................................................................................................ ..... 1-2 Model Identification............................................................................................................ ..... 1-7 Gener[...]

  • Página 12

    1-2 GENERAL INFORMA TION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tion on a motorcycle, read the preca utions given below . T o facilitate ac tual operations, notes, illustra- tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever [...]

  • Página 13

    GENERAL INFORMA TION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly . Storage of Removed Parts After all the parts including subassembly parts have been cleaned, store the parts [...]

  • Página 14

    1-4 GENERAL INFORMA TION Before Servicing Tightening Sequence Generally , when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them according to the specified se- quence to prevent case warpage or deformation which c an lead to malfunction. Conversely when loosening t[...]

  • Página 15

    GENERAL INFORMA TION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely nec[...]

  • Página 16

    1-6 GENERAL INFORMA TION Before Servicing Lubrication It is important to lubricate rotating or sliding parts during assembly to minimize wear during initial operation. Lubri- cation points are called out throughout this manual, apply the specific oil or grease as specified. Direction of Engine Rotation When rotating the crankshaft by hand, the free[...]

  • Página 17

    GENERAL INFORMA TION 1-7 Model Identification BN125-A1 (Europe) Left Side View BN125-A1 (Europe) Right Side View[...]

  • Página 18

    1-8 GENERAL INFORMA TION Model Identification BN125-A1 (Singapore) Left Side View BN125-A1 (Singapore) Right Side View[...]

  • Página 19

    GENERAL INFORMA TION 1-9 General Specifications Items BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ Dimensions Overall length 2 150 mm (84.6 in.) Overall width 780 mm (30.7 in.) Overall height 1 020 mm (40.2 in.) 1 035 mm (40.8 in.) ← 1 050 mm (41.3 in.) (US, CA) 1 045 mm (41.1 in.) BN125-A7 ∼ (N, NU) Wheelbase 1 470 mm (57.9 in.) Road clearance[...]

  • Página 20

    1-10 GENERAL INFORMA TION General Specifications Items BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ Maximum torque 9.7 N·m (0.99 kgf·m, 7.2 ft·lb) @8 000 r/min (rpm) (US)– ← 9.8 N·m (1.00 kgf·m, 7.2 ft·lb) @8 000 r/min (rpm) (BN125-A7 ∼ , N, NU) Carburetion system Carburetor , MIKUNI BS28 Starting system Electric starter Ignition system[...]

  • Página 21

    GENERAL INFORMA TION 1-1 1 General Specifications Items BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ Gear ratios: 1st 2.700 (27/10) 2nd 1.705 (29/17) 3rd 1.300 (26/20) 4th 1.090 (24/22) 5th 0.952 (20/21) Final drive system: Ty p e Chain drive Reduction ratio 3.066 (46/15) ← 2.800 (42/15) (BN125-A7 ∼ ,N , NU) Overall drive ratio 10.708 @T op gea[...]

  • Página 22

    1-12 GENERAL INFORMA TION General Specifications Items BN125-A1 ∼ A2 BN125-A3 ∼ A4 BN125-A5 ∼ T rail/brake light 12 V 5/21 W Alternator: Ty p e Single-phase AC Rated output 8.75 A/12 V @4 000 r/min (rpm): BN125-A1 15 A/14 V @8 000 r/min (rpm): BN125-A2 ∼ Specifications subject to change without notice, and may not apply to every country . ([...]

  • Página 23

    GENERAL INFORMA TION 1-13 T echnical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) Description ○ Unlike the conventional CDI, the DC-CDI uses a battery instead of a magneto as a power source. ○ The DC-CDI powered by a battery generates strong ignition spark even at low engine speeds. The conventional CDI, which uses [...]

  • Página 24

    1-14 GENERAL INFORMA TION T echnical Information-DC-CDI (Direct Cu rrent-Capacitor Discharge Ignition Sys- tem) Operation The DC-CDI circuit consists of a battery , a DC-DC converter , a d iode, a capacitor , an ignition timing controller , a crankshaft sensor , a thyristor , an igni tion coil, a spark plug, an ignition switch, and an engine stop s[...]

  • Página 25

    GENERAL INFORMA TION 1-15 T echnical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) This sudden change in the primary current induces a primary voltage (counterelectromotive force) which is equal to the capacitor voltage (about 225 V) but against the discharging current. The primary voltage induces a high secondary voltag[...]

  • Página 26

    1-16 GENERAL INFORMA TION T echnical Information-DC-CDI (Direct Cu rrent-Capacitor Discharge Ignition Sys- tem) Diode A diode functions as an electrical check valve. It conducts current easily from its cathode to its anode, but it will not permit current flow in the opposite direction. Since electric- ity attempts to flow from negative (–) to pos[...]

  • Página 27

    GENERAL INFORMA TION 1-17 T echnical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) Every time either end of the timing plate on the rotor passes by the crankshaft sensor , a pulse is generated and sent to the CDI unit, that is, two pulses are generated per one revolution of the rotor . One is a positive pulse [A] and the[...]

  • Página 28

    1-18 GENERAL INFORMA TION T echnical Information-DC-CDI (Direct Cu rrent-Capacitor Discharge Ignition Sys- tem) The crankshaft sensor generates a crankshaft sensor sig- nal and sends it to the signal generator . The signal genera- tor generates A and B signals synchronized with the crank- shaft sensor signal. These signals are shown in the figure. [...]

  • Página 29

    GENERAL INFORMA TION 1-19 T echnical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition Sys- tem) (Ignition T iming Advancing) A signal and B signal in the comparator advance the igni- tion timing. The signal generator decreases A signal as the engine rpm increases from N1, to N3 as shown, but keeps B signal unchanged. A and B signals [...]

  • Página 30

    1-20 GENERAL INFORMA TION T echnical Information-Coasting Enricher The coasting enricher [A] prevents backfiring during en- gine braking by supplying a rich fuel mixture to the engine. When the motorcycle is cruising or accelerating, the engine vacuum is low , and the return spring [3] pushes the valve in its opened position [5]. The passage [6] is[...]

  • Página 31

    GENERAL INFORMA TION 1-21 T echnical Information-Coasting Enricher Fuel and Air Supply of Enricher System[...]

  • Página 32

    1-22 GENERAL INFORMA TION Unit Conversion T able Prefixes for Units Prefix Symbol Power mega M × 1 000 000 kilo k × 1 000 centi c ×0 . 0 1 milli m × 0.001 micro µ × 0.000001 Units of Mass kg × 2.205 = lb g × 0.03527 = oz Units of V olume L × 0.2642 = gal (US) L × 0.2200 = gal (imp) L× 1 . 0 5 7 = qt (US) L × 0.8799 = qt (imp) L × 2.1 1[...]

  • Página 33

    PERIODIC MAINTENANCE 2-1 2 Periodic Maintenance T able of Contents Periodic Maintenance Chart .............. 2-2 T orque and Locking Agent ................. 2-4 Specifications .................................... 2-9 Special T ools ..................................... 2-1 1 Periodic Maintenance Procedures..... 2-12 Fuel System ....................[...]

  • Página 34

    2-2 P ERIODIC MAINTENANCE Periodic Maintenance Chart The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. FREQUENCY Whichever comes first *O D O M E T E R READING × 1 000 km ( × 1 000 mile) 1 6 12 18 24 30 36 O[...]

  • Página 35

    PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart FREQUENCY Whichever comes first *O D O M E T E R READING × 1 000 km ( × 1 000 mile) 1 6 12 18 24 30 36 OPERA TION Every (0.6) (4) (7.5) (12) (15) (20) (24) Spark plug-clean and gap † • • • • • • General lubrication-perform • • • Nuts, bolts, and fasteners tightness-inspect ?[...]

  • Página 36

    2-4 P ERIODIC MAINTENANCE T orque and Locking Agent The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or liquid gasket. Letters used in the "Remarks" column mean: L: Apply a non-permanent locking agent to the threads. M: Apply molybdenum disulfide grease. O: Apply an oil[...]

  • Página 37

    PERIODIC MAINTENANCE 2-5 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Oil Pipe Banjo Bolts M8 9.8 1.0 87 in·lb Oil Pipe Banjo Bolts M10 25 2.5 18 Oil Pipe Mounting Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb Oil Pipe Mounting Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb Camshaft Bearing Holder Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 [...]

  • Página 38

    2-6 P ERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Engine Removal/installation Engine Mounting Bolts, Nuts (M10) 44 4.5 33 Engine Mounting Bolts, Nuts (M8) 25 2.5 18 Engine Mounting Bracket Bolts, Nuts 25 2.5 18 Engine Ground T erminal Bolt 9.8 1.0 87 in·lb Crankshaft/transmission Primary Gear Nut 69 7.[...]

  • Página 39

    PERIODIC MAINTENANCE 2-7 T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks Brake Pedal Bolt 9.8 1.0 87 in·lb Suspension Front Fork T op Plugs 23 2.3 17 Front Fork Bottom Allen Bolts 20 2.0 15 L Front Fork Clamp Bolts (Upper) 20 2.0 15 Front Fork Clamp Bolts (Lower) 34 3.5 25 Rear Shock Absorber Nuts (Upper) 34 3.5 25 Rear Shock[...]

  • Página 40

    2-8 P ERIODIC MAINTENANCE T orque and Locking Agent T orque Fastener N·m kgf·m ft·lb Remarks T urn Signal Light Holder Nuts 5.9 0.60 52 in·lb Neutral Switch 15 1.5 11 Sidestand Switch Screws 3.9 0.40 35 in·lb L The table below , relating tightening torque to thread diameter , lists the basic torque for the bolts and nuts. Use this table for on[...]

  • Página 41

    PERIODIC MAINTENANCE 2-9 Specifications Item Standard Service Limit Fuel System Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Idle Speed 1 300 ±50 r/min (rpm) ––– Air Cleaner Element Oil: Grade SE, SF or SG class ––– Vis c os it y SAE 30 ––– Engine T op End V alve Clearance: Inlet 0.08 ∼ 0.12 (0.0031 ∼ 0.00[...]

  • Página 42

    2-10 PERIODIC MAINTENANCE Specifications Item Standard Service Limit (BN125-A6 ∼ ) 4.1 mm (0.161 in.) 1 mm (0.04 in.) Rear 7.3 mm (0.29 in.) 2 mm (0.08 in.) Final Drive D r i v eC h a i nS l a c k 25 ∼ 40 mm (0.98 ∼ 1.57 in.) ––– 20 Link Length 254.0 ∼ 254.6 mm (10.00 ∼ 10.02 in.) 259 mm (10.2 in.) Brakes Brake Lever Free Play Non-a[...]

  • Página 43

    PERIODIC MAINTENANCE 2-1 1 Special T ools Steering Stem Nut Wrench: 57001-1 100 Jack: 57001-1238 Fork Oil Level Gauge: 57001-1290[...]

  • Página 44

    2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures Fuel System Fuel Hose and Conn ection Inspection ○ The fuel hose is designed to be used throughout the mo- torcycle’s life without any maintenance, however , if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leaks [A] or the hose to burst. Remove the f[...]

  • Página 45

    PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures Throttle Grip Free Play Adjustment • Loosen the locknut [A]. • T urn the adjuster [B] until the proper amount of free play can be obtained. • T ighten the locknut against the adjuster . If the throttle grip free play cannot be adjusted with the adjuster , use the cable adjusters at the[...]

  • Página 46

    2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures Idle Speed Adjustment • Start the engine and warm it up thoroughly . • T urn the idle adjusting screw [A] until the idle speed is correct. ○ Open and close the throttle a few times to make sure that the idle speed is within the specified range. Readjust if necessary . Front [B] Air Cle[...]

  • Página 47

    PERIODIC MAINTENANCE 2-15 Periodic Maintenance Procedures • Remove the canister mounting bracket bolts [A] and re- move the brackets [B] and canister [C] together . • Disconnect the hoses from the canister . • Visually inspect the canister for cracks and other damage. If the canister has any cracks or bad damage, replace it with a new one. NO[...]

  • Página 48

    2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures Cylinder Head Bolt Tightness Insp ection • Check that 6 mm [A] and 9 mm [B] cylinder head bolts are tightened evenly . Standard head bolts tightening torque are shown below . Tighte ning T orque 6 mm Cyl in der Head Bolts: 12 N· m (1.2 kgf·m , 104 in·lb) 9 mm Cylind er Head Bolts: 2 6 N[...]

  • Página 49

    PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures V alve Clearance Adjustment If the valve clearance is not within the specified range, adjust the clearance by loosening the locknut and turning the adjusting screw . • T ighten the nuts to the specified torque and check the valve clearance again. T orque - V alve Adjusting Screw Locknut: 1[...]

  • Página 50

    2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Pull the clutch cable [A] tight and tighten the adjusting nuts [B] against the clutch cable bracket. • T urn the adjuster at the clutch lever until the free play is correct. • T ighten the knurled locknut at the clutch lever . WA R N I N G Be sure that the outer cable end at the clut[...]

  • Página 51

    PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures Recommended Engine Oil Grade: (BN125- A1 ∼ A3): API SE, SF or SG (BN125- A4 ∼ ): API SE, SF or SG API SH, SJ or SL with JASO MA Vis co s it y: SAE 10W-4 0 Capacity: 1.1 L (1.16 US qt) (When filter is not removed) 1 . 2L( 1 . 2 7U Sq t ) (when filte r is rem oved) 1 . 4L( 1 . 4 8U Sq t ) [...]

  • Página 52

    2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Replace the O-ring [A] with new one. • Apply grease to the O-ring and the grommet [B]. • Install the cover [C] and tighten the cover bolts. T o rque - Oil Filter Cover Bolts (BN125-A1 ∼ A3): 9.8 N·m (1.0 kgf·m, 87 in·lb) (BN125-A4 ∼ ): 8.8 N·m (0.90 kg f·m, 7 8 in ·lb ) •[...]

  • Página 53

    PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures Wheels/Tires Spoke Tightness Inspection • Check that all the spokes are tightened evenly . If spoke tightness is uneven or loose, tighten the spoke nipples evenly . T orque - Spoke Nipples: 2.0 ∼ 3.9 N·m (0.2 0 ∼ 0.40 kgf·m, 17 ∼ 35 in ·lb ) • Check the rim runout. WA R N I N G [...]

  • Página 54

    2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures Air Pressure Inspection/Adjustme nt • Remove the air valve cap. • Measure the tire air pressure with an air pressure gauge [A] when the tires are cold (that is, when the motorcycle has not been ridden more than a mile during the past 3 hours). Adjust the tire air pressure according to th[...]

  • Página 55

    PERIODIC MAINTENANCE 2-23 Periodic Maintenance Procedures Tire Wear Inspectio n As the tire tread wears down, the tire becomes more sus- ceptible to puncture and failure. An accepted estimate is that 90% of all tire failures occur during the last 10% of tread life (90% worn). So it is false economy and unsafe to use the tires until they are bald. ?[...]

