Eliminator 125 (2007) - Motorcycle MITSUBISHI - Free user manual and instructions

Product Type	Motorcycle
Brand	Mitsubishi
Model	Eliminator 125 (2007)
Engine Displacement	124 cc
Engine Type	4-stroke, single cylinder, air-cooled
Max Power	10.5 hp (7.8 kW) @ 8,500 rpm
Max Torque	9.5 Nm @ 7,000 rpm
Transmission	5-speed manual
Final Drive	Chain
Frame Type	Steel tube, double cradle
Front Suspension	Telescopic fork, 33 mm
Rear Suspension	Dual shock absorbers, adjustable preload
Front Brake	Single disc, 240 mm (optional ABS)
Rear Brake	Drum brake, 130 mm
Tire Size (Front)	90/90-18
Tire Size (Rear)	110/90-16
Wheelbase	1,470 mm (57.9 in)
Seat Height	710 mm (28.0 in)
Fuel Capacity	12 L (3.2 gal)
Dry Weight	125 kg (276 lb)
Overall Length	2,200 mm (86.6 in)
Overall Width	780 mm (30.7 in)
Overall Height	1,100 mm (43.3 in)
Manual Format	PDF, 385 pages, English

Frequently Asked Questions - Eliminator 125 (2007) MITSUBISHI

Where can I download the manual for my Mitsubishi Eliminator 125 (2007)?

You can download the PDF manual from the manual page by clicking the Download button. The manual is free and contains 385 pages in English.

Is the manual available in other languages?

Yes, you can request a translated version by selecting your desired language and providing your email address. A specifically translated version will be sent to you.

How do I ask a question about my Eliminator 125?

You can post a question by entering a Question Title, detailing the problem, your first name, and email for notifications. Your question will appear on the page for others to answer.

What is the recommended engine oil for the Eliminator 125?

The recommended engine oil is SAE 10W-40 for general use. Always check the manual for the correct grade and capacity (approximately 1.2 liters with filter change).

What tire pressure should I use?

Front tire pressure: 2.0 bar (29 psi). Rear tire pressure: 2.2 bar (32 psi). Always adjust for load and riding conditions.

How often should I change the oil?

Change the engine oil every 3,000 km (1,864 miles) or every 6 months, whichever comes first. Use a quality oil filter each time.

What is the fuel tank capacity and type?

The fuel tank holds 12 liters (3.2 gallons). Use unleaded gasoline with an octane rating of 91 RON or higher.

How do I adjust the chain tension?

Loosen the rear axle nut, then adjust the chain tension using the adjuster nuts on both sides of the swingarm. Chain slack should be 20-30 mm (0.8-1.2 in) at the midpoint.

What is the spark plug gap?

The spark plug gap should be 0.7-0.8 mm (0.028-0.031 in). Use a NGK CR7E or equivalent spark plug.

Can I install an ABS system on my Eliminator 125?

The 2007 model may have an optional ABS on the front brake. If your bike does not have it, aftermarket kits are available but require professional installation and may affect warranty.

USER MANUAL Eliminator 125 (2007) MITSUBISHI

Side profile of a black Kawasaki motorcycle with visible engine and wheelbars (no text or symbols)

Motorcycle ServiceManual

QuickReferenceGuide

GeneralInformation1
PeriodicMaintenance2
FuelSystem3
EngineTopEnd4
Clutch5
EngineLubricationSystem	6
EngineRemoval/Installation	7
Crankshaft/Transmission	8
Wheels/Tires	9
FinalDrive	10
Brakes	11
Suspension	12
Steering	13
Frame	14
ElectricalSystem	15
Appendix	16

This quick reference guidewill assist you in locating adesired topic or procedure.

• Bendthepagesbacktomatchthe blacktabofthedesiredchapternumberwiththeblacktabontheedgeateachtableofcontentspage.
  •Refertothesectionaltableofcontents fortheexactpagestolocatethespecifictopicrequired.

Motorcycle ServiceManual

Allrightsreserved.Nopartsofthispublicationmaybereproduced,storedinaretrievalsystem,or transmittedinanyformorbyanymeans,electronicmechanicalphotocopying,recordingorotherwise, withoutthepriorwrittenpermissionofQualityDivision/ConsumerProducts&MachineryCompany/Kawasaki HeavyIndustries,Ltd.,Japan.

Noliability can be accepted for any inaccuracies or missions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changestoproducts manufactured previously. See your Motorcycle dealer forthelatest information on product improvements incorporated after this publication.

All information contained in this publication is based on the latest product information available at the time of publication. Illustrationsandphotographsinthispublicationareintendedforreferenceuseonlyandmay notdepictactualmodelcomponentparts.

LISTOFABBREVIATIONS

Aampere(s)	lbpound(s)
ABDCafter	bottomdeadcenter	m	meter(s)
AC	alternatingcurrentmin		minute(s)
ATDcafter	topdeadcenter	N	newton(s)
BBDCbefore	bottomdeadcenterPapascal(s)
BDCbottom	deadcenterPShorsepower
BTDC	before top dead center	psi	pound(s) per square inch
°C	degree(s) Celsius	r	revolution
DC	direct current	rpm	revolution(s) per minute
F	farad(s)	TDC	top dead center
°F	degree(s) Fahrenheit	TIR	total indicator reading
ft	foot, feet	V	volt(s)
g	gram(s)	W	watt(s)
h	hour(s)	Ω	ohm(s)
L	liter(s)

Read OWNER'S MANUAL before operating.

EMISSIONCONTROLINFORMATION

Toprotecttheenvironmentinwhichwealllive,Kawasakihasincorporatedcrankcaseemission(1)andexhaustemission(2)controlsystemsincompliancewithapplicableregulationsof theUnitedStatesEnvironmentalProtectionAgencyandCaliforniaAirResourcesBoard.Additionally,Kawasakihasincorporatedanevaporativeemissioncontrolsystem(3)incompliance withapplicableregulationsoftheCaliforniaAirResourcesBoardonvehiclessoldinCalifornia only.

1. CrankcaseEmissionControlSystem

This system eliminates the lease of crank case vapors into the atmosphere. Instead, the vapors are routed through an oil separator to the inlet side of the engine. While the engine is operating, the vapors are drawn into combustion chamber, where they are burned along with the fuel and air supplied by the carburetionsystem.

1. ExhaustEmissionControlSystem

This system reduces the amount of pollutants discharged into the atmosphere by the exhaust of this motorcycle. The fuel, ignition, and exhaust system so this motorcycle have been carefully designed and constructed to ensure an efficient engine with low exhaust pollutants levels.

TheexhaustsystemofthismodelmotorcyclemanufacturedprimarilyforsaleinCaliforniain-cludesacatalyticconvertersystem.

1. Evaporative Emission Control System

Vaporscausedbyfuelevaporationinthefuelsystemarenotventedintotheatmosphere.Instead,fuelvaporsareroutedintotherunningenginetobeburned,orstoredinacanisterwhen theengineisstopped.Liquidfueliscaughtbyavaporseparatorandreturnedtothefueltank.

TheCleanAirAct, which is the Federal law covering motor vehicle pollution, contains what is commonly referred to the Act's "tampering provisions."

"Sec.203(a)Thefollowingactsandthecausingthereofareprohibited...

(3)(A)foranypersontoremoveorrenderinoperativeanydeviceorelementofdesigninstalled onorinamotorvehicleormotorvehicleengineincompliancewithregulationsunderthis titlepriortoitssaleanddeliverytotheultimatepurchaser,orforanymanufacturerordealer knowinglytoremoveorrenderinoperativeanysuchdeviceorelementofdesignaftersuch saleanddeliverytotheultimatepurchaser.

(3)(B)foranypersonengagedinthebusinessofrepairing,servicing,selling,leasing,ortrading motorvehiclesormotorvehicleengines,orwhooperatesafleetofmotorvehiclesknowinglytoremoveorrenderinoperativeanydeviceorelementofdesigninstalleddonorina motorvehicleormotorvehicleengineincompliancewithregulationsunderthistitlefollowingitssaleanddeliverytotheultimatepurchaser..."

NOTE

○ The phrase "remove or render inoperative any device or element of design" has been generally interpreted as follows:

1. Tamperingdoesnotincludethetemporaryremovalorrenderinginoperativeofdevicesorelementsofdesigninordertoperformmaintenance.
2. Tamperingcouldinclude:

a. Maladjustmentofvehiclecomponentssuchthattheemissionstandardsareexceeded.

b. Use of replacement parts or accessories which adversely affect the performance ordurability of the motorcycle.

c.Additionofcomponentsoraccessoriesthatresultinthevehicleexceedingthestandards.

d. Permanently removing, disconnecting, or rendering in operative any component or element of design of the emission control systems.

WERECOMMENDTHATALLDEALERSOBSERVETHESEPROVISIONSOFFEDERALLAW, THEVIOLATIONOFWHICHISPUNISHABLEBYCIVILPENALTIESNOTEXCEEDING \$10,000PERVIOLATION.

TAMPERINGWITHNOISECONTROLSYSTEMPROHIBITED

Federallawprohibitsthefollowingactsorthecausingthereof:(1)Theremovalorrendering inoperativebyanypersonotherthanforpurposesofmaintenance,repair,orreplacement,ofany deviceorelementofdesignincorporatedintoanynewvehicleforthepurposeofnoisecontrol priortoitssaleordeliverytotheultimatepurchaserorwhileitisinuse,or(2)theuseofthe vehicleaftersuchdeviceorelementofdesignhasbeenremovedorrenderedinoperativeby anyperson.

Amongthoseactspresumedtoconstitutetamperingaretheactslistedbelow:

• Replacementoftheoriginalexhaustsystemormufflerwithaccomponentnotincompliance withFederalregulations.
• Removalofthemuffler(s)oranyinternalportionofthemuffler(s).
• Removaloftheairboxorairboxcover.
• Modificationstothemuffler(s)orairinletsystembycutting,drilling,orothermeansifsuch modificationsresultinincreasednoiselevels.

Foreword

Thismanualisdesignedprimarilyforuseby trainedmechanicsinaproperlyequippedshop. However, it contains enough detail and basic information to make useful to the owner who desire to perform his own basic maintenance and repair work. Abasicknowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repairs satisfactorily. Whenever the owner has insufficient experience or doubt this ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.

Inordertoperformtheworkefficiently and toavoidcostlymistakes,readthetext,thoroughlyfamiliarizeyourselfwiththeprocedures beforestartingwork,andthendotheworkcarefullyinacleanarea.WhenIVERSpecialtoolsorequipmentarespecified,donotusemakeshift toolsorequipment.Precisionmeasurements canonlybemadeiftheproperinstrumentsare used,andtheuseofsubstitutetoolsmayadverselyaffectsafeoperation.

Forthedurationofthewarrantyperiod, werecommendthatallrepairsandscheduled maintenancebeperformedinaccordancewith thisservicemanual.Anyownermaintenanceor repair procedure not performed in accordance withthismanualmayvoidthewarranty. Togetthelongestlifeoutofyourvehicle:

• FollowthePeriodicMaintenanceChartintheServiceManual.
• Be alert for problems and non-scheduled maintenance.
• UsepropertoolsandgenuineKawasakiMotorcycleparts. Specialtools, gauges, and testersthatarenecessarywhen servicing Kawasakimotorcyclesareintroduced by the Service Manual. Genuine parts provided as sparepartsarelistedinthePartsCatalog.
• Follow the procedures in this manual carefully. Don't take shortcuts.
• Remembertokeepcompleterecordsof maintenanceandrepairwithdatesandanynew partsinstalled.

HowtoUseThisManual

In this manual, the product is divided into its majors systems and the these systems makeup them an ual's chapters. The Quick Reference

Guideshowsyoualloftheproduct'ssystem andassistsinlocatingtheirchapters. Each chapterinturnhasitsowncomprehensiveTableofContents.

Forexample, if you want ignition coil information, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Ignition Coil section.

Whenever you see these WARNING and CAUTION symbols, heed their instructions! Alwaysfollowsafeoperatingandmaintenance practices.

WARNING

This warningsymbolidentifiesspecial instructionsorprocedureswhich,ifnot correctlyfollowed,couldresultinpersonalinjuryorlossoflife.

CAUTION

Thiscautionsymbolidentifiesspecial instructionsorprocedureswhich,ifnot strictlyobserved,couldresultindam- agetoordestructionofequipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

NOTE

○This note symbol indicates points of particular interest form more efficient and convenient operation.
- Indicatesaproceduralsteporworktobe done.
○Indicatesaproceduralsub-steporhowtodo the work of the procedural step it follows. It alsoprecedesthetextofaNOTE.
★Indicatesaconditionalsteporwhatactionto takebasedontheresultsofthetestorinspection in the procedural step or sub-step it follows.

In most chapters an exploded view illustration of the system components follow the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GeneralInformation

TableofContents

Before Servicing 1-2

Model Identification.... 1-7

General Specifications.... 1-9

Technical Information-DC-CDI (Direct Current-Capacitor Discharge Ignition System).... 1-13

Technical Information-Coasting Enricher 1-20

Unit Conversion Table 1-22

1-2GENERALINFORMATION

BeforeServicing

Beforestartingtopermaninspectionserviceorcarryoutadisassemblyandreassemblyoperation on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustrations, photographs, cautions, and detailed descriptions have been included in each chapter wherever necessary. This section explains the items that require particular attention during the removal and reinstallationordisassemblyandreassemblyofgeneralparts.

Especiallynotethefollowing:

BatteryGround

Beforecompletinganyserviceonthemotorcycle, disconnectthebatterycablesfromthebatterytopreventtheenginefromaccidentallyturningover.Disconnecttheground cable(−)firstandthenthepositive(+).Whencompleted withtheservice,firstconnectthepositive(+)cabletothe positive(+)terminalofthebatterythenthenegative(−)cabletothenegativeterminal.

EdgesofParts

Liftlargeorheavypartswearingglovestopreventinjury frompossiblesharpedgesontheparts.

Solvent

Useahighflushpointsolventwhencleaningparts.High flushpointsolventshouldbeusedaccordingtodirections ofthesolventmanufacturer.

Cleaningvehiclebeforedisassembly

Cleanthevehiclethoroughlybeforedisassembly.Dirtor otherforeignmaterialsenteringintosealedareasduringveh-cledisassemblycancauseexcessivewearanddecrease performanceofthevehicle.

Illustration of a hand holding a cylindrical engine block with a no-handled hand symbol nearby (no text or labels)

Line drawing of a motorcycle with hands adjusting the wheel (no text or symbols)

BeforeServicing

ArrangementandCleaningofRemovedParts

Disassembledpartsareeasytoconfuse.Arrangethe partsaccordingtotheorderthepartsweredisassembled andcleanthepartsinorderpriortoassembly.

StorageofRemovedParts

After all the parts including subassembly part have been cleaned, store the parts in a clean area. Put a clean cloth or plastics sheet over the part stop protect from any foreign material that may collect before assembly.

Inspection

Reuseofwornordamagedpartsmayleadtoseriousaccident. Visuallyinspectremovedpartsforcorrosion,discoloration,orotherdamage. Refertotheappropriatesections ofthismanualforservicelimitsonindividualparts. Replace thepartsifanydamagehasbeenfoundorifthepartisbeyonditsservicelimit.

ReplacementParts

ReplacementpartsmustbeKAWASAKIgenuineor recommendedbyKAWASAKI.Gaskets,O-rings,oilseals, greaseseals,circlipsorcotterpinsmustbereplacedwith newoneswheneverdisassembled.

AssemblyOrder

Inmostcasesassemblyorderisthereverseofdisassembly,however,ifassemblyorderisprovidedinthisService Manual,followtheproceduresgiven.

Technical line drawing of a mechanical assembly with gears and components (no text or symbols)

Technical line drawing of a mechanical assembly with gears and components (no text or symbols)

Line drawing of a hand holding a small container with a small inset showing an eye (no text or symbols)

Line drawing of hands operating a mechanical device with gears and a handle (no text or symbols)

BeforeServicing

TighteningSequence

Generally, when installing apart with several bolts, nuts, or screws, start them all in their holes and tightent hem to as nugfit. Thentightenthem according to the specified sequence to prevent casewar page or deformation which can lead to malfunction. Conversely when loosening the bolts, nuts, or screws, first loosen allof them by about a quarter turn and then removethem. If these specified tightening sequence is not indicated, tightent he fasteners alternating diagonally.

Tightening Torque

Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fastener stothespecified torque using a good quality torque wrench. Often, the tightening sequence is followed twice - initial tightening and final tightening with torque wrench.

Force

Usecommonsenseduringdisassemblyandassembly, excessive force can cause expensive or hard to repair damage. Whennecessary,removescrewsthathaveanon-permanentlockingagentappliedusinganimpactdriver. Useaplastic-facedmalletwhenevertappingisnecessary.

Gasket, O-ring

Hardening, shrinkage, or damage of both gaskets and O-ringsafterdisassembly can reduce sealing performance. Remove old gaskets and clean these sealing surfaces thoroughly so that nogasket material or other material remains. Install new gaskets and replace used O-rings when re-assembling.

LiquidGasket,LockingAgent

For application that require Liquid Gasketora Locking agent, clean the surfaces so that no oil residue remains before applying liquid gasketor locking agent. Donot apply them excessively. Excessive application can clog oil passages and causes serious damage.

Line drawing of hands using a tool to measure a cylindrical object, no text or symbols present

Line drawing of a mechanical component being adjusted by a hand (no text or symbols)

Line drawing of two hands adjusting a flange with a sun icon, no text or symbols present

Illustration of a hand using a tool to connect components in a mechanical housing, with a no-smoking symbol nearby (no text or labels)

BeforeServicing

Press

Foritemssuchasbearingsoroilsealsthatmustbe pressedintoplace,applysmallamountofoiltothecontactarea.Besuretomaintainproperalignmentanduse smoothmovementswheninstalling.

BallBearingandNeedleBearing

Donotremovepressedballorneedleunlessremovalis absolutelynecessary.Replacewithnewoneswhenever removed.Pressbearingswiththemanufacturerandsize marksfacingout.Pressthebearingintoplacebyputting pressureonthecorrectbearingraceasshown.

Pressingtheincorrectracecancausepressurebetween theinnerandouterraceandresultinbearingdamage.

OilSeal, GreaseSeal

Donotremovepressedoilorgreasesealsunlessremoval isnecessary.Replacewithnewoneswheneverremoved. Pressnewoilsealswithmanufactureandsizemarksfacing out.Makesurethesealisalignedproperlywheninstalling.

Applyspecifiedgreasetothelipofsealbeforeinstalling theseal.

Circlips, CotterPins

Replacecirclipsorcotterpinsthatwereremovedwithnew ones. Takecarenottoopentheclipexcessivelywheninstallingtopreventdeformation.

Technical illustration of a mechanical assembly with hands and a small block labeled 'OIL' (no text or symbols on the diagram itself)

Mechanical assembly diagram showing two mechanical components with downward force arrows, one bearing a circular component (no text or symbols)

Technical illustration of a mechanical tool interacting with a workpiece, showing motion and assembly (no text or symbols)

1-6GENERALINFORMATION

BeforeServicing

Lubrication

It is important to lubricator rotating or sliding parts during assembly to minimize weard during initial operation. Lubrication points are called out throughout this manual, apply the specific oilorgrease as specified.

DirectionofEngineRotation

Whenrotatingthecrankshaftbyhand, thefreeplay amountofrotatingdirectionwillaffecttheadjustment. Rotatethecrankshafttopositivedirection(clockwiseviewed fromoutputside).

ElectricalLeads

Atwo-colorleadisidentifiedfirstbytheprimarycolorand thenthestripecolor.Unlessinstructedotherwise,electrical leadsmustbeconnectedtothoseofthesamecolor.

Instrument

Useameterthathasenoughaccuracyforanaccurate measurement.Readthemanufacture'sinstructionsthor- oughlybeforeusingthemeter.Incorrectvaluesmaylead toimproperadjustments.

Line drawing of hands assembling a tire with a tool labeled 'OIL' (no text or symbols beyond label)

Technical line drawing of a mechanical component with no visible text or symbols

Line drawing of a hand using a multimeter to test electrical components (no text or symbols visible)

ModelIdentification

BN125-A1(Europe)LeftSideView

Side profile of a black Kawasaki motorcycle with visible engine and wheel (no text or symbols)

BN125-A1(Europe)RightSideView

Side profile of a black Kawasaki motorcycle with visible engine and wheel (no text or symbols)

1-8GENERALINFORMATION

ModelIdentification

BN125-A1(Singapore)LeftSideView

Side profile of a black Kawasaki motorcycle with visible engine and wheel (no text or symbols)

BN125-A1(Singapore)RightSideView

Side profile of a black Kawasaki motorcycle with visible engine, power lines, and wheelbase (no text or symbols)

GeneralSpecifications

Items	BN125-A1 ~ A2	BN125-A3 ~ A4	BN125-A5 ~
Dimensions
Overalllength2150mm(84.6in.)
Overallwidth780mm(30.7in.)
Overallheight1020mm(40.2in.)	1035mm(40.8in.)		←1050mm(41.3in.)(US,CA)1045mm(41.1in.)BN125-A7~ (N,NU)
Wheelbase1470mm(57.9in.)
Roadclearance	145mm(5.7in.)160mm(6.3in.)		←155mm(6.1in.)(US,CA)
Seatheight680mm(26.8in.)
Drymass	128kg(1255N,282lb)	135kg(1323N,298lb)132kg(1294N,291lb)(US):(BN125-A4~)
Curbmass:Front64kg(628N,141lb)←			66kg(647N,146lb)(CAL)65kg(637N,143lb)(BN125-A7~,N,NU)
Rear:	80 kg (785 N, 176 lb)	84 kg (824 N, 185 lb)81kg(794N,179lb):(BN125-A4, US,CA)	←←82kg(804N,181lb)(CAL)83kg(814N,183lb)(BN125-A7~,N,NU)
Fueltankcapacity	13L(3.43USgal)
Performance
Minimumturningradius	2.5m(8.2ft.)
Engine
Type	4-stroke,SOHC,1-cylinder
Coolingsystem	Air-cooled
Boreandstroke	55×52.4mm(2.2×2.1in.)
Displacement	124cm3(7.6cuin.)
Compressionratio	9.6: 1
Maximumhorsepower	8.8kW(12PS)@9500r/min(rpm),(US)-		←8.5kW(11.6PS)@9500r/min(rpm)(BN125-A7~,N,NU)

GeneralSpecifications

Items	BN125-A1 ~ A2	BN125-A3 ~ A4	BN125-A5 ~
Maximum torque 9.7N·m(0.99kgf·m,7.2ft·lb)@8000r/min(rpm)(US)-			←9.8N·m(1.00kgf·m,7.2ft·lb)@8000r/min(rpm)(BN125-A7~,N,NU)
Carburetionsystem CarburetorStartingsystemIgnition systemTiming advanceIgnition timing From 10° BTDC	,MIKUNIBS28Electric starterDC-CDIElectronically advanced (analog)
	@1300r/min(rpm)to30° BTDC@4500r/min(rpm)		←From 10° BTDC@1300r/min(rpm) to35° BTDC@4500r/min(rpm)(US,CA,CAL)
Spark plug NGKCR7E	←	NGKCR7EorU22ESR-N:(BN125-A4~, US, CA)
Valvetiming:Inlet:OpenCloseDurationExhaust:OpenCloseDurationLubricationsystemEngine oil:Grade	23° BTDC57° ABDC260°64° BBDC16° ATDC260°Forcedlubrication(wetsump)
	SE, SF or SG	←(BN125-A3)APISE,SForSGAPISH,SJorSLwithJASOMA
ViscosityCapacity	SAE10W-40
	1.4L(1.48USqt)(whenengine is completely dry)
Drive TrainPrimary reduction system:TypeReduction ratioClutch typeTransmission:Type	Gear3.666(77/21)Wetmultidisc5-speed,constantmesh,returnshift

GeneralSpecifications

Items	BN125-A1 ~ A2	BN125-A3 ~ A4	BN125-A5 ~
Gear ratios:
1st	2.700(27/10)
2nd	1.705(29/17)
3rd1.300(26/20)
4th1.090(24/22)
5th0.952(20/21)
Finaldrivesystem:
TypeChaindrive
Reduction ratio 3.066(46/15)	←		2.800(42/15)(BN125-A7~, N, NU)
Overall drive ratio	10.708 @Top gear		←9.778@Topgear(BN125-A7~, N, NU)
Frame
Type	Doublecradle
Caster(rake angle)	34°
Trail	121 mm(4.8in.)	←119 mm (4.7 in.): BN125-A4 ~ (US, CA)
RimSize:
Front	17×1.85
Rear	15×2.75
Fronttire:
TypeTubetype
Size	90/90-17 M/C49P
Reartire:
TypeTubetype
Size	130/90-15 M/C66P
Frontsuspension:
TypeTelescopic fork
Wheel travel	130 mm (5.1 in.)		140 mm (5.5 in.)
Rearsuspension:
TypeSwingam
Wheel travel	60 mm (2.4 in.)		80 mm (3.1 in.)
	75mm (3.0in.)
	(BN125-A2~)
Braketype:
Front	Singledisc
Rear	Drum
Electrical Equipment
Battery	12V9Ah
Headlight:
TypeSemi-sealed beam
Bulb	12V60/55W

1-12GENERALINFORMATION

GeneralSpecifications

Items	BN125-A1 ~ A2	BN125-A3 ~ A4	BN125-A5 ~
Trail/brakelight12V5/21WAlternator:TypeRatedoutput	Single-phaseAC8.75A/12V@4000r/min(rpm):BN125-A115A/14V@8000r/min(rpm):BN125-A2~

Specificationssubjecttochangewithoutnotice, and may not apply to every country.

(CA):CanadaModel

(US):UnitedStatesModel

(N): NoCatalyticConverter

(NU): No Catalytic Converter (United Kingdom Model)

TechnicalInformation-DC-CDI(DirectCurrent-CapacitorDischargeIgnitionSystem)

Description

○ UnliketheconventionalCDI, the DC-CDlusesabatteryinsteadofamagnetoasapowersource.
The DC-CDI powered by a battery generates strong ignitions parkeven at low engines speeds. The conventional CDI, which uses AC voltages supplied by an exciter coil, generates less ignitions spark at low engines speeds.
The DC-CDI has been built-in DC-DC converter which changes battery voltage or battery-changing voltage into high voltage AC. Even if the battery loses its charge, the DC-CDI can use battery-charging voltage.
TheDC-CDI doesn't have an exciter coil, a power consumer, therefore the battery is charged better.

IgnitionSystem

TheDC-CDisconnectedasshown.

graph TD
    A["Alternator"] --> B["Regulator/Rectifier"]
    B --> C["Ignition Switch"]
    C --> D["CDI unit"]
    D --> E["Ignition Coil"]
    E --> F["Spark Plug"]
    F --> G["Battery"]
    G --> H["Crank-shaft Sensor"]
    H --> B
    B --> I["Voltage is detected"]
    I --> J["Engine Stop Switch"]
    J --> D

graph TD
    A["Alternator"] --> B["Regulator/Rectifier"]
    B --> C["Ignition Switch"]
    C --> D["CDI unit"]
    D --> E["Ignition Coil"]
    E --> F["Spark Plug"]
    F --> G["Battery"]
    G --> H["Crank-shaft Sensor"]
    B --> I["Voltage is detected"]
    D --> J["Engine Stop Switch"]

1-14GENERALINFORMATION

TechnicalInformation-DC-CDI(DirectCurrent-CapacitorDischargeIgnitionSystem)

Operation

TheDC-CDIcircuitconsistsofabattery,aDC-DCconverter,adiode,acapacitor,anignitiontiming controller, a crankshaft sensor, a thyristor, an ignition coil, a spark plug, an ignition switch, and an enginestopswitch.IftheignitionswitchortheenginestopswitchisturnedtotheOFFposition,the batterypowersupplyiscutoff,andnosparkisgenerated.

TheDC-DCconverterintheCDlunithasabuilt-intransformer,whichchanges12Vbatteryvoltageorbattery-chargingvoltageintoACvoltage.ThediodeconvertstheACvoltageintoabout225VDCtochargethecapacitor.

Firststep-ChargingtheCapacitor

Theconvertergeneratesthecurrenttochargethecapacitorthroughthediodewith225VDC.During thisprocess,thecurrentchangesslowlythroughtheprimarycoilwindingsothatthesecondarycoil windinggoesnotproduceenoughvoltagetofirethesparkplug.

graph TD
    A["Battery"] --> B["Transformer"]
    B --> C["12V DC"]
    C --> D["225V DC"]
    D --> E["Capacitor (+)"]
    E --> F["Ignition Coil (-)"]
    F --> G["Charging"]
    G --> H["Crankshaft Sensor"]
    H --> I["Ignition Timing Controller"]
    I --> J["Thyristor"]
    J --> K["A"]
    K --> L["K"]
    L --> M["G"]
    M --> N["Spark Plug"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#cff,stroke:#333
    style F fill:#ffc,stroke:#333
    style G fill:#cfc,stroke:#333
    style H fill:#fcc,stroke:#333
    style I fill:#cfc,stroke:#333
    style J fill:#fcc,stroke:#333
    style K fill:#cfc,stroke:#333
    style L fill:#fcc,stroke:#333
    style M fill:#cfc,stroke:#333
    style N fill:#fcc,stroke:#333

Secondstep-thyristorconducts

Aftercharging, the crankshaft sensor and ignition timing controllers send at triggers signal to the gate through the cathode (K → G in the figure) in the thyristor. When this happens, the current flows from the cathodeto the anode (K → A) in the thyristor.

Thirdstep-SurgingcurrentintothePrimaryWinding

Whenthethyristorconducts, the chargestored in the capacitor is released suddenly, flowing through the primary winding, backthrough the ethyristortothecapacitor.

TechnicalInformation-DC-CDI(DirectCurrent-CapacitorDischargeIgnitionSystem)

graph TD
    Battery --> DC-DC_Converter["DC-DC Converter"]
    DC-DC_Converter --> Transformer["Transformer 12V DC → 225V DC"]
    Transformer --> Oscillator["Oscillator"]
    Oscillator --> Thyristor["Thyristor"]
    Thyristor --> IgnitionTiming["Ignition Timing Controller"]
    IgnitionTiming --> Crankshaft["Crankshaft Sensor"]
    Crankshaft --> PrimaryWinding["Primary Winding"]
    PrimaryWinding --> Discharging["Discharging"]
    Discharging --> Capacitor["Capacitor (+) (-)"]
    Capacitor --> IgnitionCoil["Ignition Coil"]
    IgnitionCoil --> SparkPlug["Spark Plug"]
    SparkPlug --> SecondaryWinding["Secondary Winding"]
    SecondaryWinding --> Drone["Drone"]
    Drone --> PrimaryWinding
    PrimaryWinding --> G["G"]
    G --> K["K"]
    K --> A["A"]
    A --> G
    style DC-DC_Converter fill:#f9f,stroke:#333
    style Battery fill:#fff,stroke:#333
    style Crankshaft fill:#fff,stroke:#333
    style PrimaryWinding fill:#fff,stroke:#333
    style SecondaryWinding fill:#fff,stroke:#333
    style SparkPlug fill:#fff,stroke:#333
    style Drone fill:#fff,stroke:#333
    style SecondaryWinding fill:#fff,stroke:#333
    style G fill:#fff,stroke:#333
    style K fill:#fff,stroke:#333
    style A fill:#fff,stroke:#333
    style K fill:#fff,stroke:#333
    style G fill:#fff,stroke:#333
    style K fill:#fff,stroke:#333
    style A fill:#fff,stroke:#333
    style K fill:#fff,stroke:#333
    style K fill:#fff,stroke:#333
    style K fill:#fff,stroke:#333
    style K fill:#fff,stroke:#333
    style K fill:#fff,stroke:#333
    style K fill:#fff,stroke:#333
    style K fill:#fff,stroke:#333
    style K fill:#fff,stroke:#334

This sudden change in the primary current induces a primary voltage (counterelectromotive force) which is equal to the capacitor voltage (about 225V) but against the discharging current. The primary voltage induces a high secondary voltage in the secondary coil, generating spark plug gap. The secondary voltage multiplied by winding ratio (about 90:1) reaches about 20000V.

Finalstep-Thyristorresets

After the charge stored in the capacitor is completely released, the cathodeoanode voltage is removed in the thyroid or and the thyroid receptor stops conducting and automatically resets. Then, the DC-DC converter charges the capacitor again and operation return to first step.

The control of Ignition Timing

Sincetheignitiontimingiselectronicallyadvancedorretarded, thissystemhasnomechanicalpartssuchasacam orcontactbreakersandtherearenopartstowearoutand noperiodicmaintenanceisrequired. So, thereisneverany needtoadjustthetimingonceithasbeeninstalledcorrectly.

Generally, the spark plug must be fired at a proper crank angle before top dead center (BTDC).

Atlowandmid-rangeenginespeeds, thefastertheengine runs, thefurthertheignitionTimingadvances. This preventsknocking and preignition, and providesbetterengine performance.

Iftheenginespeedincreasesfurther,notimingadvance isrequiredbecausetheenginecanbreatheinandburnthe fuel/airmixtureinashortertime.Theignitiontimingdoes notincreasefurtherandthetimingadvancestops.This alsoprovidesbetterengineperformanceandpreventsthe enginefromoverrunningandoverheating.

Theoperationofadiodeandthyristorisexplainedhere inordertodescribehowtheignitiontimingiscontrolled.

1-16GENERALINFORMATION

TechnicalInformation-DC-CDI(DirectCurrent-CapacitorDischargeIgnitionSystem)

Diode

Adiodefunctionsasanelectricalcheckvalve.Itconducts currenteasilyfromitscathodetoitsanode,butitwillnot permitcurrentflowintheoppositedirection.Sinceelectricityattemptstoflowfromnegative(−)topositive(+),acircuitwithadonewillconductcurrentonlywhenthepolarity iscorrect,i.e.,whenthenegativechargeisappliedtothe diode'scathode.

NOTE

○ Thismanual doesn't usethe conventional current flow concept, but the electron theory current flow concept; currentissupposed to flownegative(−)topositive(+) in this text.

Thyristor(SCR)

Currentwillflowfromthecathodetoanodebutwillnot flowinthereversedirection. Thethyristordiffersfroma diodeintworespects:(a)eventhoughavoltageofthecorrectpolarity-negativetocathode-maybeapplied,thethyristorwillnotconductuntilasignalisappliedtothegateinput lead;(b)oncestarted,itwillnotstopconducting(evenifthe gateleadsignalvoltagestops)untilthecathodetoanode voltageisremovedorreversed.

Thecrankshaftsensorisinstalledonthealternatorcover sothatitwillbeclosetothealternatorrotor. Onesideof thecrankshaftsensorcorehasapermanentmagnetand theothersidehasacoiltosignaltheCDlunit.

CrankshaftSensor[A]

AlternatorRotor[B]

TimingPlate[C]

OutputVoltage[D]

TechnicalInformation-DC-CDI(DirectCurrent-CapacitorDischargeIgnitionSystem)

Everytimeeitherendofthetimingplateontherotor passesbythecrankshaftsensor,apulseisgeneratedand senttotheCDIunit,thatis,twopulsesaregeneratedper onerevolutionoftherotor.Oneisapositivepulse[A]and theotherisanegativepulse[B].

Thecrankshaftsensor,asignalgenerator,andvoltagecomparatorsdeterminetheignitiontimingintheignitiontimingcontroller.Thepowersupplycircuitisthepowersourceforthesignalgeneratorandthevoltagecomparators.

graph LR
    A["Crankshaft Sensor"] --> B["Signal Generator"]
    B --> C["A Signal"]
    B --> D["B Signal"]
    C --> E["Comparator"]
    D --> E
    E --> F["Power Supply Circuit"]
    F --> G["Thyristor"]
    G --> H["K"]
    I["G"] --> G

1-18GENERALINFORMATION

TechnicalInformation-DC-CDI(DirectCurrent-CapacitorDischargeIgnitionSystem)

Thecrankshaftsensorgeneratesacrankshaftsensorsignalandsendsittothesignalgenerator. ThesignalgeneratorgeneratesAandBsignalssynchronizedwiththecrankshaftsensorsignal.Thesesignalsareshowninthefigure.

Thatistosay, the signal generator changesthe crank-shaftsensorsignal into A and B signals.

TechnicalInformation-DC-CDI(DirectCurrent-CapacitorDischargeIgnitionSystem)

(IgnitionTimingAdvancing)

AsignalandBsignalinthecomparatoradvancetheignitiontiming.

ThesignalgeneratordecreasesAsignalastheengine rpmincreasesfromN1,toN3asshown,butkeepsBsignal unchanged.

AandBsignalsareshownwiththesignalsoverlapped.

The comparator compares Asignal with Bsignal. When Asignal voltage becomes equal to or less than Bsignal voltage, the comparators sends atriggersignal to the gate in the thyristor, firing the spark plug.

The intersection point between A and B signals indicates the timing when the spark plug fires. This point moves left (the timing advances) asthe enginerp min increases from N1 to N3 as shown.

Beforeorafteradvancingperiod,theignitiontimingisdeterminedbythecrankshaftssensorsignalandtheignition timingremainsconstant.

The figureshowstheadvancingchart.

1-20GENERALINFORMATION

TechnicalInformation-CoastingEnricher

Thecoastingenricher[A]preventsbackfiringduringenginebrakingbysupplyingarichfuelmixturetotheengine.

Close-up of a mechanical component with threaded end and labeled point A (no readable text or symbols)

Whenthemotorcycleiscruisingoraccelerating,theenginevacuumislow,andthereturnspring[3] pushesthevalveinitsopenedposition[5].Thepassage[6]isopenandtheairrunsthroughthepilot jet[7]forbetteratomization.

Duringenginebraking,ahhighvacuumisgeneratedbehindthebutterflyvalve[11]. Thisdrawsthe diaphragm[2]againstthereturnspring[3]toclosethevalve[12],andthenthepassage[6]. The mixturebecomesrichtopreventbackfiringbecausetheamountofairisreduced.