  • Página 56

    2-24 PERIODIC MAINTENANCE Periodic Maintenance Procedures • Set the motorcycle up on its center stand. ○ Rotate the rear wheel to find the position where the chain is tightest. ○ Measure the vertical movement (chain slack) [A] midway between the sprockets. If the chain slack exceeds the standard, adjust it. Chain Slack Standard: 25 ∼ 40 mm [...]

  • Página 57

    PERIODIC MAINTENANCE 2-25 Periodic Maintenance Procedures • Bend the cotter pin [A] over the nut [B]. • Check the rear brake effectiveness. WA R N I N G If the axle and torque link nuts are not securely tightened and the cotter pin and snap pin are not installed, an unsafe riding condition may result. • T ighten the chain adjuster locknuts. D[...]

  • Página 58

    2-26 PERIODIC MAINTENANCE Periodic Maintenance Procedures Drive Chain Lubrication • The chain should be lubricated with a lubricant which will both prevent the exterior from rusting and also absorb shock and reduce friction in the interior of the chain. If the chain is especially dirty , it should be washed in diesel oil o r kerosene, and afterwa[...]

  • Página 59

    PERIODIC MAINTENANCE 2-27 Periodic Maintenance Procedures • Check that the front brake cam lever [A] comes to an 80° ∼ 90° angle [C] with the rear brake rod [B] when the rear brake is fully applied. If it does not, remove the adjusting nut [D] and lever , then adjust the rear brake cam lever angle. • Check the brake pedal free play . WA R N[...]

  • Página 60

    2-28 PERIODIC MAINTENANCE Periodic Maintenance Procedures Brake Fluid Le vel I nspe ction • Check that the brake fluid level in the brake reservoir [A] is between the upper [B] and the lower [C] level line. NOTE ○ Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower l[...]

  • Página 61

    PERIODIC MAINTENANCE 2-29 Periodic Maintenance Procedures • Remove the clear plastic hose. • Install the reservoir cap. • T ighten the bleed valve, and install the rubber cap. T orque - Caliper Bleed V alv e: 7.8 N·m (0.80 kgf·m, 69 in·lb) Front Brake Reservoir Cap Screws: 2.5 N·m (0.25 kgf·m, 22 in·lb) • After c hanging the fluid, ch[...]

  • Página 62

    2-30 PERIODIC MAINTENANCE Periodic Maintenance Procedures NOTE ○ The fluid level must be checked often during the bleed- ing operation and replenished with fresh brake fluid as necessary . If the fluid in the reservoir runs completely out any time during bleeding, the bleeding operation must be done over again from the beginning since air will ha[...]

  • Página 63

    PERIODIC MAINTENANCE 2-31 Periodic Maintenance Procedures Brake/Master Cylind er Cup and Dust Seal Replacement • Refer to the Master Cylinder section in the Brakes chapter for Brake/Master Cylinder Cup and Dust Seal Replace- ment. Caliper Piston /Dust Seals Repla cement • Refer to the Calipers section in the Brakes chapter for Caliper Piston/Du[...]

  • Página 64

    2-32 PERIODIC MAINTENANCE Periodic Maintenance Procedures Suspension Front Fork Oil Change • Remove the front fork (see Suspension chapter). • Hold the outer tube vertically in a vise. • Unscrew the top plug out of the inner tube. • Remove: Spacer [A] Fork Spring Seat [B] Fork Spring [C] • Pour out the fork oil to the container [C] with t[...]

  • Página 65

    PERIODIC MAINTENANCE 2-33 Periodic Maintenance Procedures • Install the fork spring [A] with the smaller end facing [B] downward. • Install: Fork Spring Seat Spacer • Repeat the same procedure for another front fork. • Install the front fork (see Suspension chapter). Front Fork Oil Leak Inspection • Visually inspect the front forks [A] fo[...]

  • Página 66

    2-34 PERIODIC MAINTENANCE Periodic Maintenance Procedures Steering Steering Inspection • Check the steering. ○ Lift the front wheel off the ground using the jack [A]. Special T ool - Jack: 57001-1238 ○ With the front wheel pointing straight ahead, alternately tap each end of the handlebar . The front wheel should swing fully left and right fr[...]

  • Página 67

    PERIODIC MAINTENANCE 2-35 Periodic Maintenance Procedures Steering S tem Bearing Lubrication • Remove the steering stem (see Steering chapter). • Using a high-flash point solvent, wash the upper and lower steel balls. • Wipe all the old grease off the upper and lower outer races. • Visually check the races and balls. Replace the bearing ass[...]

  • Página 68

    2-36 PERIODIC MAINTENANCE Periodic Maintenance Procedures General Lubrication Lubrication • Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime. • Lubricate the points listed below with indicated lubricant. NOTE ○ Whenever the vehicle has been operated under wet or rainy condi[...]

  • Página 69

    PERIODIC MAINTENANCE 2-37 Periodic Maintenance Procedures Nut, Bolt, and Fastener Tightness Inspection Tightness Inspection • Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter p in is in place and in good condition. NOTE ○ For the engine fasteners, check the tightness of them when the engine is cold (at [...]

  • Página 70

    [...]

  • Página 71

    FUEL SYSTEM 3-1 3 Fuel System T able of Contents Exploded View ................................................................................................................... ..... 3-2 Specifications ................................................................................................................. ........ 3-8 Special T ools ....[...]

  • Página 72

    3-2 FUEL SYST EM Exploded View[...]

  • Página 73

    FUEL SYSTEM 3-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Upper Chamber Cover Mounting Screws 3.5 0.36 31 in·lb 2 Spring Seat Screws 0.8 0.080 7i n · l b 3 Choke Lever Set Screw 0.8 0.080 7i n · l b L 4 Choke Lever Pivot Screw 2.0 0.20 17 in·lb 5 Pilot Air Jet 1.8 0.18 15 in·lb 6 Coasting Enricher Cover Screws 2.0 0.20 17[...]

  • Página 74

    3-4 FUEL SYST EM Exploded View Except the California Model[...]

  • Página 75

    FUEL SYSTEM 3-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Fuel T ap Plate Screws 0.8 0.080 7i n · l b 2 Fuel T ap Diaphragm Cover Screws 1.0 0.10 9i n · l b 2.5 0.25 22 in·lb with White W asher 3 Fuel T ap Mounting Bolts 4.9 0.50 43 in·lb with Black W asher 4. Catch tank 5. V acuum switch valve (For the A T , CH, DE of BN1[...]

  • Página 76

    3-6 FUEL SYST EM Exploded View California Model[...]

  • Página 77

    FUEL SYSTEM 3-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Fuel T ap Plate Screws 0.8 0.080 7i n · l b 2 Fuel T ap Diaphragm Cover Screws 1.0 0.10 9i n · l b 2.5 0.25 22 in·lb with White Washer 3 Fuel T ap Mounting Bolts 4.9 0.50 43 in·lb with Black Wash er 4. Catch tank 5. V acuum switch valve 6. Canister 7. Separator 8. B[...]

  • Página 78

    3-8 FUEL SYST EM Specifications Item Standard Throttle Grip Free Play 2 ∼ 3 mm (0.08 ∼ 0.1 2 in.) Carburetor Make, T ype MIKUNI BS28 Idle Speed 1 300 ±50 r/min (rpm) Pilot Screw (Turns Out) 15 / 8 3.0 (BN125-A7 ∼ ,N ,N U ) (US, CA, CH) – Service Fuel Level 1 ∼ 3 mm (0.04 ∼ 0.12 in.) below from the bottom edge of the of the carburetor b[...]

  • Página 79

    FUEL SYSTEM 3-9 Specifications Pilot screw [A] P l u g[ B ]( U S ,C A ,C H ) Pilot air jet [C] Jet needle [D] Throttle valve [E] Pilot jet [F] Needle jet [G] Main jet [H] Float [I] V alve seat [J] V alve needle [K][...]

  • Página 80

    3-10 FUEL SYSTEM Special T ools Fuel Level Gauge: 57001-101 7 Carburetor Drain Plug Wrench, Hex 3: 57001-1269[...]

  • Página 81

    FUEL SYSTEM 3-1 1 Throttle Grip and Cables Free Play Inspection • Refer to the Throttle Grip Free Play Inspection in the Pe- riodic Maintenance chapter . Free Play Adjustment • Refer to the Throttle Grip Free Play Adjustment in the Periodic Maintenance chapter . Throttle Cable Installation • Install the throttle cable in accordance with the C[...]

  • Página 82

    3-12 FUEL SYSTEM Carburetor Idle Speed Inspection • Refer to the Idle Speed Inspection in the Periodic Main- tenance c hapter . Idle Speed Adjustment • Refer to the Idle Speed Adjustment in the Periodic Main- tenance c hapter . Service Fuel Level Inspection WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain condit[...]

  • Página 83

    FUEL SYSTEM 3-13 Carburetor Service Fuel Le vel Adjustment WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smo ke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. • Remove the carb[...]

  • Página 84

    3-14 FUEL SYSTEM Carburetor Fuel System Cleanliness Inspection WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. • Connect a su[...]

  • Página 85

    FUEL SYSTEM 3-15 Carburetor • Loosen the carburetor holder clamp [A] and air cleaner duct clamp. • Pull the carburetor out of the air cleaner duct end [B], and then pull it out of the carburetor holder [C] from the vehicle’s right side. • T ake out the carburetor . • Stuff pieces of lint-free, clean cloth into the carburetor holder and th[...]

  • Página 86

    3-16 FUEL SYSTEM Carburetor • Remove: Upper Chamber Cover [A] V acuum Piston and Diaphragm CAUTION During carburetor disassembly , the careful not to damage the diaphragm. N ever use a sharp edge to remove the diaphragm. • Remove the spring seat screws [D]. • Remove the jet needle [A] from the vacuum piston [B] along with the spring seat [C].[...]

  • Página 87

    FUEL SYSTEM 3-17 Carburetor • Remove the coasting enricher cover . • Remove the diaphragm [A]. Carburetor Assembly • T urn in the pilot screw [A] fully but not tightly , and then back it out the same number of turn counted during dis- assembly . • For the Swiss, United States. and Canada models, drive in a new plug [B] in the pilot screw ho[...]

  • Página 88

    3-18 FUEL SYSTEM Carburetor • Align the diaphragm tang [A] with the notch in the upper chamber , and fit the diaphragm sealing lip into its groove. • After installing the upper chamber cover , check that the vacuum piston slides up and down smoothly without bind- ing in the carburetor bore. • T ighten: T orque - Upper Chamber Cover Screws : 3[...]

  • Página 89

    FUEL SYSTEM 3-19 Carburetor Carburetor Inspection WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smo ke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. • Remove the carburetor . [...]

  • Página 90

    3-20 FUEL SYSTEM Carburetor • Check the tapered portion [A] of the pilot s crew [B] for wear or damage. If the pilot screw is worn or damaged on the tapered por- tion, it will prevent the engine from idling smoothly . Re- place it. • Check that the vacuum piston [A] moves smoothly in the carburetor body . The surface of the piston must not be e[...]

  • Página 91

    FUEL SYSTEM 3-21 Air Cleaner Air Cleaner Element Remova l • Remove the left side cover . • Remove the element cover [A]. Front [B] • Pull out the air cleaner element [A]. • Push a clean, lint-free towel into the air cleaner housing to keep dirt or other foreign material from entering. WA R N I N G If dirt or dust is allowed to pass through [...]

  • Página 92

    3-22 FUEL SYSTEM Air Cleaner Air Cleaner H ousing Removal • Remove: Side Covers and Seat (see Frame chapter) Fuel T ank (see Fuel T ank Removal) Battery (see Electrical System) and Battery Seat [A] Breather Hose of Air Cleaner Starter Relay [B] Fuse Case [C] Starter Circuit Relay [D] Housing Mounting Bolts [E] and Screws [F] • Remove the elemen[...]

  • Página 93

    FUEL SYSTEM 3-23 Fuel T ank Fuel T an k Removal WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smo ke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. • Remove the seat and side c[...]

  • Página 94

    3-24 FUEL SYSTEM Fuel T ank Fuel T ank Cleaning WA R N I N G Clean the tank in a well-ventllated area, and take care that there are no sparks or flame anywhere near the w orking area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the tank. • Remove the fuel tank and drain it. • Pour [...]

  • Página 95

    FUEL SYSTEM 3-25 Fuel T ank Fuel T ap Inspection • Remove the fuel tap. • Check the fuel tap filter screen [A] for any breaks or dete- rioration. If the fuel tap screens have any breaks or are deterio- rated, they may allow dirt to reach the carburetor , c ausing poor running. Replace the fuel tap. If the fuel tap leaks, or allows fuel to flow [...]

  • Página 96

    3-26 FUEL SYSTEM Evaporative Emission Control Sy stem ( California Model Only) The Evaporative Emission Cont rol System routes fuel va- pors from the fuel system into the running engine or stores the vapors in a canister when the engine is stopped. Al- though no adjustments are required, a thorough visual in- spection must be made at the intervals [...]

  • Página 97

    FUEL SYSTEM 3-27 Evaporative Emission Co ntrol System ( California Model Only) Separator Operation T est WA R N I N G Gasoline is extremely flammable and can be ex- plosive under certain conditions. T urn the ignition switch OFF . Do not smo ke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any app[...]

  • Página 98

    [...]

  • Página 99

    ENGINE TOP END 4-1 4 Engine T op End T able of Contents Exploded View ................................... 4-2 Specifications .................................... 4-6 Special T ools ..................................... 4-9 Clean Air System (For A T , CH, DE of BN125-A1 ∼ A2 and other than the CAL)................................................ 4[...]

  • Página 100

    4-2 ENGINE TOP END Exploded View[...]

  • Página 101

    ENGINE TOP END 4-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 V alve Adjusting Cap Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb V alve Adjusting Cap Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb 2 Camshaft Chain Cover Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb Camshaft Chain Cover Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb 3 Cylinder Head[...]

  • Página 102

    4-4 ENGINE TOP END Exploded View[...]

  • Página 103

    ENGINE TOP END 4-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Camshaft Bearing Holder Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb Camshaft B earing Holder Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb 2 Camshaft Sprocket Bolts 12 1.2 104 in·lb 3 Camshaft Chain Holder Screw 4.9 0.50 43 in·lb 4 Camshaft Chain Guide Bolt 8.8 0.90 78 in[...]

  • Página 104

    4-6 ENGINE TOP END Specifications Item Standard Service Limit Clean Air Sytem V acuum Switch V alve Closing Pressure: Open → Close ––– (A T , CH, DE, of the BN125-A1 ∼ A2 and othe r than the CAL) 45 ∼ 53 kPa (340 ∼ 400 mmHg, 6.5 ∼ 7.7 psi) ––– (CAL) 41 ∼ 52 kPa (310 ∼ 390 mmHg, 6.0 ∼ 7.5 psi) ––– Camshaft Cam Heigh[...]

  • Página 105

    ENGINE TOP END 4-7 Specifications Item Standard Service Limit Width: Exhaust 0.8 ∼ 1.2 mm (0.03 ∼ 0.05 in.) ––– Inlet 0.8 ∼ 1.2 mm (0.03 ∼ 0.05 in.) ––– V alve Spring Free Length: Exhaust 43.51 mm (1.713 in.) 42.1 mm (1.66 in.) Inlet 43.51 mm (1.713 in.) 42.1 mm (1.66 in.) Cylinder , P iston Cylinder Inside Diameter 55.000 ∼ 5[...]

  • Página 106

    4-8 ENGINE TOP END Specifications Cam Height Cam Height [A] V alve Head Thickness V alve Stem Diameter [A] V alv e Head T hicknes s [B] 45° [C] Camshaft Runout Va l v e S t e m B e n d Dial Gauge [A][...]

  • Página 107

    ENGINE TOP END 4-9 Special T ools Compression Gauge, 20 kgf/cm²: 57001-221 V alve Spring Compressor A ssembly: 57001-241 Piston Pin Puller Assembly: 57001-910 V alve Seat Cutter , 45°- 27.5: 57001-1 1 14 V alve Seat Cutter , 45° - 32: 57001-1 1 15 V alve Sea t Cutter , 32 °- 30: 57001-1 120 V alve Sea t C utter , 32 ° - 35: 57001-1 121 V alve [...]

  • Página 108

    4-10 ENGINE TOP END Special T ools Fork Oil Level Gauge: 57001-129 0 Compression Gauge Adapter , M10 × 1.0: 57001-131 7 V alve Seat Cutter Holder , 4.5: 57001-133 0 V alve G uide Arbor , 4.5: 57001-1331 V alve G ui d e Reamer , 4. 5: 57001-1333 Va l v e S e a t C u t t e r, 6 0 ° - 33: 57001-1334 ○ V alve S eat Cutter , 32°- 33: 57001-1 199 ca[...]

  • Página 109

    ENGINE TOP END 4-1 1 Clean Air System (For A T , CH, DE of BN125-A1 ∼ A2 an d other t han the C AL) AT : A u s t r i a CAL: California CH: Switzerland DE: Germany Air Suction V alve Installation • Install the air suction valve so that its number [A] of the read faces outside and downward. • T ighten: T orque - Air Suction V alve Cover Bolts: [...]

  • Página 110

    4-12 ENGINE TOP END Clean Air System (For A T , CH, DE of BN125-A1 ∼ A2 an d other th an the C AL) V acuum Switch V alve Unit T est • Remove the vacuum switch valve (see V acuum Switch V alve Removal). • Connect a commercially available vacuum gauge [A] and syringe [B] (or fork oil level gauge) to the vacuum hoses as shown. Special T ool - Fo[...]

  • Página 111

    ENGINE TOP END 4-13 Clean Air System (California Model) Va c u u m S w i t c h Va l v e T e s t • Remove the vacuum switch valve. • Connect the vacuum gauge [A] and syringe [B] or fork oil level gauge to the vacuum hoses as shown. Special T ool - Fork Oil Level Gauge : 57001–1290 Air Flow [C] • Gradually raise the vacuum (l ower the pressur[...]

  • Página 112

    4-14 ENGINE TOP END Camshaft Chain T ensioner Camshaft Chain T ensioner Removal CAUTION This is a non-return type cam chain tensioner . The push rod does not return to its original position once it moves out to take up camshaft chain slack. Observe all the rules listed below: When removing the tensioner , do not take out the mounting bolts only hal[...]

  • Página 113

    ENGINE TOP END 4-15 Camshaft Chain T ensioner • Install the O-ring in the tensioner body . • Install the tensioner so that the arrow mark [B] faces up- ward, and tighten the mounting bolts. T orque - Chain T ensioner Mounting Bolts (BN125-A1 ∼ A3): 9.8 N·m (1.0 kgf·m 87in·lb) (BN125-A4 ∼ ): 8.8 N·m (0.90 kgf·m 87in·l b ) • Remove th[...]

  • Página 114

    4-16 ENGINE TOP END Camshaft Camshaft Removal • Remove: Fuel T ank [A] (see Fuel System chapter) Camshaft Chain Cover [B] V alve Adjusting Caps [C] • Holding the camshaft center bolt [A] with a wrench, loosen the camshaft sprocket bolts [B]. • T urn the camshaft center bolt [A] clockwise so that the mark [B] on the sprocket aligns with the ti[...]

  • Página 115

    ENGINE TOP END 4-17 Camshaft • Using a screw [A] (M5 × P0.8 mm), remove the rocker shafts [B]. ○ Mark the rocker shafts so that they can be installed later in the same position. • Remove: Rocker Arms [A] Camshaft Bearing Holder [B] ○ Mark the rocker arms so that they can be installed later in the same position. • Pull out the camshaft [A[...]

  • Página 116

    4-18 ENGINE TOP END Camshaft • Install the camshaft bearing holder [A]. • Apply engine oil to the rocker shaft surface and cam por- tion of the rocker arm, and then install them at the original position. ○ Install the rocker shafts [B] so that the screw threads face outward. • Replace the rocker shaft bolt washers with new ones. • Install[...]

  • Página 117

    ENGINE TOP END 4-19 Camshaft • Remove the crank balancer gear [A]. Special T ool - Outside Circlip Pliers: 57001-144 ○ Stuff a clean cloth into the hole [B] so that the balancer damper springs will not fall into it. • Remove the camshaft chain holder [A], and pull the camshaft chain [B] upward. • Remove the cylinder head (see Cylinder Head [...]

  • Página 118

    4-20 ENGINE TOP END Camshaft ○ Align the three punch marks [D] on the balancer shaft gear [A], crank balancer gear [B], and coupling [C]. • Install the alternator (see Electrical System chapter). • Align the punch mark [A] on the crankcase with the “T” mark [B] on the rotor . • Engage the camshaft sprocket [A] with the chain [B]. Then a[...]

  • Página 119

    ENGINE TOP END 4-21 Cylinder H ead Cylinder Compression Measurement NOTE ○ Use the battery which is fully charged • W arm up the engine thoroughly . • Stop the engine. • Remove: Fuel T ank (see Fuel System chapter) Spark Plug Owner ’ s T ool - Spark Plug Wrench, Hex 16: 921 10-1 172 [A] • Attach the compression gauge [A] and adapter [B][...]

  • Página 120

    4-22 ENGINE TOP END Cylinder Head Cylinder Head Removal • Remove: Fuel T ank (see Fuel System chapter) Exhaust Pipe [A] (see Muffler Removal) Carburetor [B] (see Fuel System chapter) Oil Pipe [C] (see Engine Lubrication chapter) Spark Plug Cap Ignition Coil CDI Unit (see E lectrical System chapter) • Remove: Engine Upper Bracket [A] Camshaft Ch[...]

  • Página 121

    ENGINE TOP END 4-23 Cylinder H ead Cylinder Head Installation • Install: Dowel Pins [A ] New Cylinder Head Gasket [B] • Apply molybdenum disulfide g rease to the threads of the 9 mm cylinder head bolts [1 ∼ 4], and engine oil to both sides of the washers. • T ighten the 9 mm bolts following the tightening sequence as shown. Tighten them fir[...]

  • Página 122

    4-24 ENGINE TOP END Cylinder Head Cylinder Head Assembly • Install the rubber dampers as shown. Dampers [A] Fins [B] Front [C] Cylinder Head Cleaning • Remove the cylinder head (see Cylinder Head Removal). • Remove the valves (see V alve Removal). • W ash the head with a high-flash point solvent. • Scrape the carbon out of the combustion [...]

  • Página 123

    ENGINE TOP END 4-25 Cylinder H ead Cylinder Head Warp • Clean the cylinder head (see Cylinder Head Cleaning). • Lay a straightedge across the lower surface of the cylinder head at the positions as shown. • Use a thickness gauge [A] to measure the space between the straightedge [B] and the cylinder head. Cylinder Head War p Standard: –––[...]

  • Página 124

    4-26 ENGINE TOP END Va l v e s V alve Clearance Inspection • Refer to the V alve Clearance Inspection in the Periodic Maintenance chapter . V alve Clearance Adjustment • Refer to the V alve Clearance Adjustment in the Periodic Maintenance chapter . V alve Rem oval • Remove the cylinder head (see Cylinder Head Removal). • Remove the rocker s[...]

  • Página 125

    ENGINE TOP END 4-27 Va l v e s V alve Guide Installation • Apply oil to the valve guide outer surface before installa- tion. • Heat the area around the valve guide hole to about 120 ∼ 150°C (248 ∼ 302°F). CAUTION Do not heat the cylinder head with a torch. This will warp the cylinder head. Soak the cylinder head and heat the oil. • Driv[...]

  • Página 126

    4-28 ENGINE TOP END Va l v e s V alve Seat In spection • Remove the valve (see V alve Removal). • Check the valve seating surface [A] between the valve [B] and valve seat [C]. ○ Measure the outside diameter [D] of the seating pattern on the valve seat. If the outside diameter is too large or too small, repair the seat (see V alve Seat Repair)[...]

  • Página 127

    ENGINE TOP END 4-29 Va l v e s Seat Cutter Operation Care 1. This valve seat cutter is developed to grind the valve for repair . Therefore the cutter must not be used for other purposes than seat repair . 2. Do not drop or shock the valve seat cutter , or the dia- mond particles may fall off. 3. Do not fail to apply engine oil to the valve seat cut[...]

  • Página 128

    4-30 ENGINE TOP END Va l v e s • Measure the outside diameter of the seating surface with a v ernier caliper . If the outside diameter of the seating surface is too small, repeat the 45° grind until the diameter is within the spec- ified range. Widened Width [A] of engagement by machining with 45° cutter Ground V olume [B] by 32° cutter 32° [[...]

  • Página 129

    ENGINE TOP END 4-31 Va l v e s If the seat width is too wide, make the 60° grind [A] de- scribed below . If the seat width is within the specified range, lap the valve to the seat as described below . • Grind the seat at a 60° angle until the seat width is within the specified range. ○ T o make the 60° grind, fit 60° cutter into the holder [...]

  • Página 130

    4-32 ENGINE TOP END Va l v e s[...]

  • Página 131

    ENGINE TOP END 4-33 Cylinder , Piston Cylinder Removal • Remove: Cylinder Head (see Cylinder Head Removal) • T ap lightly up the cylinder [A] with a plastic mallet to sep- arate from the crankcase. • Remove the cylinder base gasket. Piston Removal • Remove the cylinder (see Cylinder Removal). • Place a clean cloth under the piston and rem[...]

  • Página 132

    4-34 ENGINE TOP END Cylinder , Piston ○ When installing the piston pin snap ring, compress it only enough to install it and no more. CAUTION Do not reuse snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall. NOTE ○ The oil ring rails have no "top" or "bottom". • Install the oil r[...]

  • Página 133

    ENGINE TOP END 4-35 Cylinder , Piston • Apply engine oil to the cylinder bore. • Position the piston ring openings. • Install the cylinder [B] while compressing [A] the piston rings with your thumbs. • Install the removed parts. Cylinder Wear • Since there is a difference in cylinder wear in different di- rections, take a side-to-side and[...]

  • Página 134

    4-36 ENGINE TOP END Cylinder , Piston Piston/Cylinder Clearance • Subtract the piston diameter from the cylinder inside di- ameter to get the piston/cylinder clearance. Piston/Cylinder Clearance Standard: 0.025 ∼ 0.052 mm (0.0010 ∼ 0.0020 in.) If the piston/cylinder clearance is less than the specified range, use a smaller piston or increase [...]

  • Página 135

    ENGINE TOP END 4-37 Cylinder , Piston Piston Ring Thickness • Measure the piston ring thickness. ○ Use a micrometer to measure at several points around the ring. Piston Ring Thickness (T op, Second) Standard: 0.77 ∼ 0.79 mm (0.0303 ∼ 0.031 1 in.) Service Li m it : 0.70 m m (0.028 i n .) If any of the measurements is less than the service li[...]

  • Página 136

    4-38 ENGINE TOP END Carburetor Holder Carburetor Hold er Installation • Apply grease to the O-ring [A], and install the carburetor holder . ○ T ake care not to pinch the O-ring. • T ighten: T orque - Carburetor Holder Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the insulator [B] so that its recess aligns with the boss [A] on the carbu[...]

  • Página 137

    ENGINE TOP END 4-39 Muffler WA R N I N G T o avoid a serlous burn, do not remove the muffler when the engine is still hot. Wait until the muffler cools down. Muffler Removal • loosen the muffler body clamp bolt [A]. • Remove the muffler body mounting bolt and nut [B]. • Remove the muffler body [A] backward. • Remove the exhaust pipe m ounti[...]

  • Página 138

    [...]

  • Página 139

    CLUTCH 5-1 5 Clutch T able of Contents Exploded View ................................................................................................................... ..... 5-2 Specifications ................................................................................................................. ........ 5-4 Special T ools ..............[...]

  • Página 140

    5-2 CLUTCH Exploded View[...]

  • Página 141

    CLUTCH 5-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Clutch Hub Nut 98 10.0 72 2 Clutch Spring Bolt 8.8 0.90 78 in·lb Clutch Cover Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 3 Clutch Cover Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb Oil Seal Retaining Plate Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 4 Oil Seal Retaining Plate Bolt[...]

  • Página 142

    5-4 CLUTCH Specifications Item Standard Service Limit Clutch Lever Free Play 2 ∼ 3 mm (0.08 ∼ 0.12 in.) ––– Clutch Friction Plate Thickness 2.92 ∼ 3.08 mm (0.1 15 ∼ 0.121 in.) 2.8 mm (0.1 1 in.) Friction and Steel Plate Warp 0.2 mm (0.008 in.) or less 0.3 mm (0.012 in.) Clutch Spring Free Length 35.0 mm (1.38 in.) 34.0 mm (1.34 in.)[...]

  • Página 143

    CLUTCH 5-5 Special T ools Gear Holder , m1.75: 57001-1015 Clutch Holder: 57001-1243[...]

  • Página 144

    5-6 CLUTCH Clutch Lever and Cable Due to friction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accor- dance with the Periodic Maintenance Chart. Clutch Lever Free Play Inspection • Refer to the Clutch Lever Free Play Inspection in the P e- riodic Maintenance chapter . Clutch Le ver Free Play Adjust[...]

  • Página 145

    CLUTCH 5-7 Clutch Cover Clutch Cover Removal • Drain the engine oil (see Periodic Maintenance chapter). • Remove: Front Footpeg Oil Pipe Banjo Bolt [A] • Screw the clutch lever adjuster in completely s o as to give t h ec l u t c hc a b l ep l e n t yo fp l a y . • Remove the clutch cable holder [B] of clutch release lever . • Free the cl[...]

  • Página 146

    5-8 CLUTCH Clutch Cover • With the shaft pulled a little out of the cover , turn the lever until it becomes hard to turn. ○ The release lever should have about 1 1 mm (0.43 in.) [A] clearance between the lever and the washer . • T ighten the cover bolts and clutch cable holder bolts. ○ While pushing [B] the clutch cable holder [A] rearward [...]