GB060153W3 C

1. PilotAirJet1

2.Diaphragm

1. ReturnSpring

4.Cover

1. ValveOpened

6.Passage

7.PilotJet

8.PilotAirJet2

9.PilotScrew

10.AirCleanerHousing

1. ButterflyValve(ThrottleValve)

12ValveClosed

TechnicalInformation-CoastingEnricher

FuelandAirSupplyofEnricherSystem

graph TD
    A["Fuel Tank"] --> B["Float Bowl"]
    B --> C["Main Jet"]
    D["Air Cleaner"] --> E["Carburetor Bore"]
    E --> F["Engine"]
    G["Pilot Air Jet1"] --> H["Pilot Jet"]
    I["Pilot Air Jet2"] --> H
    J["Bypass Outlet"] --> H
    K["Pilot Screw"] --> H
    L["Slow Passage"] --> H
    H --> M["Fuel"]
    H --> N["Mixture"]
    H --> O["Air"]

1-22GENERALINFORMATION

UnitConversionTable

PrefixesforUnits

PrefixSymbolPower
megaM×1000000kilok×1000centic× 0 . 0 1millim×0.001microp×0.000001

UnitsofMass

kg	×	2.205	=	lb
g	×	0.03527	=	oz

UnitsofVolume

L	×	0.2642	=	gal(US)
L	×	0.2200	=	gal(imp)
L	×	1.057	=	qt(US)
L	×	0.8799	=	qt (imp)
L	×	2.113	=	pint (US)
L	×	1.816	=	pint (imp)
mL	×	0.03381	=	oz(US)
mL	×	0.02816	=	oz(imp)
mL	×	0.06102	=	cu in

UnitsofForce

N	×	0.1020	=	kg
N	×	0.2248	=	lb
kg	×	9.807	=	N
kg	×	2.205	=	lb

UnitsofLength

km	×	0.6214 =	mile
m×	3.281 = ft
mm	×	0.03937 =	in

UnitsofTorque

N·m	×	0.1020	=	kgf·m
N·m	×	0.7376	=	ft·lb
N·m	×	8.851	=	in·lb
kgf·m	×	9.807	=	N·m
kgf·m	×	7.233	=	ft·lb
kgf·m	×	86.80	=	in·lb

UnitsofPressure

kPa	×	0.01020	=	kgf/cm2
kPa	×	0.1450	=	psi
kPa	×	0.7501	=	cm Hg
kgf/cm2	×	98.07	=	kPa
kgf/cm2	×	14.22	=	psi
cm Hg	×	1.333	=	kPa

UnitsofSpeed

km/h

×

0.6214

=

mph

UnitsofPower

kW×	1.360	=		PS
kW×	1.341	=	HP
PS	×	0.7355	=	kW
PS	×	0.9863	=	HP

Units of Temperature

PeriodicMaintenance

TableofContents

PeriodicMaintenanceChart....2-2

TorqueandLockingAgent......2-4

Specifications....2-9

SpecialTools....2-11

PeriodicMaintenanceProcedures.....2-12

FuelSystem....2-12

FuelHoseandConnection Inspection....2-12

ThrottleGripFreePlayInspection2-12

ThrottleGripFreePlay Adjustment.....2-13

IdleSpeedInspection......2-13

IdleSpeedAdjustment.....2-14

AirCleanerElementCleaning.....2-14

EvaporativeEmissionControl SystemInspection(CAL)......2-14

EngineTop....2-15

AirSuctionValveInspection......2-15

CylinderHeadBoltTightness Inspection....2-16

ValveClearanceInspection......2-16

ValveClearanceAdjustment.....2-17

Clutch....2-17

ClutchLeverFree Play Inspection2-17

ClutchLeverFreePlay Adjustment.....2-17

EngineLubricationSystem....2-18

EngineOilChange....2-18

OilFilterChange 2-19

OilScreenCleaning 2-20

Wheels/Tires....2-21

Spoke Tightness Inspection .....2-21

RimRunoutInspection......2-21

AirPressureInspection/Adjustment....2-22

TireWearInspection....2-23

FinalDrive....2-23

DriveChainSlackInspection......2-23

DriveChainSlackAdjustment.....2-24

DriveChainWear Inspection .....2-25

Drive ChainLubrication....2-26

Brakes....2-26

Brake PedalFree Play Inspection2-26

BrakeShoeLiningWear Inspection....2-27

Brake PadWearInspection.....2-27

BrakeHoseandConnection Inspection....2-27

Brake FluidLevelInspection......2-28

Brake FluidChange....2-28

Brake LineBleeding....2-29

Brake/Master CylinderCup and Dust SealReplacement....2-31

CaliperPiston/DustSeals Replacement....2-31

Brake LightSwitchInspection.....2-31

Brake CableReplacement......2-31

Suspension....2-32

Front ForkOilChange......2-32

Front ForkOilLeakInspection.....2-33

Rear Shock AbsorberOil Leak Inspection....2-33

Swingarm PivotLubrication......2-33

Steering....2-34

Steering Inspection....2-34

Steering Adjustment....2-34

SteeringStemBearing Lubrication....2-35

Electrical System 2-35

BatteryElectrolyteLevel Inspection....2-35

Spark PlugCleaning/Inspection...2-35

Spark PlugGapInspection......2-35

General Lubrication....2-36

Lubrication....2-36

Nut, Bolt, and Fastener Tightness Inspection....2-37

Tightness Inspection....2-37

PeriodicMaintenanceChart

Thescheduledmaintenancemustbedoneinaccordancewiththischarttokeepthemotorcyclein good running condition. The initial maintenance is vitally important and must not be neglected.

FREQUENCY	* O D O M E T E READING ×1000km (×1000mile)
	Whichever comesfirst →
	↓ Every	161 (0.6)	2182 (4)	4303 (7.5)	6 (12)	(15)	(20)	(24)
Fuelhose,connections-inspect†			●	●	●	●	●	●
Throttlegripplay-inspect†		●		●		●		●
Idlespeed-inspect		●		●		●		●
Aircleanerelement-clean†#				●		●		●
Evaporativeemissioncontrolsystem (CAL)-inspect†		●	●	●	●	●	●	●
Airsuctionvalve-inspect(ATCH,DE,SI,US)			●	●	●	●	●	●
Cylinderheadbolttightness-inspect†		●		●		●		●
Valveclearance-inspect†				●		●		●
Clutch-adjust		●	●	●	●	●	●	●
Engineoil-change#	6month	●	●	●	●	●	●	●
Oilfilter-replace		●		●		●		●
Oilscreen-clean		●		●		●		●
Spoketightnessandrimrunout-inspect†		●	●	●	●	●	●	●
Tirewear-inspect†			●	●	●	●	●	●
Drivechainslack-inspect†#	1000km
Drivechainwear-inspect†#			●	●	●	●	●	●
Drivechain-lubricate#	600km
Brakepedalfreeplay-inspect†		●	●	●	●	●	●	●
Brakeliningorpadwear-inspect†#			●	●	●	●	●	●
Brakehose,connections-inspect†			●	●	●	●	●	●
Brakefluidlevel-inspect†	month	●	●	●	●	●	●	●
Brakefluid-change	2years					●
Brakemastercylindercupanddust cover-replace	4years
Caliperfluidsealanddustseal-replace	4years
Brakelightswitch-inspect†		●	●	●	●	●	●	●
Brakecable-replace	2years					●
Frontforkoil-change	2years					●
Frontforkoilleak-inspect†				●		●		●
Rearshockabsorberoilleak-inspect†				●		●		●
Swingarmpivot-lubricate				●		●		●
Steering-inspect†		●	●	●	●	●	●	●
Steeringstembearing-lubricate	2years					●
Batteryelectrolytelevel-inspect†	6months		●	●	●	●	●	●

PeriodicMaintenanceChart

FREQUENCY	* O D O M E T E R READING ×1000km (×1000mile)
	Whichever comesfirst →
	↓ Every	161(0.6)	2182(4)	43036(7.5)	(12)	(15)	(20)	(24)
Sparkplug-cleanandgap†			●	●	●	●	●	●
Generallubrication-perform				●		●		●
Nuts,bolts,andfastenerstightness-inspect		●		●		●		●

: Service more frequently when operating in severe conditions; dusty, wet, muddy, high speed, or frequent starting/stopping.

*: For higher odometer readings, repeat at the frequency interval established here.
†: Replace, add, adjust, clean, ortorque if necessary.

AT: Austria

CAL: California

CH: Switzerland

DE: Germany

SG: Singapore

US: United States

TorqueandLockingAgent

The following tables list the tightening torque for them major fasteners requiring use of a non-permanent locking agentor liquid gasket.

Lettersusedinthe"Remarks"columnmean:

L: Applyanon-permanentlockingagenttothethreads.

M:Applymolybdenumdisulfidegrease.

O: Applyanoiltothethreadsandseatingsurface.

S: Tightenthefasteners following the specified sequence.

Fastener	Torque			Remarks
	N·mkgf	mft·lb
FuelSystem
UpperChamberCoverScrews3.50.3631in·lb
SpringSeatScrews	0.80.08	07 in · lb
ChokeLeverSetScrew	0.8	0.080	7 in·lb	L
ChokeLeverPivotScrew	2.00.20	17in·lb
PilotAirJet	1.80.1815	in·lb
Coasting Enricher Cover Screws	2.0	0.20	17 in·lb
PilotJet	0.80.0807	in · lb
MainJet	1.80.1815	in·lb
FloatValveHolderScrew	2.00.20	17in·lb
ChokePlungerCap	3.90.40	35in·lb
FloatBowlScrews	2.00.20	17in·lb
CarburetorDrainPlug	2.00.20	17in·lb
FuelTapPlateScr ews	0.80.08	07 in · lb
Fuel Tap Diaphragm Cover Screws	1.0	0.10	9 in·lb
FuelTapMountingBolts(WhiteWasher)	2.50.2522	in·lb
FuelTapMountingBolts(BlackWasher)	4.90.5043	in·lb
EngineTopEnd
ValveAdjustingCapBolts(Bn125-A1~ A3)	9.8	1.0	87in·lb
ValveAdjusting gCapBolts(BN125-A4~)	8.80.90	78in·lb
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
Cylinder Head Bolts M9	26	2.7	19	O, M, S(washer)
CylinderHeadBoltsM6	12	1.2104in·lb		S
CamshaftChainCoverDamperBolts(BN125-A1~ A3)	9.8	1.0	87in·lb
CamshaftChainCoverDamperBolts(BN125-A4~)	8.80.90	78in·lb
Sparkplug	13	1.3	9.5
Cylinder Head Blank Cap Bolt (BN125-A1 ~ A3)	9.8	1.0	87in·lb
CylinderHeadBlankCapBolt(BN125-A4~)	8.80.90	78in·lb
CarburetorHolderBolts	9.8	1.0	87in·lb
Air Suction Valve Cover Bolts (BN125-A1 ~ A3)	9.8	1.0	87in·lb
AirSucti onValveCoverBolts(BN125-A4~)	8.80.90	78in·lb
CylinderHeadPlug	4.90.5043	in·lb
VacuumHoseFitting	5.90.6052	in·lb

TorqueandLockingAgent

Fastener	Torque			Remarks
	N·mkgf·	mft·lb
OilPipeBanjoBoltsM89.81.087in·lb
OilPipeBanjoBoltsM10252.518
Oil Pipe Mounting Bolts (BN125-A1 ~ A3)	9.8	1.0	87 in·lb
OilPipeMountingBolts(BN125-A4~)	8.80.90	78in·lb
CamshaftBearingHolderBolts(BN125-A1~A3)	9.81.08	7in·lb
Camshaft Bearing Holder Bolts (BN125-A4 ~)	8.8	0.90	78 in·lb
Camshaft Sprocket Bolts	12	1.2	104 in·lb
Camshaft Chain Holder Screw	4.9	0.50	43 in·lb
Camshaft Chain Guide Bolts	8.8	0.90	78 in·lb
ChainTensionerMountingBolts(BN125-A1~A3)	9.81.08	7in·lb
Chain Tensioner Mounting Bolts (BN125-A4 ~)	8.80.90	78in·lb
ChainTensionerCap	4.90.50	43in·lb
ValveAdjustingScrewLocknuts	151.5	11
Rocker Shaft Bolts	8.8	0.90	78 in·lb
Muffler Mounting Nut	15	1.5	11
Clutch
Clutch Hub Bolt	98	10.0	72
ClutchSpringBolts	8.80.907	8in·lb
Clutch Cover Bolts (BN125-A1 ~ A3)	9.8	1.0	87 in·lb
ClutchCoverBolts(BN125-A4~)	8.80.90	78in·lb
Oil Seal Retaining Plate Bolts (BN125-A1 ~ A3)	9.81.08	7in·lb
Oil Seal Retaining Plate Bolts (BN125-A4 ~)	8.80.90	78in·lb
ClutchCoverDamperBolts	8.80.90	78in·lb	L
StarterLocknutSwitchScrews	1.0	0.10	9 in·lb
PrimaryGearNut	697.051
EngineLubricationSystem
EngineOilDrainPlug	181.813
Oil Screen Cover Bolts (BN125-A1 ~ A3)	9.8	1.0	87 in·lb
Oil Screen Cover Bolts (BN125-A4 ~)	8.8	0.90	78 in·lb
Oil Pressure Relief Valve	15	1.5	11
Oil Filter Cover Bolts (BN125-A1 ~ A3)	9.8	1.0	87 in·lb
OilFilterCoverBolts(BN125-A4~)	8.80.90	78in·lb
OilPumpMountingScrews	4.90.50	43in·lb
OilPumpAssyScrew	9.81.08	7in·lb
OilPipeBanjoBolt	252.518			Clutch Cover,S Cylinder Head,S
Oil Pipe Banjo Bolts	9.8	1.0	87 in·lb
OilPipeMountingBolts(BN125-A1~ A3)	9.81.08	7in·lb
OilPipeMountingBolts(BN125-A4~)	8.80.90	78in·lb
OilFillerPlug	2.50.25	22in·lb

TorqueandLockingAgent

Fastener	Torque			Remarks
	N·m	kgf·mft·lb
EngineRemoval/installation
EngineMountingBolts,Nuts(M10)	444.533
EngineMountingBolts,Nuts(M8)	252.518
EngineMountingBracketBolts,Nuts252.518
EngineGroundTerminalBolt	9.81.087	in·lb
Crankshaft/transmission
PrimaryGearNut	697.051
BalancerShaftGearNut	788.058			O
CrankcaseBolts	8.80.907	in·lb
CrankcaseBearingR etainerScrews	4.90.504	in·lb
Neutral Switch	15	1.5	11
ShiftDrumCamScrew	4.90.5043	in·lb	L
Gear Set Lever Nut	11	1.1	95 in·lb
Engine Sprocket Holder Bolts	12	1.2	104 in·lb
Shift Return Spiring Pin (Bolt)	29	3.0	21	L
Shift Lever Clamp Bolt	12	1.2	104 in·lb
ShiftPedalNut	303.122
Wheels/tires
FrontAxleNut	788.058
Rear Axle Nut	98	10.0	72
Tire Air Valve Nuts	1.5	0.15	13 in·lb
Spoke Nipples	2.0 ~ 3.9	0.20 ~ 0.40	17 ~ 35 in·lb
FinalDrive
Engine Sprocket Cover Bolts (BN125-A1 ~ A3)	9.8	1.0	87 in·lb
Engine Sprocket Cover Bolts (BN125-A4 ~)	8.8	0.90	78 in·lb
Engine Sprocket Cover Damper Bolts	8.8	0.90	78 in·lb	L
TorqueLinkBoltandNut	343.525
RearSprocketN ut	262.719
Rear Axle Nut	98	10.0	72
EngineSprocketHolderBolts	121.210	in·lb
Brakes
BrakeDiscBolt	272.820
CaliperMountingBolts	252.518
CaliperHolder ShaftBolt	181.813
CaliperPadBolts	181.813
Caliper Bleed Valves	7.8	0.80	69 in·lb
BrakeHoseBanjoBolts	252.518
Brake Lever Pivot Bolt	5.9	0.60	52 in·lb
Brake Lever Pivot Bolt Locknut	5.9	0.60	52 in·lb
FrontBrakeRes ervoirCapScrews	1.50.15	13in·lb
Front Brake Light Switch Screws	1.0	0.10	9 in·lb
Front Master Cylinder Clamp Bolts	8.8	0.90	78 in·lb	S
TorqueLinkBoltandNut	343.525

TorqueandLockingAgent

Fastener	Torque			Remarks
	N·mkgf	mft·lb
BrakePedalBolt9.81.087in·lb
Suspension
FrontForkTopPlugs232.317
FrontForkBottomAllenBolts202.015L
FrontForkClampBolts(Upper)	202.015
FrontForkClampBolts(Lower)	343.525
RearShockAbsorberNuts(Upper)	343.525
RearShockAbsorberBolts(Lower)	343.525
Swingarm Pivot Nut	98	10.0	72
Steering
SteeringStemHeadBolt	444.533
SteeringStemNut	Hand-tight or4.9	Hand-tight or0.50	Hand-tight or43in·lb
HandlebarNuts	343.525
Handlebar Holder Clamp Bolts (BN125-A3 ~)	20	2.0	15	S
Handlebar Weight Screws	-	-	-	L
Handlebar Switch Housing Screws	3.4	0.35	30 in·lb
FrontForkClampBolts(Upper)	202.015
FrontForkClampBolts(Lower)	343.525
Frame
FrontFootpegBolts	232.3	16.5
ElectricalSystem
SparkPlug	13	1.3	113 in·lb
CrankshaftSensorScrews	3.9	0.40	35in·lb
Ignition Coil Bolt	6.9	0.70	61 in·lb
Igniter Mounting Screws	4.9	0.50	43 in·lb
AlternatorCoverBolts	8.8	0.9078in·lb
Alternator Cover Damper Bolts	8.8	0.90	78 in·lb	L
Alternator Rotor Nut (BN125-A1 ~ A2)	69	7.0	51
Alternator Rotor Nut (BN125-A3)	98	10.0	72
AlternatorRotorNut(BN125-A4~)	104	10.6	76
StarterCoilBolts	13	1.3	113 in·lb
Alternator Lead Holder Bolts (BN125-A1 ~ A2)	13	1.3	113 in·lb
AlternatorLeadHolderBolts(BN125-A3~)	8.8	0.9078in·lb
StarterMotorTerminalLocknut	6.9	0.7061in·lb
StarterMotorTerminalNut	4.9	0.5043in·lb
Starter Relay Terminal Bolt	4.9	0.50	43 in·lb
Starter Motor Assembly Bolts	3.4	0.35	30 in·lb
Starter Motor Mounting Bolts	8.8	0.90	78 in·lb
Starter Motor Clutch Bolts (BN125-A1)	34	3.5	25	L
Starter Motor Clutch Bolts (BN125-A2 ~)	12	1.2	104 in·lb	L
Headlight Body Screws	2.9	0.30	26 in·lb
HandlebarSwitchHousingScrews	3.4	0.3530in·lb

2-8 PERIODIC MAINTENANCE

TorqueandLockingAgent

Fastener	Torque			Remarks
	N·m	kgf·mft·lb
TurnSignalLightHolderNuts	5.90.60	52in·lb
NeutralSwitch	151.511
SidestandSwitchScrews	3.90.40	35in·lbL

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use histable for only the bolts and nuts which do not require a specific torque value. Allof the values are for use with dry solvent-cleaned threads.

BasicTo rqueforGeneralFasteners

Threadsdia.(mm)	Torque
	N·m	kgf·m	ft·lb
5	3.4 ~ 4.9	0.35 ~ 0.50	30 ~ 43 in·lb
6	5.9 ~ 7.8	0.60 ~ 0.80	52 ~ 69 in·lb
8	14 ~ 19	1.4 ~ 1.9	10.0 ~ 13.5
10	25 ~ 34	2.6 ~ 3.5	19.0 ~ 25
12	44 ~ 61	4.5 ~ 6.2	33 ~ 45
14	73 ~ 98	7.4 ~ 10.0	54 ~ 72
16	115 ~ 155	11.5 ~ 16.0	83 ~ 115
18	165 ~ 225	17.0 ~ 23.0	125 ~ 165
20	225 ~ 325	23 ~ 33	165 ~ 240

Specifications

Item	StandardServiceLimit
FuelSystemThrottle Grip Free PlayIdleSpeed1300±50r/min(rpm)AirCleanerElementOil:GradeSE,SForSGclass--ViscositySAE30--		---
		---
EngineTopEndValveClearance:InletExhaust	0.08~0.12(0.0031~0.0047in.)0.15~0.19(0.0059~0.0075in.)	---
		---
ClutchClutch Lever Free Play	2~3mm (0.08~0.12 in.)	---
EngineLubricationSystemEngineOil:Grade:(BN125-A1~A3)APISE,SFor(BN125-A4~)ViscosityCapacity1.1L(1.16USqt)(whenfilterisnotremoved)Level	SGAPI SE, SF or SGAPISH,SJorSLwithJASOMASAE10W-40iterisnotremoved)1.2 L (1.27 US qt) (when filter is removed)1.4L(1.48USqt)(whenengineiscompletelydry)Betweenupperandlowerlevellines(Wait 2~3 minutes after idling orrunning)	---
		---
		---
		---
		---
		---
		---
TiresRimRunout(WithTireInstalled):AxialRadialAirPressure(WhenCold):Front:(BN125-A1~A2)(BN125-A3~)Rear:(BN125-A1~A2)(BN125-A3~)TreadDepth:Front:(BN125-A1~A2)(BN125-A3~A5)	TIR 0.8 mm (0.03 in.) or lessTIR 1.0 mm (0.04 in.) or lessUp to 185 kg (408 lb) load: 150 kPa (1.5kgf/cm2,21psi)Up to 155 kg (342 lb) load: 150 kPa (1.5kgf/cm2,21psi)Up to 185 kg (408 lb) load: 175 kPa(1.75kgf/cm2,25psi)Up to 155 kg (342 lb) load: 175 kPa(1.75kgf/cm2,25psi)4.5 mm (0.18 in.)4.0 mm (0.157 in.)	TIR 2.0 mm (0.08 in.)TIR 2.0 mm (0.08 in.)---
		---
		---
		---
		---
		1 mm (0.04 in.)1 mm (0.04 in.)

Specifications

ItemStandardServiceLimit
(BN125-A6 ~)Rear7.3mm(0.29in.)2mm(0.08in.)	4.1 mm (0.161 in.)	1 mm (0.04 in.)
FinalDriveDrive Chain Slack20LinkLength	25 ~ 40 mm (0.98 ~ 1.57 in.)254.0~ 254.6mm(10.00 ~ 10.02in.)	- - -259mm(10.2in.)
BrakesBrakeLeverFreePlayNon-adjustable- - -Brake Pedal Free PlayShoe Lining ThicknessBrakeFluid:GradeBrakePadLiningThickness:(BN125-A1 ~ A2)(BN125-A3 ~)BrakeLightTiming:FrontRear	20 ~ 30 mm (0.79 ~ 1.18 in.)3.85 ~ 4.15 mm (0.152 ~ 0.163 in.)DOT44.5 mm (0.177 in.)6.0 mm (0.236 in.)Pulled onOnafterabout10mm(0 .39in.)ofpedal travel	- - -2 mm (0.08 in.)- - -1 mm (0.04 in.)1 mm (0.04 in.)- - -- - - - -
SuspensionOil ViscosityOilCapacity(ParUnit):CompletelyDryWhenChangingOilOilLevel(FullyCompressed,WithoutMainSpring)	SHOWA SS-8 or equivalent191±2.5mL(6.46±0.085USoz.)Approx165mL(5.58USoz.)218±2mm(8.58±0.08in.)	- - -- - - -- - - -
ElectricalsystemSpark Plug GapBattery Electrolyte Level	0.7 ~ 0.8 mm (0.028 ~ 0.031 in.)Between level lines	- - -- - - -

SpecialTools

SteeringStemNutWrench: 57001-1100

Line drawing of a mechanical wrench with a curved handle and two notches (no text or symbols)

ForkOilLevelGauge: 57001-1290

Technical line drawing of a mechanical assembly with spring-loaded components (no text or symbols)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

2-12 PERIODIC MAINTENANCE

PeriodicMaintenanceProcedures

FuelSystem

FuelHoseandConnectionInspection

The fuelhose is designed to be used throughout the motorcycle's lifewithout anymaintenance, however, if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leaks [A] or the host of a vehicle. Remove the fuel tank (see Fuel System chapter) and check the fuel hose.

★Replacethefuelhoseifanyfraying,cracks[B]orbulges [C]arennoticed.
- Check that the hose is securely connected and clamps are tightened correctly.
- Wheninstalling, routethehoseaccordingtoCable, Wire, and HoseRoutingsectionintheAppendixchapter.
- Wheninstallingthefuelhoseavoidssharpbending,kinking,flatteningortwisting,androutethefuelhosewitha minimumofbendingsothatthefuelflowwillnotbeobstructed.
★Replacethehoseifithasbeensharplybentorkinked.

ThrottleGripFreePlayInspection

Ifthethrottlegriphasexcessivefreeplayduetocable stretchormisadjustment,therewillbeadelayinthrottleresponse.Also,thethrottlevalvemaynotopenfullyatfull throttle.Ontheotherhand,ifthethrottlegriphasnoplay, thethrottlewillbehardtocontrol,andtheidlespeedwill beerratic.CheckthethrottlegripplayperiodicallyinaccordancewiththePeriodicMaintenanceChart,andadjustthe playifnecessary.

ThethrottlecableroutingisshowninCable, Harness, HoseRoutingsectionintheAppendixchapter.

• Checkthethrottlegripfreeplay[A].
  ★Ifthefreeplayisincorrect,adjustthethrottlecable.

ThrottleGripFreePlay

Standard: 2 \~ 3 mm (0.08 \~ 0.12 in.)

• Check that the throttle grip movess smoothly from full open to close, anth throttle closes quickly and completely in all steering positions by thereturn spring.
  ★ Ifthethrottlegripdoesnotreturnproperly, checkthethrottlecablerouting, gripfreeplay, andcabledamage. Then lubricatethethrottlecable.
• Runtheengineattheidlespeed, andturnthehandlebar allthewaytotherightandlefttoensurethattheidlespeed doesnotchange.
  ★ If the idlespeed increase, check the throttlegrip free play and the cablerouting.

Mechanical component with labeled section A, showing shaft and housing assembly (no readable text or symbols)

PeriodicMaintenanceProcedures

ThrottleGripFreePlayAdjustment

• Loosenthelocknut[A].
• Turntheadjuster[B]untiltheproperamountoffreeplay canbeobtained.

• Tightenthelocknutagainsttheadjuster.
  ★ Ifthethrottlegripfreeplaycannotbeadjustedwiththe adjuster, usethecableadjustersatthelowerendsofthe throttlecables.

• Loosenthelocknut, andscrewtheadjusterattheupper endoftheacceleratorcableallthewayin.

• Tightenthelocknutsecurelyagainsttheadjuster.
• Adjustereitherlowernuts[A]oftheacceleratorcableor the deceleratorcableuntilthecorrectthrottlegripfreeplay isobtained.

★ Ifthefreeplaycannotbeadjustedwiththeloweradjusting nuts, usetheadjusterattheupperendofthecableagain.
- Check that the throttle pulley [B] stops [C] against the idle adjustingscrew [A] with the throttle grip closed.

Mechanical assembly diagram showing components like gears and springs (no visible text or labels)

IdleSpeedInspection

• Starttheengineandwarmitupthoroughly.
• Withtheengineidling,turnthehandlebartobothsides.
  ★ Ifhandlebarmovementchangestheidlespeed,thethrot-tlecablemaybeimproperlyadjustedorincorrectlyrouted,ordamaged.Besuretocorrectanyoftheseconditions beforeriding(seeCable,Wire,andHoseRoutingsection inAppendixchapter).

WARNING

Operationwithanimproperlyadjusted,incorrectly routed,ordamagedcablecouldresultinanunsafe ridingcondition.

• Checkidlespeed.
  ★ If the idlespeedis out of the specified range, adjust it.

IdleSpeed

Standard:1300±50r/min(rpm)

2-14 PERIODIC MAINTENANCE

PeriodicMaintenanceProcedures

IdleSpeedAdjustment

- Starttheengineandwarmitupthoroughly.

- Turntheidleadjustingscrew[A]untiltheidlespeedis correct.

Openandclosethethrottleafewtimestomakesurethat theidlespeediswithinthespecifiedrange.Readjustif necessary.

Front[B]

AirCleanerElementCleaning

NOTE

○ Industryareas, theelementshouldbecleanedmore frequentlythantherecommendedinterval.
○ Afterridingthroughrainoronmuddyroads, theelement should be cleaned immediately.
○ Sincerepeatedcleaningopenstheporesofthefoam element,replaceitwithanewoneinaccordancewith thePeriodicMaintenanceChart. Also,ifthereisabreak intheelementmaterialoranyotherdamagetotheelement,replacetheelementwithanewone.

WARNING

Cleantheelementinawell-ventilatedarea,and makesurethatthereisnosparkorflameanywhere neartheworkingarea. Becauseofthedangerof highlyflammableliquids,donotusegasolineora low-flashpointsolventtocleantheelement.

• Removetheaircleanerelement(seeFuelSystemchapter).
• Cleantheelementinabathofhigh-flash-pointsolvent, andthendryitwithcompressedairorbyshakingit.
• Visuallychecktheelementfortearsorbreaksandreplace thedamagedelementwithanewone.
• Aftercleaning, saturatetheelementwithSE,SF,orSG classSAE30oil,squeezeoutexcessoil.
• Wraptheelement[A]inacleanrag[B]andsqueezeitas dryaspossible.

EvaporativeEmissionControlSystemInspection (CAL)

CanisterInspection

- Removethecanistercover[A].

Mechanical assembly diagram showing components labeled A and B with no readable text or symbols

Close-up of a car's front bumper with labeled component A, mounted on a grille (no text or symbols beyond label)

PeriodicMaintenanceProcedures

• Removethecanistermountingbracketbolts[A]andremovethebrackets[B]andcanister[C]together.
• Disconnectthehosesfromthecanister.
• Visually inspect the canister for cracks and other damage.
  ★ Ifthecanisterhasanycracksorbaddamage,replaceit withanewone.

NOTE

○Thecanisterisdesignedtoworkwellthroughthemotor cycle'slifewithoutanymaintenanceifitisusedunder normalconditions.

SeparatorInspection

• Removetherightsidecover(seeFramechapter).
• Disconnect the hoses from the liquid/vapor separator [A], and remove these separator up from the bracket.
• Visually inspect these separator for cracks and other damage.
  ★ If these separator has any cracks or is badly damaged, replace it with anewone.

Close-up of mechanical components with no visible text or symbols

EngineTop

AirSuctionValveInspection

• Removetheairsuctionvalve(seeEngineTopEndchapter).
• Visually inspect thereeds[A]for cracks, folds, warps, heat damage, or other damage.
  ★ If thereisanydoubtastotheconditionofthereed, replace theairsuctionvalveasanassembly.
• Checkthereedcontactareas[B]ofthevalveholderfor grooves,scratches,anysignsofseparationfromthe holder,orheatdamage.
  ★ If there is any doubt to the condition of thereed contact areas, replace the air suction valve as an assembly.
  ★ Ifanycarbonorotherforeignparticles have accumulated between thereed and thereed contact area, wash the valve assembly with a high-flash-points solvent.

CAUTION

Donotscrapeoffthedepositswithascpraperasthis coulddamagetherubber,requiringreplacementof thesuctionvalveassembly.

2-16 PERIODIC MAINTENANCE

PeriodicMaintenanceProcedures

CylinderHeadBoltTightnessInspection

• Checkthat6mm[A]and9mm[B]cylinderheadboltsare tightenedevenly.
  ★Standardheadboltstighteningtorqueareshownbelow.

TighteningTorque

6mmCylinderHeadBolts:12N·m(1.2kgf·m,104in·lb)

9mmCylinderHeadBolts:26N·m(2.7kgf·m,19ft·lb)

ValveClearanceInspection

CAUTION

Ifvalveclearanceisleftunadjusted, wearwilleventuallycausethevalvestoremainpartyopen, which lowersperformance, burnsthevalvesandthevalve seats, and may causes seriousenginedamage.

NOTE

○ Valveclearancemustbecheckedandadjustedwhen theengineiscold(atroomtemperature).

- Remove:

ValveAdjustingCaps[A]

CamshaftChainCover[B]

• Turnthecamshaftcenterbolt[A]counterclockwisewitha wrench.
  ○Makingsurethattheinletvalveopensandthencloses, starttoturntheboltinthesamedirectionuntilthe“T”mark [C]onthecamshaftsprocketalignswiththetimingmark [B]onthecylinderhead.ThisshowsthatthepistonTDC isattheendofthecompressionstroke.

- Usingathicknessgauge[A],measurethevalveclearance betweenheadjustingscrewandvalvestem.Measure theclearanceforbothvalvesatatime.

ValveClearance(whencold)

Standard:

Inlet

0.08 \~ 0.12 mm (0.0031 \~ 0.0047 in.)

Exhaust

0.15 \~ 0.19 mm (0.0059 \~ 0.0075 in.)

Close-up of a mechanical assembly with labeled parts A and B (no readable text or symbols)

Close-up of a mechanical assembly with labeled component A (no readable text or symbols)

PeriodicMaintenanceProcedures

ValveClearanceAdjustment

★ Ifthevalveclearanceisnotwithinthespecifiedrange, adjusttheclearancebylooseningthelocknutandturning theadjustingscrew.
- Tightenthenutstothespecifiedtorqueandcheckthe valveclearanceagain.

Torque-ValveAdjustingScrewLocknut:15N·m(1.5 kgf·m,11ft·lb)

- Installthevalveadjustingcapswiththeir"up"marks[A] up.

Torque-ValveAdjustingCapBolts

(BN125-A1\~A3):9.8N·m(1.0kgf·m,87in·lb)

(BN125-A4 \~): 8.8 N·m (0.90 kgf·m, 78 in·lb)

Clutch

ClutchLeverFreePlayInspection

• Check that the clutch cable upper end is fully seated in the adjuster[A].
• Pulltheclutchlever[B]justenoughtotakeupthefree play[C].
  ○Measurethegap(freeplay)betweentheleverandthe leverholder.
  ★ Ifthegap(freeplay)istoowide, theclutchmaynotreleasefully. Ifthegapistoonarrow, theclutchmaynotengagefully. Ineithercase, adjustit.

ClutchLeverFreePlay

Standard: 2 \~ 3 mm (0.08 \~ 0.12 in.)

ClutchLeverFreePlayAdjustment

WARNING

To avoid as serious burn, nevertouch the engine or exhaust piped during clutch adjustment.

• Slidebackthedustcover.
• Loosenbothadjusternuts[A]attheclutchcablebracket asfarastheywillgo.
• Loosentheknurledlocknut[A]attheclutchlever.
• Turn the adjuster [B] so that 5 \~ 6 mm (0.20 \~ 0.24 in.) [C] of threads are visible.

Close-up of an automotive engine component with visible springs, calipers, and a circular valve (no text or symbols)

2-18 PERIODIC MAINTENANCE

PeriodicMaintenanceProcedures

• Pulltheclutchcable[A]tightandtightentheadjustingnuts [B]againsttheclutchcablebracket.
• Turntheadjusterattheclutchleveruntilthefreeplayis correct.
• Tightentheknurledlocknutattheclutchlever.

WARNING

Besurethattheoutercableendattheclutchlever isfullyseatedintheadjusterattheclutchlever,or itcouldslipintoplacelater,creatingenoughcable playtopreventclutchdisengagement.

• Turnthereleaselever[A]clockwiseuntilbecomeshard toturn,theninspecttheangleofthereleaseleverisset within80°\~90°range[C].
  ★Ifanyangleisexcept80°\~90°range,inspecttheparts oftheclutch.
• Aftertheadjustmentismade, starttheengineandcheck thattheclutchdoesnoslipandthatitreleasesproperly. ClutchCable[B]

Close-up of hands installing or adjusting a mechanical component with labeled parts A and B (no readable text or symbols)

EngineLubricationSystem

EngineOilChange

• Warmuptheenginethoroughlysothattheoilwillpickup anysedimentanddraineasily.Thenstoptheengine.
• Placeanoilpanbeneaththeengine.
• Removetheoilfillerplug.
• Removetheengineoidrainplug[A], andlettheoidrain completely. Front[B]
• Iftheoilfilteristobechanged,replaceitwithanewone.
• Checkthegasketatthedrainplugfordamage.
  ★Replacethegasketwithanewone.
• Afterdraining, installthedrainplug, and gasket.
  Torque-EngineOilDrainPlug:18N·m(1.8kgf·m,13ft·lb)
• Pourinthespecifiedtypeandamountofengineoil throughtheoilfiller.

PeriodicMaintenanceProcedures

RecommendedEngineOil

Grade:

(BN125-A1\~A3):APISE,SForSG

(BN125-A4\~):APISE,SForSG

APISH,SJorSLwithJASOMA

Viscosity:

SAE10W-40

Capacity:1.1L(1.16USqt)

(Whenfilterisnotremoved)

1.2L(1.27USqt)

(whenfilterisremoved)

1.4L(1.48USqt)

(whenengineiscompletelydry)

NOTE

Although 10W-40engineoilistherecommendedoil formostconditions, the oil viscosity may need to be changed to accommodate atmospheric conditions in your riding area.

• Installtheoilfillerplug.
Torque- OilFillerPlug:2.5N·m(0.25kgf·m,22in·lb)
- Checktheoillevel(seeEngineLubricationchapter).

OilFilterChange

• Draintheengineoil(seeEngineOilchange).
• Removetheoilfiltercoverbolts[A]andcover[B].
• Takeoffthefilter.

• Removethespring. Front[C]

• Replacethefilter[A]withanewone.

• Installthespring[B].
• Installthenewfiltersothatthegrommet[C]facetout-sideasshown.

CAUTION

If the filter is installed reversely, it can cause the engine seizure.

2-20PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

• ReplacetheO-ring[A]withnewone.
• ApplygreasetotheO-ringandthegrommet[B].
  • Installthecover[C]andtightenthecoverbolts.