  • Página 147

    CLUTCH 5-9 Clutch Clutch Removal • Remove the clutch cover (see Clutch Cover Removal). NOTE ○ If the primary gear is to be removed, remove the pri- mary gear nut before clutch removal (see Primary Gear Removal). • Remove: Clutch Spring Bolts [A] with Springs Clutch Spring Plate [B] Ball Bearing and Pusher [C] Friction Plates and Steel Plates [...]

  • Página 148

    5-10 CLUTCH Clutch • Install the washer [A] as shown. Crankcase Side [B] • T ighten the clutch hub nut [C], while holding the clutch hub with the clutch holder . Special T ool - Clutch Holder: 57001-1243 T o rque - Clutch Hub Nut: 9 8 N·m (10.0 kgf·m, 72 ft ·lb) • Install the spring seat [B], and then the spring [C] with the concave side f[...]

  • Página 149

    CLUTCH 5-1 1 Clutch Clutch Spring Free Length Measurement • Measure the free length of the clutch springs [A]. If any spring is shorter than the service limit, it must be replaced. Clutch Spring Free Length Standard: 35.0 mm (1.38 in.) Service Limit: 34.0 m m (1.34 in.) Clutch Housing F inge r Damage • Visually inspect the clutch housing finger[...]

  • Página 150

    5-12 CLUTCH Primary Gear Primary Gear Removal • Remove the clutch cover (see Clutch Cover Removal). • Using the gear holder [A], hold the primary gear and loosen the primary gear nut [B]. Special T ool - Gear Holder , m1.75: 57001-101 5 • Remove: Clutch (see Clutch Removal) [C] Primary Gear Nut [B] Spring Washer Primary Gear [D] Woodruf f Key[...]

  • Página 151

    ENGINE LUBRICA TION SYSTEM 6-1 6 Engine Lubrication System T able of Contents Exploded View ................................................................................................................... ..... 6-2 Engine Oil Flow Chart............................................................................................................. 6[...]

  • Página 152

    6-2 ENGINE LUBRICA TION SYSTEM Exploded View[...]

  • Página 153

    ENGINE LUBRICA TION SYSTEM 6-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Oil Drain Plug 18 1.8 13 Oil Screen Cover Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 2 Oil Screen Cover Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb 3 Oil Pressure Relief V alve 15 1.5 11 L Oil Filter Cover Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 4 Oi[...]

  • Página 154

    6-4 ENGINE LUBRICA TION SYSTEM Engine Oil Flow Chart 1. Oil screen 2. Oil pump 3. Clutch Cover Oil Passage 4. Oil Pressure Relief V alve 5. Oil Fi lter 6. Crankshaft Oil seal 7. Oil Pipe Banjo Bolts 8. Camshaft 9. Drive Shaft 10. Output Shaft 1 1. C amshaft C hain T unnel 12. Engine Breather Hose 13. Air Cleaner Housing A. Oil Flow B. Blowby Gas[...]

  • Página 155

    ENGINE LUBRICA TION SYSTEM 6-5 Specifications Item Standard Engine Oil Grade: (BN125-A1 ∼ A3) API SE, SF or SG (BN125-A4 ∼ ) API SE, SF or SG API SH, SJ or SL with JASO MA Vis c os i ty SAE 10W-40 Capacity 1.1 L (1.16 US qt) (when filter is not r emoved) 1.2 L (1.27 US qt) (when filter is removed) 1.4 L (1.48 US qt) (when engine is completely d[...]

  • Página 156

    6-6 ENGINE LUBRICA TION SYSTEM Special T ools Oil Pressure Gauge, 5 kgf/cm²: 57001-125 Oil P re ssure Gauge Adapter , M10 × 1.25 : 57001-1 182[...]

  • Página 157

    ENGINE LUBRICA TION SYSTEM 6-7 Engine Oil and Oil Filter WA R N I N G Motorcycle operation with insufficient, deteri- orated, or contaminated engine oil will cause accelerated wear and may result in engine or trans- mission seizure, accident, and injury . Oil Level Inspection • Situate the motorcycle so that it is vertical. • Check that the eng[...]

  • Página 158

    6-8 ENGINE LUBRICA TION SYSTEM Oil Screen Oil Screen Removal • Refer to the Oil Screen Cleaning in the Periodic Mainte- nance chapter . Oil Screen Installation • Refer to the Oil Screen Cleaning in the Periodic Mainte- nance chapter .[...]

  • Página 159

    ENGINE LUBRICA TION SYSTEM 6-9 Oil Pump Oil Pump Removal • Remove the clutch cover (see Clutch chapter). • Remove the mounting screws [A] and remove the oil pump assembly [B]. ○ T urn the pump gear so that the pump mounting screws can be removed through the pump gear holes. Oil Pump Installation • Replace the O-rings with new ones. • Inst[...]

  • Página 160

    6-10 ENGINE LUBRICA TION SYSTEM Oil Pump Oil Pump Assembly • Install the oil pump gear [A]. • Fill the rotors [B] with engine oil. • Install the cover and tighten the oil pump assembly screw . T orque - O il Pump Assembly Screw: 9.8 N·m (1.0 kgf·m, 87 in·lb) • Install the washer and circlip. • Replace the O-rings with new ones. • Che[...]

  • Página 161

    ENGINE LUBRICA TION SYSTEM 6-1 1 Oil Pressure Oil Pressure Me asureme nt • Remove the air suction valve [A] (see Engine T op End chapter). • Replace the oil pipe banjo bolt of the clutch cover [B] with the oil pressure gauge adapter (special tool) [C]. If the oil pressure gauge adapter bottoms out, add washer(s) (P/N: 1 1009-1 105) [D] under th[...]

  • Página 162

    6-12 ENGINE LUBRICA TION SYSTEM Relief V alve Relief V alve Inspection • Remove the relief valve from the clutch c over . • Check to see if the valve [A] slides smoothly when push- ing in with a wooden or other soft rod, and see if it comes back to its seat by spring [B] pressure. NOTE ○ Inspect the valve in it assembled state. Disassembly an[...]

  • Página 163

    ENGINE LUBRICA TION SYSTEM 6-13 Oil Pipe Oil Pipe Removal • Remove: Oil Pipe Banjo Bolts (Cylinder Head) [A] Oil Pipe Banjo Bolt (Clutch Cover) [B] Oil Pipe Mounting Bolt [C] • Remove: Engine Sprocket Cover (see Final Drive chapter) Oil Pipe Banjo Bolt (Left Crankcase) [A] • Remove the oil pipe from the right side of the engine. Oil Pipe Inst[...]

  • Página 164

    [...]

  • Página 165

    ENGINE REM OV AL/INST ALLA TION 7-1 7 Engine Removal/Installation T able of Contents Exploded View ................................................................................................................... ..... 7-2 Special T ool ...............................................................................................................[...]

  • Página 166

    7-2 ENGINE REMOV AL/INST ALLA TION Exploded View[...]

  • Página 167

    ENGINE REMOV AL/INST ALLA TION 7-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Engine Mounting Bolts, Nuts ( M10) 44 4.5 33 2 Engine Mounting Bolts, Nuts (M8) 25 2.5 18 3 Engine Mounting Bracket Bolts, Nuts 25 2.5 18 4 Engine Ground T erminal Bolt 9.8 1.0 87 in·lb[...]

  • Página 168

    7-4 ENGINE REMOV AL/INST ALLA TION Special T oo l Jack: 57001-123 8[...]

  • Página 169

    ENGINE REMOV AL/INST ALLA TION 7-5 Engine Removal/Installation Engine Removal • Place the jack [A] under the frame to lift the rear wheel [B] off the ground. Special T ool - Jack: 57001-1238 • Squeeze the brake lever slowly and hold it with a band [A]. WA R N I N G Be sure to hold the front brake when removing the engine, or the motorcycle may [...]

  • Página 170

    7-6 ENGINE REMOV AL/INST ALLA TION Engine Removal/Installation • Remove: Engine Mounting Bolts [A] Engine Mounting Bracket Bolts [B] ○ Pull out the mounting bolts while lifting the engine. • Lift up the engine and move it to the right side of the frame. • Remove the engine [A] from the vehicle right side. Engine Installation • Insert the [...]

  • Página 171

    ENGINE REMOV AL/INST ALLA TION 7-7 Engine Removal/Installation If the engine sprocket is hard to install, remove the master link and the clip from the drive chain, and then install the engine sprocket. ○ Install the clip [A] so that the open end [B] of the "U" points in the opposite direction of chain rotation [C]. • Install the engin[...]

  • Página 172

    [...]

  • Página 173

    CRANKSHAFT/TRANSMISSION 8-1 8 Crankshaft/T ransmission T able of Contents Exploded View ................................... 8-2 Specifications .................................... 8-6 Special T ools and Sealant ................. 8-7 Crankcase ......................................... 8 -8 Crankcase Disassembly .............. 8-8 Crankcase Assembly [...]

  • Página 174

    8-2 CRANKSHAFT/TRANSMISSION Exploded View[...]

  • Página 175

    CRANKSHAFT/TRANSMISSION 8-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Primary Gear Nut 69 7.0 51 2 Balancer Shaft Gear Nut 78 8.0 58 EO 3 Crankcase Bolts 8.8 0.90 78 in·lb 4 Crankcase Bearing Retainer Screws 4.9 0.50 43 in·lb 5. Balancer Shaft 6. Balancer shaft gear 7. Crank balancer gear 8. Crankshaft EO: Apply engine oil. [...]

  • Página 176

    8-4 CRANKSHAFT/TRANSMISSION Exploded View[...]

  • Página 177

    CRANKSHAFT/TRANSMISSION 8-5 Exploded View T orque No. Faste ner N·m kgf·m ft·lb Remarks 1 Neutral Switch 15 1.5 11 2 Shift Drum Cam Screw 4.9 0.50 43 in·lb L 3 Gear Set Lever Nut 11 1.1 95 in·lb 4 Engine Sprocket Holder Bolts 12 1.2 104 in·lb 5 Shift Shaft Return Spring Pin 29 3.0 21 L 6 Shift Lever Clamp Bolt 12 1.2 104 in·lb 7 Shift Pedal [...]

  • Página 178

    8-6 CRANKSHAFT/TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rod Connecting Rod Big End Side Clearance 0.20 ∼ 0.35 mm (0.008 ∼ 0.014 in.) 0.5 mm (0.020 in.) Connecting Rod Big End Radial Clearance 0.005 ∼ 0.017 mm (0.0002 ∼ 0.0007 in.) 0.07 mm (0.003 in.) Crankshaft Runout TIR 0.03 m m (0.0012 in.) or less T[...]

  • Página 179

    CRANKSHAFT/TRANSMISSION 8-7 Special T ools and Sealant Outside Circlip Pliers: 57001-144 Gear Holder , m1.75: 57001-1015 Bearing Driver Set: 57001-1 129 Crankshaft Jig: 57001-1 174 Crankcase Splitting T ool Assembly: 57001-1362 Kawasaki Bond (Liquid G asket-Silver): 92104-002[...]

  • Página 180

    8-8 CRANKSHAFT/TRANSMISSION Crankcase Crankcase Disassembly • Remove: Clutch (see Clutch chapter) Primary Gear (see Clutch chapter) Starter Motor (see Electrical System chapter) Alternator (see Electrical System chapter) Balancer Shaft G ear (see Balancer Shaft Gear Re- moval) Crank Balancer Gear (see Engine T op End chapter) [A] • Remove the e[...]

  • Página 181

    CRANKSHAFT/TRANSMISSION 8-9 Crankcase • Remove the transmission shaft [A], gears and balancer shaft from the right crankcase half [B]. • Remove: Shift Drum Cam Screw [A ] Shift Drum Cam [B] Woodruf f Key [C] Shift D rum [D] Gear Set Lever [E] • Support the right crankcase half [ A] with a suitable re- tainer . • Remove the crankshaft [B] fr[...]

  • Página 182

    8-10 CRANKSHAFT/TRANSMISSION Crankcase • Press the damper [A] into the crankcase with the bearing drier set. Special T ool - Bearing Driver Set: 57001-1 129 • Chip off the old gasket from the mating surfaces of the crankcase halves and clean them off with a high-flash point solvent. • Using compressed air , blow out the oil passages in the cr[...]

  • Página 183

    CRANKSHAFT/TRANSMISSION 8-1 1 Crankcase • Using compressed air [A], blow out the oil passage in the right crankshaft [B]. • Positioning the connecting rod [A] big end at BDC, put in the crankshaft jig [B] between the crankshaft flywheels. • Press the crankshaft [C] in the right crankcase half [D]. Special T ool - Crankshaft Jig: 57001-1 174 ?[...]

  • Página 184

    8-12 CRANKSHAFT/TRANSMISSION Crankcase • Check to see that the crankshaft, drive shaft, and output shaft all turn freely (in the neutral position). If the crankshaft will not turn, probably the crankshaft is not centered; T ap the mount portion [A] of the crankcase with a plastic hammer to reposition it. • Put the end of the woodruff key [A] in[...]

  • Página 185

    CRANKSHAFT/TRANSMISSION 8-13 Crankshaft Crank Balancer Gear Removal/Installation • Refer to Camshaft Chain Removal/Installation in the En- gine T op End chapter . Crankshaft Removal • Refer to the Crankcase Disassembly in this chapter . Crankshaft Installation • Refer to the Crankcase Assembly in this chapter . Crankshaft Disassembly If the c[...]

  • Página 186

    8-14 CRANKSHAFT/TRANSMISSION Crankshaft • First correct the horizontal misalignment by striking the projecting crank half [A] with a plastic, soft lead, or brass hammer as shown. • Recheck the runout with a dial gauge and repeat the process until the runout falls within the service limit. • Next, correct the vertical misalignment by either dr[...]

  • Página 187

    CRANKSHAFT/TRANSMISSION 8-15 Balancer Shaft Gear Balancer Shaft Ge ar Removal • Remove: Alternator Rotor (see Electrical System chapter) Clutch Cover (see Clutch chapter) • Using the gear holder , hold the primary gear [A] and loosen the balancer shaft gear nut [B]. Special T ool - Gear Holder , m1.75: 57001-10 15 [C] • Remove the balancer sh[...]

  • Página 188

    8-16 CRANKSHAFT/TRANSMISSION Starter Motor C lutch Starter Motor Clutch Removal/Installation • Refer to the Alternator Rotor Removal and Installation in the Electrical System chapter . Starter M otor Clutch Disassembly • Remove the alternator rotor [A] (see Electrical System chapter). • Hold the alternator rotor w ith the flywheel holder [B] [...]

  • Página 189

    CRANKSHAFT/TRANSMISSION 8-17 External Shift Mechanism Shift Pedal Heigh t Adjustment • Adjust the length of the shift linkage rod so that the dis- tance between the shift pedal [A] and the front left footpeg [B] shall be 26.5 ∼ 29.5 mm (1.04 ∼ 1.16 in.) [C]. Then, the length [D] of the shift linkage rod will be approximately 141 mm (5.55 in.)[...]

  • Página 190

    8-18 CRANKSHAFT/TRANSMISSION External Shift Mechanism • T urn the shift drum and position the neutral groove [A] as shown. • Remove the shift shaft [D] while pushing [C] the shift mechanism arm [B] toward the shaft. External Shift Mechanism Inspection • Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace it[...]

  • Página 191

    CRANKSHAFT/TRANSMISSION 8-19 T ransmission T ransmission Shaft Removal • Split the crankcase (see Crankcase Disassembly). • Pull out the shift rod [A] allowing the shift fork guide pins to free from the shift drum [B]. • Remove the shift forks [C]. • Remove the shift drum. • Pull out the drive shaft [D] and output shaft [E] together with [...]

  • Página 192

    8-20 CRANKSHAFT/TRANSMISSION T ransmission T ransmission Assembly • Replace any circlips removed with new ones. ○ Install the circlips [A] so that the opening [B] is aligned w i t has p l i n eg r o o v e[ C ] . ○ Install the toothed washer [D] so that the teeth [E] are not aligned with the opening of the c irclip. • The drive shaft gears c[...]

  • Página 193

    CRANKSHAFT/TRANSMISSION 8-21 T ransmission Shift Drum Removal/Installation • Refer to the Crankcase Disassembly/Installation in the Crankshaft/T ransmission chapter . Shift Fork Bending • Visually inspect the shift forks, and replace any fork that is bent. A bent fork could cause dif ficulty in shifting, or allow the transmission to jump out of[...]

  • Página 194

    8-22 CRANKSHAFT/TRANSMISSION Ball Bearing, and Oil Seal Ball Bearing Replacement CAUTION Do not remove the ball bearings unless it is neces- sary . Removal may damaged them. • Using a press or puller , remove the ball bearing. NOTE ○ In the absence of the above mentioned tools, satisfac- tory results may be obtained by heating the case to ap- p[...]

  • Página 195

    WHEELS/TIRES 9-1 9 Wheels/T ires T able of Contents Exploded View ................................................................................................................... ..... 9-2 Specifications ................................................................................................................. ........ 9-4 Special T ools .[...]

  • Página 196

    9-2 WHEELS/TIRES Exploded View[...]

  • Página 197

    WHEELS/TIRES 9-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Ti r e A i r V a l v e N u t s 1.5 0.15 13 in·l b 2 Spoke Nipples 2.0 ∼ 3.9 0.20 ∼ 0.40 17 ∼ 35 in·lb 3 Front Axle Nut 78 8.0 58 4 Rear Axle Nut 98 10.0 72 5. For DE of BN125-A1 ∼ A2 and On and after BN125-A3 of EUR Models G: Apply grease. R: Replacement Part[...]

  • Página 198

    9-4 WHEELS/TIRES Specifications Item Standard Service Limit Wheels (Rims) Rim Size: Front 17 × 1.85 ––– Rear 15 × 2.75 ––– Rim Runout (with tire installed): Axial TIR 0.8 mm (0.03 in.) or less 2 mm (0.08 in.) Radial TIR 1.0 mm (0.04 in.) or less 2 mm (0.08 in.) Axle Rumout/100 mm (3.9 in.) TIR 0.1 mm (0.004 in.) or less 0.2 m m (0.008[...]

  • Página 199

    WHEELS/TIRES 9-5 Special T ools Rim Protector: 57001-1063 Bead Breaker Assembly: 57001-1072 Bearing Driver Set: 57001-1 129 Jack: 57001-1238 Bearing Rem over Shaft, 9: 57001-1265 Bearing Remover Head, 15 × 17: 57001-1267[...]

  • Página 200

    9-6 WHEELS/TIRES Wheels (Rims) Front Wheel Removal • Remove the cotter pin and axle nut [A]. • Remove the speedometer cable lower end [B]. • Raise the front wheel [B] off the ground using the jack [A]. Special T ool - Jack: 57001-1238 • Pull out the axle and drop the front wheel [A] out of the forks. • Insert a wooden plate between the pa[...]

  • Página 201

    WHEELS/TIRES 9-7 Wheels (Rims) • Fit the fork leg stop [A] between the speedometer gear housing stop [B] and install the front wheel. • Install the axle from the right side and tighten the axle nut. T orque - Front Axle Nut: 78 N·m (8.0 kgf·m, 58 ft·lb) • Insert a new cotter pin [A]. NOTE ○ When inserting the cotter pin, if the slots in [...]

  • Página 202

    9-8 WHEELS/TIRES Wheels (Rims) • Remove: Chain Cover Cotter Pin [A] and Axle Nut [B] T orque Link Bolt, Nut (rear) [C] Brake Adjusting Nut [D] • Remove the brake rod [E] from the brake cam lever [F]. • Remove the drive chain [A] from the rear sprocket, then remove the rear wheel [B] to the rear . Rear Wheel Installation • Apply high-tempera[...]

  • Página 203

    WHEELS/TIRES 9-9 Wheels (Rims) • Bend the cotter pin [A] over the nut [B]. • Adjust the brake pedal free play (see Brakes chapter). • Check the rear brake effectiveness. WA R N I N G If a full brake pedal is not obtained, disassemble and inspect the brake parts. Worn parts cause lock of the brake or loss of braking. Wheel Inspection • Raise[...]

  • Página 204

    9-10 WHEELS/TIRES Ti re s Air Pressure Inspection/Adjustme nt • Refer to the Air Pressure Inspection/Adjustment in the Pe- riodic Maintenance chapter . Tire Inspection • Refer to the T ire Wear Inspection in the Periodic Mainte- nance chapter . Tire R emo va l • Remove the following. Wheel (see this chapter) Brake Disc (front) Brake Panel (re[...]

  • Página 205

    WHEELS/TIRES 9-1 1 Ti re s ○ For easier removal, always drop the tire bead opposite the valve stem into the rim well [A], and pry the tire bead a little at a time. • Do the same for the other side of the tire, then remove the rim from the tire. • Remove the protectors. Tire In sta ll ati on WA R N I N G T o ensure safe handling and stability [...]

  • Página 206

    9-12 WHEELS/TIRES Hub Bearings (Wheel Bearings) Removal • Remove the wheel, and take out the following. Speedometer Gear (from front hub) [A] Collars [B] Grease Seals [C] ○ Use a screwdriver for the grease seal removal. • Remove the hub bearings [A]. CAUTION Do not lay the wheel on the ground with the disc facing down. This can damage or warp[...]

  • Página 207

    WHEELS/TIRES 9-13 Hub Bearings (Wheel Bearing s) Inspection ○ Since the hub bearings are made to extremely close tol- erances, the clearance cannot normally be measured. NOTE ○ Do not remove any bearings for inspection. If any bear - ings are removed, they will need to be replaced with new ones. • Spin [A] the bearing by hand to check its con[...]

  • Página 208

    [...]

  • Página 209

    FINAL DRIVE 10-1 10 Final Drive T able of Contents Exploded View ................................................................................................................... ..... 10-2 Specifications ................................................................................................................. ........ 10-4 Special T ools [...]

  • Página 210

    10-2 FINAL DRIVE Exploded View[...]

  • Página 211

    FINAL DRIVE 10-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks Engine Sprocket Cover Bolts (BN125-A1 ∼ A3) 9.8 1.0 87 in·lb 1 Engine Sprocket Cover Bolts (BN125-A4 ∼ ) 8.8 0.90 78 in·lb 2 Engine Sprocket Cover Damper Bolts 8.8 0.90 78 in·lb L 3 T orque Link Bolt and Nut 34 3.5 25 4 Rear Sprocket Nuts 26 2.7 19 5 Rear Axle Nut[...]

  • Página 212

    10-4 FINAL DRIVE Specifications Item Standard Service Limit Drive Chain Standard Chain: Make/type: ENUMA CHAIN (BN125-A1 ∼ A2) ––– Joint Endless EK428SH-R DAIDO (BN125-A3 ∼ ) Joint Endless DID424HG Link: 132 links ––– 130 links (BN125-A7 ∼ ,N ,N U ) ––– Chain Slack 25 ∼ 40 mm (0.98 ∼ 1.57 in.) ––– 20-link Length 25[...]

  • Página 213

    FINAL DRIVE 10-5 Special T ools Bearing Driver Set: 57001-1 129 Jack: 57001-1238[...]

  • Página 214

    10-6 FINAL DRIVE Drive C hain Chain Slack Inspection • Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter . Chain Slack Adjustment • Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter . Wear Inspection • Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter . Lubrica[...]

  • Página 215

    FINAL DRIVE 10-7 Sprocket, Coupling Engine Sprocket Removal • Remove the engine sprocket cover bolts [A] and sprocket cover [B]. • Remove the engine sprocket bolts [A]. • Pull the engine sprocket [A] off the output shaft along with the chain. Engine Sprocket I nstallation • Install the engine sprocket so that the punch mark [A] face the out[...]

  • Página 216

    10-8 FINAL DRIVE Sprocket, Coupling Rear Sprocket Removal • Remove the rear wheel (see Wheels/T ires chapter). • Remove the drive chain (see Drive Chain Removal). • Remove the rear sprocket nuts [A] and separate the rear sprocket [B] from the coupling. Rear Sprocket Installation • Install the sprocket with the tooth number marking [A] out- [...]

  • Página 217

    FINAL DRIVE 10-9 Sprocket, Coupling Coupling Installation • Grease [A] the following and install the coupling. Coupling Grease Seal Lips. Coupling Internal Surface • Install the rear sprocket and the coupling (see this chap- ter). • Install the rear wheel (see Wheels/Tires chapter). Coupling Bearing Removal • Remove the coupling. • Pry th[...]

  • Página 218

    [...]

  • Página 219

    BRAKES 1 1-1 11 Brakes T able of Contents Exploded View ................................... 1 1-2 Specifications .................................... 1 1-6 Special T ools ..................................... 1 1-7 Caliper ............................................... 1 1-8 Caliper Removal .......................... 1 1-8 Caliper Installation ...[...]

  • Página 220

    1 1-2 BRAKES Exploded View[...]

  • Página 221

    BRAKES 1 1-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Brake Disc Bolts 27 2.8 20 L 2 Caliper Mounting Bolts 25 2.5 18 3 Caliper Holder Shaft Bolts 18 1.8 13 4 Caliper Pad Bolts 18 1.8 13 5 Caliper Bleed V alve 7.8 0.80 69 in·lb 6 Brake Hose Banjo Bolts 25 2.5 18 7 Brake Lever Pivot Bolt 5.9 0.60 52 in·lb 8 Brake Lever Pivot[...]

  • Página 222

    1 1-4 BRAKES Exploded View[...]

  • Página 223

    BRAKES 1 1-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Brake Pedal Bolt 9.8 1.0 87 in·lb 2 T orque Link Bolt and Nut 34 3.5 25 G: Apply grease. R: Replacement Parts[...]

  • Página 224

    1 1-6 BRAKES Specifications Item Standard Service Limit Front Brake Pad Lining Thickness: 4.5 mm (0.177 in.) (BN125-A1 ∼ A2) 1m( 0 . 0 4i n . ) 6.0 mm (0.236 in.) (BN125-A3 ∼ ) 1m ( 0 . 0 4i n . ) Disk Thickness 3.8 ∼ 4.2 mm (0.150 ∼ 0.165 in.) 3.5 mm (0.138 in.) 4.3 ∼ 4.7 mm (0.169 ∼ 0.185 in.) 4.0 mm (0.157 in.) (BN125-A3, NO, ES) (BN[...]

  • Página 225

    BRAKES 1 1-7 Special T ools Inside Circlip Pliers: 57001-143 Jack: 57001-1238[...]

  • Página 226

    1 1-8 BRAKES Caliper Caliper Removal • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely . • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. • Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose Removal/Installation). CAUTION Immediately wash away [...]

  • Página 227

    BRAKES 1 1-9 Caliper ○ Insert a w ooden board [A] 5 mm (0.2 in.) thick inside the caliper opening. ○ Apply compressed air [B] to the banjo bolt hole to allow the pistons [C] to protrude and stop at the w ooden board. ○ Remove the wooden board and pull out the pistons by hand. If compressed air is not available, with the brake hose still attac[...]

  • Página 228

    1 1-10 BRAKES Caliper • Apply brake fluid to the inside of the cylinders and to the outside of the pistons and push the pistons [A] into the cylinders. • Check the friction boot [B] and dust boot [C] and replace them with new ones if they are damaged. • Apply a thin coat of silicon grease to the holder shafts [D] and the holder holes. • Ins[...]

  • Página 229

    BRAKES 1 1-1 1 Caliper Caliper Dust Seal/Friction Boo t Damage • Check that the dust seal and friction boot [C] are not cracked, worn, swollen, or otherwise damaged. • If they show any damage, replace it. Caliper Piston and Cylinder Damage • Visually inspect the piston [D] and cylinder surfaces for damage. Replace the caliper if the cylinder [...]

  • Página 230

    1 1-12 BRAKES Front Brake Pads Brake Pad Removal (BN125-A1 ∼ A2) • Remove the caliper with the hose attached. • Remove: Caliper Pad B olts [A] Outer Pad [B] • Remove the inner pad (piston side pad) [C]. Brake Pad Removal (BN125-A3 ∼ ) • Loosen the caliper pad bolts [A]. • Remove the caliper with the hose attached. • Remove: Caliper [...]

  • Página 231

    BRAKES 1 1-13 Master Cylinder Master Cylinder Removal • Remove the brake fluid from the reservoir with a syringe or other suitable device. • Disconnect the front brake light switch connectors [A]. • Remove the banjo bolt [B] to disconnect the brake hose from the master cylinder (see Brake H ose Removal/In- stallation). ○ When removing the b[...]

  • Página 232

    1 1-14 BRAKES Master Cylinder Master Cylinder Assembly • Before assembly , clean all parts including the master cylinder with brake fluid or alcohol. CAUTION Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts, Gasoline, eng[...]

  • Página 233

    BRAKES 1 1-15 Front Brake Disc Brake Disc Removal • Remove the wheel (see Wheels/T ires chapter). • Unscrew the mounting bolts, and take off the disc. Brake Disc Installation • Install the brake disc on the wheel so that the m arked side [A] faces out. • T ighten: T orque - Brake Disc Mounting Bolts [B]: 27 N·m (2.8 kgf·m, 20 ft·lb) Brak[...]

  • Página 234

    1 1-16 BRAKES Brake Fluid Brake Fluid Le vel I nspe ction • Refer to the Brake Fluid Level Inspection in Periodic Main- tenance c hapter . Brake Fluid Change • Refer to the Brake Fluid Change in Periodic Maintenance chapter . B r a k eL i n eB l e e d i n g • Refer to the Brake Line Bleeding in Periodic Maintenance chapter .[...]

  • Página 235

    BRAKES 1 1-17 Brake Hose Brake H ose Removal/Installation CAUTION Brake fluid quickly ruins painted or plastic sur- faces; any spilled fluid should be completely wiped up immediately with wet cloth. • When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. • When removing the brake hose [A], tempora[...]