Torque-OilFilterCoverBolts

(BN125-A1\~A3):9.8N·m(1.0kgf·m,87in·lb)

(BN125-A4 \~): 8.8 N·m (0.90 kgf·m, 78 in·lb)

- Pourinthespecifiedtypeandamountofoil(seeEngine OilChange).

OilScreenCleaning

• Removetheoilscreencover[A].
• Removethegasket.
• Removetheoilscreen[B]fromtheclutchcover.

- Cleantheoilscreen[A]thoroughlywheneveritisremoved foranyreason.

- Cleantheoilscreenwithahigh-flashpointsolventand removeanyparticlesstucktoit.

WARNING

Cleanthescreeninawell-ventilatedarea,andtake carethatthereisnosparkorflameanywherenear theworkingarea.Becauseofthedangerofhighly flammableliquids,donotusegasolineorlow-flash pointsolvents.

Isometric line drawing of a rectangular device with a grid pattern on the surface and a labeled point A (no text or symbols beyond label)

@605000BS1 C

NOTE

○ Whilecleaningthescreen, checkforanymetalparticles that might indicate internalenginedamage.

• Checkthescreencarefullyforanydamage, holes, broken wires, gasketpullingoff.
  ★Ifthescreenisdamaged,replaceit.

• Installtheoilscreen[A].

Inserttheoilscreenwith"UP"mark[B]facingupandthe narrowside[C]ofthescreengoingfirst.
• Installthenewgasketandoilscreencover.
- Tightentheoilscreencoverbolts.

Torque-OilScreenCoverBolts

(BN125-A1\~A3):9.8N·m(1.0kgf·m,87in·lb)

(BN125-A4 \~): 8.8 N·m (0.90 kgf·m, 78 in·lb)

GG05014BS1 C

PeriodicMaintenanceProcedures

Wheels/Tires

Spoke Tightness Inspection

• Checkthatallthespokesaretightenedevenly.
  ★ Ifspoketightnessisunevenorloose, tightenthespoke nipplesevenly.

Torque - Spoke Nipples: 2.0 \~ 3.9 N·m (0.20 \~ 0.40 kgf·m, 17\~35in·lb)

- Checktherimrunout.

WARNING

Ifanyspokebreaks, it should bere placed immediately. A missingspoke places an additional load on the others spokes, which willeventually cause other spokes to break.

RimRunoutInspection

• Placethejackundertheframesothatthefront/rearwheel offtheground.
  SpecialTool-Jack:57001-1238
• Inspecttherimforsmallcracks, dents, bending, or warping.
  ★ Ifthereisanydamagetotherim, it must bereplaced.
• Removethewheelsandsetthemonthesuitablejig.
• Setadialgaugetothesideoftherim, and rotatetherim to measure axialrunout[A]. Thedifference between the highest and lowest dialreadings is the amount of runout.
• Setadialgaugetotheoutercircumferenceoftherim, androtatetherimtomeasureradialrunout[B]. Thedifferencebetween the highest and lowest dialreadings is the amount of runout.
  ★ Ifrimrunoutexceedstheservicelimit, checkthehubbearingsfirst. Replace them if they are damaged. If the problem is not to the bearings, correct their warp (runout). Acertain amount of interim warpcan be corrected by recent ring therim. Loosensomespokes and tighten others within the standard torque can be corrected by recent ring therim. If their imis badly bent, however, it must bere placed.

RimRunout(withtireInstalled)
Standard:

Axial	TIR0.8mm(0.03in.)orless
Radial	TIR1.0mm(0.04in.)orless

ServiceLimit:

Axial	TIR2.0mm(0.08in.)
Radial	TIR2.0mm(0.08in.)

2-22PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

AirPressureInspection/Adjustment

• Removetheairvalvecap.
• Measure the air pressure with an air pressure gauge [A] when the tires are cold (thatis, when the motorcycle has not been ridden more than a mile during the past 3 hours).
  ★Adjust the tire air pressure according to the specifications if necessary.

AirPressure(whencold)

Front	BN125-A1~ A2U	pto185kg(408lb)	150kPa( 1.5 kgf/cm^2 ,21psi)
	BN125-A3~ Upto155kg(342lb)
Rear	BN125-A1~ A2U	pto185kg(408lb)	175kPa( 1.75 kgf/cm^2 ,25psi)
	BN125-A3~ Upto155kg(342lb)

• Installtheairvalvecapcertainlyafterairpressureinspection.

PeriodicMaintenanceProcedures

TireWearInspection

Asthetiretreadwearsdown, the tirebecomesmoresusceptibletopuncture 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 unsafetouse the tires until they are bald.

• Removeanyimbeddedstonesorotherforeignparticles fromthetread.
• Visuallyinspectthetireforcracksandcuts,replacingthe tireincaseofdamage.Swellingorhighspotsindicate internaldamage,requiringtirereplacement.
• Measurethetreaddepthatthecenterofthetreadwitha depthgauge[A].Sincethetiremaywearunevenly,take measurementatseveralplaces.
  ★ Ifanymeasurementislessthantheservicelimit,replace thetire.

TreadDepth

Standard:

Front	(BN125-A1~ A2)4.5mm(0.18in.)
	(BN125-A3~ A5)4.0mm(0.16in.)
	(BN125-A6~) 4 . 1 mm ( 0 . 1 6 in . )
Rear	7.3mm(0.29in.)

ServiceLimit:

Front 1mm(0.04in.)

Rear 2mm(0.08in.)

NOTE

○Mostcountriesmayhavetheirownregulationsrequiring aminimumtiretreaddepth;besuretofollowthem.
○Checkandbalancethewheelwhenatireisreplaced withanewone.

WARNING

Toensuresafehandlingandstability,useonlythe recommendedstandardtiresforreplacement,inflatedtothestandardpressure.

FinalDrive

DriveChainSlackInspection

• Checktoseethatthenotches[A]onthealignmentindicatorsonbothsidesareinthesamerelativepositionattherearend[B]oftheholeineachswingarm.
  ★ Iftheyarenot,adjustthechainslackandalignthem.

WARNING

Misalignmentofthewheelwill resultinabnormal wearandmayresultinanunsaferidingcondition.

Close-up of a mechanical component with labeled parts A and B, connected by chains (no readable text or symbols)

NOTE

○Cleanthechainifitisdirty, and lubricateitifitappears dry.

2-24PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

• Setthemotorcycleuponitscenterstand.
  ○Rotatetherearwheeltofindthepositionwherethechain istightest.
  ○Measuretheverticalmovement(chainslack)[A]midway betweenthesprockets.
  ★ If the chains lack exceed the standard, adjust it.

ChainSlack

Standard: 25 \~ 40 mm (0.98 \~ 1.57 in.)

DriveChainSlackAdjustment

• Removethecotterpin[A]fromtherearaxlenut.
• Loosen:
  TorqueLinkNut[B]
  RearAxleNut[C]
  BothChainAdjusterLocknuts[D]
• TurnbothchainadjustersEevenlyuntilthedrivechain hasthecorrectamountofslack.
• Checktoseethatnotchesonthealignmentindicatorsare inthesamerelativepositiononbothsides.

WARNING

Misalignmentofthewheelwillresultinabnormal wearandmayresultinanunsaferidingcondition.

Torque-RearAxleNut:98N·m(10.0kgf·m,72ft·lb)

TorqueLinkNut:34N·m(3.5kgf·m,25ft·lb)

WARNING

If the axlenut and torquelink nut are not securely tightened, an unsaferiding condition may result.

• Turnthewheel, measure the chainslack again at the tightest position, and readjustif necessary.
• Insertanewcotterpin[A].

NOTE

When inserting the cotterpin, if the slots in then the not align with the cotterpin hole in the axle, tighten the nut clockwise [B] uptonextalignment.
○ Itshouldbewithin30degree.
○ Loosenonceandtightenagainwhentheslotgoespast thenaresthole.

PeriodicMaintenanceProcedures

• Bendthecotterpin[A]overthenut[B].
• Checktherearbrakeeffectiveness.

A WARNING

If the axle and torque link nuts are not securely tightened and the cotterpin and snappin are not installed, an unsaferiding condition may result.

- Tightenthechainadjusterlocknuts.

DriveChainWearInspection

• Removethechaincover(seeFinalDrivechapter).
• Rotatetherearwheeltoinspectthedrivechainfordamagedrollers, and loosepinsandlinks.
  ★ Ifthereisanyirregularity, replacethedrivechain.
  ★ Lubricatethedrivechainifitappearsdry.
• Stretchthechaintautbyhanginga98N(10kg,20lb) weight[A]onthechain.
• Measurethelengthof20links[B]onthestraightpart[C]of thechainfromthepincenterofthe1stpintothepincenter ofthe21stpin.Sincethechainmaywearunevenly,take measurementsatseveralplaces.
  ★ Ifanymeasurementsexceedtheservicelimit,replace the chain.Also,replacethefrontandrearsprocketswhenthe drivechainisreplaced.

Chain20-linkLength

Standard: 254.0 \~ 254.6 mm (10.00 \~ 10.02 in.)

ServiceLimit:259mm(10.2in.)

WARNING

Ifthedrivechainwearexceedstheservicelimit,re- placethechainoranunsaferidingconditionmay result.Achainthatbrakesorjumpsoffthesprock- etscouldsnagontheenginesprocketorlockthe rearwheel,severelydamagingthemotorcycleand causingittogooutofcontrol.Forsafety,useonly thestandardchain.

StandardChain

BN125-A1\~A2

Make: ENUMACHAIN

Type: JointEndlessEK428SH-R

Link:132Links

BN125-A3 \~ (except the N, NU of BN125-A7 \~)

Make: DAIDO

Type: JointEndlessDID424HG

Link:132Links

130 Links (BN125-A7 \~ ) N, NU

N: CatalyticConverterModel

NU: CatalyticConverter(United KingdomModel)

2-26PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

DriveChainLubrication

• Thechainshouldbelubricatedwithalubricantwhichwill bothpreventtheexteriorfromrustingandalsoabsorb shockandreducefrictionintheinteriorofthechain.
  ★Ifthechainisespeciallydirty, it should bewashed in diesel oilorkerosene, and afterward soaked in a heavy oil. Shakethechain while it is in the oil so that oil will penetrate to the inside of each roller.
• Aneffective, good quality lubricants specially formulated for chainsis best for regular chain lubrication.
  ★Ifaspeciallubricantisnotavailable,aheavyoilsuchas SAE90ispreferredtoalighteroilbecauseitwillstayon thechainlongerandprovidebetterlubrication.
• Applyoiltothesidesoftherollerssothatoilwillpenetrate totherollersandbushings.
• Wipeoffanyexcessoil. OilAppliedAreas[A]

Brakes

BrakePedalFreePlayInspection

- Checkthebrakepedalfreeplay[A]whenthepedalis pusheddownlightlybyhand.

BrakePedalFreePlay

Standard: 20 \~ 30 mm (0.79 in \~ 1.18 in.)

★Ifthepedalhasimproperplay,adjustit.
○Turntheadjustingnut[B]atthebrakecamleversothat theleverhasproperplay.
- Operatethepedalafewtimestoseethatitreturnstoits restpositionimmediatelyuponrelease.
- Rotatetherearwheeltocheckforbrakedrag.
- Checkbrakingeffectiveness.
★Ifthereisanydoubtastotheconditionsofthebrake, checkthebrakepartsforwearordamage.
- Check that the brakeling wear indicator [A] points within the USABLERANGE [B] when the brake lever is fully applied.
★ Ifitdoesnot, thebrakeshoesmustbereplacedandother brakepartsmustbeexamined.

Mechanical assembly diagram showing two views of a robotic arm with labeled parts (A and B), no readable text or symbols present.

PeriodicMaintenanceProcedures

• Check that the front brake cam lever [A] comestoan 80° \~ 90° angle [C] with therear brakerod [B] when therear brake is fully applied.
  ★ Ifitdoesnot,removtheadjustingnut[D]andlever,then adjusttherearbrakecamleverangle.
• Checkthebrakepedalfreeplay.

WARNING

Sinceacamleveranglegreaterthan90° reduces brakingeffectiveness, camleverangleadjustment should not be neglected. A change in cam lever angle is caused by wear of internal brake parts. Whenever the cam lever angle is adjusted, also check for drag and proper operation, taking particular note of the brakelining wear indicator position. In case of doubt, a braking effectiveness, disassemble and inspect all internal brake parts. Worn part scould cause the braketolock or fall.

BrakeShoeLiningWearInspection

• Removethebrakeshoes(seeBrakeschapter).
• Measuretheliningthickness[A],atafewpoint.
  ○Useacalipersorscale, andmeasureatseveralpoints.

ShoeLiningThickness

Standard: 3.85 \~ 4.15 mm (0.152 \~ 0.163 in.)

ServiceLimit:2mm(0.08in.)

★ Ifthelini ngthicknessisgreaterthantheservicelimit,replacebothshoesasaset.
• Installthebrakeshoes(seeBrakeschapter).

BrakePadWearInspection

• Removethepads.(seeBrakeschapter).
• Checktheliningthickness[A]ofthepadsinthecaliper.
  ★ Iftheliningthicknessofeitherpadislessthantheservice limit[B],replacebothpadsinthecaliperasaset. Brakepad[C]

BrakePadThickness

Standard:(BN125-A1\~A2)4.5mm(0.177in.) (BN125-A3\~)6.0mm(0.236in.)

ServiceLimit: 1mm(0.04in.)

• Installthepadsandpadbolts(seeBrakeschapter).

BrakeHoseandConnectionInspection

• Inspect the brake hose and fittings for deterioration, cracksandsignsofleakage.
  ○Thehighpressureinsidethebrakelinecancausefluidto leak[A]orthehosetoburstifthelineisnotproperlymaintained. Bendandtwisttherubberhosewhileexamining it.
  ★Replacethehoseifanycracks[B]orbulges[C]arenoticed.
  ★ Tightenanyloosefittings.

2-28PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

BrakeFluidLevelInspection

- Check that the brake fluid level in the braker reservoir [A] is between the upper [B] and the lower [C] levelline.

NOTE

○ Holdthereservoirhorizontalbyturningthehandlebar whencheckingbrakefluidlevel.

★Ifthefluidlevelislowerthanthelowerlevelline,fillthe reservoirtotheupperlevellineinthereservoir.

WARNING

Donotmixtwobrandsoffluid. Changethebrake fluidinthebrakelinecompletelyifthebrakefluid mustberefilledbutthetypeandbrandofthebrake fluidthatisalreadyinthereservoirareunidentified. Afterchangingthefluid,useonlythesametypeand brandoffluidthereafter.

RecommendedDiscBrakeFluid Grade:DOT4

BrakeFluidChange

• Levelthebrakefluidreservoir.
• Removethereservoircap.
• Removetherubbercapfromthebleedvalve[A]onthe caliper.
• Attachaclearplastichose[B]tothebleedvalve,andrun theotherendofthehoseintoacontainer.
• Fillthereservoirwithfreshspecifiedbrakefluid.
• Changethebrakefluidasfollows:

NOTE

○ Thefluidlevelmustbecheckedoftenduringthechangingoperationandreplenishedwithfreshbrakefluid. If thefluidinthereservoirrunsoutanytimeduringthe changingoperation,thebrakeswillneedtobebled sinceairwillhaveenteredthebrakeline.

○Repeatthisoperationuntilfreshbrakefluidcomesout fromtheplastichoseorthecolorofthefluidchanges.

Openthebleedvalve[A]. Pumpthebrakeleverandholdit[B]. Closethebleedvalve[C]. Releasethebrakelever[D].

PeriodicMaintenanceProcedures

• Removetheclearplastichose.
  • Installthereservoircap.
• Tightenthebleedvalve, and installtherubbercap.

Torque-CaliperBleedValve:7.8N·m(0.80kgf·m,69in·lb) FrontBrakeReservoirCapScrews:2.5N·m(0.25 kgf·m,22in·lb)

• Afterchangingthefluid, checkthebrakeforgoodbraking power, nobrakedrag, andnofluidleakage.
  ★ If necessary, bleed the air from the lines (see Brake Line Bleeding).

BrakeLineBleeding

Thebrakefluidhasaverylowcompressioncoefficientso thatalmostallthemovementofthebrakeleveristransmitteddirectlytothecaliperforbrakingaction.Air,however,is easilycompressed.Whenairentersthebrakelines,brake levermovementwillbepartiallyusedincompressingthe air.Thiswillmaketheleverfeelspongy,anditwillbealoss inbrakingpower.

WARNING

Besuretobleedtheairfromthebrakelinewhen-everbrakeleveractionfeelssoftorspongyafter thebrakefluidischanged,orwheneverabrakeline fittinghasbeenloosenedforanyreason.

• Removethereservoircap, and fill the reservoir with fresh brake fluid to the upper level in the reservoir.
• Withthereservoircapoff,slowlypumpthebrakelever severaltimesuntilnoairbubblescanbeseenrisingup throughthefluidfromtheholesatthebottomofthereservoir.
  ○ Bleedtheaircompletelyfromthemastercylinderbythis operation.
  • Installthereservoircap.
• Removetherubbercapfromthebleedvalveonthe caliper.
• Attachaclearplastichosetothebleedvalve, andrunthe otherendofthehoseintoacontainer.
• Bleedthebrakelineandthecaliperasfollows.
  ○ Repeat this operation until nomore air can be seen coming out into the plastichose.
• Pumpthebrakeleveruntilbecomeshard, and apply thebrakeandholdit[A].
• Quickly open and close [B] the bleed valv while holding the brake applied.
• Releasethebrake[C].

NOTE

○ Thefluidlevelmustbecheckedoftenduringthebleedingoperationandreplenishedwithfreshbrakefluidas necessary. If thefluidinthereservoirrunscompletely outanytimeduringbleeding, thebleedingoperation must bedoneoveragainfromthebeginningsinceair will have enteredtheline.
○ Tapthebrakehoselightlyfromthecalipertothereservoirformorecompletebleeding.

• Removetheclearplastichose.
• Tighten:

Torque-CaliperBleedValve:7.8N·m(0.80kgf·m,69in·lb)

FrontBrakeReservoirCapScrews:2.5N·m(0.25 kgf·m,22in·lb)

• Checkthefluidlevel.
• Afterbleedingisdone, checkthebrakeforgoodbraking power, nobrakedrag, andnofluidleakage.

WARNING

When working with the disc brake, observ the precautions listed below.

1. Neverreuseoldbrakefluid.
2. Donotusefluidfromacontainerthathasbeenleft unsealedorthathasbeenopenforalongtime.

3. Donotmixtwotypesandbrandsoffluidforusein thebrake. Thislowersthebrakefluidboilingpoint andcouldcausethebraketobeineffective. It may also cause therubberbrakepartstodeteriorate.

4. Don'tleavethereservoircapofforanylengthof timetoavoidmoisturecontaminationofthefluid.

5. Don't changethe fluid in therain or when a strong wind is blowing.

6. Except forthediscpadsanddisc, use only disc brake fluid, isopropyl alcohol, orethyl alcohol for cleaning brake parts. Donot use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely and while eventually deteriorate the rubber used in the disc brake.

7. When handling the discpadsordisc, be careful that nodiscbrakefluidoranyoilgetsonthem. Cleanoff any fluidorol that in advertently gets on the pads or disc with a high-flash points solvent. Donotuse one which will leave an oily residue. Replacethepads with new ones if they cannot be cleaned satisfactorily.

8. Brake fluid quickly ruins painted surfaces; any spilled fluid should be completely washed away immediately.

9. If any of the brakeline fittings or the bleed valve is opened at any time, the AIR MUST BE BLED FROM THE BRAKE LINE.

PeriodicMaintenanceProcedures

Brake/MasterCylinderCupandDustSeal Replacement

- RefertotheMasterCylinderintersectionintheBrakeschapter forBrake/MasterCylinderCupandDustSealReplacement.

CaliperPiston/DustSealsReplacement

- RefertotheCaliperssectionintheBrakeschapterfor CaliperPiston/DustSealsReplacement.

BrakeLightSwitchInspection

FrontBrakeLightTimingInspection

• Turnontheignitionswitch.
- Thebrakelightshouldgoonwhenthefrontbrakeisapplied.
★ Ifitdoesnot, replacetheswitch.

RearBrakeLightTimingInspection

• Turnontheignitionswitch.
- Checktheoperationoftherearbrakelightswitchbydepressingthebrakepedal.
- Ifitdoesnotasspecified,adjustthebrakelighttiming.

BrakeLightTiming

Standard: On After about 10 mm (0.39 in.) of pedal travel [A]

RearBrakeLightTimingAdjustment

- Whileholdingtheswitchbody,turntheadjustingnut[A] toadjusttheswitch.

CAUTION

To avoid damaging the electrical connections in sidetheswitch, besure that the switch body does not turn during adjustment.

NOTE

○Brakelightturnsonsoonerastheswitchbodyrises[B], andturnsonlaterastheswitchbodylowers[C].

BrakeCableReplacement

• Wheneverthebrakecableisremoved,lubricateit.
• Withthecabledisconnectedatbothends, thecable shouldmovefreely[A]withinthecablehousing.
  ★ Ifcablemovementisnotfreeafterlubricating,ifthecable isfrayed[B],orifthecablehousingiskinked[C],replace thecable.

Close-up of a mechanical component with labeled parts (A) and no visible text or symbols

2-32 PERIODIC MAINTENANCE

PeriodicMaintenanceProcedures

Suspension

FrontForkOilChange

• Removethefrontfork(seeSuspensionchapter).
• Holdtheoutertubeverticallyinavise.
• Unscrewthetopplugoutoftheinnertube.
• Remove:

Spacer[A]

ForkSpringSeat[B]

ForkSpring[C]

• Pourouttheforkoiltothecontainer[C]withtheforkup-sidedown[B].
  OPumptheoutertube[A]upanddowntoexpeltheoilfrom thefork.
• Holdingtheforktubeupright, presstheinnertubeallthe waydown.

NOTE

○ Thespringshouldnotbeinstalled.

- Fillthefrontforkwiththespecifiedoil.

ForkOilViscosity:SHOWASS-8orequivalent ForkOilCapacity

(whenchangingoil):Approx.165mL(5.58USoz.)

• Waitforaboutfiveminutessothatanysuspendedairbubblesansurface.
• Measuretheoillevel, usingtheforkoillevelgauge[A].

SpecialTool-ForkOilLevelGauge:57001-1290

○Setthegaugestopper[B]sothatitslowersideshowsthe oilleveldistancespecified[C].
○Insertthegaugetubeintotheinnertube[D]andposition thestopperacrossthetopoftheinnertubeE.
OPullthehandleslowlytodrawouttheexcessoiluntilno moreoilcomesupthetube.
★Ifnooilisdrawnout,thereisnotenoughoilinthefork. Pourinsomemoreoil,thendrawouttheexcess.

FrontForkOilLevel(Fullycompressedwithoutfork spring)

Standard:218±2mm(8.58±0.08in.)

PeriodicMaintenanceProcedures

• Installtheforkspring[A]withthesmallerendfacing[B] downward.
• Install: ForkSpringSeat Spacer
• Repeatthesameprocedureforanotherfrontfork.
• Installthefrontfork(seeSuspensionchapter).

FrontForkOilLeakInspection

• Visually inspect the front forks [A] for oilleakage, scoring or scratches on the outersurface of the innertubes.
  ★Replaceorrepairanydefectiveparts,ifnecessary.

Close-up of a bicycle wheel and suspension bracket with labeled component A (no text or symbols beyond label)

RearShockAbsorberOilLeakInspection

• Visually inspect therearshockabsorbers[A]foroilleakage.
  ★ Iftheyareoilleaked, oneunitfeelsweakerthantheother, replacebothshockabsorberasaset.

Close-up of a motorcycle's wheel and suspension system (no visible text or symbols)

SwingarmPivotLubrication

• Removetheswingarm(seeSuspensionchapter).
• Using high-flash-points solvent, wash the following parts, and apply plenty of molybdenum disulfide greasethem.
  NeedleBearings[A]
  GreaseSeals[B]
  Sleeve[C]
  SwingarmPivotShaft(exceptforthreads)[D]

○ Thispreventstheshaftandtheboltfromrustingorseizing.

2-34PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

Steering

SteeringInspection

- Checkthesteering.

○Liftthefrontwheeloffthegroundusingthejack[A].

SpecialTool-Jack:57001-1238

With the front wheelpointing straight ahead, alternately tapeachendof the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hit the stop.

★Ifthewheelbindsorcatchesbeforethestop, thesteering istootight.

○Feelforsteeringloosenessbypushingandpulling[A]the forks.

★Ifyoufeellooseness,thesteeringistooloose.

NOTE

○ Thecablesandwiringwillhavesomeeffectonthemotionoftheforkwhichmustbetakenintoaccount.Be surethewiresandcablesareproperlyrouted.

○ Thebearingsmustbeingoodconditionandproperly lubricatedinorderforanytesttobevalid.

SteeringAdjustment

- Loosen:

FrontForkLowerClampBolts(bothsides)[A] SteeringStemHeadBolt[B]

- Liftthefrontwheeloffthegroundusingthejack.

SpecialTool-Jack:57001-1238

- Adjustthesteering.

SpecialTool-SteeringStemNutWrench:57001-1100

★Ifthesteeringistootight,loosenthestemnut[C]afractionofaturn.

★Ifthesteeringistooloose,tightenthestemnutafraction ofaturn.

NOTE

○ Turnthestemnut1/8turnatatimemaximum.

Torque-SteeringStemNut:4.9N·m(0.50kgf·m,43in·lb)

- Tighten:

Torque-SteeringStemHeadBolt:44N·m(4.5kgf·m,33ft·lb)

FrontForkClampBolts(Lower):34N·m(3.5 kgf·m,25ft·lb)

- Checkthesteeringagain.

★ If the steering is still toight tortoolose, inspect the steering parts.

Close-up of a motorcycle wheel and its mechanical assembly with labeled component A (no readable text or symbols)

Close-up of a bicycle wheel with a hand adjusting the rim, showing no visible text or symbols.

PeriodicMaintenanceProcedures

SteeringStemBearingLubrication

• Removethesteeringstem(seeSteeringchapter).
• Usingahigh-flashpointsolvent, washtheupperand lowersteelballs.
• Wipealltheoldgreaseofftheupperandlowerouter races.
• Visuallychecktheracesandballs.
  ★Replacethebearingassembliesiftheyshowwearor damage.
• Applygreaseliberallytotheupperandlowerraces,and stickthesteelballs[A]inplacewithgrease.
• Installthesteeringstem(seeSteeringchapter), and adjustthesteering(seeSteeringAdjustment).

ElectricalSystem

BatteryElectrolyteLevelInspection

• Visuallychecktheelectrolytevelinthebattery.
  ★ Ifthelevellineofelectrolyteinanycellisbelowthelower levelline[A]onthebatterycase,addistilledwateronly tothatcelluntilthelevelisattheupperlevelline[B].

CAUTION

Ordinarytapwaterisnotasubstitutefordistilled waterandwillshortenthelifeofthebattery.

SparkPlugCleaning/Inspection

• Cleanthesparkplug, preferablyinasandblastingdevice, andthencleanoffanyabrasiveparticles. Theplugmay also be cleaned using a high-flash points solvent and a wire brushor others suitable tool.
  ★ Ifthesparkplugcenterelectrode[A]and/orsideelectrode[B]arecorrodedordamaged,oriftheinsulator[C]iscracked,replacetheplug.
• Usethestandardsparkplugoritsequivalent.

SparkPlugGapInspection

• Measurethegap[D]withawire-typethicknessgauge.
  ★ Ifthegapisincorrect, carefully bend the side electrode with suitable tool to obtain the correct gap.

Spark Plug Gap: 0.7 \~ 0.8 mm (0.028 \~ 0.031 in.)

2-36PERIODICMAINTENANCE

PeriodicMaintenanceProcedures

GeneralLubrication

Lubrication

• Beforelubricatingeachpart,cleanoffanyrustyspotswith rustremoverandwipeoffanygrease,oil,dirt,orgrime.
• Lubricatethepointslistedbelowwithindicatedlubricant.

NOTE

○ Wheneverthevehiclehasbeenoperatedunder wetorrainyconditions,orespeciallyafterusinga high-pressurewaterspray,performthegenerallubrication.

Pivots:LubricatewithMotorOil

Sidestand BrakePedal ClutchLever

Points:LubricatewithGrease.

ThrottleInnerCableUpperEnds[A]

SpeedometerInnerCable*

ClutchInnerCableUpperEnd

BrakeLever**

(*): Greasethelowerpartoftheinnercablesparingly.

(**):Applysiliconegrease.

Cables:LubricatewithCableLubricant.

ThrottleInnerCable

ClutchInnerCable

• Lubricatethecablesbyseepingtheoilbetweenthecable andhousing.
  ○Thecablemaybelubricatedbyusingacommercially availablepressurecablelubricatorwithanaerosolcable lubricant.
• With the cabled disconnected at the both ends, the cable should move freely [A] within the cable housing.
  ★Ifcablemovementisnotfreeafterlubricating,ifthecable isfrayed[B],orifthecablehousingiskinked[C],replace thecable.

Line drawing of hands using a tool to apply liquid onto a cylindrical object (no text or symbols)

PeriodicMaintenanceProcedures

Nut, Bolt, and Fastener Tightness Inspection

TightnessInspection

- Checkthetightnessoftheboltsandnutslistedhere. Also, checktoseethateachcotterpinisinplaceandingood condition.

NOTE

○Fortheenginefasteners, checkthetightnessofthem whentheengineiscold(atroomtemperature).

★ Ifthereareloosefasteners,retightenthemtothespecifiedtorquefollowingthespecifiedtighteningsequence. Refertotheappropriatechapterfortorquespecifications. Iftorquespecificationsarenotintheappropriatechapter, seetheStandardTorqueTableinthissection.Foreach fastener,firstloosenitby1/2turn,thentightenit.

★ Ifcotterpinsaredamaged, replacethemwithnewones.

Nut, Boltand Fastenertobechecked

Wheels:

FrontAxleNut

RearAxleNutCotterPin

RearAxleNut

FinalDrive:

ChainAdjusterLocknuts

RearSprocketNuts

Brakes:

BrakeLeverPivotNut

BrakePedalCotterPin

BrakeRodJointCotterPin

TorqueLinkNut

BrakeCamLeverNut

CaliperMountingBolts

FrontMasterCylinderClampBolts

Suspension:

FrontForkClampBolts

FrontFenderBolts

RearShockAbsorberBoltsandNuts

SwingarmPivotNut

Steering:

StemHeadBolt

HandlebarHolderClampNuts

Engine:

ThrottleCableAdjusterLocknut

EngineMountingBoltsandNuts

ShiftPedalBolt

MufflerMountingBoltsandNuts

ClutchCableAdjusterLocknut

ClutchLeverPivotNut

Others:

SidestandBoltandNut

FrontFootpegMountingBolts

RearFootpegMountingBolts

FuelSystem

TableofContents

Exploded View 3-2

Specifications 3-8

Special Tools 3-10

Throttle Grip and Cables 3-11

Free Play Inspection 3-11

Free Play Adjustment.... 3-11

Throttle Cable Installation 3-11

Throttle Cable Lubrication and Inspection 3-11

Carburetor 3-12

Idle Speed Inspection 3-12

Idle Speed Adjustment.... 3-12

Service Fuel Level Inspection 3-12

Service Fuel Level Adjustment 3-13

Fuel System Cleanliness Inspection 3-14

Carburetor Removal.... 3-14

Carburetor Installation.... 3-15

Carburetor Disassembly 3-15

Carburetor Assembly 3-17

Carburetor Cleaning.... 3-18

Carburetor Inspection 3-19

Air Cleaner 3-21

Air Cleaner Element Removal.... 3-21

Element Cleaning and Inspection 3-21

Air Cleaner Draining.... 3-21

Air Cleaner Housing Removal 3-22

Air Cleaner Housing Installation.... 3-22

Fuel Tank 3-23

Fuel Tank Removal 3-23

Fuel Tank Installation 3-23

Fuel Tank Inspection 3-23

Fuel Tank Cleaning 3-24

Fuel Tap Removal 3-24

Fuel Tap Installation 3-24

Fuel Tap Inspection 3-25

Evaporative Emission Control System ( California Model Only) 3-26

Parts Removal/Installation 3-26

Hose Inspection 3-26

Separator Inspection 3-26

Separator Operation Test 3-27

Canister Inspection 3-27

ExplodedView

No.Fa	stener	Torque			Remarks
		N·mkgf	mft·lb
1	Upper Chamber Cover Mounting Screws	3.5	0.36	31 in·lb
2	Spring Seat Screws	0.8	0.080	7 in·lb
3	ChokeLeverSetScrew	0.80.08	07 in·lb	L
4	ChokeLeverPivotScrew	2.00.2017in·lb
5	Pilot Air Jet	1.8	0.18	15 in·lb
6	CoastingEnricherCoverScrews	2.00.20	17in·lb
7	Pilot Jet	0.8	0.080	7 in·lb
8	Main Jet	1.8	0.18	15 in·lb
9	Float Valve Holder Screw	2.0	0.20	17 in·lb
10	Choke Plunger Cap	3.9	0.40	35 in·lb
11	Float Bowl Screws	2.0	0.20	17 in·lb
12	CarburetorDrainPlug	2.00.20	17in·lb

1. Throttleable (accelerator)
2. Throttleable(decelerator)
   15.Plug(CA,CH,US)
   16.Pilotscrew
3. Valveneedle
   18.Needlejet
   19.Float
   20.Jetneedle
   21.BN125-A1\~A2
   22.BN125-A3\~
   CL:Applycablelubricant.
   G:Applygrease.
   L: Applyanon-permanentlockingagent.
   CA:Canada
   CH:Switzerland
   US:UnitedStates

ExcepttheCaliforniaModel

ExplodedView

No.Fa	stener	Torque			Remarks
		N·mkgf	·mft·lb
1Fuel	TapPlateScrews0.80.0807 i n · l b
2	Fuel Tap Diaphragm Cover Screws	1.0	0.10	9 in·lb
3Fuel	TapMountingBolts	2.5	0.25	22 in·lb	with White Washer
		4.9	0.50	43 in·lb	with Black Washer

1. Catch tank
2. Vacuum switch valve (For the AT, CH, DE of BN125-A1 \~ A2 and All Models of BN125-A3 \~)
3. FortheAT, CH, DEofBN125-A1, and Except the EUR of BN125-A7\~
4. On and after EUR of BN125-A7
5. Air cleanerelement

OR: Apply high-quality-foam-air filter oil.

AT: Austria

CH:Switzerland

DE:Germany

EUR: Europe

CaliforniaModel

ExplodedView

No.Fa	stener	Torque			Remarks
		N·mkgf	f·mft·lb
1Fuel	ITapPlateScrews0.80.0807 i n · l b
2	Fuel Tap Diaphragm Cover Screws	1.0	0.10	9 in·lb
3Fuel	ITapMountingBolts	2.5	0.25	22 in·lb	with White Washer
		4.9	0.50	43 in·lb	with Black Washer

1. Catch tank

2. Vacuum switchvalve

6.Canister

7.Separator

8.BN125-A5 only

1. On and after BN125-A7

2. Air cleanerelement

OR: Apply high-quality-foam-air filter oil.

Specifications

ItemStandard
Throttle Grip Free Play	2 ~ 3 mm (0.08 ~ 0.12 in.)
CarburetorMake,TypeMIKUNIBS28IdleSpeed1300±50r/min(rpm)PilotScrew(TurnsOut)1 5 / 8Service Fuel LevelFloatHeight19.4±2mm(0.76±0.08in.)MainJet#105NeedleJet(No.)0-8(807)JetNeedleMark4DH24-3PilotJet(SlowJet) #30PilotAirJet(SlowAirJet) #95ThrottleValve	3.0(BN125-A7~, N , N U )(US,CA,CH)-1 ~ 3 mm (0.04 ~ 0.12 in.) below from the bottom edge of theofthecarburetorbodyskirt.#125(US,CA)#122.5(BN125-A7~, N , N U )0-8M(891)(US,CA)0-7M(891)(BN125-A7~, N , N U )4C17-1(US,CA)4C31-2(BN125-A7~,N,NU)#32.5(US,CAandBN125-A7~,N,NU)#90(US,CA)#70 (BN125-A6 ~ US, CA and BN125-A7~, N, NU)#110#105(US,CAa ndBN125-A7~,N,NU)
Air Cleaner Element OilGradeViscosity	High-quality-foam-air-filter oilAPISE,SF,orSGclassSAE30

CA:Canada

CH:Switzerland

US:UnitedStates

N: No Catalytic Converter Model

NU:NoCatalyticConverter(UnitedKingdomModel)

Specifications

Pilotscrew[A]

Plug [B] (US, CA, CH)

Pilotairjet[C]

Jetneedle[D]

ThrottlevalveE

Pilotjet[F]

Needlejet[G]

Mainjet[H]

Float[l]

Valveseat[J]

Valveneedle[K]

3-10FUELSYSTEM

SpecialTools

FuelLevelGauge: 57001-1017

Technical line drawing of a cylindrical mechanical part with internal grooves (no text or symbols)

CarburetorDrainPlugWrench,Hex3:57001-1269

Line drawing of a T-shaped tool or tool with a handle and base, no text or symbols present

ThrottleGripandCables

FreePlayInspection

- RefertotheThrottleGripFreePlayInspectioninthePeriodicMaintenancechapter.

FreePlayAdjustment

- RefertotheThrottleGripFreePlayAdjustmentinthe PeriodicMaintenancechapter.

Throttle Cable Installation

• InstallthethrottlecableinaccordancewiththeCable, Wire,andHoseRoutingsectionintheAppendixchapter.
• Installtheupperendsofthethrottlecablesinthegrip afterinstallingthelowerendsofthethrottlecableonthe carburetor.

- Tighten:

Torque-HandlebarSwitchHousingScrews:3.4N·m(0.35 kgf·m,30in·lb)

- AfterInstallation,adjustthecableproperly.

WARNING

Operationwithincorrectlyroutedorimproperlyadjustedcablescouldresultinanunsaferidingcondition.