  • Página 236

    1 1-18 BRAKES Rear Brake Pedal and B rake Cable Brake Pedal Po sition Inspection/Adjustment • Check that the brake pedal [A] is in the correct position. Pedal Position [C] Standard: About 80 mm (3.15 in.) above footpeg top [B] If it is incorrect, adjust the brake pedal position. • Loosen the locknut [A], and turn the adjusting bolt [B] until th[...]

  • Página 237

    BRAKES 1 1-19 Rear Brake Pedal and Brake Cable • Remove the brake pedal [A] and return spring [B]. Brake Pedal Installation • Apply grease to the brake pedal pivot. • T emporarily install the brake return spring onto the brake shaft and hook the spring onto the brake pedal. • Push [B] the brake pedal [A] across the brake shaft and insert th[...]

  • Página 238

    1 1-20 BRAKES Rear Brake Pedal and B rake Cable • Remove: Cotter Pin and Joint Pin Brake Cable Nut [A] • Remove the silencer (see Engine T op End chapter). • Remove the adjusting nut on the end of the brake rod, and take off the joint pin and brake rod from the brake cam lever . • Remove the cable dust boot [A]. • Pull the outer cable hou[...]

  • Página 239

    BRAKES 1 1-21 Rear Brake Panel and Drum Brake Panel Removal • Remove the rear wheel (see Wheels/T ires chapter). • Separate the brake panel from the wheel hub. Brake Panel Installation • Fit the brake panel into the rear wheel, and then install the rear wheel (see Wheels/T ires chapter). Brake Panel Disassembly • Remove the brake panel (see[...]

  • Página 240

    1 1-22 BRAKES Rear Brake Panel and Drum • Install the brake cam seal and fit the indicator [A] on the serration so that it points to the extreme right of the US- ABLE RANGE [B]. • Install the cam lever in its original position on the camshaft, and tighten its bolt. Brake Panel Inspection • Remove the brake panel (see Brake Panel Removal). •[...]

  • Página 241

    BRAKES 1 1-23 Rear Brake Panel and Drum Brake Shoe Spring s Inspection • Visually inspect the brake shoe springs for breaks or dis- tortion. If the springs are damaged in any way , replace them. • Measure the free length of the brake shoe springs. If either is stretched beyond the service limit, replace both springs. Brake Shoe Springs Free Len[...]

  • Página 242

    [...]

  • Página 243

    SUSPENSION 12-1 12 Suspension T able of Contents Exploded View ................................................................................................................... ..... 12-2 Specifications ................................................................................................................. ........ 12-6 Special T ools ..[...]

  • Página 244

    12-2 SUSPENSION Exploded View[...]

  • Página 245

    SUSPENSION 12-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front Fork T op Plugs 23 2.3 17 2 Front Fork Bottom Allen Bolts 20 2.0 15 3 Front Fork Clamp Bolt (Upper) 20 2.0 15 4 Front Fork Clamp Bolt (Lower) 34 3.5 25 5. Fork cover (BN125-A1 ∼ A5) 6. Brake hose clamp (BN125-A1 only) 7. Other than the US and CA Models 8. Speedm[...]

  • Página 246

    12-4 SUSPENSION Exploded View[...]

  • Página 247

    SUSPENSION 12-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Rear Shock Absorber Nuts and Bolts 34 3.5 25 2 Swingarm Pivot Nut 98 10.0 72 3. Chain guard (BN125-A1 ∼ A2 only) 4. Face the manufacture’s marks out.[...]

  • Página 248

    12-6 SUSPENSION Specifications Item Standard Front Fork (Per One Unit) Fork Inner T ube Diameter 33 mm (1.30 in.) Fork Spring Setting Non-adjustable Air Pressure Atmospheric pressure (non-adjustable) Damper Setting Non adjustable Fork Oil Viscosity SHOWA SS-8 or equivalent Fork Oil Capacity 191 ±2.5 mL (6.46 ±0.085 US oz.) (completely dry) approx[...]

  • Página 249

    SUSPENSION 12-7 Special T ools Fork Cylinder Holder Handle: 57001-183 Fork Cylinder Holder Adapter: 57001-101 1 Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1 129 Fork Outer T ube Weight: 57001-1218 Front Fork Oil Seal Driver: 57001-1219 Jack: 57001-1238 Hook Wrench (Owner ’ s T ool): 921 10-1 143[...]

  • Página 250

    12-8 SUSPENSION Front F ork Fork Oil Change • Refer to the Front Fork Oil Change in the Periodic Main- tenance c hapter . Fork Removal If the fork leg is to be disassembled, loosen the top plug beforehand. T o loosen the fork top plug, loosen the fork upper clamp bolts. • Remove: Brake Caliper (see Brakes chapter) Front Wheel (see Wheels/T ire [...]

  • Página 251

    SUSPENSION 12-9 Front F ork • Check the front brake effectiveness after installation. WA R N I N G Do not attempt to ride the motorcycle until a full brake lever is obtained by pumping the brake lever until the pads are against the disc. The brake will not function to the first application of the lever if this is not done. Fork Disassembly • Re[...]

  • Página 252

    12-10 SUSPENSION Front F ork • Use the fork outer tube weight [A] to separate the outer tube [B] from the inner tube [C]. Holding the inner tube by hand, pull the outer tube several times to pull out the inner tube. Special T ool - Fork Outer T ube Weight: 57001-1218 • T ake out the cylinder base out of the outer tube. • Remove the guide bush[...]

  • Página 253

    SUSPENSION 12-1 1 Front F ork • Apply molybdenum disulfide grease to the oil seal lips and install the washer and oil seal [A] into the outer tube. Special T ool - Front Fork Oil Seal Driver: 57001-1219 [B] • Install the retaining ring and dust seal by hand. • Put the new gasket on the bottom of the outer tube. • Apply a non-permanent locki[...]

  • Página 254

    12-12 SUSPENSION Front F ork Spring Inspection • Since the fork spring [A] becomes shorter as it weakens, check its free length [B] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of the replacement spring and that of the remaining spring vary greatly , the remaini[...]

  • Página 255

    SUSPENSION 12-13 Rear Shock Absorbers Spring Preload Adjustment • T o adjust the spring force, turn the adjuster on each s hock absorber to the desired position. Owner ’ s T ool - Hook Wrench: 921 10-1 143 [A] Spring Preload Adjustment Adjuster Position 1 2 3 4 5 Spring T ension → Stronger WA R N I N G If a pair of adjusters are not adjusted [...]

  • Página 256

    12-14 SUSPENSION Swingarm Swingarm Removal • Remove: Chain Cover Rear Wheel (see Wheels/T ires chapter) Rear Shock Absorber Lower Mounting Bolts [A] (see this chapter) Silencer [B] (see Engine T op End chapter) Brake Cable [C] (see Brakes chapter) Pivot Nut [D] Front [E] • Pull out the swingarm pivot shaft, and remove the swingarm [A]. • Sepa[...]

  • Página 257

    SUSPENSION 12-15 Swingarm Swingarm Pivot Check • Remove: Rear Wheel (see Wheels/T ires chapter) Rear Shock Absorber Bolts • Move the swingarm up and down to check for abnormal friction, and push and pull it to check for bushings play [A]. A small amount of play on the pivot is normal and no corrective action is needed. However , if excessive pl[...]

  • Página 258

    [...]

  • Página 259

    STEERING 13-1 13 Steering T able of Contents Exploded View ................................................................................................................... ..... 13-2 Special T ools ................................................................................................................... ....... 13-4 Steering ...........[...]

  • Página 260

    13-2 STEERING Exploded View BN125-A1 ∼[...]

  • Página 261

    STEERING 13-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Steering Stem Head Bolts 44 4.5 33 2 Steering Stem Nut Hand-tight or 4.9 Hand-tight or 0.50 Hand-tight or 43 in·lb 3 Handlebar Nuts 34 3.5 25 4 Handlebar Weight Screws – – – L 5 Handlebar Switch Housing Screws 3.4 0.35 30 in·lb 6 Front Fork Clamp Bolts (Lower) 34 [...]

  • Página 262

    13-4 STEERING Special T ools Steering Stem Bearing Driver: 57001-137 Steering S tem Bearing Driver Adapter , 34.5: 57001-107 4 Head Pipe Outer Race Press Shaft: 57001-107 5 Head Pipe Outer Race Driver , 51.5: 57001-107 6 Head Pipe Outer Race Driver , 46.5: 57001-1 106 Steering Stem Nut Wrenc h: 57001-1 100 Jack: 57001-1238[...]

  • Página 263

    STEERING 13-5 Steering Steering Inspection • Refer to the Steering Inspection in the Periodic Mainte- nance chapter . Steering Adjustment • Refer to the Steering Adjustment in the Periodic Mainte- nance chapter .[...]

  • Página 264

    13-6 STEERING Steering Stem Steering Stem Removal • Loosen the steering stem head bolt [A]. • Open the headlight body and pull off the connectors in the headlight body (see Electrical System chapter). • Remove the clutch cable upper end and lead connector . • Loosen the turn signal light holder bolts and nuts [B]. • Remove the nuts [A] an[...]

  • Página 265

    STEERING 13-7 Steering Stem Steering Stem Installation • Apply grease to the upper and lower outer races in the head pipe so that the steel balls will stick in place during stem insertion. Install the upper steel balls (23) [A] and lower steel balls (23). All the steel balls are the same size. • Put on the upper inner race and steering stem cap[...]

  • Página 266

    13-8 STEERING Steering Stem • Install the front fork (see Suspension chapter). NOTE ○ Install the front fork at the correct position. Tighten the fork upper clamp bolts [A] first, next the stem head bolt [B], last the fork lower clamp bolts. T orque - Front Fork Clamp Bolts (Upper) : 20 N·m (2.0 kgf·m, 15 ft·lb) Steering Stem Head Bolt: 44 N[...]

  • Página 267

    STEERING 13-9 Steering Stem Bearing Steering Stem Bearing Removal If the bearing is damaged, remove it. • T o remove the outer races [A] pressed in the head pipe, insert a bar [C] into the head pipe [B], and hammer evenly around the circumference of the opposite race to drive it out. • Hammer the bottom [A] of the lower inner race with a chisel[...]

  • Página 268

    13-10 STEERING Handlebar Handlebar Removal (BN125-A1/A2) • Remove: Throttle Cables [A] (see Fuel System chapter) Brake Master Cylinder [B] (see Brakes chapter) Left Handlebar Switch Housing [C] Clutch Cable Upper End [D] Speedometer Unit [E] (with Cable) • Remove the handlebar nuts [A] and take off the handle- bar . Handlebar Removal (BN125-A3 [...]

  • Página 269

    STEERING 13-1 1 Handlebar • The front half of the right and left switch housings [A] has a small projection [B]. Fit the projection into the small hole [C] in the handlebar . • Install the handlebar switch housing. • T ighten: T o rque - Handleb ar Switch Hous ing S cre ws: 3.4 N·m (0.35 kgf·m, 30 in·lb) Handlebar Installation (BN125-A3 ?[...]

  • Página 270

    [...]

  • Página 271

    FRAME 14-1 14 Frame T able of Contents Exploded View ................................................................................................................... ..... 14-2 Special T ool .................................................................................................................... ........ 14-6 Side Covers .............[...]

  • Página 272

    14-2 FRA ME Exploded View[...]

  • Página 273

    FRAME 14-3 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Front F ootpeg Bolts 23 2.3 17 O: Apply oil.[...]

  • Página 274

    14-4 FRA ME Exploded View[...]

  • Página 275

    FRAME 14-5 Exploded View IT : Italy SG: Singapore US: United States (BN125-A4 ∼ )[...]

  • Página 276

    14-6 FRA ME Special T oo l Jack: 57001-123 8[...]

  • Página 277

    FRAME 14-7 Side Covers Left Side Cover Removal • Remove the screws [A]. • Pull [B] the front part of the left side cover outward to clear the stopper . • Pull [C] the cover rearward to clear the hook, and remove it. Left Side Cover Insta llation • Slip the stopper [A] of the left side cover onto the hook [B]. • Push the stopper of the c o[...]

  • Página 278

    14-8 FRA ME Seat Seat Removal • For the models other than the S ingapore and U.S.A. mod- els, remove the bolts [A] and loosen the bolts [B] on both sides. • Remove the pad assembly [C]. • For the Singapore and U.S.A. models remove the bolts [A], cover [B], and collar [C] on both sides. Front [D] • Remove the seat bolts [A] and take off the [...]

  • Página 279

    FRAME 14-9 Fenders Front Fender Removal CAUTION Be careful not to scratch the pained surface during removal or installation. • Remove the mounting bolts [A] and take off the front fender [B]. Front Fender Installation • Install the front fender so that the narrower side [A] faces forward [B]. Rear Fender Rear Removal • Remove the seat (see th[...]

  • Página 280

    14-10 FR AME Fenders Rear Fender Rea r Disassembly • Remove the nuts [A] and take off the rear turn signal light assembly [B]. • Remove the nuts [C] and take off the tail/brake light as- sembly [D]. Rear Fender Front Removal • Remove: Rear Fender Rear (see this chapter) D r i v eC h a i nC l i p Rear Brake Rod Rear End • Remove the rear axl[...]

  • Página 281

    FRAME 14-1 1 Frame Frame Inspection • Visually inspect the frame [A] for cracks, dents, bending, or warp. If there is any damage to the frame, replace it. WA R N I N G A repaired frame may fail in use, possibly causing an accident. If the frame is bent, dented, cracked, or warped, replace it.[...]

  • Página 282

    [...]

  • Página 283

    ELECTRICAL SYSTEM 15-1 15 Electrical System T able of Contents Parts Location.................................... 15-2 Exploded View ................................... 15-4 Specifications .................................... 15-10 Special T ools and Sealant ................. 15-12 Wiring Diagram ................................. 15-13 Precautions.[...]

  • Página 284

    15-2 ELECTRICAL SYSTEM Parts Lo cation[...]

  • Página 285

    ELECTRICAL SYSTEM 15-3 Parts Lo cation 1. Speedometer 2. Starter lockout switch 3. Ignition coil 4. Starter motor 5. Ignition switch 6. Crankshaft sensor 7. Alternator 8. Neutral switch 9. Sidestand switch 10. Regulator/rectifier 1 1. Fuse unit 12. Starter circuit relay 13. Starter relay 14. T urn signal relay 15. Battery 16. CDI unit 17. Front bra[...]

  • Página 286

    15-4 ELECTRICAL SYSTEM Exploded View[...]

  • Página 287

    ELECTRICAL SYSTEM 15-5 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Alternator Cover Bolts 8.8 0.90 78 i n·lb 2 Starter Motor Mounting Bolts 8.8 0.90 78 i n·lb 3 Starter Motor T erminal Locknut 6.9 0.70 61 i n·lb 4 Starter Motor Assembly Bolts 3.4 0.35 30 i n·lb 5 Stator Coil Bolts 13 1.3 11 3 i n · l b 6 Alternator Lead Hol[...]