Throttle Cable Lubrication and Inspection

• Whenever the cable are removed, or in accordance with the Periodic Maintenance Chart, lubricatethethrottle cable (see General Lubrication in Periodic Maintenance chapter).
• Applyathincoatingofgreasetothecableupperend.
• Usethepressurecablelubbertolubricatethecable.
• With the cabled disconnected at both ends, the cable should move freely in the cable housing.
  ★ Ifthecablemovementisnotfreeafterlubricating,ifthe cableisfrayed,orifthehousingiskinked,replacethe cable.

Carburetor

IdleSpeedInspection

- RefertotheldleSpeedInspectioninthePeriodicMaintenancechapter.

IdleSpeedAdjustment

- RefertotheIdleSpeedAdjustmentinthePeriodicMaintenancechapter.

ServiceFuelLevelInspection

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Turntheignition switchOFF.Donotsmoke.Makesuretheareais well-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

• Removethecarburetor, and hold it upright on a stand (see Carburetor Removal).
• Prepareanauxiliaryfueltankandconnectthefueltapto thecarburetorusingasuitablehose.
• Prepareasuitablefuelhose.
• Connectthefuellevelgauge[A]tothecarburetorfloat bowlwiththefuelhose.

SpecialTool-FuelLevelGauge:57001-1017

• Holdthegaugeverticallyagainstthesideofthecarbutorbodysothatthemiddleline[B]isseveralmillimeters higherthanthebottomedge[C]ofthecarbutorbody.
• TurnthefueltaptotheONpositiontofeedfueltothe carburetor, thenturnoutthecarburetordrainplug[D]a fewturns.

SpecialTool-CarburetorDrainPlugWrench, Hex3: 57001-1269

• Waituntilthefuellevelinthegaugesettles.
• Keepingthegaugevertical, slowly lower the gauge until the "middle" line is even with the bottom edge E of the carburetorbody.

NOTE

○ Do not lower the “middle” line below the bottom edge of thecarburetorbody. Ifthegaugeisloweredandthen raisedagain, thefuellevelmeasured showssomewhat higher than the actual fuel level. If the gauge is lowered too far, dump the fuel out of it into suitable container and starttheprocedureoveragain.

- Read the fuel level in the gauge and compare to the specification.

ServiceFuelLevel

Standard: 1 \~ 3 mm (0.04 \~ 0.12 in.)

below from the mating surface of the float bowl.

• Tightenthe drainplug, turnthe fueltaptotheOFFposition andremovethefuellevelgauge.
  ★ If the fuel level is incorrect, adjustit (see Service Fuel Level Adjustment).

Carburetor

ServiceFuelLevelAdjustment

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Turntheignition switchOFF.Donotsmoke.Makesuretheareais well-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

• Removethecarburetor, and drain the fuel into as suitable container.
• Removethefloatbowlscrews[A]andfloatbowl[B].
• Slideoutthepivotpin[A]andremovethefloat[B].
• Whenremovingandinstallingthepivotpin,notethefollowings.
  ○Becarefulnottosnapthepinholderleg[C].
  ○Whenremovingit,tap[D]theleftendofthepin.
  Wheninstallingit, pressEtherightendofthepin. Front[F]

- Bendthetang[A]onthefloatarmveryslightlytochange thefloatheight.

• Driveinthepivotpintoinstallthefloat[C].
• Removethefloatchambergasket.
• Measurethefloatheight[D]tiltingthecarburetorsothat thetangonthefloatjusttouchestheneedlerodinthe floatvalve.
  ○ Increasingthefloatheightlowersthefulevelelanddecreasingthefloatheightraisesthefuellevel. FloatBowlMatingSurface[A] FloatValveNeedleRod(contactedbutunloaded)[B]

FloatHeight

Standard:19.4±2mm(0.76±0.08in.)

NOTE

○Donotpushtheneedlerodinduringfloatheightmeasurement.

• Assemblethecarburetor, andrecheckthefuellevel.
  ★ Ifthefuellevelcannotbeadjustedbythismethod,the floatorthefloatvalveisdamaged.

Carburetor

FuelSystemCleanlinessInspection

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Turntheignition switchOFF.Donotsmoke.Makesuretheareais well-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

• Connectasuitablehosetothefittingatthebottomofthe carburetorfloatbowl.
• Runthelowerendofthehoseintoasuitablecontainer.
• TurnthefueltaptothePRIposition.
• Turnoutthedrainplug[A]afewturnsanddrainthefloat bowl.
  Front[B]

SpecialTool-CarburetorDrainPlugWrench,Hex3:57001-1269

- Checktoseeifwaterordirtcomesout.

- TightenthedrainplugandturnthefueltaptotheON position.

Torque-CarburetorDrainPlug:2.0N·m(0.20kgf·m,17in·lb)

★Ifanywaterordirtappearsduringtheaboveinspection, cleanthefuelsystem(seeCarburetorCleaningandFuel TankCleaning).

CarburetorRemoval

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Turntheignition switchOFF.Donotsmoke.Makesuretheareais well-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

• Remove:
  FuelTank(seeFuelTankRemoval) ThrottleCableLowerEnds[A]
• Move back the air cleaner housing (see Air Cleaner HousingRemoval).

Close-up mechanical assembly showing gears and springs (no visible text or symbols)

Carburetor

• Loosenthecarburetorholderclamp[A]andaircleaner ductclamp.
• Pullthecarburetoroutoftheaircleanerductend[B], and then pullitoutofthecarburetorholder[C] from the vehicle's rightside.
  • Takeoutthecarburetor.
• Stuffpiecesoflint-free,cleanclothintothecarburetor holderandtheaircleanerducttokeepdirtoutoftheengineandaircleaner.

WARNING

Ifdirtordustisallowedtopassthroughintothe carburetor, thethrottlemaybecomestuck, possibly causinganaccident.

CAUTION

Ifdirtgetsthroughintotheengine,excessiveenginewearandpossiblyenginedamagewilloccur.

Carburetor Installation

- Wheninstallingthecarburetorintothecarburetorholder, fittheridge[B]ofthecarburetorintotherecess[A]ofthe carburetorholder.

• Tightentheclampscrews[A]sothatfacethescrewpositionandscrewheaddirection.
• Checkfuelleakagefromthecarburetor.

WARNING

Fuelspilledfromthecarburetorishazardous.

• Adjust the following items if necessary. Throttle Cable IdleSpeed

CarburetorDisassembly

- Removethecarburetor(seeCarburetorRemoval).

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Turntheignition switchOFF.Donotsmoke.Makesuretheareais well-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

Close-up of a mechanical engine assembly with labeled parts (A, B, C), no visible text or symbols beyond labels.

Close-up mechanical assembly showing components labeled A and B (no readable text or symbols beyond labels)

3-16FUELSYSTEM

Carburetor

- Remove:

UpperChamberCover[A]

VacuumPistonandDiaphragm

CAUTION

Duringcarburetordisassembly, the careful not to damagehediaphragm. Never use a sharpedgeto removal of diaphragm.

• Removethespringseatscrews[D].
• Removethejetneedle[A]fromthevacuumpiston[B] alongwiththespringseat[C].
• Thepilotscrewissetatthefactoryandshouldnotbe removed. Butifnecessary, removethepilotscrewas follows.
• ReplacetheO-ringwithanewone.
  ○FortheSwiss,UnitedStates.andCanadamodels,pry outthepilotscrewplugwithanawlorothersuitabletool.
• Turninthepilotscrewandcountthenumberofturnsuntil itseatsfullybutnottightly,andthenremovethescrew. Usethisnumberofturnstosetthescrewtoitsoriginal positionduringassembly.

NOTE

○Acarburetorhasdifferent"turnsout"ofthepilotscrew foreachindividualunit. Whensettingthepilotscrew, usethe "turnsout" determined during disassembly. Use the specification in this manual only if the original number is unknown.

- Remove:

FloatBowl

FloatPivotPin[A]

Float[B]withFloatValveNeedle

PilotJet[C]

MainJet[D]

- Pushtheneedlejet[A]outfromtheinsideofthecarbure-torborewithyourfinger.

Close-up of a mechanical component with a labeled section (A) and no visible text or symbols on the main subject.

Close-up of a mechanical component with labeled point A (no readable text or symbols beyond label)

Carburetor

• Removethecoastingenrichercover.
• Removethediaphragm[A].

Close-up of a mechanical component with a tool inserted, showing internal parts and a labeled section A (no readable text or symbols)

CarburetorAssembly

• Turninthepilotscrew[A]fullybutnottightly, and then backitoutthesamenumberofturncountedduringdisassembly.
• FortheSwiss,UnitedStates.andCanadamodels,drive inanewplug[B]inthepilotscrewholeofthecarburetor body[C]asshown.

CAUTION

Donotforcetheneedlejetandmainjetorover-tightenthem. They could bedamaged requiring replacement.

- Tighten:

Torque-MainJet:1.8N·m(0.18kgf·m,15in·lb) PilotJet:0.8N·m(0.080kgf·m,7in·lb)

• Putthefloatvalveneedleintothevalveseat.
• Beforeinstallingthefloat,insertthetangonthefloatplate throughtheclip[A]onthevalveneedle.
• Pressthepivotpin[B]intotheholderlegandfloat.
• Setthefloatheightasspecified(seeServiceFuelLevel Adjustment).

- Slipthejetneedle[A]throughtheholeinthecenterofthe vacuumpiston[B],andputthespringseat[C]onthetop oftheneedle.

- Tightenthespringseatscrews[D]. Torque-SpringSeatScrew:0.8N·m(0.080kgf·m,7in·lb)

Mechanical assembly diagram showing internal components with labeled parts A and B (no readable text or symbols beyond labels)

Carburetor

• Alignthediaphragmtang[A]withthenotchintheupper chamber,andfitthediaphragmsealinglipintoitsgroove.
• Afterinstallingtheupperchambercover, checkthatthe vacuumpistonslidesupanddownsmoothlywithoutbindinginthecarburetorbore.
• Tighten:

Torque-UpperChamberCoverScrews:3.5N·m(0.36 kgf·m,31in·lb) FloatBowlScrews:2.0N·m(0.20kgf·m,17in·lb) CoastingEnricherScrews:2.0N·m(0.20kgf·m,17 in·lb)

Close-up of a mechanical component with a circular housing and mounting holes (no visible text or symbols)

CarburetorCleaning

WARNING

Cleanthecarburetorinawell-ventilatedarea,and takecarethatthereisnosparkorflameanywhere neartheworkingarea;thisincludesanyappliance withapilotlight.Becauseofthedangerofhighly flammableliquids,donotusegasolineorlow-flash pointsolventstocleanthecarburetor.

CAUTION

Donotusecompressedaironanassembledcarburetor,orthefloatsmaybecrushedbythepressure. Removeasmanyrubberorplasticpartsfromthe carburetoraspossiblebeforecleaningthecarburetorwithacleaningsolution. Thiswillpreventdamagetoordeteriorationofthe parts. Thecarburetorbodyhasplasticpartsthatcannotberemoved.Donotuseastrongcarburetor cleaningsolutionwhichcouldattacktheseparts; instead,useamildhigh-flashpointcleaningsolutionsafeforplasticparts. Donotusewireoranyotherhardinstrumentto cleancarburetorparts,especiallyjets,astheymay bedamaged.

• Disassemblethecarburetor.
- Immerseallthemetalpartsinacarburetorcleaningsolution.
- Rinsethepartsinwater.
- Whenthepartsareclean, drythemwithcompressedair.
- Blowthroughtheairandfuelpassageswithcompressed air.
- Assemblethecarburetor.

Carburetor

CarburetorInspection

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Turntheignition switchOFF.Donotsmoke.Makesuretheareais well-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

• Removethecarburetor.
• Beforedisassemblingthecarburetor, checkthefuellevel (seeFuelLevelInspection).
• Movethestarterplungerleverupanddowntocheckthat thestarterplungermovessmoothly.
  ★ Ifthestarterplungerdoesnotworkproperly,replace the plunger,leveland/orthecarburetor.

• Turnthethrottlecablepulleytocheckthatthethrottle valve[A]movessmoothlyandreturnbyspringface.
  ★ Ifthethrottlevalvedoesnotmovessmoothly,replace the carburetor.

• Disassemblethecarburetor(seeCarburetorDisassembly).

• Cleanthecarburetor(seeCarburetorCleaning).

• Check that the diaphragm [A] on the vacuum piston is good condition.
  ★ Ifanyofthediaphragmisnotingoodcondition,replace them.

• Checktheplastictip[A]ofthefloatvalveneedle[B].It shouldbesmooth,withoutanygrooves,scratches,or tears.
  ★ Iftheplastictipisdamaged[C], replacetheneedle.

• Pushtherod[D]intheotherendofthefloatvalveneedle, andthenreleaseitE.
  ★ Iftheroddoesnotspringout, replacethefloatvalveneedle.

Close-up mechanical component with threaded shaft and circular housing, no visible text or symbols

Close-up of a mechanical component with labeled section A (no text or symbols beyond label)

3-20FUELSYSTEM

Carburetor

• Checkthetaperedportion[A]ofthepilotscrew[B]for wearordamage.
  ★ Ifthepilotscrewiswornordamagedonthetaperedportion, it will prevent the engine from midlings smoothly. Replace it.

• Check that the vacuum-piston[A]movessmoothly in the carburetorbody. Thesurface of the piston must not be excessively worn.
  ★Ifthevacuumpistondoesnotmovessmoothly,orifit isverylooseinthecarburetorbody,replacethepiston and/orthecarburetor.

• Disassemblethecarburetor, andcleanthefuel, airpassages with a high-flash-points solvent and compressed air.
• Stuffthelint-free, cleancloths into the aircleanerhousing to keep dirtor other foreign material from entering.

WARNING

Ifdirtordustisallowedtopassthroughintothe carburetor,thethrottlevalvemaystuck,possibly causinganaccident.

AirCleaner

AirCleanerElementRemoval

• Removetheleftsidecover.

• Removetheelementcover[A]. Front[B]

• Pullouttheaircleanerelement[A].

• Pushaclean, lint-freetowel into the air cleaner housing to keep dir for other foreign material from entering.

WARNING

Ifdirtordustisallowedtopassthroughintothecar-buretor, thethrottlevalvemaybecomestuck, possiblycausinganaccident.

CAUTION

Ifdirtgetsthroughintotheengine,excessiveenginewearandpossiblyenginedamagewilloccur.

ElementCleaningandInspection

- RefertotheAirCleanerElementCleaningandInspection inthePeriodicMaintenancechapter.

AirCleanerDraining

Acatchtankisprovidedbeneaththeaircleanerhousing, andcatchesthewateroroilfromthebottomofthehousing. Usuallywateroroildoesnotcollectatthebottomofthe housing. Intheeventthatrainwaterisdrawninthroughthe aircleaner, orifengineoilisblownback, drainthehousing.

• Visuallycheckthecatchtank[A]ifthewateroroilaccumulatesinthetank.
  ★Ifanywateroroilaccumulatesinthetank,drainitby takingoffthedrainplug[B]atthelowerendofthedrain hose.
• Installthecatchtankwiththearrow[C]onitpointingupward.
• Besuretoinstalltheplugfirmly.

WARNING

Besuretoinstallthepluginthedrainhoseafterdraining.Oilcoulddrainfromtheopenhoseandgetonthetireswhichcouldcauseanaccidentandinjury.

Close-up of a mechanical component with labeled parts (A, D) and no visible text or symbols

3-22FUELSYSTEM

AirCleaner

AirCleanerHousingRemoval

- Remove:

SideCoversandSeat(seeFramechapter)

FuelTank(seeFuelTankRemoval)

Battery(seeElectricalSystem)andBatterySeat[A]

BreatherHoseofAirCleaner

StarterRelay[B]

FuseCase[C]

StarterCircuitRelay[D]

HousingMountingBoltsEandScrews[F]

• Removetheelementcover[A]andelement.
• Moveback[B]theaircleanerhousing.
• RemovethecarburetorC.

- Removetheaircleanerhousing[A]fromthevehicle's rightside. Front[B]

AirCleanerHousingInstallation

- Besuretofittheenginebreatherhoseanddraininghoses intotheaircleanerhousing.

FuelTank

FuelTankRemoval

A WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Turntheignition switchOFF.Donotsmoke.Makesuretheareais well-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

• Removetheseatandsidecovers(seeFramechapter).
• Removethefueltankmountingbolts[A].
• TurnthefueltaptotheOFFForRESposition.
• Pullthehoseoffthetap.

Close-up of a high-speed train on tracks with a circular marker labeled 'A' (no visible text or symbols beyond the label)

- Disconnecttheindicatorlightleadconnector[A].

- Removethefueltank.

- Drainthefueltank.

○Placeasuitablecontainerunderthefueltank.

○TurnthefueltaptothePRIpositiontodra thecontainer.

FuelTankInstallation

• ReadtheaboveWARNING.
• Checktherubberdampers[A]ontheframe.
  ★ If the dampers are damaged, deteriorated, replace them.
• Routethehoseandleadscorrectly.
• Connecttheindicatorlightconnector.
• Besurethehoseareclampedsecurely.

Mechanical assembly diagram showing linkage components and labeled parts (no readable text or symbols)

FuelTankInspection

• Removethehosesfromthefueltank, andopenthetank cap.
• Checktoseeifthebreatherpipeandwaterdrainpipein tankarenotclogged.
  ★ Iftheyareclogged,removethetank anddrainit,andthen blowpipesfreewithcompressedair.

CAUTION

Do not apply compressed air to the air vent holes in thetankcap. This could cause damage and clogging of the labyrinth in the cap.

FuelTank

FuelTankCleaning

WARNING

Cleanthetankinawell-ventilatedarea,andtake carethattherearenosparksorflameanywhere neartheworkingarea.Becauseofthedangerof highlyflammableliquids,donotusegasolineor low-flashpointsolventstocleanthetank.

• Removethefueltankanddrainit.
• Poursomehigh-flashpointsolventintothefueltankand shakethetanktoremovedirtandfueldeposits.
• Pourthesolventoutofthetank.
• Removethefueltapfromthetank(seeFuelTapRemoval).
• Cleanthefueltapfilterscreensinahigh-flashpointsolvent.
• Pourhigh-flashpointsolventthroughthetapinallever positions.
• Drythetankandthefueltapwithcompressedair.
  • Installthetapinthetank.
  • Installthefueltank.

FuelTapRemoval

- Removethefueltankanddrainit.

- Removethetapbolts[A]withnylonflatwashersandtake outthefueltap.

Mechanical assembly diagram showing a linkage mechanism with labeled component A (no readable text or symbols)

FuelTapInstallation

• ReplacetheO-rings[A]withanewone.
• Besuretoclampthefuelhosetothetaptopreventleaks.
• Besuretheflatwashers[B]areingoodconditiontopreventleaks.
  ○Donotusesteelwashersinplaceoftheflatwashers, because they will not seal the bolts properly and fuel will leak.
• Tighten:

Torque-FuelTapMountingBolts:

2.5N·m(0.25kgf·m,22in·lb)(WhiteWasher)

4.9N·m(0.50kgf·m,43in·lb)(BlackWasher)

FuelTank

FuelTapInspection

• Removethefueltap.
• Checkthefueltapfilterscreen[A]foranybreaksordeterioration.
  ★ Ifthefueltapscreenshaveanybreaksoraredeteriorated,theymayallowdirttoreachthecarburetor,causing poorrunning.Replacethefueltap.
  ★ Ifthefueltapleaks,orallowsfueltoflowwhenitisat OnorRESpositionwithoutenginerunning,replacethe damagedgasket[B]orO-ring[C].

Torque-FuelTapPlateScrews:0.8N·m(0.080kgf·m,7in·lb)

FuelTapDiaphragmCoverScrews:1.0N·m(0.10 kgf·m,9in·lb)

EvaporativeEmissionControlSystem(CaliforniaModelOnly)

The Evaporative Emission Control System routes fuel vapors from the fuels system into other running engine or stores the vapors in a canister when the engine is stopped. Although no adjustments are required, a thorough visual inspection must be made at the interval specified by the Periodic Maintenance Chart.

PartsRemoval/Installation

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Turntheignition switchOFF.Donotsmoke.Makesuretheareais well-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

CAUTION

If gasoline, solvent, water or any other liquidenters the canister, the canister's vapor absorbing capacity is greatly reduced. If the canister does become contaminated, replace it with anewone.

• Topreventthegasolinefromflowingintooroutofthe canister, holdtheseparatorperpendiculartotheground.
• Connectthehosesaccordingtothediagramofthesystem.Makesuretheydonotgetpinchedorkinked.
• Routehoseswithaminimumofbendingsothattheairor vaporwillnotbeobstructed.
• Besuretoplugthereturnhosetopreventfuelspilling beforefueltankremoval.

WARNING

Whenremovingthefueltank,becarefulnottospill thegasolinethroughthereturnhose.Spilledfuelis hazardous.

★Ifliquidgasolineflowsintothebreatherhose,removethe hoseandblowitcleanwithcompressedair.

HoseInspection

• Check that the hoses are securely connected.
• Replaceanykinked, deterioratedordamaged hoses.

SeparatorInspection

- RefertotheEvaporativeEmissionControlSystem InspectioninthePeriodicMaintenancechapter.

EvaporativeEmissionControlSystem(CaliforniaModelOnly)

SeparatorOperationTest

WARNING

Gasolineisextremelyflammableandcanbeexplosiveundercertainconditions.Turntheignition switchOFF.Donotsmoke.Makesuretheareais well-ventilatedandfreefromanysourceofflame orsparks;thisincludesanyappliancewithapilot light.

- Connectthehosestotheseparator, and install these separatoronthemotorcycle.

• Disconnectthebreatherhosefromtheseparator, and injectabout20mL(0.68USoz)ofgasoline[A]intotheseparator[B]throughthehosefitting.
• Disconnectthefuelreturnhose[C]fromthefueltank[D].
• Placetheopenendofthereturnhoseintothecontainer andholditwiththesamelevelofthetanktopE.
• Starttheengine, and letitidle.
  ★ Ifthegasolineintheseparatorcomesoutofthehose,the separatorworkswell.Ifitdoesnot,replacetheseparator withanewone.

CanisterInspection

- RefertotheEvaporativeEmissionControlSystemInspectioninthePeriodicMaintenancechapter.

EngineTopEnd

TableofContents

ExplodedView....4-2

Specifications....4-6

SpecialTools....4-9

CleanAirSystem(ForAT,CH,DEof BN125-A1\~A2andotherthanthe CAL)....4-11

AirSuctionValveInstallation......4-11

AirSuctionValveInspection......4-11

VacuumSwitchValveRemoval...4-11

VacuumSwitchValveInstallation 4-11

VacuumSwitchValveUnitTest.... 4-12

CleanAirSystemHose Inspection.... 4-12

CleanAirSystem(CaliforniaModel). 4-13

VacuumSwitchValveTest 4-13

CamshaftChainTensioner 4-14

Camshaft Chain Tensioner Removal.... 4-14

Camshaft Chain Tensioner Installation.... 4-14

Camshaft 4-16

CamshaftRemoval.... 4-16

CamshaftInstallation.... 4-17

CamshaftChainRemoval...... 4-18

CamshaftChainInstallation...... 4-19

CylinderHead 4-21

CylinderCompression Measurement 4-21

CylinderHeadRemoval 4-22

CylinderHeadInstallation 4-23

CylinderHeadAssembly.... 4-24

CylinderHeadCleaning 4-24

CylinderHeadWarp 4-25

Valves 4-26

ValveClearanceInspection...... 4-26

ValveClearanceAdjustment...... 4-26

Valve Removal 4-26

ValveInstallation 4-26

ValveGuideRemoval.... 4-26

ValveGuideInstallation.... 4-27

Valve-to-Guide Clearance Measurement(Wobble Method).... 4-27

ValveSeatInspection...... 4-28

ValveSeatRepair.... 4-28

Cylinder, Piston.... 4-33

CylinderRemoval.... 4-33

PistonRemoval.... 4-33

Cylinder,PistonInstallation...... 4-33

CylinderWear 4-35

PistonWear.... 4-35

Piston/CylinderClearance...... 4-36

PistonRing, PistonRingGroove Wear.... 4-36

PistonRingGrooveWidth.... 4-36

PistonRingThickness.... 4-37

PistonRingEndGap.... 4-37

CarburetorHolder 4-38

CarburetorHolderInstallation ..... 4-38

Muffler.... 4-39

MufflerRemoval 4-39

MufflerInstallation 4-39

ExplodedView

No.	Fastener	Torque			Remarks
		N·mkgf	·mft·lb
1	Valve Adjusting Cap Bolts (BN125-A1 ~ A3)	9.8	1.0	87 in·lb
	Valve Adjusting Cap Bolts (BN125-A4 ~)	8.8	0.90	78 in·lb
2	CamshaftChainCoverBolts(BN125-A1~ A3)	9.81.08	7in·lb
	Camshaft Chain Cover Bolts (BN125-A4 ~)	8.8	0.90	78 in·lb
3	Cylinder Head Bolts (M9)	26	2.7	19	S, M
4	Cylinder Head Bolts (M6)	12	1.2	104 in·lb	S
5	Spark Plug	13	1.3	9.5
6	CamshaftChainCoverDamperBolts(BN125-A1 ~ A3)	9.81.08	7in·lb
	CamshaftChainCoverDamperBolts(BN125-A4 ~)	8.80.90	78in·lb
7	CarburetorHolderBolts	9.81.08	7in·lb
8	Air Suction Valve Cover Bolts (BN125-A1 ~ A3)	9.8	1.0	87 in·lb
	Air Suction Valve Cover Bolts (BN125-A4 ~)	8.8	0.90	78 in·lb
9	Cylinder Head Blank Cap Bolts (BN125-A1 ~ A3)	9.81.08	7in·lb
	Cylinder Head Blank Cap Bolts (BN125-A4 ~)	8.8	0.90	78 in·lb
10	Vacuum Switch Valve Pipe Mounting Bolts	8.8	0.90	78 in·lb
11	Vacuum Hose Fitting	5.9	0.60	52 in·lb
12	Oil Pipe Banjo Bolt (M10)	25	2.5	18
13	Oil Pipe Banjo Bolts (M8)	9.8	1.0	87 in·lb
14	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

15."R"markedsidefacesup.
16."RN"markedsidefacesup.
17. Air suction valve (For AT, CH, DE of BN125-A1 \~ A2 and other than the CAL of BN125A3 \~)
18. Other than AT, CH, DE of among the BN125-A1 \~ A2)
19. CaliforniaModel
EO: Applyengineoil.
G: Applygrease.
L: Applyanon-permanentlockingagent.
M: Applymolybdenumdisulfidegrease.
MO: Apply molybdenum disulfide oil. The molybdenum disulfide oil is a mixture of engine oil and molybdenumdisulfidegreasewithaweightratio(10:1).
R: ReplacementParts
S: Followthespecifictighteningsequence.
AT: Austria
CAL: California
CH: Switzerland
DE: Germany

ExplodedView

ExplodedView

No.	Fastener	Torque			Remarks
		N·mkgf	·mft·lb
1	Camshaft Bearing Holder Bolts (BN125-A1 ~ A3)	9.8	1.0	87 in·lb
	Camshaft Bearing Holder Bolts (BN125-A4 ~)	8.8	0.90	78 in·lb
2	CamshaftSprocketBolts	12	1.2104	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·lb
5	Chain Tensioner Mounting Bolts (BN125-A1 ~ A3)	9.8	1.0	87 in·lb
	Chain Tensioner Mounting Bolts (BN125-A4 ~)	8.8	0.90	78 in·lb
6	Chain Tensioner Cap	4.9	0.50	43 in·lb
7	ValveAdjustingScrewLocknut	15	1.5	11
8	Rocker Shaft Bolts	8.8	0.90	78 in·lb
9	Muffler Body Mounting Nut	15	1.5	11

M: Apply molybdenum disulfide grease.
MO: Apply molybdenum disulfide oil. The molybdenum disulfide oil is a mixture of engine oil and molybdenumdisulfidegreasewithaweightratio(10: 1).
R: Replacementparts

Specifications

ItemStandardServiceLimit
CleanAirSytemVacuumSwitchValveClosingPressure:(AT,CH,DE,oftheBN125-A1~A2andothethantheCAL)(CAL)	Open→ Close--45 ~ 53 kPa (340 ~ 400 mmHg, 6.5 ~ 7.7 psi)41 ~ 52 kPa (310 ~ 390 mmHg, 6.0 ~ 7.5 psi)	---
CamshaftCamHeight:ExhaustInletCamshaft RunoutRocker Arm Inside diameterRocker Shaft Diameter	39.348~ 39.464mm( 1.5491~ 1.5537in.)39.707 ~ 39.823 mm (1.5633 ~ 1.5678 in.)TIR 0.02 mm (0.0008 in.) or less13.000 ~ 13.018 mm (0.5118 ~ 0.5125 in.)12.983 ~ 12.994 mm (0.5111 ~ 0.5116 in.)	39.25mm(1.545in.)39.61 mm (1.559 in.)TIR 0.1 mm (0.004 in.)13.05 mm (0.514 in.)12.96 mm (0.510 in.)
CylinderHeadCylinderCompressionCylinderHead Warp	(Usablerange)960 ~ 1 470 kPa (9.8 ~ 15.0 kgf/cm2, 139 ~ 213psi)@500r/min(rpm)-- --	---0.05mm(0.002 in.)
ValvesValveClearance:ExhaustInletValveHeadThickness:ExhaustInletValve Stem BendValveStemDiameter:ExhaustInletValveGuideInsideDiameter:ExhaustInletValve/valveGuideClearance(WobbleMethod):ExhaustInletValveSeatCuttingAngleValveSeatSurfaceOutsideDiameter:ExhaustInlet	0.15 ~ 0.19 mm (0.006 ~ 0.007 in.)0.08 ~ 0.12 mm (0.003 ~ 0.005 in.)0.9 ~ 1.1 mm (0.035 ~ 0.043 in.)0.6 ~ 0.8 mm (0.024 ~ 0.031 in.)TIR 0.01 mm (0.0004 in.) or less4.455 ~ 4.470 mm (0.1754 ~ 0.1760 in.)4.475 ~ 4.490 mm (0.1762 ~ 0.1768 in.)4.500 ~ 4.512 mm (0.1772 ~ 0.1776 in.)4.500 ~ 4.512mm(0.1772~ 0.1776in.)0.14 ~ 0.19 mm (0.006 ~ 0.007 in.)0.03 ~ 0.13 mm (0.001 ~ 0.005 in.)45°,32°,60°	---0.5 mm (0.02 in.)0.4 mm (0.01 in.)TIR0.05mm(0.002in.)4.44 mm (0.175 in.)4.46 mm (0.176 in.)4.57 mm (0.180 in.)4.57mm(0.1 80in.)0.38 mm (0.015 in.)0.33 mm (0.013 in.)---

Specifications

ItemStandardServiceLimit
Width:
Exhaust	0.8~1.2mm(0.03~0.05in.)	-- --
Inlet	0.8~1.2mm(0.03~0.05in.)	-- --
ValveSpringFreeLength:
Exhaust	43.51mm(1.713in.)42.1mm(1.66in.)
Inlet43.51mm(1.713in.)42.1mm(1.66in.)
Cylinder,Piston
Cylinder Inside Diameter	55.000 ~ 55.012 mm (2.1654 ~ 2.1658 in.)	55.10 mm (2.169 in.)
Piston Diameter	54.960 ~ 54.975 mm (2.1638 ~ 2.1644 in.)	54.81 mm (2.158 in.)
	54.968 ~ 54.982 mm (2.1641 ~ 2.1646 in.)	54.82 mm (2.158 in.)
	(BN125-A7~, N , N U)
Piston/cylinder Clearance	0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in.)	-- --
	0.0241 ~ 0.0385 mm (0.0009 ~ 0.0015 in.)
	(BN125-A7~, N , NU )
OversizePistonandRings	+0.5mm(0.02in.),+1.0mm(0.04in.)	-- --
Piston Ring/groove
Clearance:
Top	0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in.)	0.17 mm (0.0067 in.)
Second	0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in.)	0.16 mm (0.0063 in.)
PistonRingGrooveWidth:
Top	0.82 ~ 0.84 mm (0.0323 ~ 0.0331 in.)	0.92 mm (0.0362 in.)
Second	0.81 ~ 0.83 mm (0.0319 ~ 0.0327 in.)	0.91 mm (0.0358 in.)
PistonRingThickness:
Top	0.77 ~ 0.79 mm (0.0303 ~ 0.0311 in.)	0.70 mm (0.028 in.)
Second	0.77 ~ 0.79 mm (0.0303 ~ 0.0311 in.)	0.70 mm (0.028 in.)
PistonRingEndGap:
Top	0.15 ~ 0.30 mm (0.006 ~ 0.012 in.)	0.60 mm (0.024 in.)
Second	0.30 ~ 0.45 mm (0.012 ~ 0.018 in.)	0.70 mm (0.028 in.)
Oil	0.20 ~ 0.70 mm (0.008 ~ 0.028 in.)	1.0 mm (0.04 in.)

AT: Austria
CAL:California
CH:Switzerland
DE:Germany
N: No Catalytic Converter Model
NU:NoCatalyticConverter(UnitedKingdom
Model)

4-8ENGINETOPEND

Specifications

CamHeight

CamHeight[A]

ValveHeadThickness

ValveStemDiameter[A]
ValveHeadThickness[B]
45^[C]

CamshaftRunout

Technical line drawing of a mechanical assembly with a pressure gauge and shaft (no text or symbols)

ValveStemBend

DialGauge[A]

SpecialTools

CompressionGauge,20kgf/cm²: 57001-221

Technical line drawing of a pressure gauge with no text or symbols

ValveSpringCompressorAssembly: 57001-241

Line drawing of a mechanical clamp or spring-loaded tool with no text or symbols

PistonPinPullerAssembly: 57001-910

Technical line drawing of a mechanical component with multiple bolted and cylindrical features (no text or symbols)

ValveSeatCutter,45°-27φ5:57001-1114

Simple line drawing of a cylindrical object with a textured top and central hole, no text or symbols present.

ValveSeatCutter,45°-32:φ 57001-1115

Isometric line drawing of a cylindrical object with concentric rings and textured top surface (no text or symbols)

ValveSeatCutter,32°-30φ 57001-1120

Simple line drawing of a cylindrical object with a textured top and central hole, labeled 'ST571120ST C' at bottom (no other text or symbols)

ValveSeatCutter,32°-35:φ 57001-1121

Isometric line drawing of a cylindrical object with concentric rings and textured top surface (no text or symbols)

ValveSeatCutter,60°-30φ 57001-1123

Line drawing of a conical object with a circular top and textured base, labeled 'ST571123ST C' at bottom (no other text or symbols)

ValveSeatCutterHolderBar: 57001-1128

Simple line drawing of a cylindrical object with no text or symbols

ValveSpringCompressorAdapter,22φ 57001-1202

Technical line drawing of a mechanical component (no text or symbols)

SpecialTools

ForkOilLevelGauge: 57001-1290

Technical line drawing of mechanical components including a cylindrical spring and a threaded rod (no text or symbols)

CompressionGaugeAdapter, M10×1.0: 57001-1317

Line drawing of a U-shaped mechanical component with two connectors and a shaft (no text or symbols)

ValveSeatCutterHolder,4.5p 57001-1330

Line drawing of a cylindrical electronic component with a short shaft and end cap (no text or symbols)

ValveGuideArbor,4.5: 57001-1331

Line drawing of a mechanical tool or rod with textured end and shaft (no text or symbols)

ValveGuideReamer,4.51 57001-1333

Technical line drawing of a mechanical tool or rod with flanged ends and a tapered shaft (no text or symbols)

ValveSeatCutter,60°-33: 57001-1334

Isometric line drawing of a conical object with a circular top and textured base (no text or symbols)

○ValveSeatCutter,32°-33φ57001-1199can alsobeusedinsteadofValveSeatCutter, 32°-φ35:57001-1121

○ValveSeatCutter,45°-30φ57001-1187can alsobeusedinsteadofValveSeatCutter, 45°-φ27.5:57001-1114

Clean Air System (For AT, CH, DE of BN125-A1 \~ A2 and other than the CAL)

AT:Austria

CAL:California

CH:Switzerland

DE:Germany

AirSuctionValveInstallation

• Installtheairsuctionvalvesothatitsnumber[A]ofthe readfacesoutsideanddownward.
• Tighten:

Torque-AirSuctionValveCoverBolts:

(BN125-A1\~A3):9.8N·m(1.0kgf·m,87in·lb)

(BN125-A4 \~): 8.8 N·m (0.90 kgf·m, 78 in·lb)

Close-up of a hand adjusting a mechanical component with a labeled part (A) and '6LDS' logo, no readable text or symbols beyond the label.

AirSuctionValveInspection

- RefertotheAirSuctionValveInspectioninthePeriodic Maintenancechapter.

VacuumSwitchValveRemoval

• Removetherightsidecover(seeFramechapter).
• Removethehose[A]fromtheaircleanerhousing.
• Pullthedamper[B]upwardtocleanerthestopper[C].
• Remove:

Pipe[D]

VacuumHose

VacuumSwitchValveE

VacuumSwitchValveInstallation

• InstallthehoseAsothatthemark [B]onitfacesupward.
• Alignthevacuumpipe[C], thearrowmark[D] on the damperE, andthemark[F] on the airhose[G] (toair cleaner).

Clamps[H]

VacuumSwitchValve[l]

Facethetabs[J]asshown.

- Routethehosescorrectly(seeAppendixchapter).

Clean Air System (For AT, CH, DE of BN125-A1 \~ A2 and other than the CAL)

VacuumSwitchValveUnitTest

• Removethevacuumswitchvalve(seeVacuumSwitchValveRemoval).
• Connectacommerciallyavailablevacuumgauge[A]and syringeBtothevacuumhoses asshown.

SpecialTool-ForkOilLevelGauge:57001-1290

AirFlow[C]

- Graduallyraisethevacuum(lowerthepressure)applied tothevacuumswitchvalve,andcheckthevalveoperation.Whenthevacuumislow,thevacuumswitchvalve shouldpermitairtoflow.Whenthevacuumraisesto valveclosingpressure,itshouldstopairflow.