  • Página 288

    15-6 ELECTRICAL SYSTEM Exploded View[...]

  • Página 289

    ELECTRICAL SYSTEM 15-7 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Neutral Switch 15 1.5 11 2 Sidestand Switch Screws 3.9 0.40 35 in·lb L 3 Handlebar Switch Housing Screws 3.4 0.35 30 in·lb 4. Ignition switch 5. T urn signal relay 6. Starter circuit relay 7. Interlock diode 8. Fuse case (BN125-A1) 9. Rear brake light switch 10[...]

  • Página 290

    15-8 ELECTRICAL SYSTEM Exploded View[...]

  • Página 291

    ELECTRICAL SYSTEM 15-9 Exploded View T orque No. Fastener N·m kgf·m ft·lb Remarks 1 Headlight Body Screws 2.9 0.30 26 in·lb 2 T urn Signal Light Holder Nuts 5.9 0.60 52 in·lb 3. Headlight unit 4. T urn signal lights 5. T ail/brake light 6. Canada and United Kingdom Models (BN125-A6 ∼ ) 7. Other than Canada and United Kingdom Models 8. United[...]

  • Página 292

    15-10 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery Capacity 12 V 9 Ah –– – Electrolyte Level between level lines ––– Specific Gravity of E lectrolyte 1.280 ±0.01 @20°C (68°F) ––– Charging System T ype: (BN125-A1/A2) Single-phase AC ––– (BN125-A3 ∼ ) Three-phase AC ––– Charging V oltage 14 ?[...]

  • Página 293

    ELECTRICAL SYSTEM 15-1 1 Specifications Item Standard Service Limit Switches Rear Brake Light Switch T iming ON after about 10 mm (0.39 in.) pedal travel –––[...]

  • Página 294

    15-12 ELECTRICAL SYSTEM Special T ools an d Sealant Flywheel Puller , M 3 0 × 1.5: 57001-1 191 Rotor Puller , M16/M18/M20/M22 × 1.5: 57001-121 6 Timi ng Light: 57001-124 1 S p a r kP l u gW r e n c h , H e x1 6 : 57001-126 2 Flywheel Holder: 57001-1313 Hand T ester: 57001-1394 Peak V olt age Adapter: 57001-1415 Kawasaki Bond (Silicone Sealant): 5[...]

  • Página 295

    ELECTRICAL SYSTEM 15-13 Wiring Diagram Dummy Page[...]

  • Página 296

    15-14 ELECTRICAL SYSTEM Wiring Diagram BN125-A1[...]

  • Página 297

    ELECTRICAL SYSTEM 15-15 Wiring Diagram[...]

  • Página 298

    15-16 ELECTRICAL SYSTEM Wiring Diagram BN125-A2 ∼ (Singapore ) a nd BN125-A4 (United State s)[...]

  • Página 299

    ELECTRICAL SYSTEM 15-17 Wiring Diagram[...]

  • Página 300

    15-18 ELECTRICAL SYSTEM Wiring Diagram BN125-A2 ∼ A5 (Europe)[...]

  • Página 301

    ELECTRICAL SYSTEM 15-19 Wiring Diagram[...]

  • Página 302

    15-20 ELECTRICAL SYSTEM Wiring Diagram BN125-A5 (United States and Canada)[...]

  • Página 303

    ELECTRICAL SYSTEM 15-21 Wiring Diagram[...]

  • Página 304

    15-22 ELECTRICAL SYSTEM Wiring Diagram BN125-A6 ∼ (U S, CA, N, NU)[...]

  • Página 305

    ELECTRICAL SYSTEM 15-23 Wiring Diagram[...]

  • Página 306

    15-24 ELECTRICAL SYSTEM Precautions There are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below . ○ Do not reverse the battery cable connections. This will burn out the diodes on the electrical parts. ○ Always check battery condition before condemning other parts of an el[...]

  • Página 307

    ELECTRICAL SYSTEM 15-25 Precautions ○ Electrical Connectors Connectors [A] Connectors [B][...]

  • Página 308

    [...]

  • Página 309

    ELECTRICAL SYSTEM 15-27 Battery Battery Removal/Installation • Remove: Right Side Cover (see Frame chapter) Battery Holder • Disconnect the battery negative (–) cable [A] first, and t h e nt h ep o s i t i v e( + )c a b l e[ B ] . Front [C] • When installing the battery , connect the positive (+) cable [A] first and then the negative cable [...]

  • Página 310

    15-28 ELECTRICAL SYSTEM Battery Initial Charging WA R N I N G Keep the battery away from sparks and open flames during charging, since the battery gives off an ex- plosive gas mixture of hydrogen and oxygen. When using a battery charger , connect the battery to the charger before turning on the charger . This proce- dure prevents sparks at the batt[...]

  • Página 311

    ELECTRICAL SYSTEM 15-29 Battery Ordinary Charging • Remove the battery (see Battery Removal). • If any of the cells are low , fill them to the LOWER level line with distilled water only . The electrolyte will expand during charging, and the level will rise. WA R N I N G Keep the battery away from sparks and open flames during charging, since th[...]

  • Página 312

    15-30 ELECTRICAL SYSTEM Battery Battery Charging Rate/Tim e T able (12 V 9 Ah)[...]

  • Página 313

    ELECTRICAL SYSTEM 15-31 Charging System Alternator Cover Removal • Drain the engine oil (see E ngine Lubrication System chapter). • Remove: Engine Sprocket Cover (see Final Drive chapter) Alternator Lead Connector [A] • Remove: Alternator Cover B olts [A] Alternator Cover [B] • Remove the torque limiter [A]. Alternator Cover I nsta llation [...]

  • Página 314

    15-32 ELECTRICAL SYSTEM Charging System • Using the flywheel puller [A] and rotor puller [B], remove the alternator rotor [C] from the crankshaft. Special T ools - Flywheel Puller , M30 × 1.5: 57001-1 191 Rotor Puller , M16/M18/M20/ M22 × 1.5: 57001 -1216 ○ Holding the flywheel puller , screw in the rotor puller while tapping the head of the [...]

  • Página 315

    ELECTRICAL SYSTEM 15-33 Charging System Stator Coil Installation • T ighten: T orque - Stator Coil Bolts [A]: 13 N·m (1.3 kgf·m, 1 13 in·lb) Crankshaft Sensor Screws [B]: 3.9 N·m (0.40 kgf·m, 35 in·lb) Alternator Lead Holder Bolts (BN125-A3 ∼ ): 8.8 N·m (0.9 0 kg f·m, 7 8 in ·lb ) (BN125-A1 ∼ A2): 13 N·m (1.3 kgf·m, 1 13 in·lb) ?[...]

  • Página 316

    15-34 ELECTRICAL SYSTEM Charging System • Check the stator coil resistance as follows. ○ Stop the engine. ○ Connect the hand tester as shown in the table. ○ Note the resistance readings. Stator Coil Resistance (BN125-A1/A2) Connections Te s t e r Range Meter (+ ) to Me ter ( − )t o Reading ×1 Ω Pink lead Engine ground 0.1 ∼ 0.8 Ω S[...]

  • Página 317

    ELECTRICAL SYSTEM 15-35 Charging System Regulator/Recti fier Internal Resistance (BN125-A3 ∼ ) Unit: k Ω T ester (+) Lead Connection Te r m i n a l W Y Y Y BK/Y W – ∞ ∞ ∞ ∞ Y 0.5 ∼ 10 – ∞ ∞ ∞ Y 0.5 ∼ 10 ∞ – ∞ ∞ Y 0.5 ∼ 10 ∞ ∞ – ∞ ( − )* BK/Y 0.5 ∼ 20 0.5 ∼ 10 0.5 ∼ 10 0.5 ∼ 10 – (–)*: T este[...]

  • Página 318

    15-36 ELECTRICAL SYSTEM Charging System Charging System Circuit (BN125-A1/A2) 1. Ignition switch 2. Alt ernator 3. Regulator/rectifier 4. Controller 5. Battery 6. Mai n fuse 15 A 7. Starter relay 8. Light fuse 10 A 9. Load[...]

  • Página 319

    ELECTRICAL SYSTEM 15-37 Charging System Charging System Circuit (BN125-A3 ∼ ) 1. Ignition switch 2. Alternator 3. Regulator/rectifier 4. Battery 5. Main fuse 30 A 6. Starter relay 7. Light fuse 15 A 8. Load[...]

  • Página 320

    15-38 ELECTRICAL SYSTEM Ignition System CDI Unit Connectors [A] CAUTION Do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running. This is to prevent CDI unit damage. Do not install the battery back- wards. The negative side is grounded. This is to prevent damage to the d[...]

  • Página 321

    ELECTRICAL SYSTEM 15-39 Ignition System • Set the hand tester [B] to the × 25 V DC range, and con- nect it to the peak voltage adapter [C] as shown in the diagram. • Connect the black lead of the adapter to W/Y lead and red lead to G/W lead in the crankshaft sensor connector [A]. • T urn the ignition switch. • Pushing the starter button, t[...]

  • Página 322

    15-40 ELECTRICAL SYSTEM Ignition System Ignition Timing Engine speed Head timing mark [A] aligns with: 1 300 ±100 r/min (rpm) “T” mark [B] on cams haft sprocket If the ignition timing is incorrect, inspect the CDI unit and the crankshaft sensor . Ignition Coil Removal • Remove the fuel tank (see Fuel System chapter). • Disconnect the prima[...]

  • Página 323

    ELECTRICAL SYSTEM 15-41 Ignition System If the coil tester is not available, the coil can be checked for a broken or badly shorted winding with the hand tester . NOTE ○ The hand tester cannot detect layer shorts and shorts resulting from insulation breakdown under high voltage. • Measure the primary winding resistance as follows. ○ Connect th[...]

  • Página 324

    15-42 ELECTRICAL SYSTEM Ignition System • T urn the ignition switch and engine stop switch on. • Pushing the starter button, turn the engine 4 ∼ 5 seconds with the transmission gear in neutral to measure the igni- tion coil primary peak voltage. • Repeat the measurement 5 or more times. Ignition Coil Primary Peak V oltage Standard: 11 0 V o[...]

  • Página 325

    ELECTRICAL SYSTEM 15-43 Ignition System CDI Unit Inspection CAUTION When inspecting the CDI Unit [A], observe the fol- lowing to avoid damage to the CDI Unit. Do not disconnect the CDI Unit with the ignition switch on. This may damage the CDI Unit. Do not disconnect the battery leads while the engine is run- ning. This m ay damage the CDI Unit. CDI[...]

  • Página 326

    15-44 ELECTRICAL SYSTEM Ignition System CDI Unit Internal Resistance (BN125-A1/A2) Unit: k Ω T ester (+) Lead Connection T erminal 1 2 3 4 5 6 7 8 1 – 10 ∼ 41 10 ∼ 41 11 ∼ 44 35 ∼ 140 14 ∼ 56 18.5 ∼ 74 ∞ 2 8.5 ∼ 34 – 0 0.5 ∼ 2.2 18.5 ∼ 74 2.5 ∼ 10 3 ∼ 13 ∞ 3 8.5 ∼ 34 0 – 0.6 ∼ 2.4 18.5 ∼ 74 2.5 ∼ 10 3 ∼ 1[...]

  • Página 327

    ELECTRICAL SYSTEM 15-45 Ignition System Ignition System T roubleshooting[...]

  • Página 328

    15-46 ELECTRICAL SYSTEM Ignition System Ignition System Circuit (BN125-A1/A2) 1. Neutral switch 2. Interlock diodes 3. Sidestand switch 4. Starter lockout switch 5. Engine stop switch 6. Ignition fuse 10 A 7. Ignition switch 8. Regulator/rectifier 9. Crankshaft sensor 10. CDI unit 1 1. Ignition coil 12. Spark plug 13. Battery 14. Main fuse 15 A[...]

  • Página 329

    ELECTRICAL SYSTEM 15-47 Ignition System Ignition System Circuit (BN125-A3 ∼ ) 1. Ignition switch 2. Starter lockout switch 3. Crankshaft sensor 4. Interlock diodes 5. Sidestand switch 6. Ignition fuse 15 A 7. Engine stop switch 8. Neutral switch 9. CDI unit 10. Ignition coil 1 1. Spark plug 12. Main fuse 30 A 13. Battery 14. Regulator/rectifier[...]

  • Página 330

    15-48 ELECTRICAL SYSTEM Electric Starter System Starter Motor Removal CAUTION Do not tap the starter motor shaft or body . T apping the shaft or body could damage the motor . • Remove: Oil Pipe (see Engine Lubrication System chapter) • Slide back the rubber cap. • Remove the starter motor terminal nut [A]. • Remove the starter motor mountin[...]

  • Página 331

    ELECTRICAL SYSTEM 15-49 Electric Starter System • Remove the terminal locknut [A] and terminal bolt [B], and then remove the brush with the brush plate from the yoke. Starter Motor Assembly • Replace the O-rings with new ones. • Apply a thin coat of grease to the oil seal [A] and needle bearing [B]. • Fit the toothed washer [C] into the end[...]

  • Página 332

    15-50 ELECTRICAL SYSTEM Electric Starter System Brush Inspection • Measure the length [A] of each brush. If any is worn down to the service limit, replace the carbon brush holder assembly [B]. Starter Motor Brush Length Standard: 9.5 ∼ 10.5 mm (0.37 ∼ 0. 41 in .) Service Limit: 8 mm (0 .31 in. ) Commutator Clean ing and Inspection • Smooth [...]

  • Página 333

    ELECTRICAL SYSTEM 15-51 Electric Starter System Brush Lead Inspection • Using the × 1 Ω hand tester range, measure the resis- tance as shown. T erminal Bolt and Positive Brush [A] Brush Plate and Negative Brush [B] Special T ool - Hand T ester: 57001-139 4 If there is not close to 0 Ω , the brush has an open. Re- place the terminal bolt asse[...]

  • Página 334

    15-52 ELECTRICAL SYSTEM Electric Starter System Starter Circuit Relay Inspection • Remove: Right Side Cover (see Frame chapter) Starter Circuit Relay • Connect the hand tester [A] and 12 V battery [B] as shown. Relay Coil T erminal [1] and [2] Relay Switch T erminal [3] and [4] If the relay [C] does not work as specified, the relay is defective[...]

  • Página 335

    ELECTRICAL SYSTEM 15-53 Electric Starter System Electric Starter Circuit (BN125-A1/A2) 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Starter circuit relay 5. Ignition fuse 10 A 6. Starter lockout switch 7. Interlock diodes 8. CDI unit 9. Starter motor 10. Starter relay 1 1 . M a i nf u s e1 5A 12. Battery 13. Neutral switch[...]

  • Página 336

    15-54 ELECTRICAL SYSTEM Electric Starter System Electric Starter Circuit (BN125-A3 ∼ ) 1. Ignition switch 2. Engine stop switch 3. Starter button 4. Starter circuit relay 5. Ignition fuse 15 A 6. Starter lockout switch 7. Interlock Diodes 8. CDI unit 9. Sta rter motor 10. Starter relay 1 1. Main fuse 30 A 12. Battery[...]