★Ifthevacuumswitchvalvedoesnotoperateasdescribed, replaceitwithanewone.

NOTE

○ Tocheckairflowthroughthevacuumswitchvalve, just blowthroughtheaircleanerhose.

VacuumSwitchValveClosingPressure(Open→ Close) Standard: 45 \~ 53 kPa (340 \~ 400mmHg, 6.5 \~ 7.7 psi)

CleanAirSystemHoseInspection

- Be certain that all the hoses are routed without being flattenedorkinked, and are connected correctly to the rightaircleanerhousing, vacuumswitchvalve, carburetorholder, and airsuctionvalvecovers.

★Iftheyarenot,correctthem. Replacethemiftheyare damaged.

CleanAirSystem(CaliforniaModel)

VacuumSwitchValveTest

• Removethevacuumswitchvalve.
• Connectthevacuumgauge[A]andsyringe[B]orforkoil levelgaugetothevacuumhosesasshown.

SpecialTool-ForkOilLevelGauge:57001-1290

AirFlow[C]

- Graduallyraisethevacuum(lowerthepressure)applied tothevacuumswitchvalve,andcheckthevalveoperation.Whenthevacuumislow,thevacuumswitchvalve shouldpermitairtoflow.Whenthevacuumraisesto valveclosingpressure,itshouldstopairflow.

Spring[A]

Diaphragm[B]

Valve[C]

LowVacuum[D]

SecondaryAirFlowE

HighVacuum[F]

SecondaryAirFlowCannotFlow[G]

★ If the vacuum switch valved does not operate as described, replace it with anewone.

NOTE

○Tocheckairflowthroughthevacuumswitchvalve,just blowthroughtheaircleanerhose.

VacuumSwitchValveClosingPressure(Open→ Close)

Standard: 41 \~ 52 kPa (310 \~ 390 mmHg)

CamshaftChainTensioner

CamshaftChain TensionerRemoval

CAUTION

Thisisanon-returntypecamchaintensioner. The pushroddoesnotreturntoitsoriginalposition onceitmovesouttotakeupcamshaftchainslack. Observealltheruleslistedbelow: When removing the tensioner, donottakeoutthemountingbolts onlyhalfway. Retighteningthemountingbolts from this position could damage the tensioner and the camshaftchain. Oncetheboltsareloosened, the tensioner must be removed and reset as described in "CamshaftChain Tensioner Installation." Donot turnover the crankshaft while the tensioner is removed. This could upset the camchaintiming, and damage the valves.

• Removethechaintensionercap[A]togetherwithO-ring.
• Removethemountingbolts[B]andtakeoffthecamshaft chaintensioner.

Close-up of mechanical components with labeled parts A and B, no readable text or symbols beyond labels

CamshaftChainTensionerInstallation

- Whilecompressingthepushrod[A],turn[C]itclockwise withasuitablescrewdriver[B]untiltherodstops.

CAUTION

Donotturntherodcounterclockwiseatinstallation. Thiscoulddetachtherodandthetensionercannot bereinstalled.

- Whileholdingtherodinpositionwiththescrewdriverora holderplate[A],installthetensioneronthecylinderblock.

NOTE

○ Tomaketheprocedureeasy, useaholderplatetokeep therodfrompushingout. Areplacementchaintensioner(spareparts) hasaholderplate.

- Theholderplatecanbemadeof1mm(0.04in.) thick aluminumplateasshown.

CamshaftChainTensioner

• InstalltheO-ringinthetensionerbody.
- Installthetensionersothatthearrowmark[B]facesupward,andtightenthemountingbolts.
Torque-ChainTensionerMountingBolts
(BN125-A1 \~ A3): 9.8 N·m (1.0 kgf·m 87in·lb)
(BN125-A4 \~): 8.8 N·m (0.90 kgf·m 87in·lb)
- Removethescrewdriver(ortheholderplate[A])and tightenthecap.
Torque-ChainTensionerCap:4.9N·m(0.50kgf·m,43in·lb)

4-16ENGINETOPEND

Camshaft

CamshaftRemoval

- Remove:

FuelTankA

CamshaftChainCover[B]

ValveAdjustingCaps[C]

- Holdingthecamshaftcenterbolt[A]withawrench,loosen thecamshaftsprocketbolts[B].

- Turnthecamshaftcenterbolt[A]clockwisesothatthe mark[B]onthesprocketalignswiththetimingmark [C]onthecylinderhead.Besuretopositionthepiston TDCattheendofthecompressionstrokebyturningthe camshaft.(Alignthemarkwhentheinletvalveagain comesupafteritwentdownonce.)

- Remove:

CamshaftChainTensioner(seethischapter) CamshaftSprocket[A]

NOTE

○ Holdthecamshaftchainwithsometoolsothatthechain doesnotfallintotheengine.

- Remove:

IgnitionCoil[A]

LeftCylinderHeadBolts[B]

RockerShaftBolts[C]

○Discardtherockershaftboltwashers.

Close-up of hands assembling a mechanical component with no visible text or symbols

Camshaft

• UsingascrewA,removetherocker shafts[B].
  ○ Marktherockershaftssothattheycanbeinstalledlater inthesameposition.

- Remove: RockerArms[A] CamshaftBearingHolder[B]

○ Marktherockerarmssothattheycanbeinstalledlaterin thesameposition.

- Pulloutthecamshaft[A].

CAUTION

Thecrankshaftmaybeturnedwhilethecamshaftis removed.Alwayspullthechaintautwhileturning thecrankshaft.Thisavoidskinkingthechainonthe lower(crankshaft)sprocket.Akinkedchaincould damageboththechainandthesprocket.

CamshaftInstallation

• Blowthroughtheoilpassage[B]withcompressedair[A].
• Applyengineoiltoallcamparts, journalandbearing.
  ○ Ifthecamshaftisreplacedwithanewone,applyathin coatofmolybdenumdisulfidegreasetothenewcampart surfacesandjournal.

- Installthecamshaftwiththecamportion[A]downandthe hole[B]up.

Close-up of mechanical components with labeled parts A and B, showing wiring and assembly (no readable text or symbols)

Close-up of a mechanical assembly with a hand holding a component, no visible text or symbols

4-18ENGINETOPEND

Camshaft

- Installthecamshaftbearingholder[A]. - Applyengineoiltotherockershaftsurfaceandcamportionoftherockerarm,andtheninstallthemattheoriginal position.

○Installtherockershafts[B]sothatthescrewthreadsface outward.

- Replacetherockershaftboltwasherswithnewones.

- Install: CylinderHeadBolts(seeCylinderHeadInstallation) RockerShaftBolts

- Tighten: Torque-CamshaftBearingHolderBolts (BN125-A1 \~ A3): 9.8 N·m (1.0 kgf·m, 87 in·lb) (BN125-A4\~): 8.8N·m (0.90kgf·m, 78in·lb) RockerShaftBolts: 8.8N·m (0.90kgf·m, 78in·lb)

- Engagethecamshaftsprocket[A]withthechain[B]. Then, alignthe"T"mark[C]onthesprocketwiththe timingmark[D]onthecylinderhead.

NOTE

○ Pullthetensionside(exhaustside)ofthechainupto removeslack.

Torque-CamshaftSprocketBolts:12N·m(1.2kgf·m,104in·lb)

- Installthecamshaftchaintensioner(seeCamshaftChain TensionerInstallation).

- Checkthevalveclearance(seePeriodicMaintenance chapter).

- Tighten: Torque-CamshaftChainCoverBolts (BN125-A1 \~ A3): 9.8 N·m (1.0 kgf·m, 87 in·lb) (BN125-A4\~):8.8N·m(0.90kgf·m,78in·lb)

CamshaftChainRemoval

- Remove: CamshaftSprocketA Alternator(seeElectricalSystemchapter)

Close-up of a mechanical assembly with hands adjusting components (no visible text or symbols)

Camshaft

• Removethecrankbalancergear[A].
  SpecialTool-OutsideCirclipPliers:57001-144
  ○ Stuffacleanclothintothehole[B]sothatthebalancer damperspringswillnotfallintoit.

• Removethecamshaftchainholder[A], and pull the camshaftchain[B] upward.

• Removethecylinderhead(seeCylinderHeadRemoval).
• Removetherearcamshaftchainguidebolt[C], and pull therearcamshaftchainguide[D].

Mechanical gear assembly diagram showing two meshed gears with labeled points A and B (no text or symbols beyond labels)

CamshaftChainInstallation

• Install: RearCamshaftChainGuide[A] CylinderHead(seeCylinderHeadInstallation)

- Tighten: Torque-CamshaftChainGuideBolt:8.8N·m(0.90kgf·m, 78in·lb)

- Engagethecamshaftchain[B]withthecranksprocket, andinstallthecamshaftchainholder[C].

- Tighten: Torque-CamshaftChainHolderscrews:4.9N·m(0.50 kgf·m,43in·lb)

○ Pullthecamshaftchainandtietheupperendofthechain withacordsothatthechainisnotkinking.

- Installtheinnerandoutersprings[B]intothegroovenear thepunchmark[A]onthecrankbalancergear, and install thefivespringsandpins[C]intotheothergrooves.

○Theinnerandouterspringsarealittlelongerthanthefive identicalsprings.

4-20ENGINETOPEND

Camshaft

○Alignthethreepunchmarks[D]onthebalancershaftgear [A],crankbalancergear[B],andcoupling[C].

• Installthealternator(seeElectricalSystemchapter).
- Alignthepunchmark[A]onthecrankcasewiththe“T” mark[B]ontherotor.

- Engagethecamshaftsprocket[A]withthechain[B]. Then alignthe"T"mark[C]onthesprocketwiththetimingmark[D]onthecylinderhead.

NOTE

○ Pullthetensionside(exhaustside)ofthechainupto removeslack.

- Tighten:

Torque-CamshaftSprocketBolts:12N·m(1.2kgf·m,104in·lb)

- Install:

CamshaftChaintensioner(seeCamshaftChainTensionerInstallation)

AlternatorRotor(seeElectricalSystemchapter)

AlternatorCover(seeElectricalSystemchapter)

CamshaftChainCover

- Tighten:

Torque-CamshaftChainCoverBolts

(BN125-A1 \~ A3): 9.8 N·m (1.0 kgf·m, 87 in·lb)

(BN125-A4\~):8.8N·m(0.90kgf·m,78in·lb)

CylinderHead

CylinderCompressionMeasurement

NOTE

○Usethebatterywhichisfullycharged

• Warmuptheenginethoroughly.
• Stoptheengine.
• Remove:

FuelTank(seeFuelSystemchapter) SparkPlug

Owner's Tool-SparkPlugWrench, Hex16:92110-1172[A]

- Attachthecompressiongauge[A]andadapter[B]firmly intothesparkplughole.

SpecialTools-CompressionGauge,20kgf/cm²:57001-221 CompressionGaugeAdapter,M10×1.0: 57001-1317

- Usingthestartermotor, turntheengineoverwiththethrottlefullyopenuntilthecompressiongaugestopsrising; the compressionisthehighestreadingobtainable.

CylinderCompression

UsableRange: 960 \~ 1 470 kPa (9.8 \~ 15.0 kgf/cm², 139

\~ 213psi)@500r/min(rpm)

• Installthesparkplugandtightenit.

Torque-SparkPlug:13N·m(1.3kgf·m,113in·lb)

Close-up of a hand using a tool to adjust or install an engine component (no visible text or symbols)

The following tables should be consulted if the obtainable compression reading is not within the usability range.

ProblemDiagnosis	Remedy(Action)
Cylinder compression ishigherthan usablerange	Carbonaccumulationonpistonandin combustionchamberpossiblydueto damagedvalvestemoilsealand/or damagedpistonoilrings(Thismaybe indicatedbywhiteexhaustsmoke).	Removethecarbo ndepositsandreplace damagedpartsifnecessary.
	Incorrectcylinderheadgasket thickness.	Replacethegasketwithastandardpart.
Cylinder compression islowerthan usablerange	Gasleakagearoundcylinderhead	Replacedamagedgasketandcheck cylinderheadwarp.
	Badconditionofvalveseating	Repairifnecessary.
	Incorrectvalveclearance.	Adjustthevalveclearance.
	Incorrectpiston/cylinderclearance	Replacethepistonand/orcylinder
	Pistonseizure.	Inspectthecylinder(andliner)and replace/repairthecylinderand/orpiston asnecessary.
	Badconditionofpistonringand/or pistonringgrooves	Replacethepistonand/orthepistonrings.

4-22ENGINETOPEND

CylinderHead

CylinderHeadRemoval

- Remove:

FuelTank(seeFuelSystemchapter) ExhaustPipeA CarburetorB OilPipeC SparkPlugCap IgnitionCoil CDIUnit(seeElectricalSystemchapter)

- Remove:

EngineUpperBracket[A] CamshaftChainCover[B]

- Removethecamshaftsprocketfromthecamshaftchain (seeCamshaftRemoval).

- Remove:

6mmCylinderHeadBolts[A] 9mmCylinderHeadBolts[B] Front[C]

- Removethe9mmcylinderheadbolt[A]attherearright alongwiththecylinderhead. Front[B]

NOTE

○ Ifnecessarytaplightlywithaplastichammerasshown. Nevertaponthefins.

- Clearthechainguides[B], andremovethecylinderhead [A].

Close-up of an automotive engine bay with labeled components (A, B, C), no visible text or symbols beyond labels.

CylinderHead

CylinderHeadInstallation

- Install:

DowelPins[A]

NewCylinderHeadGasket[B]

• Applymolybdenumdisulfidegreasetothethreadsofthe 9mmcylinderheadbolts[1\~4], andengineoiltoboth sidesofthewashers.
• Tightenthe9mmboltsfollowingthetighteningsequence asshown. Tightenthemfirsttothetorqueof12N·m(1.2 kgf·m, 104in·lb), andthentightenthemtothespecified torque.

Torque-9mmCylinderHeadBolts:26N·m(2.7kgf·m,19ft·lb)

- Tightenthe6mmbolts[5\~6].

Torque-6mmCylinderHeadBolts:12N·m(1.2kgf·m,104in·lb)

- Install:

CamshaftSprocket(seeCamshaftInstallation)

CamshaftChainTensioner(seeCamshaftChainTensionerInstallation)

ValveAdjustingCaps

• ApplygreasetotheO-ring, and install the camshaft chain cover.
• Tighten:

Torque-CamshaftChainCoverBolts

(BN125-A1\~A3):9.8N·m(1.0kgf·m,87in·lb)

(BN125-A4 \~): 8.8 N·m (0.90 kgf·m, 78 in·lb)

OilPipeBanjoBolts[A]

(M10):25N·m(2.5kgf·m,18ft·lb)

(M8):9.8N·m(1.0kgf·m,87in·lb)

OilPipeMountingBolts[B]

(BN125-A1\~A3):9.8N·m(1.0kgf·m,87in·lb)

(BN125-A4 \~): 8.8 N·m (0.90 kgf·m, 78 in·lb)

CylinderHeadMountingBolts:25N·m(2.5kgf·m, 18in·lb)

- Install:

Carburetor(seeFuelSystemchapter)

Exhaustpipe(seeMufflerRemoval)

FuelTank(seeFuelSystemchapter)

CylinderHead

CylinderHeadAssembly

• Installtherubberdampersasshown.

Dampers[A]

Fins[B]

Front[C]

CylinderHeadCleaning

• Removethecylinderhead(seeCylinderHeadRemoval).
• Removethevalves(seeValveRemoval).
• Washtheheadwithahigh-flashpointsolvent.
• Scrapethecarbonoutofthecombustionchamberand exhaustportwithasuitabletool.
• Cleanthecylinderheadinabathofhigh-flashpointsolvent.
• Usingcompressedair, blowout[A]anyparticles which may obstruct the oil passage in the cylinder head.
  • Installthevalves(seeValveInstallation).

CylinderHead

CylinderHeadWarp

- Cleanthecylinderhead(seeCylinderHeadCleaning).

- Layastraightedgeacrossthelowersurfaceofthecylinder headatthepositionsasshown.

- Useathicknessgauge[A]tomeasurethespacebetween thestraightedge[B]andthecylinderhead.

CylinderHeadWarp

Standard: ---

ServiceLimit:0.05mm(0.002in.)

★ Ifthecylinderheadiswarpedmorethantheservicelimit, replaceit.

★ Ifthecylinderheadiswarpedlessthantheservicelimit, repairtheheadbyrubbingthelowersurfaceonemery papersecuredtoasurfaceplate(firstNo.200, thenNo.400).

Valves

ValveClearanceInspection

- RefertotheValveClearanceInspectioninthePeriodic Maintenancechapter.

ValveClearanceAdjustment

- RefertotheValveClearanceAdjustmentinthePeriodic Maintenancechapter.

ValveRemoval

- Removethecylinderhead(seeCylinderHeadRemoval).

- Removetherockershaftsandrockerarms(seeCamshaft Removal).

○Markandrecordtherockershafts, rockerarms, and valveslocationssothattheycanbeinstalledintheiroriginalpositionstokeepthevalveclearanceunchanged.

- Using the valvespringcompressorassembly, remove the valves.

SpecialTools-ValveSpringCompressorAssembly:57001-241[A]

ValveSpringCompressorAdapter, 57001-1202[B] 22

ValveInstallation

- Replacetheoilseal[C]withanewone.

- Applyathincoatofmolybdenumdisulfidegreasetothe valvestem[A]beforevalveinstallation.

- Checkthefollowing: Valvemovesssmoothlyupanddownintheguide. Valveseatsproperlyinthevalveseat.

- Installthespring[D]sothattheclosedcoilendfacesthe springseatB.

- PutthespringretainerEonthesprings, and fitthesplit keepers[F] between theretainer and the stem while compressing the valvespring.

SpecialTools-ValveSpringCompressorAssembly:57001-241

ValveSpringCompressorAdapter, 22: 57001-1202

ValveGuideRemoval

- Remove:

Valve (see Valve Removal) OilSeal SpringSeat

- Heattheareaaroundthevalveguideto120\~150°C(248\~302°F),andhammerlightlyonthevalveguidearbor[A]toremovetheguidefromthetopofthehead.

SpecialTool-ValveGuideArbor, 4.5:57001-1331

Close-up of a mechanical component with labeled point A and directional arrow (no readable text or symbols)

CAUTION

Donotheatthecylinderheadwithatorch. This will warpthecylinderhead. Soakthecylinderhead and heattheoil.

Valves

ValveGuideInstallation

• Applyoiltothevalveguideoutersurfacebeforeinstallation.
• Heattheareaaroundthevalveguideholetoabout120\~150°C(248\~302°F).

CAUTION

Donotheatthecylinderheadwithatorch. This will warpthecylinderhead. Soakthecylinderhead and heattheoil.

- Drivethevalveguideinfromthetopoftheheadusing thevalveguidearboruntilthecirclipstopstheguidefrom goingintoofar.

SpecialTool-ValveGuideArbor,4.5:57001-1331

- Reamthevalveguidewithvalveguidereamer[A]evenif theoldguideisreused.

SpecialTool-ValveGuideReamer,4.5:57001-1333

Mechanical component diagram showing internal gears and a rotating arrow (no text or symbols)

Valve-to-GuideClearanceMeasurement(Wobble Method)

Ifasmallboregaugeisnotavailable,inspectthevalve guidewearbymeasuringthevalvetovalveguideclearance withthewobblemethodasindicatedbelow.

• Insertanewvalve[A]intotheguide[B]andsetadial gaugeagainstthestemperpendiculartoitascloseas possibletothecylinderheadmatingsurface.
• Movethestembackandforth[C]tomeasurevalve/valve guideclearance.
• Repeatthemeasurementinadirectionatarightangleto thefirst.
  ★ Ifthereadingexceedstheservicelimit, replacetheguide.

NOTE

○Thereadingisnotactualvalve/valveguideclearance becausethemeasuringpointisabovetheguide.

Valve/ValveGuideClearance(WobbleMethod)

Standard:

Exhaust 0.14 \~ 0.19 mm (0.006 \~ 0.007 in.)

Inlet 0.03 \~ 0.13 mm (0.001 \~ 0.005 in.)

ServiceLimit:

Exhaust 0.38mm(0.015in.)

Inlet 0.33mm(0.013in.)

Valves

ValveSeatInspection

• Removethevalve(seeValveRemoval).
• Checkthevalveseatingsurface[A]betweenthevalve[B] andvalveseat[C].
  ○Measuretheoutsidediameter[D]oftheseatingpattern onthevalveseat.
  ★ Iftheoutsidediameteristoolargeortoosmall,repairthe seat(seeValveSeatRepair).

ValveSeatingSurfaceOutsideDiameter

Standard:

Exhaust 25.5 \~ 25.7 mm (1.00 \~ 1.01 in.)

Inlet 29.5 \~ 29.7 mm (1.16 \~ 1.17 in.)

○MeasuretheseatwidthEoftheportionwherethereis nobuild-upcarbon(whiteportion)ofthevalveseatwitha verniercaliper.

Good[F]

TooWide[G]

TooNarrow[H]

Uneven[J]

★ Ifthewidthistoowide, toonarroworuneven, repair the seat(seeValveSeatRepair).

ValveSeatingSurfaceWidth

Standard:

Exhaust, Inlet: 0.8 \~ 1.2 mm (0.03 \~ 0.05 in.)

ValveSeatRepair

• Repairthevalveseatwiththevalveseatcutters[A].
  SpecialTools-ValveSeatCutterHolder,4.5:57001-1330
  [B]
  ValveSeatCutterHolderBar: 57001-1128
  [C]

[ForExhaustValveSeat]

ValveSeatCutter,45°- φ27.5:57001-1114or30φ

57001-1187

ValveSeatCutter,32°- φ30:57001-1120

ValveSeatCutter,60°- φ30:57001-1123

○Valve Seat Cutter, 45°-φ30: 57001-1187 can also be used instead of Valve Seat Cutter, 45°-φ27.5:57001-1114

[ForInletValveSeat]

ValveSeatCutter,45°- φ32:57001-1115

ValveSeatCutter,32°- φ35: 57001-1121or φ3:

57001-1199

ValveSeatCutter,60°- φ33:57001-1334

○Valve Seat Cutter, 32°-φ33: 57001-1199 can also be used instead of Valve Seat Cutter, 32°-φ35: 57001-1121

★ Ifthemanufacturer's instructions are not available, use the following procedure.

Valves

SeatCutterOperationCare

1. This valveseatcutterisdeveloped to grind the valve for repair. Therefore the cutterm must not be used for other purpose sthan seat repair.
2. Donotdroporshockthevalveseatcutter, orthedia-mondparticles may falloff.
3. Donotfailtoapplyengineoiltothevalveseatcutter beforegrindingtheseatsurface. Also washoffground particlesstickingtothecutterwithwashingoil.

NOTE

○Donotuseawirebrushtoremovethemetalparticles fromthecutter.Itwilltakeoffthediamondparticles.

1. Setting the valveseatcutterholderinposition, operate the cutterinonehand. Donotapplytoomuchforceto the diamond portion.

NOTE

○Priorogrinding, applyengineoiltothecutterandduringtheoperation, washoffanygroundparticlessticking tothecutterwithwashingoil.

1. Afteruse, washit with washing oil and apply thin layer of engine oil before storing.

MarksStampedontheCutter

Themarksstampedonthebackofthecutter[A]represent the following.

60°....Cutterangle[B]

37.5 ....Outerdiameterofcutter[C]

OperatingProcedures

• Cleantheseatareacarefully.
• Coattheseatwithmachinist'sdye.
• Fita45° cutter into the holder and slide it into the valve guide.
• Pressdownlightlyonthehandleandturnitrightorleft. Grindtheseatingsurfaceonlyuntilissmooth.

CAUTION

Donotgrindtheseattoomuch.Overgrindingwill reducevalveclearancebysinkingthevalveintothe head.Ifthevalvesinkstoofarintothehead,itwill beimpossibletoadjusttheclearance,andthecylinderheadmustbereplaced.

Valves

• Measuretheoutsidediameteroftheseatingsurfacewithaverniercaliper.
  ★ Iftheoutsidediameteroftheseatingsurfaceistoosmall, repeatthe45°grinduntilthediameteriswithinthespecifiedrange.
  WidenedWidth[A]ofengagementbymachiningwith 45°cutter
  GroundVolume[B]by32°cutter 32°[C]
  CorrectWidth[D]
  GroundVolumeEby60°cutter 60°F

• Measuretheoutsidediametortheseatingsurfacewithaverniercaliper.
  ★Iftheoutsidediameteroftheseatingsurfaceistoosmall, repeatthe45°grind[A]untilthediamteriswithinthespecifiedrange.
  OriginalSeatingSurface[B]

NOTE

○ Remove all pitting offlaws from 45° grounds surface.
○Aftergrindingwith45°cutter,applythincoatofmachinist'sdyetoseatingsurface. Thismakesseatingsurface distinctand32°and60°grindingoperationeasier.
○ Whenthevalveguideisreplaced, besuretogrind with 45° cutterforcentering and good contact.

★ Iftheoutsidediameter[A]oftheseatingsurfaceistoo large, makethe32°grinddescribedbelow.
★ Iftheoutsidediameteroftheseatingsurfaceiswithinthe specifiedrange,measuretheseatwidthasdescribedbelow.
- Grindtheseatata32°angle[B]untiltheseatoutside diameter.iswithinthespecifiedrange.

• Tomakethe32°grind, fita32°cutterintotheholder, and slideitintothevalveguide.
  ○Turntheholderoneturnatatimewhilepressingdown verylightly.Checktheseataftereachturn.

CAUTION

The32°cutterremovesmaterialveryquickly. Checktheseatoutsidediameterfrequentlytoppreventovergrinding.

○Aftermakingthe32°grind,returntotheseatoutsidediameter.measurementstepabove.
- Tomeasuretheseatwidth, useaverniercalipertomea- surethewidthofthe45°angleportionoftheseatatseveralplacesaroundtheseat.
★ If theseatwidthistoonarrow, repeat the 45° grind until theseatisslightly toowide, and then return to theseat outsidediameter.measurementstepabove.

Valves

★ If theseatwidthhistoowide, makethe60°grind[A]describedbelow.
★ If theseatwidth this within the specified range, lap the valve to theseatas described below.
- Grindtheseatata60°angleuntiltheseatwidththiswithin thespecifiedrange.
○ Tomakethe60°grind, fit60°cutterintotheholder, and slideitintothevalveguide.
○Turntheholder,whilepressingdownlightly.
○ Aftermakingthe60°grind, returntotheseatwidthmeasurementstepabove. CorrectWidth[B]

• Lapthevalvetotheseat, oncetheseatwidth and O.D. are within therangesspecified above.

• Putalittlecoarsegrindingcompoundonthefaceofthe valveinanumberofplacesaroundthevalvehead.
  ○ Spinthevalveagainsttheseatuntilthegrindingcompoundproducesasmooth, matchedsurfaceonboththe seatandthevalve.
  ○ Repeat the process with a fine grinding compound. Lapper[A] ValveSeat[B] Valve[C]

• Theseatingareashouldbemarkedaboutinthemiddle ofthevalveface.
  ★ Iftheseatareaisnotintherightplaceonthevalve,check tobesurethevalveisthecorrectpart.Ifitis,itmayhave beenrefusedtoomuch;replaceit.

• Besuretoremoveallgrindingcompoundbeforeassembly.
• Whentheengineisassembled, besuretoadjustthevalve clearance(seeValveClearanceAdjustment).

Valves

graph TD
    A["START"] --> B["Machinist's dye on seat"]
    B --> C["45° Grind\nTool: 45° Cutter\nPurpose: make seating area smooth and round"]
    C --> D["Measure Seat Outside Diameter\nTool: Vernier Caliper\nPurpose: check seat outside diameter against specification."]
    D --> E["Results"]
    E --> F["Too small"]
    E --> G["OK"]
    E --> H["Too big"]
    F --> I["45° Grind\nTool: 45° Cutter\nPurpose: increase outside diameter of seat area to specification."]
    G --> J["Measure Seating Width\nTool: Vernier Caliper\nPurpose: check seat width against specification."]
    H --> K["Machinist's dye on seat"]
    K --> L["32° Grind\nTool: 32° Cutter\nPurpose: reduce outside diameter of seat area to specification."]
    L --> M["Results"]
    M --> N["Too narrow"]
    M --> O["OK"]
    M --> P["Too wide"]
    N --> Q["45° Grind\nTool: 45° Cutter\nPurpose: increase width of seat area beyond specification to increase outside diameter"]
    O --> R["Lap Valve\nTool: Valve lapper, grinding compound\nPurpose: perfectly match valve and seat are; check valve head for damage"]
    P --> S["Machinist's dye on seat"]
    S --> T["60° Grind\nTool: 60° Cutter\nPurpose: reduce seat width to specification."]
    T --> U["FINISHED"]

Cylinder, Piston

CylinderRemoval

- Remove:

CylinderHead(see CylinderHeadRemoval)

• Taplightlyupthecylinder[A]withaplasticmallettoseparatefromthecrankcase.
• Removethecylinderbasegasket.

PistonRemoval

• Removethecylinder(seeCylinderRemoval).
• Placeacleanclothunderthepistonandremovethepistonpinsnapring[A]fromtheoutsideofthepiston.

CAUTION

Donotreusesnaprings,asremovalweakensand deformsthem.Theycouldfalloutandscorethe cylinderwall.

• Removethepistonpin.
  SpecialTools-PistonPinPullerAssembly:57001-910[A] Adapter[B]

• Removethepiston.

• Carefullyspreadtheringopeningwithyourthumbsand thenpushupontheoppositeside[A]oftheringtoremove it.

• Removethe3-pieceoilringwithyourthumbsinthesame manner.

Cylinder, Piston Installation

NOTE

○Ifanewpistonorcylinderisused, checkpistontocylinder clearance(seePiston/CylinderClearance), and use newpistonring.

• Applyengineoiltotheinnersurfaceoftheconnectingrod smallend.
• Thetriangularmarkonthepistonheadmustpointtoward thefrontoftheengine.
• Fitanewpistonpinsnapringintothesideofthepiston sothattheringopening[A]doesnotcoincidewiththeslit [B]ofthepistonpinhole.

Close-up of a car engine cylinder head with attached pipe and valve, no visible text or symbols

Close-up mechanical assembly showing a piston and crankshaft mechanism (no visible text or symbols)

Line drawing of a hand holding a mechanical component with a circular mark and directional arrows (no text or symbols)

4-34ENGINETOPEND

Cylinder, Piston

When installing the piston pinsnapring, compressit only enough to install it and nomore.

CAUTION

Donotreusesnaprings,asremovalweakensand deformsthem.Theycouldfalloutandscorethe cylinderwall.

NOTE

○ Theoilringrailshaveno "top" or "bottom".

• Installtheoilringexpander[A]inthebottompistonring groovesotheends[B]butttogether.

• Installtheoilringsteelrails,oneabovetheexpanderand onebelowit.
  ○Spreadtherailwithyourthumbs,butonlyenoughtofit therailoverthepiston.
  ○Releasetherailintothebottompistonringgroove.

• Donotmixupthetopringandsecondring.

• Installthesecondring[C]sothatthe"RN"mark[D]faces up.
• Installthetopring[A]sothatthe"R"mark[B]facesup.

- Install: DowelPins[A] NewCylinderBaseGasket[B]

- Thepistonringopeningsmustbepositionedasshownin thefigure.Theopeningsoftheoilringsteelrailsmustbe about30\~40°ofanglefromtheopeningofthetopring. TopRing[A] SecondRing[B] OilRingSteelRails[C] OilRingExpander[D] TriangularMarkE

Cylinder, Piston

• Applyengineoiltothecylinderbore.
• Positionthepistonringopenings.
• Installthecylinder[B]whilecompressing[A]thepiston ringswithyourthumbs.
  • Installtheremovedparts.

CylinderWear

- Sincethereisadifferenceincylinderwearindifferentdirections, takeaside-to-sideandafront-to-backmeasurementateachofthethreelocations(totalofsixmeasurements)showninthefigure.

10mm(0.39in.)[A]

40mm(1.57in.)[B]

20mm(0.79in.)[C]

★ Ifanyofthecylinderinsidediametermeasurementsexceedstheservicelimit,replacethecylinder.

CylinderInsideDiameter

Standard: 55.000 \~ 55.012 mm (2.1654 \~ 2.1658 in.), and less than 0.01 mm (0.0004 in.) difference between any two measurements.

ServiceLimit:55.10mm(2.169in.),or0.05mm (0.002in.)differencebetweenanytwo measurements.

PistonWear

• Measuretheoutsidediameter[A]ofeachpiston5mm (0.20in.)[B]upfromthebottomofthepistonataright angletothedirectionofthepistonpin.
  ★ Ifthemeasurementisunderservicelimit, replacethepiston.

PistonDiameter

Standard: 54.960 \~ 54.975 mm (2.1638 \~ 2.1644 in.) 54.968 \~ 54.982 mm (2.1641 \~ 2.1646 in.) (BN125-A7\~, N, N U) N:NoCatalyticConverterModel NU:NoCatalyticConverter(United KingdomModel)

ServiceLimit:54.81mm(2.158in.)

Piston/CylinderClearance

- Subtract the pistondiameter from the cylinder insidediametertoget the piston/cylinder clearance.

Piston/CylinderClearance

Standard: 0.025 \~ 0.052 mm (0.0010 \~ 0.0020 in.)

★Ifthepiston/cylinderclearanceislessthanthespecified range,useasmallerpistonorincreasethecylinderinside diameterbyhoning.
★ Ifthepiston/cylinderclearance is greater than specified range, usealarger piston.
★Ifonlyapistonisreplaced, theclearancemayexceedthe standardslightly. Butitmustnotbelessthantheminimum inordertoavoidpistonseizure.

PistonRing, PistonRing Groove Wear

• Checkforunevengroovewearbyinspectingtheringseating.
  ★Theringsshouldfitperfectlyparalleltogroovesurfaces. Ifnot, replacethepistonandallthepistonrings.
• With the piston rings in their grooves, makes several measurements with a thickness gauge [A] to determine piston ring/groove clearance.

PistonRing/GrooveClearance

Standard:

Top 0.03 \~ 0.07 mm (0.0012 \~ 0.0028 in.)

Second 0.02 \~ 0.06 mm (0.0008 \~ 0.0024 in.)

ServiceLimit:

Top 0.17mm(0.0067in.)

Second0.16mm(0.0063in.)

★Ifthepistonringgrooveclearanceisgreaterthantheservicelimit,measuretheringthicknessandgroovewidthas followstodecidewhethertoreplacetherings,thepiston orboth.

PistonRingGrooveWidth

• Measurethepistonringgroovewidth.
  ○Useaverniercaliperatseveralpointsaroundthepiston.

PistonRingGrooveWidth

Standard:

Top 0.82 \~ 0.84 mm (0.0323 \~ 0.0331 in.)

Second 0.81 \~ 0.83 mm (0.0319 \~ 0.0327 in.)

ServiceLimit:

Top 0.92mm(0.0362in.)

Second0.91mm(0.0358in.)

★ If the width of any of the two grooves is wider than the service limit at an midpoint, replace the piston.

Line drawing of hands assembling a mechanical component with a labeled part (A), no text or symbols present.

Cylinder, Piston

PistonRingThickness

• Measurethepistonringthickness.
  ○Useamicrometertomeasureatseveralpointsaround thering.

PistonRingThickness(Top, Second)

Standard: 0.77 \~ 0.79 mm (0.0303 \~ 0.0311 in.)

ServiceLimit:0.70mm(0.028in.)

★ Ifanyofthemeasurementsislessthantheservicelimit oneitheroftherings,replacealltherings.

NOTE

○Whenusingnewringsinausedpiston, checkforun-evengroovewear. Theringsshouldfitperfectlyparallel tothegroovesides. Ifnot, replacethepiston.

PistonRingEndGap

• Placethepistonring[A]insidethecylinder,usingthepistontolocatetheringsquarelyinplace.Setitclosetothe bottomofthecylinder,wherecylinderwearislow.
• Measurethegap[B]betweentheendsoftheringwitha thicknessgauge.

PistonRingEndGap

Standard:

Top 0.15 \~ 0.30 mm (0.006 \~ 0.012 in.)

Second 0.30 \~ 0.45 mm (0.012 \~ 0.018 in.)

Oil 0.20 \~ 0.70 mm (0.008 \~ 0.028 in.)

ServiceLimit:

Top 0.6mm(0.024in.)

Second0.7mm(0.028in.)

Oil1.0mm(0.04in.)

★ Iftheendgapofeitherringisgreaterthantheservice limit,replacealltherings.

4-38ENGINETOPEND

CarburetorHolder

CarburetorHolderInstallation

- ApplygreasetotheO-ring[A], and install the carburetor holder.

○TakecarenottopinchtheO-ring.

- Tighten:

Torque-CarburetorHolderBolts:9.8N·m(1.0kgf·m,87in·lb)

- Installtheinsulator[B]sothatitsrecessalignswiththe boss[A]onthecarburetorholder.

Close-up of a mechanical component with labeled parts (A) and no visible text or symbols beyond the label.

Close-up of a mechanical assembly with labeled parts A and B, showing internal components and wiring (no readable text or symbols beyond labels)

Muffler

WARNING

Toavoidaserlousburn, donotremovethemuffler whentheengineisstillhot. Waituntilthemuffler coolsdown.

MufflerRemoval

• loosenthemufflerbodyclampbolt[A].

• Removethemufflerbodymountingboltandnut[B].

• Removethemufflerbody[A]backward.

• Removetheexhaustpipemountingbolt[B].

- Remove:

ExhaustPipeHolderNuts[A] ExhaustPipe[B]

NOTE

○Whenremovingthemufflerbodyandexhaustpipeassembly, donotloosenthemufflerbodyclampbolt.

MufflerInstallation

• Checktheexhaustpipeholdergasketforsingsofdamage.
  ★ Ifnecessary, replacethegasketwithanewone.
• Checkthegasket[A]oftheclampforsingsofdamage andthatitfitsinplacesecurely.
  ★ Ifnecessary, replacethegasketwithanewone.
• Tighten:

Torque-MufflerBodyMountingNut:15N·m(1.5kgf·m,11ft·lb)

• Firsttightenalltheboltsandnutstoasnugfit.
• Nexttightentheexhaustpipeholdernutsevenlytoavoid exhaustleaks.
• Lastly, tightentherestoftheboltsandclampboltsecurely.
• Thoroughlywarmuptheengine, waituntiltheengine coolsdown, and thenretightentheexhaustpipeholder nuts, and the clampbolt securely.

Close-up of a motorcycle's side panel showing engine components and a labeled section (A) with no readable text or symbols.

Close-up of a mechanical component with a labeled section A, showing internal structure and mounting points (no readable text or symbols)

Clutch

TableofContents

Exploded View 5-2

Specifications 5-4

Special Tools 5-5

Clutch Lever and Cable 5-6

Clutch Lever Free Play Inspection 5-6

ClutchLeverFreePlayAdjustment....5-6

Clutch Lever Installation.... 5-6

Clutch Cable Removal 5-6

Clutch Cable Installation 5-6

Clutch Cable Lubrication 5-6

Clutch Cover 5-7

Clutch Cover Removal 5-7

Clutch Cover Installation 5-7

Clutch Cover Assembly 5-8

Clutch 5-9

Clutch Removal 5-9

Clutch Installation 5-9

FrictionandSteelPlateDamage,Wear....5-10

Friction and Steel Plate Warp 5-10

ClutchSpringFreeLengthMeasurement....5-11

Clutch Housing Finger Damage.... 5-11

Clutch Hub Spline Damage.... 5-11

Primary Gear 5-12

Primary Gear Removal 5-12

Primary Gear Installation 5-12

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf·mft·lb
1ClutchHubNut9810.072
2ClutchSpringBolt8.80.9078in·lb
	ClutchCoverBolts(BN125-A1~A3)	9.81.087in·lb
	Clutch Cover Bolts (BN125-A4 ~)	8.8	0.90	78 in·lb
	Oil Seal Retaining Plate Bolts (BN125-A1 ~ A3)	9.81.087in·lb
	Oil Seal Retaining Plate Bolts (BN125-A4 ~)	8.8	0.90	78 in·lb
5	Clutch Cover Damper Bolt	8.8	0.90	78 in·lb	L
6	Starter Lockout Switch Screws	1.0	0.10	9 in·lb
7	PrimaryGearNut	69	7.0	11
8	Oil Pressure Relief Valve	15	1.5	11	L

1. Starter lockoutswitch

CL: Apply cablelubricant.

EO: Apply engineoil.

G: Apply grease.

L: Applyanon-parmanent lockingagent.

M: Applymolybdenumdisulfide grease.

Specifications

ItemStandardServiceLimit
Clutch Lever Free Play	2 ~ 3 mm (0.08 ~ 0.12 in.)	-- --
Clutch
Friction Plate Thickness	2.92 ~ 3.08 mm (0.115 ~ 0.121 in.)	2.8 mm (0.11 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.)

SpecialTools

GearHolder,m1.75: 57001-1015

Technical line drawing of a mechanical gear assembly with no visible text or symbols

ClutchHolder: 57001-1243

Technical line drawing of a mechanical clamp or lever assembly (no text or symbols)

ClutchLeverandCable

Duetofrictionplatewearandclutchcablestretchchover alongperiodofuse, theclutchmustbeadjustedinaccordancewiththePeriodicMaintenanceChart.

ClutchLeverFreePlayInspection

- RefertotheClutchLeverFreePlayInspectioninthePeriodicMaintenancechapter.

ClutchLeverFreePlayAdjustment

- RefertotheClutchLeverFreePlayAdjustmentinthe PeriodicMaintenancechapter.

ClutchLeverInstallation

- Installtheclutchleversothatthematingsurfaceofthe leverholderisalignedwiththepunchmark[A]onthe handlebar.

ClutchCableRemoval

- Loosenthelocknut[A]attheclutchlever,andscrewin theadjuster[B].

- Lineuptheslots[C]intheclutchlever,locknut,andadjusterandthenfreethecablefromthelever.

- Freetheclutchinnercabletipfromtheclutchrelease lever.

- Pushthereleaselevertowardthefrontofthemotorcycle andtapethereleaselevertotheclochcovertoprevent thereleaseshaftfromfallingout.

- Pulltheclutchcableoutoftheframe.

ClutchCableInstallation

- Runtheclutchcablecorrectly(seeAppendixchapter).

- Adjusttheclutchleverfreeplay(seePeriodicMaintenancechapter).

ClutchCableLubrication

- RefertotheGeneralLubricationinthePeriodicMaintenancechapter.

Mechanical assembly diagram showing a shaft and housing component with labeled point A (no text or symbols beyond label)

ClutchCover

ClutchCoverRemoval

• Draintheengineoil(seePeriodicMaintenancechapter).
• Remove:

FrontFootpeg OilPipeBanjoBolt[A]

• Screwtheclutchleveradjusterincompletelysoastogivetheclutchcableplentyofplay.
• Removetheclutchcableholder[B]ofclutchreleaselever.
• Freetheclutchinnercabletipfromtheclutchrelease lever[C].
• Removetheclutchcoverbolts, and removetheclutch cover[A].
  ○Turnthereleaselevertowardthereartofreetherlease shaft[B]fromtheclutchspringplatepusherandremove theclutchcover.

CAUTION

Donotremovetheclutchreleaseleverandshaft assemblyunlessitisabsolutelynecessary.Ifremoved,theoilsealreplacementmayberequired. Applyhightemperaturegreasetotheoilseallips.

ClutchCoverInstallation

• Installthedowelpins[A]andreplacethecovergasket withanewone.

• InstalltheO-ring[B].

• Installtheclutchcoverwiththeclutchreleaselevertoward therear.

• Enginetheclutchreleaseshaftwiththeclutchspringplate pusherbyturningtheclutchreleaselever[A]towardthe front.

Mechanical assembly diagram showing gears and housing components (no text or labels visible)

Close-up of a car engine bay with labeled components (A) and a hand holding a tool, no readable text or symbols present.

ClutchCover

• Withtheshaftpulledalittleoutofthecover,turnthelever untilbecomeshardtoturn.
  ○Thereleaselevershouldhaveabout11mm(0.43in.)[A] clearancebetweentheleverandthewasher.

- Tightenthecoverboltsandclutchcableholderbolts. ○Whilepushing[B]theclutchcableholder[A]rearward untiltheholdertouchestheclutchcover,tightentheclutch cableholderbolt.

Torque-ClutchCoverBolts

(BN125-A1\~A3):9.8N·m(1.0kgf·m,87in·lb)

(BN125-A4 \~): 8.8 N·m (0.90 kgf·m, 78 in·lb)

- Replacethebanjoboltwasherswithnewones.

- Tightentheoilpipebanjobolt.

Torque-OilPipeBanjoBolt:25N·m(2.5kgf·m,18in·lb)

- Pourinthespecifiedtypeandamountofoil(seePeriodic Maintenancechapter).

• Installthefrontfootpeg.

- Adjustandinspectthefollowing.

ClutchLeverFreePlay RearBrake

RearBrakeLightSwitch

WARNING

Ifafullbrakepedalisnotobtained,disassemble andinspecttherearbrakeparts.

Wornpartscauselockofthebrakeorlossofbraking.

ClutchCoverAssembly

- Installtheoilsealretainerwiththe"UP"markfacing[A] upward.

★Iftheoilsealisdamaged,replaceitwithanewone.

- Tighten:

Torque-OilSealRetainingPlateBolts

(BN125-A1\~A3):9.8N·m(1.0kgf·m,87in·lb)

(BN125-A4 \~): 8.8 N·m (0.90 kgf·m, 78 in·lb)

Close-up of an automotive engine bay with hoses and a labeled component (A), no readable text or symbols present.

Close-up mechanical component with labeled parts (A and 5), no readable text or symbols beyond labels

Clutch

ClutchRemoval

- Removetheclutchcover(seeClutchCoverRemoval).

NOTE

○Iftheprimarygearistoberemoved,removetheprimarygearnutbeforeclutchremoval(seePrimaryGearRemoval).

- Remove:

ClutchSpringBolts[A]withSprings ClutchSpringPlate[B] BallBearingandPusher[C] FrictionPlatesandSteelPlates

• Usingtheclutchholder[A], holdthehubtoremovethe clutchhubnut[B].
  SpecialTool-ClutchHolder:57001-1243
• Removethespringwasher.

- Remove:

ClutchHub[A] Spacer[B] ClutchHousing[C]

Mechanical assembly diagram showing gear and housing components (no readable text or symbols)

ClutchInstallation

• Applymolybdenumdisulfidegreasetotheclutchhousing bearinghole[A].
• Install: ClutchHousing[B] Spacer ClutchHub

Mechanical gear assembly with labeled components (A and B), no visible text or symbols beyond labels

Clutch

• Installthewasher[A]asshown. CrankcaseSide[B]
- Tightentheclutchhubnut[C], while holding the clutch hub with the clutch holder.

SpecialTool-ClutchHolder:57001-1243

Torque-ClutchHubNut:98N·m(10.0kgf·m,72ft·lb)

• Installthespringseat[B], and thenthespring[C] with the concaveside facing to the clutch cover.
• Wheninstallingthefrictionplatesandsteelplates,firstinstallthefrictionplate[A]whoseinsidediameterislarger thantheothersandtheninstallasteelplate[D]andalternatingthem.

CAUTION

If new dry friction plates and steel plates are installed, apply engine oil to the surfaces of each plateto avoid clutch plates seizure.

• Applymolybdenumdisulfidegreasetothepusherends [A]andinstallthethrustbearing.
• Tightentheclutchspringbolts.

Torque-ClutchSpringBolts:8.8N·m(0.90kgf·m,78in·lb)

FrictionandSteelPlateDamage, Wear

• Visually inspect the friction and steel plates for sign of seizure, overheating (discoloration), or uneven wear.
• Measurethethicknessofthefrictionplates[A]atseveral points.
  ★Ifanyplatesshowsignsofdamage,oriftheyhaveworn pasttheservicelimit,replacethemwithnewones.

FrictionPlateThickness

Standard: 2.92 \~ 3.08 mm (0.115 \~ 0.121 in.)

ServiceLimit:2.8mm(0.11in.)

FrictionandSteelPlateWarp

• Placefrictionplateorsteelplate[B]onasurfaceplate, andmeasurethegapbetweenhesurfaceplate[A]with athicknessgauge[C].Thegapistheamountoffriction orsteelplatewarp.
  ★ Ifanyplateiswarpedovertheservicelimit,replaceitwith anewone.

FrictionandSteelPlateWarp

Standard:0.2mm(0.008in.)orless

ServiceLimit: 0.3mm(0.012in.)

Close-up mechanical assembly showing gear and shaft components (no visible text or symbols)

Clutch

ClutchSpringFreeLengthMeasurement

• Measurethefreelengthoftheclutchsprings[A].
  ★ Ifanyspringisshorterthantheservicelimit, it must be replaced.

ClutchSpringFreeLength

Standard:35.0mm(1.38in.)

ServiceLimit:34.0mm(1.34in.)

ClutchHousingFingerDamage

• Visuallyinspecttheclutchhousingfingers[A]wherethe frictionplatetangshitthem.
  ★ Iftheyarebadlywornoriftherearegroovecutswhrethe tangshit,replacethehosing.Also,replacethefriction platesiftheirtangsaredamaged.

Close-up of a mechanical component with visible teeth and central bore, no text or symbols present

ClutchHubSplineDamage

• Visuallyinspectwheretheteethonthesteelplateswear againsttheclutchhubsplines.
  ★ Iftherearenotcheswornintotheclutchhubsplines[A], replacetheclutchhub. Also, replacethesteelpatesif theirteetharedamaged.

Mechanical component with labeled section A, showing internal gears and housing (no readable text or symbols)

PrimaryGear

PrimaryGearRemoval

• Removetheclutchcover(seeClutchCoverRemoval).
• Using the gearholder[A], hold the primary gear and loosent the primary gear nut[B].

SpecialTool-GearHolder,m1.75:57001-1015

- Remove:

Clutch(seeClutchRemoval)[C]

PrimaryGearNut[B]

SpringWasher

PrimaryGear[D]

WoodruffKey

PrimaryGearInstallation

- Fitthewoodruffkey[B]securelyintheslotbeforeinstallingtheprimarygear[A].

• Installthespringwasher[A]withtheconcavesidefacing tothecrankcase.

• Installtheclutch.
  • Temporarilytightentheprimarygearnut[B].

• Using the gearholder[A], hold the primary gearasshown.

• Tightentheprimarygearnut[B].

Torque-PrimaryGearNut:69N·m(7.0kgf·m,51ft·lb)

SpecialTool-GearHolder,m1.75:57001-1015

- Installtheclutchcover(seeClutchCoverInstallation).

Mechanical gear assembly diagram showing two labeled components (A and B) with no visible text or symbols

Mechanical gear assembly diagram showing interlocking gears and a labeled component (A, B), no readable text or symbols present.

EngineLubricationSystem

TableofContents

Exploded View 6-2

Engine Oil Flow Chart 6-4

Specifications 6-5

Special Tools 6-6

Engine Oil and Oil Filter 6-7

Oil Level Inspection.... 6-7

Engine Oil Change 6-7

Oil Filter Change 6-7

Oil Screen 6-8

Oil Screen Removal 6-8

Oil Screen Installation 6-8

Oil Pump 6-9

Oil Pump Removal 6-9

Oil Pump Installation 6-9

Oil Pump Disassembly 6-9

Oil Pump Assembly 6-10

Oil Pump Inspection 6-10

Oil Pressure 6-11

Oil Pressure Measurement 6-11

Relief Valve 6-12

Relief Valve Inspection.... 6-12

Oil Pipe 6-13

Oil Pipe Removal 6-13

Oil Pipe Installation 6-13

ExplodedView

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf	·mft·lb
1EngineOilDrainPlug181.813
2	Oil Screen Cover Bolts (BN125-A1 ~ A3)	9.8	1.0	87 in·lb
	Oil Screen Cover Bolts (BN125-A4 ~)	8.8	0.90	78in·lb
3	Oil Pressure Relief Valve	15	1.5	11	L
4	Oil Filter Cover Bolts (BN125-A1 ~ A3)	9.8	1.0	87 in·lb
	Oil Filter Cover Bolts (BN125-A4 ~)	8.8	0.90	78 in·lb
5	Oil Pump Mounting Screws	4.9	0.50	43 in·lb
6	Oil Pump Assembly Screw	9.8	1.0	87 in·lb
7	OilPipeBanjoBolt(ClutchCover)	252.619			S
8	Oil Pipe Banjo Bolt (Left Crankcase)	9.8	1.0	87 in·lb	S
9	Oil Pipe Banjo Bolt (Cylinder Head)	9.8	1.0	87 in·lb	S
10	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
11	Oil Filler Plug	2.5	0.25	22 in·lb

EO:Applyengineoil.
G:Applygrease.
L: Applyanon-permanentlockingagent.
R: Replacementparts
S: Followthespecifictighteningsequence.

EngineOilFlowChart

0604010BW4 C

1.Oilscreen
2.Oilpump
3. ClutchCoverOilPassage
4.OilPressureReliefValve
5.OilFilter
6.CrankshaftOilseal
7.OilPipeBanjoBolts
8.Camshaft

9.DriveShaft
10. OutputShaft
11.CamshaftChainTunnel
12. EngineBreatherHose
13.AirCleanerHousing

A.OilFlow

B.BlowbyGas

Specifications

ItemStandard
EngineOilGrade:(BN125-A1~A3)APISE,SForSG(BN125-A4~)APISE,SForSGViscositySAE10W-40Capacity1.1L(1.16USqt)(whenfilterisnotremoved)LevelBetweenupperandlowerlevellines	APISH,SJorSLwithJASOMA1.2L(1.27USqt)(whenfilterisremoved)1.4L(1.48USqt)(whenengineiscompletelydry)
OilPressureMeasurementOilPressure@4000r/min(rpm),OilTemperature90°C(194°F)	13 ~ 32 kPa (0.13 ~ 0.33 kgf/cm2, 1.8 ~ 4.7 psi)

SpecialTools

OilPressureGauge,5kgf/cm²: 57001-125

Technical line drawing of a pressure gauge with attached pipe fitting (no text or symbols)

OilPressureGaugeAdapter,M10×1.25:57001-1182

Technical line drawing of a hexagonal bolt with threaded shaft (no text or symbols)

EngineOilandOilFilter

WARNING

Motorcycleoperationwithinsufficient,deteriorated,orcontaminatedengineoilwillcause acceleratedwearandmayresultinengineortransmissionseizure,accident,andinjury.

OilLevelInspection

• Situatethemotorcyclesothatitisvertical.
• Check that the engine oil level is between the upper [A] and lower [B] levels in the gauge.

NOTE

○Situate themotorcycles that atitisperpendicularto the ground.
○Ifthemotorcyclehasjustbeenused, waitseveralminutesforalltheoiltodraindown.
○Iftheoilhasjustbeenchanged,starttheengineand runitforseveralminutesatidlespeed. Thisfillstheoil filterwithoil. Stoptheengine,thenwaitseveralminutes untiltheoilsettles.

GG050108S1 C

CAUTION

Racingtheenginebeforetheoilreacheseverypart cancauseengineseizure.

★ Iftheoillevelistoohigh,removetheexcessoilthrough thefilleropening,usingasyringeorsomeothersuitable device.
★ If the oil level to oil, add the correct amount of oil through the oil filler opening. Use the same type and make of oil that is already in the engine.

NOTE

○Iftheengineoiltypeandmakeareunknown,useany brandofthespecifiedoiltotopoffthelevelratherthan runningtheenginewiththeoillevellow. Thenatyour earliestconvenience,changetheoilcompletely.

EngineOilChange

- RefertotheEngineOilChangeinthePeriodicMaintenancechapter.

OilFilterChange

- RefertotheOilFilterChangeinthePeriodicMaintenance chapter.

6-8 ENGINE LUBRICATION SYSTEM

OilScreen

OilScreenRemoval

- RefertotheOilScreenCleaninginthePeriodicMaintenancechapter.

OilScreenInstallation

- RefertotheOilScreenCleaninginthePeriodicMaintenancechapter.

OilPump

OilPumpRemoval

• Removetheclutchcover(seeClutchchapter).
• Removethemountingscrews[A]andremovetheoil pumpassembly[B].
  ○Turnthepumpgearsothatthepumpmountingscrews canberemovedthroughthepumpgearholes.

Mechanical gear assembly diagram showing two labeled components A and B, with no visible text or symbols beyond labels.

OilPumpInstallation

• ReplacetheO-ringswithnewones.
• InstalltheO-rings[A].
• Installthedowelpin[B].

• Installtheoilpumpassembly.
- Tighten:
Torque-OilPumpMountingScrews[A]:4.9N·m(0.50 kgf·m,43in·lb)
- Installtheclutchcover(seeClutchchapter).

Close-up mechanical gear assembly with labeled component A (no readable text or symbols)

OilPumpDisassembly

• Remove:
  OilPump(seethischapter)
  CirclipandWasher[A]
  OilPumpAssemblyScrew[B]

- Removetheoilpumpcover[C].

- Remove:

InnerRotor[A]

OuterRotor[B]

OilPump

OilPumpAssembly

• Installtheoilpumpgear[A].
- Filltherotors[B]withengineoil.
- Installthecoverandtightentheoilpumpassemblyscrew.
Torque-OilPumpAssemblyScrew:9.8N·m(1.0kgf·m,87in·lb)
• Installthewasherandcirclip.
- ReplacetheO-ringswithnewones.
- Check that the pump gear turns freely after assembly.

OilPumpInspection

• Disassembletheoilpump(seeOilPumpDisassembly).
• Visually inspect the oil pump body, outer and inner rotors, and cover.
  ★ If there is any damage or uneven wear, replacether rotors, cover, body, or the oil pump assembly.

OilPressure

OilPressureMeasurement

• RemovetheairsuctionvalveA.
• Replacetheoilpipebanjoboltoftheclutchcover[B]with theoilpressuregaugeadapter(specialtool)[C].
  ★ If the oil pressure gauge adapter bottoms out, add washer(s)(P/N:11009-1105)[D] under the adapter.
• AttachtheoilPressuregaugeE.

SpecialTools-OilPressureGauge,5kgf/cm²:57001-125 OilPressureGaugeAdapter,M10×1.25: 57001-1376

• Installtheairsuctionvalve(seeEngineTopEndchapter).
• Starttheengineandwarmuptheenginethoroughly.
• Runtheengineatthespecifiedspeed,andreadtheoil pressuregauge.
  ★ If the oil pressure is much lower than the standard, check the oil pump, crank shaft oil seal of the clutch cover and oil pump relief valve.
  ★ Ifthereadingismuchhigherthanthestandard,checkthe oilpumpscreenandtheoilfilterfirst,andoilpassagesfor dirtorclogging.

OilPressure

Standard: 13 \~ 32 kPa (0.13 \~ 0.33 kgf/cm², 1.8 \~ 4.7 psi)@4000r/min(rpm),oiltemperature 90°C(194°F)

- Stoptheengine, and removetheoil pressure gauge and adapter.

WARNING

Takecareagainstburnsfromhotengineoilthatwill drainthroughtheoilpassagewhentheoilpressure gaugeadapterisremoved.

• Installthenewcopperwashers.
- Tighten:
Torque-OilPipeBanjoBolt:25N·m(2.5kgf·m,18ft·lb)

ReliefValve

ReliefValveInspection

• Removethereliefvalvefromtheclutchcover.
• Checktoseeifthevalve[A]slidessmoothlywhenpushinginwithawoodenorthersoftrod,andseeifitcomes backtoitsseatbyspring[B]pressure.

NOTE

○ Inspectthevalveinitassembledstate.Disassembly andassemblymaychangethevalveperformance.

★Ifanyroughsportsarefoundduringaboveinspection, washthevalvecleanwithahigh-flashpointsolventand blowoutanyforeignparticlesthatmaybeinthevalvewith compressedair.

WARNING

Cleanthereliefvalveinawell-ventilatedarea,and takecarethatthereisnosparkorflameanywhere neartheworkingarea.Becauseofthedangerof highlyflammableliquids,donotusegasolineorlow -flashpointsolvent.

★Ifcleaningdoesnotsolvetheproblem,replacetherelief valveasanassembly. Thereliefvalveisprecisionmade withnoallowanceforreplacementofindividualparts.

OilPipe

OilPipeRemoval

- Remove:

OilPipeBanjoBolts(CylinderHead)[A] OilPipeBanjoBolt(ClutchCover)[B] OilPipeMountingBolt[C]

- Remove:

EngineSprocketCover(seeFinalDrivechapter) OilPipeBanjoBolt(LeftCrankcase)[A]

- Removetheoilpipefromtherightsideoftheengine.

Close-up of a car engine bay with labeled components (A, B, C), no visible text or symbols beyond labels.

Close-up of a mechanical gear assembly with labeled components (no readable text or symbols)

OilPipeInstallation

• Replacethewashersonbothsidesoftheoilpipebanjo boltwithnewones.
• Tightenthefollowingbanjoboltsintheorderlistedtopreventpipewarp.

Torque-OilPipeBanjoBolts

(ClutchCover):25N·m(2.5kgf·m,18ft·lb) (LeftCrankcase):9.8N·m(1.0kgf·m,87in·lb) (CylinderHead):9.8N·m(1.0kgf·m,87in·lb)

- Tighten:

Torque-OilPipeMountingBolt

(BN125-A1\~A3):9.8N·m(1.0kgf·m,87in·lb) (BN125-A4\~):8.8N·m(0.90kgf·m,78in·lb)

EngineRemoval/Installation

TableofContents

Exploded View 7-2

Special Tool 7-4

Engine Removal/Installation 7-5

Engine Removal 7-5

Engine Installation.... 7-6

7-2ENGINEREMOVAL/INSTALLATION

ExplodedView

ExplodedView

No.Fastener		Torque			Remarks
		N·m	kgf·mft·lb
1	EngineMountingBolts,Nuts(M10)	444.53	3
2	EngineMountingBolts,Nuts(M8)252.518
3	Engine Mounting Bracket Bolts, Nuts	25	2.5	18
4	EngineGroundTerminalBolt	9.81.08	7in·lb

7-4ENGINEREMOVAL/INSTALLATION

SpecialTool

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

EngineRemoval/Installation

EngineRemoval

- Placethejack[A]undertheframetolifttherearwheel[B]offtheground.

SpecialTool-Jack:57001-1238

- Squeezethebrakeleverslowlyandholditwithaband [A].

WARNING

Besuretoholdthefrontbrakewhenremovingthe engine,orthemotorcyclemayfallover.Itcould causeanaccidentandinjury.

• Draintheengineoil(seePeriodicMaintenancechapter).
• Remove:

SideCoversandSeat(seeFramechapter)

FuelTank(seeFuelSystemchapter)

- Disconnectthecablesandwiringleadsfromtheengine.

AlternatorLeadConnector[A]

EngineGroundLead[B]

ElectricStarterMotorCableTerminal[C]

SparkPlugCap

BreatherTube

Technical line drawing of a mechanical assembly with labeled component A (no text or symbols beyond label)

Close-up of a car engine bay with visible components and a marked section (A), no readable text or symbols present.

Mechanical assembly diagrams showing two views of a vehicle's engine components (no text or symbols visible)

- Remove:

Muffler(seeEngineTopEndchapter)

CylinderHeadBracket[A]

CarburetorB

ShiftPedal(seeCrankshaft/Transmissionchapter)

ChainCoverandEngineSprocket(seeFinalDrivechapter)

ClutchCableLowerEnd(seeClutchchapter)

Close-up of a mechanical assembly with labeled parts A and B, showing internal components and wiring (no readable text or symbols)

7-6ENGINEREMOVAL/INSTALLATION

EngineRemoval/Installation

- Remove:

EngineMountingBolts[A]

EngineMountingBracketBolts[B]

○Pulloutthemountingboltswhileliftingtheengine.

• Liftuptheengineandmoveittotherightsideoftheframe.
• Removetheengine[A]fromthevehiclerightside.

Engine Installation

• Insertthemountingboltsfromtheleftsideoftheengine andinstallthenutsontherightside.
• Tightentheenginemountingboltswiththespecified torque.

Torque-EngineMountingBolts, Nuts(M10)[A]:44N·m (4.5kgf·m, 33ft·lb)

EngineMountingBolts, Nuts(M8)[B]:25N·m(2.5 kgf·m, 18ft·lb)

EngineMountingBracketBolts:25N·m(2.5 kgf·m,18ft·lb)

CylinderHeadBracketBolts, Nuts: 25N·m (2.5 kgf·m, 18ft·lb)

- Installthedrivechain[A]andenginesprocket[B].

Close-up of a mechanical assembly with labeled component A (no readable text or symbols)

EngineRemoval/Installation

★ Iftheenginesprocketishardtoinstall,removethemaster linkandtheclipfromthedrivechain,andtheninstallthe enginesprocket.
○Installtheclip[A]sothattheopenend[B]ofthe"U"points intheoppositedirectionofchainrotation[C].

• Installtheenginegroundcable[A]asshown.Runthe cablenearthemountingboss[B].
• Tighten:

Torque-EngineGroundTerminalBolt:9.8N·m(1.0kgf·m, 87in·lb)

• Runthecables, hoses, and leads according to the Cable, Wire, and HoseRoutingsection of the Appendix chapter.
• Installtheremovedparts(seeappropriatechapters).
• Adjust:

ThrottleCable(seeFuelSystemchapter)

ClutchCable(seeClutchchapter)

DriveChain(seeFinalDrivechapter)

• Filltheenginewithengineoil(seeEngineLubrication Systemchapter).
• Adjusttheidlespeed(seeFuelSystemchapter).
• Checktheclutchoperation.
• Checkthebrakeeffectiveness.

WARNING

Donotattempttodrivethemotorcycleuntilafull brakeleverisobtainedbypumpingthebrakelever untilthepadsareagainstthedisc.Thebrakewill notfunctiononthefirstapplicationoftheleverif thisisnotdone.

WARNING

If a full brake pedal is not obtained, disassemble and inspect the brake parts. Worn part scan cause lock of the brake or loss of braking.

Crankshaft/Transmission

TableofContents

ExplodedView....8-2

Specifications....8-6

SpecialToolsandSealant......8-7

Crankcase....8-8

CrankcaseDisassembly......8-8

CrankcaseAssembly......8-9

Crankshaft....8-13

CrankBalancerGear Removal/Installation....8-13

CrankshaftRemoval......8-13

CrankshaftInstallation......8-13

CrankshaftDisassembly......8-13

ConnectingRodBigEnd Seizures....8-13

ConnectingRodBigEndRadial Clearance....8-13

ConnectingRodBigEndSide Clearance....8-13

CrankshaftRunout......8-13

BalancerShaftGear....8-15

BalancerShaftGearRemoval.....8-15

BalancerShaftGearInstallation..8-15

StarterMotorClutch....8-16

StarterMotorClutch Removal/Installation....8-16

StarterMotorClutchDisassembly8-16

StarterMotorClutchAssembly....8-16

StarterMotorClutchInspection...8-16

TorqueLimiterInspection......8-16

ExternalShiftMechanism......8-17

ShiftPedalHeightAdjustment.....8-17

ShiftPedalRemoval....8-17

ExternalShiftMechanism Removal....8-17

ExternalShiftMechanism Inspection......8-18

Transmission....8-19

TransmissionShaftRemoval......8-19

TransmissionShaftInstallation....8-19

TransmissionDisassembly...... 8-19

TransmissionAssembly......8-20

ShiftDrumRemoval/Installation... 8-21

ShiftForkBending.... 8-21

ShiftFork/GearGrooveWear..... 8-21

ShiftForkGuidePin/Drum GrooveWear.... 8-21

GearDogandGearDogHole Damage.... 8-21

BallBearing,andOilSeal.... 8-22

BallBearingReplacement...... 8-22

BallBearingWear.... 8-22

OilSealInspection 8-22

8-2CRANKSHAFT/TRANSMISSION

ExplodedView

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf	mft·lb
1PrimaryGearNut697.051
2BalancerShaftGearNut788.058EO
3	CrankcaseBolts	8.80.90	78in·lb
4	Crankcase Bearing Retainer Screws	4.9	0.50	43 in·lb

1. BalancerShaft
2. Balancershaft gear
3. Crankbalancer gear
4. Crankshaft

EO: Applyengine oil.

G: Apply grease.

LG: Applyliquid gasket.

WL: Applysoapandwater solution.

ExplodedView

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf	mft·lb
1NeutralSwitch151.511
2ShiftDrumCamScrew4.90.5043in·lbL
3	GearSetLeverNut	111.1	95in·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 Nut	30	3.1	22

EO: Applyengineoil.
G: Applygrease.
L: Applyanon-permanentlockingagent.
M: Applymolybdenumdisulfidegrease.
R: ReplacementParts

Specifications

ItemStandardServiceLimit
Crankshaft,ConnectingRodConnectingRodBigEndSide ClearanceConnectingRodBigEndRadial ClearanceCrankshaftRunoutTIR0.03mm(0.0012in.)orlessTIR0.07mm		0.5 mm (0.020 in.)0.07 mm (0.003 in.)(0.003in.)
TransmissionShift Fork Ear ThicknessGear Shift Fork Groove WidthShift Fork Guide Pin DiameterShift Drum Groove Width	4.9 ~ 5.0 mm (0.193 ~ 0.197 in.)5.05 ~ 5.15 mm (0.199 ~ 0.203 in.)5.9 ~ 6.0 mm (0.232 ~ 0.236 in.)6.05 ~ 6.20 mm (0.238 ~ 0.244 in.)	4.8 mm (0.189 in.)5.25 mm (0.207 in.)5.8 mm (0.228 in.)6.3 mm (0.248 in.)

SpecialToolsandSealant

OutsideCirclipPliers: 57001-144

Line drawing of a pair of pliers (no text or symbols on the diagram itself)

GearHolder,m1.75: 57001-1015

Technical line drawing of a mechanical gear assembly (no text or symbols)

BearingDriverSet: 57001-1129

Isometric line drawing of a box containing multiple circular components, no text or symbols present

CrankshaftJig: 57001-1174

Technical line drawing of a mechanical clamp or bracket component (no text or symbols)

CrankcaseSplittingToolAssembly: 57001-1362

Technical line drawing of a mechanical clamp or bracket assembly with four pins and bolts (no text or symbols)

KawasakiBond(LiquidGasket-Silver): 92104-002

8-8CRANKSHAFT/TRANSMISSION

Crankcase

CrankcaseDisassembly

- Remove:

Clutch(seeClutchchapter)

PrimaryGear(seeClutchchapter)

StarterMotor(seeElectricalSystemchapter)

Alternator(seeElectricalSystemchapter)

BalancerShaftGear(seeBalancerShaftGearRemoval)

CrankBalancerGear(seeEngineTopEndchapter)[A]

- Removetheengine(seeEngineRemoval/Installation chapter).

- Settheengineonacleansurfaceandholdtheengine steadywhilepartsarebeingremoved.

★Ifthecrankshaftistoberemoved,removethefollowing.

CamshaftChain(seeEngineTopEndchapter)

CylinderHead(seeEngineTopEndchapter)

CylinderandPiston(seeEngineTopEndchapter)

- Removetheexternalshiftmechanism(seeExternalShift MechanismRemoval).

- Removetheallcrankcasebolts[A]fromtheleftsideof thecrankcase.

- Removetheoutputshaftsleeve[A]andO-ring[B].
○DonotreusetheremovedO-ring.

- Screwthecrankcasesplittingtool[A]intotheleftsideof thecrankcase[B].Becertaintoscrewtheadaptersinall theway.

SpecialTool-CrankcaseSplittingToolAssembly:57001-1362

- Tightenthecenterboltofthecrankcasesplittingtoolto splitthecrankcase.

○Removetheleftcrankcasehalf.

Mechanical gear assembly with labeled component A, no visible text or symbols

Mechanical gear assembly diagram showing interconnected components (no text or labels visible)

Crankcase

• Removethetransmissionshaft[A], gearsandbalancer shaftfromtherightcrankcasehalf[B].
• Remove: ShiftDrumCamScrew[A] ShiftDrumCam[B] WoodruffKey[C] ShiftDrum[D] GearSetLeverE
• Supporttherightcrankcasehalf[A]withasuitablere-tainer.
• Removethecrankshaft[B]fromtherightcrankcasehalf usingapress.

CAUTION

Donotremovetheballbearingsandtheoilseals unlessitisnecessary.Iftheyareremoved,replace themwithnewones.

CrankcaseAssembly

CAUTION

Rightandleftcrankcasehalvesaremachinedatthe factoryintheassembledstate,soifreplaced,they mustbereplacedasaset.

- Applysoapandwatersolutionaroundtheengine damper [A]beforepressingitintothecrankcase.

Technical line drawing of a mechanical assembly with labeled component A (no text or symbols beyond label)

CAUTION

Donotapplyengineoiltopreventrubberdamper deterioration.

Crankcase

- Pressthedamper[A]intothecrankcasewiththebearing drierset.

SpecialTool-BearingDriverSet:57001-1129

Technical line drawing of a mechanical assembly with no visible text or symbols

• Chipofftheoldgasketfromthematingsurfacesofthe crankcasehalvesandcleanthemoffwithahigh-flash pointsolvent.
• Usingcompressedair, blowout the oil passages in the crankcase halves.

WARNING

Cleantheenginepartsinawell-ventilatedarea,and takecarethattherearenosparksorflameany-whereneartheworkingarea;thisincludesanyappliancewithapilotlight.Donotusegasolineora low-flashpointsolventtocleanparts.Afireorexplosionscouldresult.

• Supportthecrankcasebearingbosswithasuitableretainer[A].
• Usingapressandthebearingdriverset[C],installnew bearings[B]untiltheybottomsout.

SpecialTool-BearingDriverSet:57001-1129

CAUTION

Supportthecrankcasebearingbosswhenthebearingsarepressed,orthecrankcasecouldbedamaged.

- Presstheoutputshaftbearing[A]inthelleftcrankcase half[B]sothatthesealedside[C]facestotheoilseal.

SpecialTool-BearingDriverSet:57001-1129

- Tightenthebearingretainingscrewssecurelyintheright crankcasehalf.

Torque-BearingRetainingScrews:4.9N·m(0.50kgf·m,43in·lb)

- Puttheoutputshaftoilseal[D]in, beingcarefulofthe properdirectionasshown.

G104D90BS1 C

Crankcase

- Usingcompressedair[A], blowout the oil passage in the right crankshaft[B].

• Positioningtheconnectingrod[A]bigendatBDC,putin thecrankshaftjig[B]betweenthecrankshaftflywheels.
• Pressthecrankshaft[C]intherightcrankcasehalf[D]. SpecialTool-CrankshaftJig:57001-1174
• Applyengineoiltothetransmissiongears, bearings, shift forks, shiftdrumandcrankshaftbearing.

- Install: ShiftDrum[A] TransmissionShafts[B] ShiftForks[C] BalancerShaftD

- Checkthattheshiftdrumisinneutralposition.

• Checkthattwodowelpins[A]areinplaceoftheright crankcasehalf.
• Applyliquidgaskettothematingsurface[B]oftheleft crankcasehalf.
  Sealant-KawasakiBond(LiquidGasket-Silver):92104-002
• Usingasuitabletoolontheleftcrankcasetopressaround theholeforthecrankshaft,fitthecrankcasehalvestogetherwithapressonthetool.
• Removethecrankshaftjig.
• Installthecrankcasebolts[A]inthelleftcrankcasehalf [B]andtightenthem,startingwiththenearestonestothe crankshaft,thenfartherones.

Torque-CrankcaseBolts:8.8N·m(0.90kgf·m,78in·lb)

8-12CRANKSHAFT/TRANSMISSION

Crankcase

• Checktoseethatthecrankshaft,driveshaft,andoutput shaftallturnfreely(intheneutralposition).
  ★Ifthecrankshaftwillnotturn,probablythecrankshaftis notcentered;Tapthemountportion[A]ofthecrankcase withaplastichammertorepositionit.

- Puttheendofthewoodruffkey[A]intotheinsideofthe ballbearing[B]sothatthekeycanseatsecurely.