  • Página 337

    ELECTRICAL SYSTEM 15-55 Lighting System Headlight Beam Horizontal/V ertical Adjustment • T urn the horizontal adjuster [A] on the headlight with a screwdriver in or out until the beam points straight ahead. ○ T urn the horizontal adjuster clockwise to face the head- light left. • T urn the vertical adjuster [B] on the headlight in or out to a[...]

  • Página 338

    15-56 ELECTRICAL SYSTEM Lighting System • Replace the headlight bulb [A]. CAUTION When handling the quartz-halogen bulb, never touch the glass portion with bare hands. Always use a clean cloth. Oil contamination from hands or dirty rags can reduce bulb life or cause the bulb to explode. NOTE ○ Clean off any contamination that inadvertently gets[...]

  • Página 339

    ELECTRICAL SYSTEM 15-57 Lighting System Headlight Circuit (BN125-A1/A2) 1. High beam indicator light 2. Headlight 3. Dimmer switch 4. Alternator 5. Regulator/rectifier 6. Headlight switch Headlight Circuit (BN125-A3 ∼ A5) 1. High beam indicator light 2. Headlight 3. Dimmer switch 4. Headlight switch 5. Alternator 6. Regulator/rectifier 7. Ignitio[...]

  • Página 340

    15-58 ELECTRICAL SYSTEM Lighting System Headlight Circuit (BN125-A6 ∼ ) 1. High beam indicator light 2. Headlight 3. Dim mer switch 4. Alt ernator 5. Regulator/rectifier 6. Ignition switch 7. Headlight fuse 15 A T ail/Brake Light Bulb R epla cement • Remove the tail/brake light lens [A]. • Push the bulb [A] in the socket, turn it counterclock[...]

  • Página 341

    ELECTRICAL SYSTEM 15-59 Lighting System • With the front pin [A] down, insert the new bulb by aligning the front pin with the groove [B] in the walls of the socket. • Push the bulb in, turn it clockw ise, and replace it. It should lock in position. • T ighten the lens screws. Be careful not to overtighten them. T urn Signal Relay Inspectio n [...]

  • Página 342

    15-60 ELECTRICAL SYSTEM Lighting System T urn Signal Light Circuit (BN125-A1 /A2) 1. T urn signal indicator light 2. T urn signal relay 3. Ignition fuse 10 A 4. Front right turn signal light 5. Front left turn signal light 6. Rear right turn signal light 7. Rear left turn signal light 8. T urn signal switch 9. Ignition switch 10. Starter relay 1 1.[...]

  • Página 343

    ELECTRICAL SYSTEM 15-61 Lighting System T urn Signal Light Circuit (BN125-A3 ∼ A5) 1. T urn signal indicator light 2. T urn signal relay 3. Ignition fuse 15 A 4. Front right turn signal light 5. Front left turn signal light 6. Rear right turn signal light 7. Rear left turn signal light 8. T urn signal switch 9. Ignition switch 10. Starter relay 1[...]

  • Página 344

    15-62 ELECTRICAL SYSTEM Lighting System T urn Signal Light Circuit (BN125-A6 ∼ ) 1. T urn signal indicator light 2. T urn signal relay 3. Ignition fuse 15 A 4. Front right turn signal light 5. Front left turn signal light 6. Rear right turn signal light 7. Rear left turn signal light 8. T urn signal switch 9. Ignition switch 10. Starter relay 1 1[...]

  • Página 345

    ELECTRICAL SYSTEM 15-63 Meter , Gauge, Indicator Unit Speedometer Removal • Remove the speedometer cable upper end [A]. • Remove the meter unit [C] by taking off the mounting bolts [B]. CAUTION Place the m eter so that the face is up. If a meter is left upside down or sideways for any length of time, it will malfunction. Speedometer Disassembly[...]

  • Página 346

    15-64 ELECTRICAL SYSTEM Switches an d Sensors Front Brake Light Switch Inspection • Refer to the Front Brake Light Switch Inspection in the Periodic Maintenance chapter . Rear Brake Light Timing Inspection • Refer to the Rear Brake Light T iming Inspection in the Periodic Maintenance chapter . Rear Brake Light Timing Adjustment • Refer to the[...]

  • Página 347

    ELECTRICAL SYSTEM 15-65 Fuse Main Fuse 15 A Removal • Remove the right side cover (see Frame chapter). • Disconnect the starter relay connector . • Pull out the main fuse [B] from the s tarter relay [A] with needle nose pliers. Main Fuse 15 A Inspection • Remove the fuse (see Fuse Removal). • Inspect the fuse element. If it is blown out, [...]

  • Página 348

    15-66 ELECTRICAL SYSTEM Fuse Fuse 10 A Inspection • Inspect the fuse element. If it is blown out, replace the fuse. Fuse Element [A] Blown Element [B][...]

  • Página 349

    APPENDIX 16-1 16 Appendix T able of Contents Cable, Wire, and Hose Routing .............................................................................................. 16-2 T roubleshooting Guide ........................................................................................................... 16-32[...]

  • Página 350

    16-2 APPE N DIX Cable, Wire, a nd Hose Routing BN125-A1 ∼[...]

  • Página 351

    APPENDIX 16-3 Cable, Wire, and Hose Routing 1. Crankshaft Sensor 2. Oil Pipe 3. Clamp 4. Run the alternator lead under the oil pipe. 5. Alternator Lead 6. Run the neutral switch lead so that it shall not out of guide rib. 7. Guide Rib 8. Neutral Switch 9. T urn Signal Relay 10. Engine Ground Lead 1 1. Holder 12. Carburetor Drain Hose 13. Battery V [...]

  • Página 352

    16-4 APPE N DIX Cable, Wire, a nd Hose Routing BN125-A1 ∼[...]

  • Página 353

    APPENDIX 16-5 Cable, Wire, and Hose Routing 1. CDI Unit 2. Ignition Coil Lead 3. Engine Breather Hose 4. T o Fuel T ap 5. Insulator 6. Run the ignition coil lead under the engine breather hose. 7. Clamp 8. Install the hose as shown. 9. Other than A T , DE, SG, CH Models AT : A u s t r i a CH: Switzerland DE: Germany SG: Singapore[...]

  • Página 354

    16-6 APPE N DIX Cable, Wire, a nd Hose Routing Clean Air System[...]

  • Página 355

    APPENDIX 16-7 Cable, Wire, and Hose Routing 1. V acuum Hose 2. Three-way Joint 3. T o Fuel T ap 4. Air Hose 5. Air Pipe 6. Engine Breather Hose 7. Air Cleaner Duct 8. Air Cleaner Housing 9. V acuum Switch 10. Carburetor 1 1. Air Suction V alve 12. Insulator 13. Run the vacuum hose onto the left side of the duct (7), and then behind the hose (6) and[...]

  • Página 356

    16-8 APPE N DIX Cable, Wire, a nd Hose Routing BN125-A1 ∼ A4[...]

  • Página 357

    APPENDIX 16-9 Cable, Wire, and Hose Routing 1. Ignition Switch 2. Run the ignition switch lead to the right. 3. Sidestand Switch Lead 4. Run the sidestand switch lead to the right. 5. Body Ground 6. Ignition Coil 7. Alternator Lead Connector 8. Sidestand Switch 9. Clamp 10. Band[...]

  • Página 358

    16-10 APPENDIX Cable, Wire, a nd Hose Routing BN125-A5 ∼[...]

  • Página 359

    APPENDIX 16-1 1 Cable, Wire, and Hose Routing 1. Indicator Light Connector (Move it to the right side after connected.) 2. Horn 3. Sidestand switch connector 4. Ignition coil 5. Regulator/Rectifier 6. Ground Lead 7. Alternator Lead 8. Put the connectors into the gusset after c onnecting them. 9. Sidestand Switch 10. Band 1 1. Left Handlebar Switch [...]

  • Página 360

    16-12 APPENDIX Cable, Wire, a nd Hose Routing BN125-A1 ∼[...]

  • Página 361

    APPENDIX 16-13 Cable, Wire, and Hose Routing 1. Rear Left T urn Signal Light 2. T ail/Brake Light 3. Rear Right Turn Signal Light 4. Rear Fender Rear 5. Rear Fender Front 6. Throttle Cables 7. Carburetor Air V ent Hose 8. Engine Breather Hose 9. Right Handlebar Switch 10. Brake Hose 1 1. Clutch Cable 12. Rear Brake Light Switch 13. Battery V ent Ho[...]

  • Página 362

    16-14 APPENDIX Cable, Wire, a nd Hose Routing BN125-A1 ∼[...]

  • Página 363

    APPENDIX 16-15 Cable, Wire, and Hose Routing 1. Throttle Cables 2. Clutch Cable 3. Speedometer Cable 4. Left Handlebar Switch H arness 5. Right Handlebar Switch Harness 6. Sidestand Switch 7. Holder 8. Band 9. Clamp 10. BN125-A3 ∼[...]

  • Página 364

    16-16 APPENDIX Cable, Wire, a nd Hose Routing BN125-A1 ∼ A2[...]

  • Página 365

    APPENDIX 16-17 Cable, Wire, and Hose Routing 1. T ail/Brake Light Connector 2. Rear Left T urn Signal Light Connector 3. White T ape 4. Ignition Coil Connector 5. Body Ground 6. Front Left T urn Signal Light Connector 7. Front Right T urn Signal Light Connector 8. Join connectors in the headlight unit. 9. Speedometer Light Connector 10. Headlight C[...]

  • Página 366

    16-18 APPENDIX Cable, Wire, a nd Hose Routing BN125-A3 ∼ A4[...]

  • Página 367

    APPENDIX 16-19 Cable, Wire, and Hose Routing 1. Rear Left T urn Signal Light Connector 2. T ail/Brake Light Connector 3. Band 4. Ground Lead 5. Ignition Coil Lead 6. Regulator/Rectifier Connector 7. CDI Unit Connector 8. Left Handlebar Switch Connector 9. Horn Connector 10. Indicator Light Connector 1 1. Sidestand Switch Connector 12. Headlight Con[...]

  • Página 368

    16-20 APPENDIX Cable, Wire, a nd Hose Routing BN125-A5 ∼[...]

  • Página 369

    APPENDIX 16-21 Cable, Wire, and Hose Routing 1. Rear Left T urn Signal Light Connector 2. T ail/Brake Light Connector 3. Band 4. White T ape 5. Ground Lead 6. Regulator/Rectifier Connector 7. Ignition Coil Lead 8. Left Handlebar Switch Connector 9. Horn Connector 10. Indicator Light Connector 1 1. Sidestand Switch Connector 12. Front Left T urn Sig[...]

  • Página 370

    16-22 APPENDIX Cable, Wire, a nd Hose Routing BN125-A5 ∼[...]

  • Página 371

    APPENDIX 16-23 Cable, Wire, and Hose Routing 1. Diode Connector 2. Fuse Box Connector 3. Battery Positive Lead 4. Clamp 5. T urn Signal Relay 6. Alternator Connector 7. Battery Negative Lead 8. Band 9. CDI Unit Connector 10. Ignition Coil Lead 1 1. Run the indicator light lead from left side. 12. Connect them in the headlight housing. 13. City Ligh[...]

  • Página 372

    16-24 APPENDIX Cable, Wire, a nd Hose Routing Evaporative Emission Control System (BN125-A5 ∼ : California Model)[...]

  • Página 373

    APPENDIX 16-25 Cable, Wire, and Hose Routing 1. Fuel T ank 2. Separator 3. Canister 4. V acuum Switch V alve 5. Air Cleaner Housing 6. Label (Blue) 7. Label (Red) 8. Hose (with blue stripe) 9. Hose (with blue stripe) 10. Hose (with red stripe) 1 1. Hose (with white stripe) 12. White Paint Mark 13. White Paint Mark[...]

  • Página 374

    16-26 APPENDIX Cable, Wire, a nd Hose Routing Evaporative Emission Control System (BN125-A5 ∼ : California Model)[...]

  • Página 375

    APPENDIX 16-27 Cable, Wire, and Hose Routing 1. V acuum Switch V alve 2. Go to the fuel tap 3. Carburetor Holder 4. Separator[...]

  • Página 376

    16-28 APPENDIX Cable, Wire, a nd Hose Routing Evaporative Emission Control System (BN125-A5 ∼ : California Model)[...]

  • Página 377

    APPENDIX 16-29 Cable, Wire, and Hose Routing 1. Run the ignition coil primary lead under the throttle cables, secondary air hose and breather hose. 2. Go T o Left Side 3. Separator 4. Go T o The Fuel T ank 5. Breather Hose 6. Secondary Air Hose 7. Air V ent Hose 8. Throttle Cables 9. V acuum Switch V alve 10. Carburetor Holder 1 1. Canister 12. Go [...]

  • Página 378

    16-30 APPENDIX Cable, Wire, a nd Hose Routing Evaporative Emission Control System (BN125-A5 ∼ : California Model)[...]

  • Página 379

    APPENDIX 16-31 Cable, Wire, and Hose Routing 1. Main Harness 2. Breather Hose 3. Secondary Air Hose 4. Air V ent Hose 5. Go to the fuel tank 6. Separator 7. Go to the canist er 8. Clamp 9. Front[...]

  • Página 380

    16-32 APPENDIX T roubleshooting Guide NOTE ○ This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doesn’t Start, Starting Difficulty: Starter motor not rotating: Starter lockout switch or neutral swi[...]

  • Página 381

    APPENDIX 16-33 T roubleshooting Guide Fuel level in carburetor float bowl too high or too low Fuel tank air vent obstructed Carburetor holder loose Air cleaner duct loose Fuel tap clogged Air cleaner O-ring damaged Compression low: Spark plug loose Cylinder head not sufficiently tightened down No valve clearance Cylinder , piston worn Piston ring b[...]

  • Página 382

    16-34 APPENDIX T roubleshooting Guide Fuel/air mixture incorrect: Main jet clogged or wrong size Fuel level in carburetor float bowl too low Carburetor holder loose Air cleaner duct loose Air cleaner poorly sealed, or missing Air c leaner O-ring damaged Air cleaner clogged Compression high: Carbon built up in combustion chamber Engine load faulty: [...]

  • Página 383

    APPENDIX 16-35 T roubleshooting Guide Abnormal Drive T rain Noise: Clutch noise: Clutch rubber damper weak or damaged Clutch housing finger/friction plate tang clearance excessive Clutch housing gear worn Metal chips jammed in clutch housing gear T ransmission noise: Bearings worn T ransmission gears worn or chipped Metal chips jammed in gear teeth[...]

  • Página 384

    16-36 APPENDIX T roubleshooting Guide Disc warped Contaminated pad Brake fluid deteriorated Primary or secondary cup damaged in mas- ter cylinder Brake master cylinder scratched inside Drum brake: Brake maladjusted Brake linings or drum worn Overheated W ater in brake drum Brake cam, camshaft worn Oil on brake linings Battery T rouble: Battery disc[...]