- Applyanon-permanentlockingagenttotheshiftdrum camscrew[A]andtightenit. Torque-ShiftDrumCamScrew:4.9N·m(0.50kgf·m,43 in·lb)

- Installthegearsetlever[B]andtightenthenut[C]. Torque-GearSetLeverNut:11N·m(1.1kgf·m,95in·lb) - InstalltheexternalshiftmechanismD.

- Checktoseethatgearsshiftsmoothlyfrom1stto5th gear,and5thto1stwhilespinningtheoutputshaft. - Settheshiftdrumintheneutralposition.

- Replace the O-ring [A] on the output shaft with anewone. - Apply greasetothe inside of the output shaft collar [B]. - Insert the collar with the oil groove end [C] facing in. - Install theremoved parts (see appropriate chapters).

Mechanical assembly diagram showing interconnected gears and housing (no text or labels visible)

Crankshaft

CrankBalancerGearRemoval/Installation

- RefertoCamshaftChainRemoval/InstallationintheEngineTopEndchapter.

CrankshaftRemoval

- RefertotheCrankcaseDisassemblyinthischapter.

CrankshaftInstallation

- RefertotheCrankcaseAssemblyinthischapter.

CrankshaftDisassembly

Ifthecrankshaftisdamaged,replaceitasaset.Notfor saletoeachpartofthecrankshaft.

ConnectingRodBigEndSeizures

- Incaseofseizure, replacethecrankshaftassembly.

ConnectingRodBigEndRadialClearance

• Supportthecrankshaftwithbothside,andplaceadial gauge[A]againsttheconnectingrodbigend.
• Push[B]theconnectingrodfirsttowardsthegaugeand thenintheoppositedirection. Thedifferencebetween twogaugereadingsisteradialclearance.

ConnectingRodBigEndRadialClearance

Standard: 0.005 \~ 0.017 mm (0.0002 \~ 0.0007 in.)

ServiceLimit:0.07mm(0.003in.)

★ Iftheradialclearanceexceedstheservicelimit,replace thecrankshaftassembly.

ConnectingRodBigEndSideClearance

- Measureconnectingrodbigendsideclearance[A].

ConnectingRodBigEndSideClearance

Standard: 0.20 \~ 0.35 mm (0.008 \~ 0.014 in.)

ServiceLimit:0.50mm(0.020in.)

★ Iftheclearanceexceedstheservicelimit,replace the crankshaftassembly.

CrankshaftRunout

- Supporting the crankshaft from both side, placeadial gauge as shown and turn the crankshaft slowly. The maximum difference in gaugereading is the crankshaft runout.

Standard: TIR0.03mm(0.0012in.) or less

ServiceLimit: TIR0.07mm(0.003in.)

★ Iftherunoutateeitherpointexceedstheservicelimit,replace the crankshaft assembly with a new one or align the crankshaftsothattherunoutfallswithintheservicelimit.

8-14CRANKSHAFT/TRANSMISSION

Crankshaft

• Firstcorrectthehorizontalmisalignmentbystrikingthe projectingcrankhalf[A]withaplastic,softlead,orbrass hammerasshown.
• Rechecktherunoutwithadialgaugeandrepeatthe processuntiltherunoutfallswithintheservicelimit.

- Next, correct the vertical misalignment by either driving a wedge[A] in between the crank halves or by squeezing them in advice, depending on the nature of them misalignment.

CAUTION

Donothammerthecrankhalfatthepoint[B].

BalancerShaftGear

BalancerShaftGearRemoval

- Remove:

AlternatorRotor(seeElectricalSystemchapter) ClutchCover(seeClutchchapter)

- Using the gearholder, hold the primary gear [A] and loosenthe balancershaft gear nut [B].

SpecialTool-GearHolder,m1.75:57001-1015[C]

- Removethebalancershaftgear[D]alongwiththe woodruffkey.

BalancerShaftGearInstallation

• Fitthewoodruffkey[A]securelyintothegroove,then installthebalancershaftgear[B].
• Alignthetimingmarks[A]onthebalancershaftgearand thecrankbalancergear. BalancerShaftGearNut[B]
• Using the gearholder, hold the primary gear [A]asshown.
• Applyoiltothethreadsandseatingsurfaceofthebalancershaftgearnut.
• Tightenthebalancershaftgearnut[B].

Torque-BalancerShaftGearNut:78N·m(8.0kgf·m,58 ft·lb)

SpecialTool-GearHolder,m1.75:57001-1015

- Install:

AlternatorRotor(seeElectricalSystemchapter) AlternatorCover(seeElectricalSystemchapter) ClutchCover(seeClutchchapter)

Mechanical gear assembly with labeled components (A, C), no visible text or symbols beyond labels

Mechanical gear assembly diagram showing two meshed gears with labeled components (B and D), no readable text or symbols present.

Mechanical gear assembly diagram showing interconnected gears and shafts (no text or symbols visible)

Mechanical gear assembly diagram showing two interconnected gears labeled A and B (no text or symbols beyond labels)

Mechanical gear assembly diagram showing two interconnected gears labeled A and B (no text or symbols beyond labels)

8-16CRANKSHAFT/TRANSMISSION

StarterMotorClutch

StarterMotorClutchRemoval/Installation

- RefertotheAlternatorRotorRemovalandInstallationin theElectricalSystemchapter.

StarterMotorClutchDisassembly

• RemovethealternatorrotorA.
• Holdthealternatorrotorwiththeflywheelholder[B]and removethestartermotorclutchbolts[C].
  SpecialTool-FlywheelHolder:57001-1313
• Removetheartermotorclutch[D].

StarterMotorClutchAssembly

- Applyanon-permanentlockingagenttothethreadsof thestartermotorclutchbolts[A], andtightenthem.

Torque-StarterMotorClutchBolts

(BN125-A1):34N·m(3.5kgf·m,25ft·lb)

(BN125-A2\~):12N·m(1.2kgf·m,104in·lb)

StarterMotorClutchInspection

• Removethealternatorcover(seeElectricalSystemchapter).
• Turnthestartergear[A]byhand. Thestartergearshould turnclockwise[B]freely, but should not turncounterclockwise[C]by the starterclutch function.
  ★ Ifthestartermotorclutchdoesnotoperateasitshould orifitmakesnoise,disassemblethestartermotorclutch, andvisuallyinspecttheclutchparts.Ifthereisanyworn ordamagedpart,replaceit.
• Visuallyinspectthestartergearandcrankshaft.
  ★ Iftheslidingsurface[A]iswornordamaged,replace the startergearand/orcrankshaft.

TorqueLimiterInspection

• Removethetorquelimiter[A]andvisuallyinspectit.
  ★ Ifthelimiterhasanywear, discoloration, orotherdamage, replaceitasaunit.

Mechanical gear assembly with labeled components (A, B, C), no readable text or symbols beyond labels

Mechanical gear assembly diagrams showing two views of a shaft and rotor components (no text or symbols)

Close-up of mechanical components with no visible text or symbols

ExternalShiftMechanism

ShiftPedalHeightAdjustment

- Adjustthelengthoftheshiftlinkagerodsothatthedistancebetweentheshiftpedal[A]andthefrontleftfootpeg [B] shall be 26.5 \~ 29.5 mm (1.04 \~ 1.16 in.) [C]. Then, thelength[D]oftheshiftlinkagerodwillbeapproximately 141mm(5.55in.)asillustrated.

ShiftPedalRemoval

• RemovetheenginesprocketcoverA.
• Removetheclampbolt[B].
• Removetheshiftlever[C]fromtheshiftshaft.

NOTE

Wheninstallingtheshiftleverontotheshiftshaft, align thegrooveoftheleverwiththepunchmarkoftheshift shaft.

- Remove: Bolts[A] FrontLeftFootpeg[B] ShiftPedal[C]

- Remove: Nut[A] ShiftPedal[B]

ExternalShiftMechanismRemoval

• Draintheengineoil(seeEngineLubricationSystem chapter).
• Remove: Clutch(seeClutchchapter) EngineSprocketCover(seeFinalDrivechapter)
• Unscrewtheshiftleverclampboltandremovetheshift leverfromtheshiftshaft.

8-18CRANKSHAFT/TRANSMISSION

ExternalShiftMechanism

• Turntheshiftdrumandpositiontheneutralgroove[A]as shown.
• Removetheshiftshaft[D]whilepushing[C]theshift mechanismarm[B]towardtheshaft.

ExternalShiftMechanismInspection

• Examinetheshiftshaft[A]foranydamage.
  ★Iftheshaftisbent, straightenorreplaceit.
  ★Ifthesplines[B]aredamaged,replacetheshaft.
  ★Ifthesprings[C][D]aredamagedinanyway,replace them.
  ★IftheshiftpawlEisdamagedinanyway,replace the shiftshaftassembly.

• Checkthereturnspringpin[A]isnotloose.
  ★Ifitisloose,unscrewittoapplyanon-permanentlocking agenttothethreads,andtightenit.

Torque-ShiftShaftReturnSpringPin:29N·m(3.0kgf·m, 21ft·lb)

• Check the gear positioning lever [B], and their spring [C] for breaksordistortion.
  ★Iftheleverorspringsaredamagedinanyway,replace them.
• Visuallyinspecttheshiftdrumcam[D].
  ★ Ifthecamisbadlywornorifitshowsanydamage,replace it.

Transmission

TransmissionShaftRemoval

• Splitthecrankcase(seeCrankcaseDisassembly).
• Pullouttheshiftrod[A]allowingtheshiftforkguidepins tofreefromtheshiftdrum[B].
• Removetheshiftforks[C].
• Removetheshiftdrum.
• Pulloutthedriveshaft[D]andoutputshaftEtogether withtheirgearsmeshed.

TransmissionShaftInstallation

• Applyengineoiltotheslidingportionsofeverygearand bearing.

• Installthedriveshaftandoutputshaft[B]intheright crankcasewiththeirgears[A]meshed.

• Applyasmallamountofengineoiltotheshiftforkfingers andfiteachshiftforkintothegrooveofthepropergear.

• Theshiftforkscanbeidentifiedbytheirshapeornumber.Installthemnotingthedirectionshown.
  ○ Thedriveshaftfork[A]istheshortest, and installit with itsmark "65"[B]facingtheengineleftside.
  ○ Installtheoutputshaftfork[C]withitsmark"64"[D]facing theengineleftside.
  ○InstalltheleftoutputshaftforkEasshown.
• Fiteachshiftforkguidepinintothecorrespondinggroove intheshiftdrum.
• Applyasmallamountofengineoiltotheshiftrodand slidethemintotheshiftforks.
• Assemblethecrankcase(seeCrankcaseAssembly).

TransmissionDisassembly

• Removethetransmissionshafts.
• Removethecirclips, washers, thengears.
  SpecialTool-OutsideCirclipPliers:57001-144[A]
• Donotreusetheremovedcirclips.

Close-up of hands assembling a mechanical gear assembly (no visible text or symbols)

Close-up of a mechanical component with a labeled section A, showing interlocking gears and a shaft (no text or symbols beyond label)

Transmission

TransmissionAssembly

- Replaceanycirclipsremovedwithnewones.

○Installthecirclips[A]sothattheopening[B]isaligned with asplinegroove[C].

○Installthetoothedwasher[D]sothattheteethEarenot alignedwiththeopeningofthecirclip.

- Thedriveshaftgearscanberecognizedbysize:thegear withthesmallestdiameteris1stgear,andthelargestone is5thgear.Besurethatallpartsareputbackinthecorrectsequenceandallcirclipsandwashersareproperlyin place.

- Theoutputshaftgearscanberecognizedbysize:the gearwiththelargestdiameteris1stgear,andthesmall-estoneis5thgear.Besurethatallpartsareputback inthecorrectsequenceandallcirclipsandwashersare properlyinplace.

- Checkthateachgearspinsorslidesfreelyonthetransmissionshaftswithoutbindingafterassembly.

1.Circlip

2.Circlip

3.Washer

1. Toothed Washer

5.DriveGear-2nd

6.Collar

7.DriveGear-3rdand4th

8.DriveGear-5th

9.DriveShaft

1. OutputGear-2nd

11.OutputGear-4th

12.OutputGear-3rd

13.OutputGear-5th

1. OutputGear-Low

2. OutputShaft

Transmission

ShiftDrumRemoval/Installation

- RefertotheCrankcaseDisassembly/Installationinthe Crankshaft/Transmissionchapter.

ShiftForkBending

- Visuallyinspecttheshiftforks, and replaceanyforkthatis bent. Abentforkcouldcauseddifficultyinshifting, orallow thetransmissiontojumpoutofgearwhenunderpower. 90°[A]

ShiftFork/GearGrooveWear

- Measurethethicknessoftheshiftforkears[A], and measurethewidth[B]ofthegeargrooves.

ShiftForkEarThickness

Standard: 4.9 \~ 5.0 mm (0.193 \~ 0.197 in.)

ServiceLimit:4.8mm(0.189in.)

GearGrooveWidth

Standard: 5.05 \~ 5.15 mm (0.199 \~ 0.203 in.)

ServiceLimit: 5.25mm(0.207in.)

★ Ifthethicknessofashiftforkearislessthantheservice limit, theshiftforkmustbereplaced.
★ If the gear groove is worn over the service limit, the gear must be replaced.

ShiftForkGuidePin/DrumGrooveWear

- Measurethediameterofeachshiftforkguidepin[A], and measurethewidth[B]ofeachshiftdrumgroove.

ShiftForkGuidePinDiameter

Standard: 5.9 \~ 6.0 mm (0.232 \~ 0.236 in.)

Service Limit: 5.8 mm (0.228 in.)

ShiftDrumGrooveWidth

Standard: 6.05 \~ 6.20 mm (0.238 \~ 0.244 in.)

ServiceLimit: 6.3mm(0.248in.)

★ Iftheguidepinonanyshiftforkislessthantheservice limit, theforkmustbereplaced.
★ Ifanyshiftdrumgrooveiswornovertheservicelimit, the drummustbereplaced.

GearDogandGearDogHoleDamage

• Visuallyinspectthegeardogs[A]andgeardogholes[B].
  ★Replaceanydamagedgearsorgearswithexcessively worndogsordogholes.

Technical line drawing of two mechanical components labeled A and B, showing assembly details without any text or symbols.

8-22CRANKSHAFT/TRANSMISSION

BallBearing, and Oil Seal

BallBearingReplacement

CAUTION

Donotremovetheballbearingsunlessitisnecessary.Removalmaydamagedthem.

- Usingapressorpuller,removetheballbearing.

NOTE

○ Intheabsenceoftheabovementionedtools, satisfactoryresultsmaybeobtainedbyheatingthecasetoapproximately93°C(200°F)max,andtappingthebearinginorout.

CAUTION

Donotheatthecasewithatorch. This will warp the case. Soakthecaseinoilandheattheoil.

- Usingapressandthebearingdriverset[A],installthe newbearinguntilitstopsatthebottomofitshousing. SpecialTool-BearingDriverSet:57001-1129

BallBearingWear

CAUTION

Donotremovethebearingsforinspection. Removalmaydamagethem.

- Checktheballbearings.

○Sincetheballbearingsaremadetoextremelyclosetolerances,thewearmustbejudgedbyfeelratherthanmeasurement.Cleaneachbearinginahigh-flashpointsolvent,dryit(donotspinthebearingwhileitisdry),andoil itwithengineoil.

○Spin[A]thebearingbyhandtocheckitscondition.

★ Ifthebearingisnoisy, does not spinsmoothly, or has any roughspots, replace it.

OilSealInspection

- Inspecttheoilseals.

★Replaceitifthelipsaremisshapen,discolored(indicating thattherubberhasdeteriorated),hardenedorotherwise damaged.

Wheels/Tires

TableofContents

Exploded View.... 9-2

Specifications 9-4

Special Tools 9-5

Wheels (Rims) 9-6

Front Wheel Removal 9-6

Front Wheel Installation 9-6

Rear Wheel Removal 9-7

Rear Wheel Installation.... 9-8

Wheel Inspection 9-9

Spoke Inspection 9-9

Rim Inspection 9-9

Axle Inspection.... 9-9

Tires 9-10

Air Pressure Inspection/Adjustment 9-10

Tire Inspection 9-10

Tire Removal 9-10

Tire Installation.... 9-11

Hub Bearings (Wheel Bearings) 9-12

Removal.... 9-12

Installation.... 9-12

Inspection.... 9-13

Lubrication 9-13

ExplodedView

No.Fastener		Torque			Remarks
		N·m	kgf·mft·lb
1	Tire Air Valve Nuts	1.5	0.15	13 in·lb
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

1. For DE of BN125-A1 \~ A2 and On and after BN125-A3 of EUR Models

G: Applygrease.

R: ReplacementParts

WL: Applysoapandwatersolutionorrubberlubricant.

DE: Germany

EUR: Europe

Specifications

ItemStandardServiceLimit
Wheels(Rims)RimSize:Front17×1.85--Rear15×2.75--RimRunout(withtireinstalled):AxialTIR0.8mm(0.03in.)orless2mm(0.08in.)RadialTIR1.0mm(0.04in.)orless2mm(0.08in.)Axle Rumout/100 mm (3.9 in.)	TIR 0.1 mm (0.004 in.) or less	0.2 mm (0.008 in.)
TiresAirPressure(WhenCold):Front:(BN125-A1 ~ A2)(BN125-A3 ~)Rear:(BN125-A1 ~ A2)(BN125-A3 ~)	Up to 185 kg (408 lb) load: 150 kPa (1.5 kgf/cm2,21psi)Up to 155 kg (342 lb) load: 150 kPa (1.5 kgf/cm2,21psi)	---
	Up to 185 kg (408 lb) load: 175 kPa (1.75kgf/cm2,25psi)Up to 155 kg (342 lb) load: 175 kPa (1.75kgf/cm2,25psi)	---
TreadDepth:Front:(BN125-A1~A2)4.5mm(0.18in.)BN125-A3 ~ A5)(BN125-A6 ~)Rear:	4.0 mm (0.157 in.)4.1 mm (0.161 in.)	1 mm (0.04 in.)
	7.3mm(0.29in.)	2mm(0.08in.)
StandardTires:Front:(BN125-A1 ~ A2)(BN125-A3 ~ A5)(BN125-A6 ~)Rear:(BN125-A1 ~ A2)(BN125-A3 ~)	Make, Type	Size
	DUNLOP D404F, tube typeIRC NF53 Tube typeIRC NF53 Tube type	90/90 -17 49P90/90-17 49P90/90 -17 M/C 49P
	DUNLOP D404, tube typeIRC NR67 Tube type	130/90-15 M/C 66P130/90 -15 M/C 66P
Replacement Tires:FrontRear	Make, Type	Size
	METZELER PERFECT ME77, tube typeMETZELER PERFECT ME77, tube type	3.00-1750P130/90-15 M/C 66S

WARNING

Usethesamemanufacture'stiresonbothfrontandrearwheels.

SpecialTools

RimProtector: 57001-1063

Technical line drawing of six curved metal tools or clips (no text or symbols)

BeadBreakerAssembly: 57001-1072

Line drawing of a manual pliers tool (no text or symbols present)

BearingDriverSet: 57001-1129

Isometric line drawing of a box containing multiple circular components, no text or symbols present

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

BearingRemoverShaft,9: 57001-1265

Line drawing of a mechanical tool or tool with a long handle and flange (no text or symbols)

BearingRemoverHead,15 ^17 : 57001-1267

Technical line drawing of a mechanical connector or fitting (no text or symbols)

Wheels(Rims)

FrontWheelRemoval

• Removethecotterpinandaxlenut[A].
• Removethespeedometercablelowerend[B].

- Raisethefrontwheel[B]offthegroundusingthejack[A]. SpecialTool-Jack:57001-1238

- Pullouttheaxleanddropthefrontwheel[A]outofthe forks. - Insertawoodenplatebetweenthepadsinthecaliperto preventthecaliperpistonfromjumpingout.

CAUTION

Donotlaythewheeldownonthedisc. This can damageorwarpthedisc. Placeblocksunderthe wheelsothatthediscdoesnottouchtheground.

FrontWheelInstallation

• Applygreasetotheseallip[A]ofthespeedometergear.
• Installthespeedometergearhousingsothattheprojections[C]fitinthedrivenotches[B].

• Fitthecollar[A]ontherightsideofthehub.

Close-up of mechanical components with labeled parts A and B, no readable text or symbols present.

Close-up of a motorcycle wheel with visible tire, disc, and mounting bracket (no text or symbols)

Close-up of a motorcycle wheel with labeled component A, showing tread pattern and mounting bracket (no readable text or symbols beyond labels)

Wheels(Rims)

• Fittheforklegstop[A]betweenthespeedometergear housingstop[B]andinstallthefrontwheel.
  • Installtheaxlefromtherightsideandtightentheaxlenut.
  Torque-FrontAxleNut:78N·m(8.0kgf·m,58ft·lb)

- Insertanewcotterpin[A].

NOTE

When inserting the cotterpin, if the slots in thenut do not align with the cotterpinhole in the axle, tighten the nut clockwise [B] uptonextalignment.
○Itshouldbewithin30degree.
○Loosenonceandtightenagainwhentheslotgoespast thenaresthole.

- Bendthecotterpin[A]overthenut[B].

Close-up of mechanical components with labeled parts A and B, no readable text or symbols present

- Checkthefrontbrakeeffectiveness.

WARNING

Donotattempttodrivethemotorcycleuntilafull brakeleverisobtainedbypumpingthebrakelever untilthepadsareagainstthedisc.Thebrakewill notfunctiononthefirstapplicationoftheleverif thisisnotdone.

RearWheelRemoval

• Raisetherearwheel[B]offthegroundusingthejack[A]. SpecialTool-Jack:57001-1238

9-8WHEELS/TIRES

Wheels(Rims)

- Remove:

ChainCover

CotterPin[A]andAxleNut[B]

TorqueLinkBolt, Nut(rear)[C]

BrakeAdjustingNut[D]

- RemovethebrakerodEfromthebrakecamlever[F].

- Removethedrivechain[A]fromtherearsprocket,then removetherearwheel[B]totherear.

RearWheelInstallation

• Applyhigh-temperaturegreaseseallipsandtheinnercircumferenceofthesprocketcoupling(seeFinalDrivechapter).
  • Installthecollar[A]onthebothsideofthehub.
• Engagethedrivechainwiththerearsprocket, and install therearwheel.
• Checkthedrivechainslack(seePeriodicMaintenance chapter).
• Tighten:

Torque-RearAxleNut:98N·m(10.0kgf·m,72ft·lb)

- Insertanewcotterpin[A].

NOTE

When inserting the cotterpin, if the slots in then the nut align with the cotterpin hole in the axle, tighten the nut clockwise [B] uptonextalignment.
○ Itshouldbewithin30degree.
○ Loosenonceandtightenagainwhentheslotgoespast thenaresthole.

Wheels(Rims)

- Bendthecotterpin[A]overthenut[B].

• Adjustthebrakepedalfreeplay(seeBrakeschapter).
• Checktherearbrakeeffectiveness.

WARNING

Ifafullbrakepedalisnotobtained,disassemble andinspectthebrakeparts.Wornpartscauselock ofthebrakeorlossofbraking.

Close-up of mechanical components with labeled parts (A), no readable text or symbols present

WheelInspection

- Raisethefront/rearwheelofftheground.

SpecialTool-Jack:57001-1238

• Spinthewheellightly, and check for roughnessor binding.
  ★ Ifroughnessorbindingisfound, replacethehubbearings.

SpokeInspection

- RefertotheSpokeTightnessInspectioninthePeriodic Maintenancechapter.

RimInspection

- RefertotheRimRunoutInspectioninthePeriodicMaintenancechapter.

AxleInspection

• Visuallyinspectthefrontorrearaxlefordamage.
  ★ Iftheaxleisdamagedorbent,replaceit.
• PlacetheaxleontheVblocksthatare100mm(3.9in.) [A]apart, andsetadialgauge[B]ontheaxleatapoint halfwaybetweentheblocks. Turn[C]theaxletomeasure therunout. Thedifferencebetweenthehighestandlow- estdialreadingsistheamountofrunout.
  ★ Ifaxlerunoutexceedstheservicelimit, replacetheaxle.

AxleRunout/100mm(3.9in.)

Standard: TIR0.1mm(0.004in.) or less

ServiceLimit: TIR0.2mm(0.008in.)

Tires

AirPressureInspection/Adjustment

- RefertotheAirPressureInspection/AdjustmentinthePeriodicMaintenancechapter.

TireInspection

- RefertotheTireWearInspectioninthePeriodicMaintenancechapter.

TireRemoval

- Removethefollowing. Wheel(seethischapter) BrakeDisc(front) BrakePanel(rear) ValveCore(letouttheair)

- Tomaintainwheelbalance, marktheairvalvepositionon thetirewithchalksothatthetirecanbereinstalledinthe sameposition. AirValve[A] ChalkMark[B]

- Lubricatethetirebeadsandrimflangesonbothsideswith asoapandwatersolutionorrubberlubricant. This helps the tirebeadsslipofftherimflanges.

CAUTION

Neverlubricatewithengineoilorpetroleumdistillatesbecausetheywilldeterioratethetire.

- Breakthebeadsawayfrombothsidesoftherimwiththe beadbreaker[A]. SpecialTool-BeadBreakerAssembly:57001-1072

- Installtherimprotectors[A]aroundthevalvestem.Lubricatethetireirons[B]andrimprotectorswithsoapandwatersolution,orrubberlubricant. - Steponthesideofthetireoppositethevalvestem,and startpryingthetireofftherimnearthevalvestemwith tireirons(specialtools).

SpecialTools-RimProtector:57001-1063 BeadBreakerAssembly:57001-1072

Tires

○Foreasierremoval,alwaysdropthetirebeadopposite thevalvestemintotherimwell[A],andprythetirebead alittleatatime.
- Dothesamefortheothersideofthetire, thenremovethe rimfromthetire.
- Removetheprotectors.

Technical line drawing of a mechanical component with labeled point A and reference number 0J05056BS1 (no text or symbols beyond labels)

TireInstallation

WARNING

Toensuresafehandlingandstability,useonlythe recommendedstandardtiresforreplacement,inflatedtothestandardpressure.Usethesamemanufacturer'stiresonbothfrontandrearwheels.

NOTE

○Replacetherimbandwithanewonewheneverthetire isreplaced.

• Position the tire on ther im so that the a thetire balance markB.
• Tighten:

Torque - Tire Air Valve Nut: 1.5 N·m (0.15 kgf·m, 13 in·lb) BrakeDiscBolts:27N·m(2.8kgf·m,20ft·lb)

- Checkthetirerotationmark[A]onthefront/reartireand installitontherimaccordingly.

NOTE

○ Thedirectionofthetirerotation[B]isshownbyanarrow onthetiresidewall.

HubBearings(WheelBearings)

Removal

- Removethewheel, and takeout the following.

SpeedometerGear(fromfronthub)[A]

Collars[B]

GreaseSeals[C]

○Useascrewdriverforthegreasesealremoval.

- Removethehubbearings[A].

CAUTION

Donotlaythewheelonthegroundwiththedisc facingdown. This candamageorwarpthedisc. Placeblocksunderthewheelsothatthediscdoes nottouchtheground.

SpecialTools-BearingRemoverShaft,9:57001-1265[B]

BearingRemoverHead, 15×1757001

-1267[C]

Installation

- Beforeinstallingthewheelbearings, blowanydirtorforeignparticlesoutofthehubwithcompressedairtopreventcontaminationofthebearings.

- Replacethebearingswithnewones.

○Installthebearingsssothatthemarkedsidefacesout.

○Pressineachrightbearing[A]firstuntilitbottomsout.

SpecialTool-BearingDriverSet:57001-1129[B]

WARNING

Besuretobottomouttherightbearingsonboth frontandrearwheels,ormisalignmentofthewheel willresultinabnormaldrivechainwear,andmay resultinanunsaferidingcondition.

- Replacethegreasesealinthefronthubwithanewone.

- Pressinthegreaseseal[A]sothatthesealsurfaceflush [B]withtheendofthehole.

○Applyhightemperaturegreasetothegreaseseallips.

SpecialTool-BearingDriverSet:57001-1129[C]

HubBearings(WheelBearings)

Inspection

○ Sincethehubbearingsaremadetoextremelyclosetolerances, the clearance cannot normally be measured.

NOTE

- Donotremoveanybearingsforinspection.Ifanybearingsareremoved,theywillneedtobereplacedwith newones.

• Spin[A]thebearingbyhandtocheckitscondition.
  ★ Ifitisnoisy, does not spins smoothly, or has any rough spots, it must bereplaced.
• Examinetherearhubbearingseal[B]fortearsorleakage.
  ★ Ifthesealistornorisleaking, replacethebearing.

Lubrication

CAUTION

Donotremoveanybearingsforlubrication.Ifany bearingsareremoved,theywillneedtobereplaced withnewones.

- Packthefronthubbearingswithgoodqualitybearing grease. Turnthebearingsaroundbyhandafewtimes tomakesurethegreaseisdistributedevenlyinsidethe bearings.

NOTE

○Sincetherearhubbearingarepackedwithgreaseand sealed,lubricationisnotrequired.

FinalDrive

TableofContents

Exploded View.... 10-2

Specifications 10-4

Special Tools 10-5

Drive Chain.... 10-6

Chain Slack Inspection 10-6

Chain Slack Adjustment.... 10-6

Wear Inspection.... 10-6

Lubrication 10-6

Drive Chain Removal 10-6

Drive Chain Installation 10-6

Sprocket, Coupling 10-7

Engine Sprocket Removal 10-7

Engine Sprocket Installation 10-7

Rear Sprocket Removal 10-8

Rear Sprocket Installation.... 10-8

Sprocket Wear 10-8

Sprocket Warp Inspection.... 10-8

Coupling Removal.... 10-8

Coupling Installation.... 10-9

Coupling Bearing Removal 10-9

Coupling Bearing Installation 10-9

Coupling Bearing Wear/Lubrication 10-9

Damper Inspection.... 10-9

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf	·mft·lb
1	Engine Sprocket Cover Bolts (BN125-A1 ~ A3)	9.8	1.0	87 in·lb
	Engine Sprocket Cover Bolts (BN125-A4 ~)	8.8	0.90	78 in·lb
2	EngineSprocketCoverDamperBolts	8.80.90	78in·lbL
3	Torque Link Bolt and Nut	34	3.5	25
4	Rear Sprocket Nuts	26	2.7	19
5	Rear Axle Nuts	98	10.0	72
6	Engine Sprocket Bolts	12	1.2	102 in·lb

1. Facethe punchmark outward.
2. For DE of BN125-A1 \~ A2 and On and after BN125-A3 of EUR Models
3. BN125-A1 \~ A2 Models only
   CO:Apply chainoil.
   L: Applyanon-permanentlocking agent.
   R: Replacement Parts
   DE:Germany
   EUR: Europe

Specifications

ItemStandardServiceLimit
DriveChain
StandardChain:Make/type:	ENUMA CHAIN (BN125-A1 ~ A2)JointEndlessEK428SH-RDAIDO(BN125-A3~ )JointEndlessDID424HG	---
Link:132links-- --	130links(BN125-A7~, N , N U ) -- --25 ~ 40 mm (0.98 ~ 1.57 in.)254.0 ~ 254.6 mm (10.00 ~ 10.02 in.)	---259mm(10.2in.)
Chain Slack20-linkLength
SprocketsRearSprocketWarpTIR0.4mm(0.016in.)orless		TIR0.5mm(0.020in.)

N: No Catalytic Converter Model
NU:NoCatalyticConverter(UnitedKingdomModel)

SpecialTools

BearingDriverSet: 57001-1129

Isometric line drawing of a box containing multiple circular components, no text or symbols present

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

DriveChain

ChainSlackInspection

- RefertotheDriveChainSlackInspectioninthePeriodic Maintenancechapter.

ChainSlackAdjustment

- RefertotheDriveChainSlackAdjustmentinthePeriodic Maintenancechapter.

WearInspection

- RefertotheDriveChainWearInspectioninthePeriodic Maintenancechapter.

Lubrication

- RefertotheDriveChainLubricationinthePeriodicMaintenancechapter.

DriveChainRemoval

- Removetheenginesprocketcover[A].

• Removetheclip[A]fromthemasterlinkusingpliers,and removethechainfromtherearsprocket.
  • Takethechainoffthemotorcycle.

Close-up of a mechanical component with labeled parts (A) and mounting holes, no readable text or symbols beyond labels

Close-up of a mechanical chain component with labeled point A (no readable text or symbols beyond label)

DriveChainInstallation

WARNING

Forsafety, useonlythestandardchain.

• Fitthedrivechainbackontothesprocketswiththeends attherearsprocket.
  • Installthemasterlinkfromtheframeside.
• Installtheclip[A]sothattheclosedendofthe"U"[B] pointedinthedirectionofchainrotation[C].
• Adjustthedrivechainslack(seePeriodicMaintenance chapter).
• Checkthebrakeforgoodbrakingpower,andnobrake drag(seeBrakeschapter).

WARNING

Ifafullbrakepedalisnotobtained,disassemble andinspectthebrakeparts.Wornpartscauselock ofthebrakeorlossofbraking.

Sprocket, Coupling

EngineSprocketRemoval

- Removetheenginesprocketcoverbolts[A]andsprocket cover[B].

- Removetheenginesprocketbolts[A].

- Pulltheenginesprocket[A]offtheoutputshaftalongwith thechain.

EngineSprocketInstallation

• Installtheenginesprocketsothatthepunchmark[A]face theoutward.
• Tightentheenginesprocketbolts

Torque-EngineSprocketBolts:12N·m(1.2kgf·m,104in·lb)

NOTE

○Whentighteningtheholderbolts, holdtherearbrake on.

- Installtheenginesprocketcover, andtightenthebolts withspecifiedtorque.

Torque-EngineSprocketCoverBolts

(BN125-A1\~A3):9.8N·m(1.0kgf·m,87in·lb)

(BN125-A4\~): 8.8 N·m (0.90 kgf·m, 78 in·lb)

- Runthealternatorleads, crankshaftsensorleads[A], and neutralswitchleads[B]asshown.

Runundertheoilpipe[C].

GuideRib[D]

- Adjustthedrivechain(seePeriodicMaintenancechapter).

Mechanical assembly diagram showing chain links and components (no readable text or symbols)

Close-up of hands assembling a mechanical component with chains and gears (no visible text or symbols)

10-8FINALDRIVE

Sprocket, Coupling

RearSprocketRemoval

• Removetherearwheel(seeWheels/Tireschapter).
• Removethedrivechain(seeDriveChainRemoval).
• Removetherearsprocketnuts[A]andseparatetherearsprocket[B]fromthecoupling.

RearSprocketInstallation

• Installthesprocketwiththetoothnumbermarking[A]outward.
• Tightentherearsprocketnuts.
  Torque-RearSprocketNuts:26N·m(2.7kgf·m,19ft·lb)

SprocketWear

• Visuallyinspecttheengineandrearsprocketteeth.
  ★Iftheteetharewornasillustrated, replacethesprockets, and inspect the drivechain (see Periodic Maintenance chapter).

NOTE

○ Sprocketwearisexaggeratedforillustration.

WornTooth(EngineSprocket)[A]

WornTooth(RearSprocket)[B]

DirectionofRotation[C]

CAUTION

Ifasprocketrequiresreplacement,thedrivechain isprobablywornalso.Uponreplacingtherear sprocket,inspectthechainandenginesprocket.

SprocketWarpInspection

• Raisetherearwheeloffthegroundwithajack.
  SpecialTool-Jack:57001-1238
• Setadialgauge[A]againsttherearsprocket[B]nearthe teethasshown.
• Turn[C]therearwheel. Thedifferencebetweenthehighestandlowestdialgaugereadingsistheamountofrunout (warp).
  ★If the runout exceeds the service limit, replace the rear sprocket.

RearSprocketWarp

Standard: TIR0.4mm(0.016in.) or less

ServiceLimit: TIR0.5mm(0.020in.)

CouplingRemoval

• Removetherearwheel(seeWheels/Tireschapter).
• Removetherearsprocket(seethischapter).

Sprocket, Coupling

Coupling Installation

- Grease[A]thefollowingandinstallthecoupling. CouplingGreaseSealLips. CouplingInternalSurface

• Installtherearsprocketandthecoupling(seethischapter).
  • Installtherearwheel(seeWheels/Tireschapter).

CouplingBearingRemoval

• Removethecoupling.
• Prythegreasesealout.
• Removethebearing[A]bytappingfromthewheelside. SpecialTool-BearingDriverSet:57001-1129[B]

CouplingBearingInstallation

• Replacethebearing[A]withanewone.
• Pressinthebearingwiththemarkedsideoutunititbottomsout.

SpecialTool-BearingDriverSet:57001-1129[B]

CouplingBearingWear/Lubrication

- SeethelInspectionandLubricationsectionsoftherear hubbearingsinWheels/Tireschapter.

DamperInspection

• Removetherearwheelcoupling, and inspecttherubber dampers[A].
• Replacethedamperifitappearsdamagedordeteriorated.

Brakes

TableofContents

ExplodedView....11-2

Specifications....11-6

SpecialTools....11-7

Caliper....11-8

CaliperRemoval....11-8

CaliperInstallation....11-8

CaliperDisassembly......11-8

CaliperAssembly....11-9

CaliperFluidSealDamage......11-10

CaliperDustSeal/FrictionBoot Damage....11-11

CaliperPistonandCylinder Damage....11-11

CaliperHolderShaftWear......11-11

FrontBrakePads....11-12

BrakePadRemoval(BN125-A1\~A2)....11-12

BrakePadRemoval(BN125-A3\~)....11-12

BrakePadInstallation(BN125-A1 \~ A2)....11-12

BrakePadInstallation(BN125-A3 \~)....11-12

BrakePadWearInspection......11-12

MasterCylinder....11-13

MasterCylinderRemoval......11-13

MasterCylinderInstallation.....11-13

MasterCylinderDisassembly.....11-13

MasterCylinderAssembly......11-14

MasterCylinderInspection(Visual Inspection)....11-14

FrontBrakeDisc....11-15

BrakeDiscRemoval....11-15

BrakeDisclInstallation....11-15

BrakeDiscWear....11-15

BrakeDiscWarp....11-15

BrakeFluid....11-16

BrakeFluidLevelInspection......11-16

BrakeFluidChange....11-16

BrakeLineBleeding....11-16

BrakeHose....11-17

BrakeHoseRemoval/Installation.11-17

BrakeHoseInspection......11-17

RearBrakePedalandBrakeCable..11-18

BrakePedalPosition Inspection/Adjustment.....11-18

BrakePedal Free Play Inspection/Adjustment.....11-18

BrakePedalRemoval....11-18

BrakePedallInstallation....11-19

BrakeCableRemoval....11-19

BrakeCableInstallation....11-20

BrakeCableLubrication....11-20

RearBrakePanelandDrum......11-21

BrakePanelRemoval....11-21

BrakePanelInstallation....11-21

BrakePanelDisassembly......11-21

BrakePanelAssembly....11-21

BrakePanelInspection....11-22

Brake Shoe LiningWear Inspection....11-22

BrakeShoeSpringsInspection....11-23

BrakeDrumWearInspection......11-23

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf	·mft·lb
1BrakeDiscBolts272.820L
2CaliperMountingBolts252.518
3CaliperHolderShaftBolts181.813
4CaliperPadBolts181.813
5	Caliper Bleed Valve	7.8	0.80	69 in·lb
6BrakeHoseBanjoBolts	252.518
7	Brake Lever Pivot Bolt	5.9	0.60	52 in·lb
8	Brake Lever Pivot Bolt Locknut	5.9	0.60	52 in·lb
9	FrontMasterCylinderClampBolts	8.8	0.90	78in·lb	S
10	Front Brake Reservoir Cap Screws	1.5	0.15	13 in·lb
11	Front Brake Light Switch Screws	1.0	0.10	9 in·lb

1. Diaphragm plate (BN125-A1 \~ A2)
2. BN125-A1 \~ A2
   B: Applybrake fluid.
   R: ReplacementParts
   S: Follow the specific tightening sequence.
   Si: ApplysiliconegreaseorPBCgrease.

ExplodedView

No.Fastener	Torque			Remarks
	N·mkgf	·mft·lb
1BrakePedalBolt9.81.087in·lb
2TorqueLinkBoltandNut343.525

G:Applygrease.
R: ReplacementParts

Specifications

ItemStandardServiceLimit
FrontBrake
PadLiningThickness:	4.5 mm (0.177 in.) (BN125-A1 ~ A2)	1 m (0.04 in.)
	6.0 mm (0.236 in.) (BN125-A3 ~ )	1 m (0.04 in.)
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)
	(BN125-A4~ )
DiscRunout	Lessthan0.2mm(0.008in.)0.3mm(0.012in.)
BrakeFluid:
Grade	DOT4	-- --
RearBrake
ShoeSpringFreeLength:
Long	44.5 ~ 45.5 mm (1.752 ~ 1.791 in.)	47.2 mm (1.86 in.)
Short	32.5 mm (1.280 in.)	34.1 mm (1.34 in.)
Cam Lever Angle	80 ~ 90°	-- --
Brake Pedal Free Play	20 ~ 30 mm (0.79 ~ 1.18 in.)	-- --
BrakeMaintenance
Brake Drum Inside Diameter	130.00 ~ 130.16 mm (5.118 ~ 5.124 in.)	130.75 mm (5.148 in.)
Brake Shoe Lining Thickness	3.85 ~ 4.15 mm (0.152 ~ 0.163 in.)	2 mm (0.08 in.)
Brake Camshaft Diameter	11.957 ~ 11.984 m (0.471 ~ 0.472 in.)	11.88 mm (0.47 in.)
	(BN125-A1~ A6)
	14.95 ~ 14.99 mm (0.589 ~ 0.590 in.)	14.88 mm (0.59 in.)
	(BN125-A7 ~ and A8 ~, US)
Brake Camshaft Hole Diameter	12.000 ~ 12.027 mm (0.472 ~ 0.474 in.)	12.15 mm (0.478 in.)
	(BN125-A1~ A6)
	15.000 ~ 15.027 mm (0.591 ~ 0.592 in.)	15.15 mm (0.596 in.)
	(BN125-A7 ~ and A8 ~, US)

ES:Spain
NO:Norway
US:UnitedStates

SpecialTools

InsideCirclipPliers: 57001-143

Line drawing of a pair of pliers (no text or symbols on the image itself)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

Caliper

CaliperRemoval

• Loosenthebanjobolt[A]atthebrakehoselowerend, andtightenitloosely.
• Unscrewthecalipermountingbolts[B], and detach the caliper[C] fromthedisc.
• Unscrewthebanjoboltandremovethebrakehose[D] fromthecaliper(seeBrakeHoseRemoval/Installation).

CAUTION

Immediatelywashawayanybrakefluidthatspills.

NOTE

○ Ifthecaliperistobedisassembledafterremovalandif compressedairisnotavailable,disassemblethecaliper beforethebrakehoseisremoved(seeCaliperDisassembly).

CaliperInstallation

• Installthecaliperandbrakehoselowerend.
  ○Replacethewashersthatareoneachsideofhosefitting withnewones.
• Tighten:

Torque-CaliperMountingBolts:25N·m(2.5kgf·m,18ft·lb)

BrakeHoseBanjoBolt:25N·m(2.5kgf·m,18ft·lb)

• Checkthefluidlevelinthebrakereservoir.
• Bleedthebrakeline(seeBleedingtheBrakeLine).
• Checkthebrakeforgoodbrakingpower,nobrakedrag, andnofluidleakage.

WARNING

Donotattempttodrivethemotorcycleuntilafull brakeleverisobtainedbypumpingthebrakelever untilthepadsareagainstthedisc. Thebrakewill notfunctiononthefirstapplicationoftheleverif thisisnotdone.

CaliperDisassembly

• Removethecaliper(seeCaliperRemoval).
• Removethepadsandspring(seeBrakePadRemoval).
• Usingcompressedair,removethepistons.
  ○Lightlyapplycompressedairtothehosejointopening.

WARNING

To avoid serious injury, never place your fingers or palminidethecaliper opening. If you apply compressed air into the caliper, the piston may crush your hand or fingers.

Caliper

○Insertawoodenboard[A]5mm(0.2in.)thickinsidethe caliperopening.
○Applycompressedair[B]tothebanjoboltholetoallow thepistons[C]toprotrudeandstopatthewoodenboard.
○Removethewoodenboardandpulloutthepistonsby hand.
★ Ifcompressedairisnotavailable, withthebrakehose stillattached, applythebrakelevertoremovethepistons. Theremainingprocessisasdescribedabove.

- Remove: DustSeals[A] FluidSeals(pistonseals)[B] CaliperHolder[C] FrictionBoot[D] BleedValve RubberCap

CAUTION

Immediatelywashawaybrakefluidthatspills.

BN125-A1\~A2

BN125-A3\~

GLO5083BS1 C

CaliperAssembly

- Cleanallpartsotherthantheouterandinnerpads.

CAUTION

Forcleaningtheparts, use only discbrakefluid, isopropylalcohol, orethylalcohol

• Installthebleedvalve[A]andtherubbercap[B].
- Tighten:
Torque-CaliperBleedValve:7.8N·m(0.80kgf·m,69in·lb)
- Replacethefluidseals[A]withnewones,applybrake fluidtothem,andinstalltheminthecaliperbody.Either sideofthefluidsealmayfaceoutboard.
- Checkthedustseals[B]andreplacethemwithnewones iftheyaredamaged.

GL05015BS1 C

GL050402S1 C

11-10BRAKES

Caliper

• Applybrakefluidtotheinsideofthecylindersandtothe outsideofthepistonsandpushthepistons[A]intothe cylinders.
• Checkthefrictionboot[B]anddustboot[C]andreplace themwithnewonesiftheyaredamaged.
• Applyathincoatofsilicongreasetotheholdershafts[D] andtheholderholes.

• Install:
  PadSpring[A]
  CaliperHolder[B]
  PadsandCaliperPadBolts

- Tighten:

Torque-CaliperPadBolts:18N·m(1.8kgf·m,13ft·lb)

- Installthecaliper(seeCaliperInstallation).

CaliperFluidSealDamage

Thefluidseal(pistonseal)[A]isplacedaroundthepistontomaintainclearancebetweenthepadandthedisc. If thesealisinapoorcondition, itcouldleadthepadtowear excessivelyorthebraketodrag, whichmaycausethetemperatureofthediscorthebrakefluidtoincrease.

- Replacethefluidsealifitexhibitsanyoftheconditions listedbelow.

○Brakefluidleakagearoundthepad.

○Brakesoverheat.

○Considerabledifferenceininnerandouterpadwear.

○Sealandpistonarestucktogether.

★Ifthefluidsealisreplaced, replacethedustseal[B]as well. Also, replaceallsealseveryothertimethepadsare changed.

Caliper

CaliperDustSeal/FrictionBootDamage

• Check that the dust seal and friction boot[C] are not cracked, worn, swollen, or other wisedamaged.
• Iftheyshowanydamage,replaceit.

CaliperPistonandCylinderDamage

• Visually inspect the piston[D] and cylinders surfaces for damage.
  ★Replacethecaliperifthecylinderandpistonarebadly scoredorrusty.

CaliperHolderShaftsE

CaliperHolderShaftWear

Thecaliperbodymustslidesmoothlyonthecaliperholder shafts.Ifthebodydoesnotslidesmoothly,onlyonepad willwearmorethantheother,padwearwillincrease,and constantdragonthediscwillraisethebrakeandbrakefluid temperature.

• Visually inspect the caliper holders' shafts for excessive wear or warp, and rubber friction boots for damage.
  ★ Iftherubberfrictionbootisdamaged, replacetherubber frictionboot.
  ★ Ifthecaliperholdershaftisdamage, replacethecaliper holder.

FrontBrakePads

BrakePadRemoval(BN125-A1 \~A2)

• Removethecaliperwiththehoseattached.
• Remove:

CaliperPadBolts[A]

OuterPad[B]

- Removetheinnerpad(pistonsidepad)[C].

BrakePadRemoval(BN125-A3 \~)

• Loosenthecaliperpadbolts[A].
• Removethecaliperwiththehoseattached.
• Remove:

CaliperPadBolts

Pads

BrakePadInstallation(BN125-A1 \~A2)

• Beforeinstallation,cleanthepadswithahigh-flashpoint solvent.
• Pushthecaliperpistoninbyhandasfarastheywillgo.
  ○Theinnerpadhasawear-protectplate[A].Donotmixup theouterpadandtheinnerpad.
• Tighten:

Torque-CaliperPadBolts:18N·m(1.8kgf·m,13ft·lb)

BrakePadInstallation(BN125-A3

• Beforeinstallation,clanthepadswithahigh-flashpoint solvent.
• Pushthecaliperpistonsinbyhand[A]asfarastheywill go.
  • Installthepadsandcaliperpadbolts.
• Tighten:

Torque-CaliperPadBolts:18N·m(1.8kgf·m,13ft·lb)

- Instalthecaliper(seeCaliperInstallation).

WARNING

Donotattempttodrivethemotorcycleuntilafull brakeleverisobtainedbypumpingthebrakelever untilthepadsareagainstthedisc. Thebrakewill notfunctiononthefirstapplicationoftheleverif thisisnotdone.

BrakePadWearInspection

- RefertotheBrakePadWearInspectioninthePeriodic Maintenancechapter.

Close-up of hands assembling mechanical components with visible wiring and a labeled section (no readable text or symbols)

MasterCylinder

MasterCylinderRemoval

• Removethebrakefluidfromthereservoirwithasyringe orothersuitabledevice.
• Disconnectthefrontbrakelightswitchconnectors[A].
• Removethebanjobolt[B]todisconnectthebrakehose fromthemastercylinder(seeBrakeHoseRemoval/Installation).
  When removing the brakehose, temporarily secure the endof the brakehosetosamehigh placeto keep fluid lossto a minimum.
• Unscrewtheclampbolts[A], and takeoffthemastercylinder[B] as an assembly with the reservoir, brakelever, and brakeswitch installed.
  When removing themastercylindertakecarenottospill thebrakefluidonthepaintedorplasticparts.

CAUTION

Immediatelywashawayanybrakefluidthatspills.

MasterCylinderInstallation

• Setthemastercylindertomatchitsmatingfacetothe punchedmark[A]ofthehandlebar.
• Themastercylinderclampmustbeinstalledwiththearrowmark[B]facedupward.
• Tightentheupperclampbolt[C]first,andthenthelower clampbolt[D].Therewillbeagapatthelowerpartofthe clampaftertightening.

Torque-MasterCylinderClampBolts:8.8N·m(0.90kgf·m, 78in·lb)

• Replacethewashersthatareoneachsideofthehose fittingwithnewones.
• Tighten:

Torque-BrakeHoseBanjoBolt:25N·m(2.5kgf·m,18ft·lb)

• Bleedthebrakeline(seeBleedingtheBrakeLine).
• Checkthebrakeforgoodbrakingpower,nobrakedrag, andnofluidleakage.

MasterCylinderDisassembly

• Removethemastercylinder(seeMasterCylinderRemoval).
• Removethereservoircapanddiaphragm, and pour the brakefluid into a container.
• Unscrewthepivotnutandpivotbolt, andremovethe brakelever.
• Pullthedustcoveroutofplace, andremovethecirclip. SpecialTool-InsideCirclipPliers:57001-143
• Pulloutthepistonassembly[A], returnspring[B].

CAUTION

Donotremovethesecondarycup[C]fromthepistonsinceremovalwilldamageit.

Mechanical assembly diagram showing components labeled A and B, with no readable text or symbols beyond labels

MasterCylinderAssembly

- Beforeassembly, cleanallpartsincludingthemaster cylinderwithbrakefluidoralcohol.

CAUTION

Exceptforthediscpadsanddisc,useonlydisc brakefluid,isopropylalcohol,orethylalcoholfor cleaningbrakeparts.Donotuseanyotherfluidfor cleaningtheseparts,Gasoline,engineoil,orany otherpetroleumdistillatewillcausedeteriorationof therubberparts.Oilspilledonanypartwillbedifficulttowashoffcompletely,andwilleventuallydeterioratetherubberusedinthediscbrake.

• Applybrakefluidtotheremovedpartsandtotheinner wallofthecylinder.
• Takecarenottoscratchthepistonortheinnerwallofthe cylinder.
• Applysiliconegrease(ex.PBCgrease)tothefollowing points.
  BrakeLeverPivotBolt BrakeLeverPivotContact DustCover

- Tighten:

Torque-BrakeReservoirCapScrews:1.5N·m(0.15kgf·m, 13in·lb)

BrakeLeverPivotBolt:5.9N·m(0.60kgf·m,52in·lb)

BrakeLeverPivotLocknut:5.9N·m(0.60kgf·m, 52in·lb)

MasterCylinderInspection(VisualInspection)

• Disassemblethemastercylinder.
• Check that there are nos scratches, rust or pitting on the inner wall [A] of them a Master cylinder and on the outside of the piston [B].
  ★Ifamastercylinderorpistonshowsanydamage,replace them.
• Inspecttheprimarycup[C]andsecondarycup[D].
  ★Ifacupisworn,damagedsoftened(rotted),orswollen, thepistonassemblyshouldbereplacedtorenewthe cups.
  ★Iffluidleakageisnotedatthebrakelever,thepistonassemblyshouldbereplacedtorenewthecups.
• CheckthedustcoverEfordamage.
  ★Ifthedustcoverisdamaged,replaceit.
• Checktherelief[F]andsupply[G]portsarenotplugged.
  ★Ifthereliefportbecomesplugged,thebrakepadswill dragonthedisc.Blowtheportscleanwithcompressed air.
• Checkthepistonreturnsprings[H]foranydamage.
  ★Ifthespringisdamaged,replaceit.

FrontBrakeDisc

BrakeDiscRemoval

• Removethewheel(seeWheels/Tireschapter).
• Unscrewthemountingbolts, and takeoffthedisc.

BrakeDiscInstallation

• Installthebrakedisconthewheelsothatthemarkedside [A]facesout.
• Tighten:

Torque-BrakeDiscMountingBolts[B]:27N·m(2.8kgf·m, 20ft·lb)

BrakeDiscWear

• Visuallyinspectthedisk.
  ★Replacethediscifitshowsanydamageorcrack.
• Measurethethicknessofthedisc[A]atthepointwhereit haswornthemost.
  ★ Ifthedischaswornpasttheservicelimit,replaceit. [B]MeasuringArea

BrakeDiscThickness

Standard: 3.8 \~ 4.2 mm (0.150 \~ 0.165 in.) 4.3 \~ 4.7 mm (0.169 \~ 0.185 in.) (BN125-A3, Norway and Spain) (BN125-A4\~ )

ServiceLimit:3.5mm(0.138in.) 4.0mm(0.157in.) (BN125-A3,NorwayandSpain) (BN125-A4\~ )

Technical drawing of a mechanical bearing assembly with circular components and mounting holes (no text or symbols)

BrakeDiscWarp

• Usingajack, raisethewheelofftheground(see Wheels/Tireschapter).
  SpecialTool-Jack:57001-1238
  ○Forfrontdiscinspection,turnthehandlebarfullytoone side.
• Setupadialgaugeagainstthedisc[B]asshownand measureddiscrunout,whileturning[A]thewheelbyhand.
  ★ Ifrunoutexceedstheservicelimit, replacethedisc.

DiscRunout

Standard: Less than 0.12mm (0.008in.) or less ServiceLimit: 0.3mm (0.012in.)

BrakeFluid

BrakeFluidLevelInspection

- RefertotheBrakeFluidLevelInspectioninPeriodicMaintenancechapter.

BrakeFluidChange

- RefertotheBrakeFluidChangeinPeriodicMaintenance chapter.

Brake Line Bleeding

- RefertotheBrakeLineBleedinginPeriodicMaintenance chapter.

BrakeHose

BrakeHoseRemoval/Installation

CAUTION

Brakefluidquicklyruinspaintedorplasticsurfaces;anyspilledfluidshouldbecompletelywiped upimmediatelywithwetcloth.

• Whenremovingthebrakehose,takecarenottospillthe brakefluidonthepaintedorplasticparts.
• When removing the brakehose[A], temporarily secure the end of the brakehosetosome high placeto keep fluid loss to a minimum.
• Therearewashers[B]oneachsideofthebrakehose fitting. Replacethemwithnewoneswheninstalling.
• Wheninstallingthehoses, avoidsharpbending, kinking, flatteningortwisting, and routethehos according to Cable, WireandHoseRoutingsection in Appendix chapter.
• Tighten:

Torque-BrakeHoseBanjoBolts[C]:25N·m(2.5kgf·m,18 ft·lb)

- Bleedthebrakelineafterinstallingthebrakehose(see BrakeLineBleeding).

BrakeHoseInspection

- RefertotheBrakeHoseCheckinthePeriodicMaintenancechapter.

11-18BRAKES

RearBrakePedalandBrakeCable

BrakePedalPositionInspection/Adjustment

- Check that the brake pedal [A] is in the correct position.

PedalPosition[C]

Standard: About80mm(3.15in.) abovefootpegtop [B]

★Ifitisincorrect,adjustthebrakepedalposition.

• Loosenthelocknut[A], and turnthead adjusting bolt[B] until the brake pedal is correctly positioned.
• Tightenthelocknut.
• Check:
  RearBrakeLightSwitchTiming(seeElectricalSystem chapter)
  BrakePedalFreePlay(seeBrakePedalFreePlayInspection)

NOTE

○ Ifthepedalpositioncannotbeadjustedbyturningthe adjustingbolt,thebrakepedalmaybeformedorin-correctlyinstalled.

BrakePedalFreePlayInspection/Adjustment

- RefertotheBrakePedalFreePlayCheckinthePeriodic Maintenancechapter.

BrakePedalRemoval

- Removtheadjustingnutfromtheendofthebrakerod, andtakeoffthejointandbrakerodfromthebrakecam lever.

- Remove:

Bands[A]

Cover[B]

FrontFootpegMountingBolts[C]

- Remove:

CotterPinandJointPin[A]

BrakeCableNut[B]

BrakePedalBolts[C]

RearBrakeLightSwitchSpring[D]

RearBrakePedalandBrakeCable

- Removethebrakepedal[A]andreturnspring[B].

BrakePedallInstallation

• Applygreasetothebrakepedalpivot.
• Temporarily install the braker returns spring onto the brake shaft and hook the spring onto the brake pedal.
• Push[B]thebrakepedal[A]acrossthebrakeshaftand insertthepedalontotheshaft.

• Lightlytightenthebrakepedalbolt[A].
- Prythebrakereturnspring[B]ontothebrakeshaftwitha screwdriver.
- Tightenthebrakepedalbolt.
Torque-BrakePedalBolt:9.8N·m(1.0kgf·m,87ft·lb)

• Hooktherearbrakelightswitchspringandbrakereturn springlowerend.

• Insertanewcotterpinthroughthejointpin, andspread itsends.

• Check:
  BrakePedalPosition(seeBrakePedalPositionInspection/Adjustment)
  BrakePedalFreePlay(seePeriodicMaintenancechapter)
  RearBrakeLightSwitchTiming(seePeriodicMaintenancechapter)

• Installthepartsremoved.

BrakeCableRemoval

- Remove:

Bands[A]

Cover[B]

FrontFootpegMountingBolts[C]

11-20BRAKES

RearBrakePedalandBrakeCable

- Remove: CotterPinandJointPin BrakeCableNut[A]

• Removethesilencer(seeEngineTopEndchapter).
• Removetheadjustingnutontheendofthebrakerod, andtakeoffthejointpinandbrakerodfromthebrake camlever.
• Removethecabledustboot[A].
• Pulltheoutercablehousing[B]forward,andtakeoutthe innercable[C]fromthegrooveofthestay.
• Pullthebrakecableoutoftheframe.

BrakeCableInstallation

• Lubricatethecablebeforeinstallation.
• Adjustthebrakepedalpositionandfreeplay.

BrakeCableLubrication

- Wheneverthecableisremoved,orinaccordancewiththe PeriodicMaintenanceChart,lubricatethebrakecable. RefertoGeneralLubricationinthePeriodicMaintenance chapter.

○Applyathincoatingofgreasetothecableupperend.
○Useacommerciallyavailablepressurecablelubricatorto lubricatethecable.
With the cable disconnected at both ends, the cable should move freely in the cable housing.

RearBrakePanelandDrum

BrakePanelRemoval

• Removetherearwheel(seeWheels/Tireschapter).
• Separatethebrakepanelfromthewheelhub.

BrakePanelInstallation

- Fitthebrakepanelintotherearwheel, and then install therearwheel (see Wheels/Tireschapter).

BrakePanelDisassembly

• Removethebrakepanel(seeBrakePanelRemoval).
• Before removing the brake cam lever, mark[A] the position of the cam lever so that it can be installed later in the same position.

• Beforeeremovingthebrakeliningwearindicator, markthe positionofthebrakecamshaftandliningwearindicator sothatitcanbeinstalledlaterinthesameposition.

• Usingacleancloth[B]aroundtheliningstopprevent greaseoroilfromgettingonthem,removethebrake shoes[A]bypullingup[C]onthecenterofthelinings.

• Removethesprings[D]toseparatethetwoshoes.

Close-up of mechanical components with no visible text or symbols

BrakePanelAssembly

• Cleantheoldgreasefromthecamshaftandbrakeshoe anchorpin,andregreasethem.
  ○Applygreasetothecenterofshaftandverylightlyonthe camsurfaces.Donotovergrease.
• Pushthecamshaftintothepanelsothatthetriangular mark[A]onthecamsurfacepointstowardthecenterof thepanel.

WARNING

ImproperInstallationwillcauseineffectivebraking.

• Visuallyinspectthebrakeshoespringsforbreaksordistortion.
  ★ Ifthespringsaredamagedinanyway, replacethem.
• Fitthelargespring[A]andsmallspring[B]ontothebrake shoesasshown.
• Wrapacleanclotharoundtheliningstoppreventgrease oroilfromgettingonthem, and install theshoesonthe brakepanel.

Mechanical component diagram showing internal parts and a labeled section (A), no readable text or symbols present.

RearBrakePanelandDrum

• Installthebrakecamsealandfittheindicator[A]onthe serrationsothatitpointstotheextremerightoftheUS-ABLERANGE[B].
• Installthecamleverinitsoriginalpositiononthe camshaft,andtightenitsbolt.

BrakePanellInspection

• Removethebrakepanel(seeBrakePanelRemoval).
• Checkthebrakecamshaftdiameterandthebrake camshaftholediameterofbrakepanels.

BrakeCamshaftDiameter

Standard:

BN125-A1 \~ A6 11.957 \~ 11.984 mm

(0.471\~0.472in.)

BN125-A7 \~ and A8 \~, United 14.95\~ 14.99mm

StatesModels (0.589\~0.590in.)

ServiceLimit:

BN125-A1\~A6 11.88mm(0.47in.)

BN125-A7 \~ and A8 \~, United 14.88mm(0.59in.)

StatesModels

BrakeCamshaftHoleInsideDiameter

Standard:

BN125-A1\~A6 12.000\~12.027mm(0.472\~0.474in.)

BN125-A7 \~ and A8 \~, 15.000\~ 15.027mm(0.591

UnitedStatesModels \~ 0.592in.)

ServiceLimit:

BN125-A1\~A6 12.15mm(0.478in.)

BN125-A7 \~ and A8 \~, 15.15mm(0.596in.)

UnitedStatesModels

★Iftheyareexceedtheservicelimit,replacetheaffected partsofthem.

BrakeShoeLiningWearInspection

- RefertotheBrakeShoeLiningWearInspectioninthe PeriodicMaintenancechapter.

RearBrakePanelandDrum

BrakeShoeSpringsInspection

• Visuallyinspectthebrakeshoespringsforbreaksordistortion.
  ★ Ifthespringsaredamagedinanyway, replacethem.
• Measurethefreelengthofthebrakeshoesprings.
  ★ Ifeitherisstretchedbeyondtheservicelimit,replaceboth springs.

BrakeShoeSpringsFreeLength

Standard:

Long 44.5 \~ 45.5 mm (1.752 \~ 1.791 in.)

Short32.5mm(1.280in.)

ServiceLimit:

Long 47.2mm(1.86in.)

Short34.1mm(1.34in.)

BrakeDrumWearInspection

• Removetherearwheel(seeWheels/Tireschapter).
• Removethebrakepanel.
• Measuretheinsidediameter[A]ofthedrum.

○ Usecalipersandmeasureatseveralpoints.

★ Ifanymeasurementisgreaterthantheservicelimit,re-placethewheelhub.
★ Ifthedrumiswornunevenlyorscored, lightlyturnthe drumonabrakedrumlatheorreplacethewheelhub.Do notturnthedrumbeyondtheservicelimit.

DrumInsideDiameter

Standard: 130.00 \~ 130.16 mm (5.118 \~ 5.124 in.)

ServiceLimit:130.75mm(5.148in.)

Suspension

TableofContents

Exploded View.... 12-2

Specifications 12-6

Special Tools 12-7

Front Fork 12-8

Fork Oil Change 12-8

Fork Removal 12-8

Fork Installation.... 12-8

Fork Disassembly 12-9

Fork Assembly 12-10

Inner Tube, Outer Tube Inspection 12-11

Spring Inspection 12-12

Rear Shock Absorbers 12-13

Spring Preload Adjustment 12-13

Removal.... 12-13

Installation.... 12-13

Swingarm.... 12-14

Swingarm Removal 12-14

Swingarm Installation.... 12-14

Swingarm Bearing Removal 12-14

Swingarm Bearing Installation 12-14

Swingarm Pivot Check 12-15

SwingarmBearing, SleeveInspection....12-15

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf	mft·lb
1FrontForkTopPlugs232.317
2FrontForkBottomAllenBolts202.015
3	FrontForkClampBolt(Upper)	202.015
4FrontForkClampBolt(Lower)343.525

5.Forkcover(BN125-A1\~A5)
6. Brakehoseclamp(BN125-A1only)
7. Other than the US and CAM models
8. Speedmetercableguide and Brakehoseguide (USandCAModels)

FO:Applyforkoil.

L: Applyanon-permanentlockingagent.

M:Applymolybdenumdisulfidegrease.

R: ReplacementParts

CA:Canada

US:UnitedStates

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf	mft·lb
1	Rear Shock Absorber Nuts and Bolts	34	3.5	25
2SwingarmPivotNut9810.072

1. Chainguard(BN125-A1 \~ A2only)
2. Facethemanufacture's marksout.

Specifications

ItemStandard
FrontFork(PerOneUnit)
ForkInnerTubeDiameter33mm(1.30in.)
ForkSpringSettingNon-adjustable
AirPressureAtmosphericpressure(non-adjustable)
DamperSettingNonadjustable
ForkOilViscositySHOWASS-8orequivalent
ForkOilCapacity191±2.5mL(6.46±0.085USoz.)(completelydry)
ForkOilLevel218±2mm(8.58±0.08in.)belowfrominnertubetopwithfully
ForkSpringFreeLength398.5mm(15.7in.)(Servicelimit:391mm(15.4in.))
RearShockAbsorbers
Spring Preload	1st step (Adjustable range : 1st ~ 5th steps)
GasPressureNogas

SpecialTools

ForkCylinderHolderHandle: 57001-183

Simple line drawing of a T-shaped tool or rod with a base, no text or symbols present.

ForkCylinderHolderAdapter: 57001-1011

Technical line drawing of a conical mechanical component (no text or symbols)

OilSeal&BearingRemover: 57001-1058

Technical line drawing of mechanical components including a shaft, flange, and housing (no text or symbols)

BearingDriverSet: 57001-1129

Isometric line drawing of a box containing multiple circular components, no text or symbols present

ForkOuterTubeWeight: 57001-1218

Technical line drawing of a mechanical component with no visible text or symbols

FrontForkOilSealDriver: 57001-1219

Technical line drawing of a cylindrical mechanical component with internal cavities (no text or symbols)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

HookWrench(Owner'sTool): 92110-1143

Line drawing of a wrench tool (no text or symbols on the object itself)

FrontFork

ForkOilChange

- RefertotheFrontForkOilChangeinthePeriodicMaintenancechapter.

ForkRemoval

★ Iftheforklegistobedisassembled, loosenthetopplug beforehand. Toloosentheforktopplug, loosenthefork upperclampbolts.

- Remove: BrakeCaliper(seeBrakeschapter) FrontWheel(seeWheels/Tirechapter)

★ Iftheforklegistobedisassembled, loosentheforkbottomAllenbolt[A]beforehand.

- Loosentheupper[A]andlowerforkclampbolts[B].

- Loosentheturnsignallightholderboltandnut[C].

- Withatwistingmotion,worktheforkleg[A]downandout.

ForkInstallation

• Installtheforksothatthetopend[A]oftheinnertubeis flushwiththeuppersurfaceofthesteeringstemhead[B].
• Runthecables, wires, and hosesasshownintheCable, Wire, and HoseRoutingsectionoftheAppendixchapter.
• Tighten:

Torque-FrontForkClampBolts(Upper):20N·m(2.0 kgf·m,15ft·lb)

FrontForkClampBolts(Lower):34N·m(3.4 kgf·m,25ft·lb)

ForkTopPlugs:23N·m(2.3kgf·m,17ft·lb)

TurnSignalLightHolderNut:5.9N·m(0.60kgf·m, 52in·lb)

• Installthefrontwheel(seeWheels/Tireschapter).

FrontFork

- Checkthefrontbrakeeffectivenessafterinstallation.

A WARNING

Donotattempttoridethemotorcycleuntilafull brakeleverisobtainedbypumpingthebrakelever untilthepadsareagainstthedisc.Thebrakewill notfunctiontothefirstapplicationoftheleverif thisisnotdone.

ForkDisassembly

• Removethefrontfork(seeFrontForkRemoval).
• Draintheforkoil(seePeriodicMaintenancechapter).
  ○ The following parts are removed during draining the fork oil.

TopRug

Spacer

ForkSpringSeat

ForkSpring

• Holdthefrontforkhorizontallyinavise[A].
• Stopthecylinderunit[B]fromturningbyusingthespecial toolsandAllenwrench.
• UnscrewtheAllenbolt[C], andtakethegasketoutofthe bottomoftheoutertube.

SpecialTools-ForkCylinderHolderHandle:57001-183[D] ForkCylinderHolderAdapter:57001-1011 E

• Takethecylinderunitoutoftheinnertube.

- Removethedustseal[A]fromtheoutertubewithascrewdriver.

- Removetheretainingring[A]fromtheoutertubewitha screwdriver.

12-10 SUSPENSION

FrontFork

- Usetheforkoutertubeweight[A]toseparatetheouter tube[B]fromtheinnertube[C].Holdingtheinnertube byhand,pulltheoutertubeseveraltimestopulloutthe innertube.

SpecialTool-ForkOuterTubeWeight:57001-1218

• Takeoutthecylinderbaseoutoftheoutertube.

- Removetheguidebushings[A], washer[B], and oilseal [C] from the innertube.

ForkAssembly

- ChecktheO-ringonthetopplugandreplaceitwithanew one.

- Replacethefollowingpartswithnewonesafterremoval. DustSeal[A]

RetainingRing[B]

OilSeal[C]

InnerGuideBushing[D]

OuterGuideBushingE

BottomAllenBoltGasket[F]

- Putthecylinderunit[A]withthespringintotheinnertube[B]protrudingfromtheinnertube,andinstallthecylinderbase[C]ontothebottomendofthecylinderunit.

○Installthecylinderbasewiththetaperedend[D]up.

- Installtheinnertube,cylinderunit,andcylinderbaseas asetintotheoutertube.

- Installthenewguidebushing[A]withausedguidebushing[B]onitbytappingtheusedguidebushingwiththe forkoilsealdriver[C]untilitstops.

○Thesplit[D]ofthebushingsshouldfacetowardthesideof thevehicle.

SpecialTool-FrontForkOilSealDriver:57001-1219

○Removetheusedguidebushing.

FrontFork

- Applymolybdenumdisulfidegreasetotheoilseallipsand installthewasherandoilseal[A]intotheoutertube.

SpecialTool-FrontForkOilSealDriver:57001-1219[B]

- Installtheretainingringanddustsealbyhand.

• Putthenewgasketonthebottomoftheoutertube.
• Applyanon-permanentlockingagenttothethreadsof theAllenboltandscrewtheAllenboltintothebottomof theoutertube.
• Holdtheoutertubehorizontallyinavise[A].
• Holdthecylinderunit[B]withthespecialtoolsandAllen wrench,tightentheAllenbolt[C].

Torque-BottomAllenBolt:20N·m(2.0kgf·m,15ft·lb)

SpecialTools-ForkCylinderHolderHandle:57001-183[D]

ForkCylinderHolderAdapter:57001-1011

E

- Pourinthespecifiedtypeofoilandinstallthepartsremoved.

ForkOilViscosity:

SHOWASS-8orequivalent

ForkOilCapacity(completelydry):

191±2.5mL(6.46±0.085USoz.)

InnerTube, OuterTubeInspection

• Visuallyinspecttheinnertube[A]andrepairanydamage.
• Nickorrustdamagecansometimesberepairedbyusing awet-stonetoremovesharpedgesorraisedareaswhich causesealdamage.
  ★ Ifthedamageisnotrepairable,replacetheinnertube. Sincedamagetotheinnertubedamagestheoilseal, replacetheoilsealwhenevertheinnertubeisrepaired orreplaced.

CAUTION

Iftheinnertubeisbadlybentorcreased,replace it.Excessivebending,followedbysubsequent straightening,canweakentheinnertube.

• Temporarily assemble the inner and outertubes[B], and pump them back and forth manually to check for smooth operation.
  ★ If you feel binding or catching, the inner and outer tubes must bereplaced.

WARNING

Astraightenedinnerorouterforktubemayfailin use, possibly causing an accident. Replace abadly bentordamagedinneroroutertube, and inspect theothertubecarefully before reusing it.

FrontFork

SpringInspection

• Sincetheforkspring[A]becomesshorterasitweakens, checkitsfreelength[B]todetermineitscondition.
  ★Ifthespringofeitherforklegisshorterthantheservice limit, it must bereplaced. Ifthelengthofthereplacement spring and that oftheremainingspring vary greatly, the remainingsprings should also bereplaced in order to keep the fork legs balanced form motorcycle stability.

ForkSpringFreeLength

Standard:398.5mm(15.7in.)

ServiceLimit:391mm(15.4in.)

RearShockAbsorbers

SpringPreloadAdjustment

- Toadjustthespringforce, turntheadjusteroneachshock absorbertothedesiredposition.

Owner's Tool-HookWrench:92110-1143[A]

SpringPreloadAdjustment

AdjusterPosition1234					5
SpringTension→ Stronger

WARNING

Ifapairofadjustersarenotadjustedequally, handlingmaybeimpairedandahazardouscondition mayresult.

Removal

- Raisetherearwheelofftheground.

SpecialTool- Jack:57001-1238

- Unscrew the upper mounting nut and lower mounting bolts[A], and removetherearshockabsorber[B].

Close-up of a car engine component with a spring and labeled section A (no readable text or symbols)

Installation

• Installtherearshockabsorbers.
- Tightentherearshockabsorbernutsandbolts.

Torque-RearShockAbsorberMountingNutandBolt:34 N·m(3.5kgf·m,25ft·lb)

Swingarm

SwingarmRemoval

- Remove:

ChainCover

RearWheel(seeWheels/Tireschapter)

RearShockAbsorberLowerMountingBoltsA

SilencerB

BrakeCableC

PivotNut[D]

FrontE

• Pullouttheswingarmpivotshaft, andremovethe swingarm[A].
• Separatethedrivechain.

SwingarmInstallation

• Applyplentyofgreasetotheinsideoftheneedlebearings andgreaseseals.
• Loopthedrivechain[A]ontotheswingarm.
  • Installtheswingarm.
• Installtheremovedparts(seeappropriatechapters).
• Tightenthefollowing:

Torque-SwingarmPivotNut:98N·m(10.0kgf·m,72ft·lb)

RearShockAbsorberBolts:34N·m(3.5kgf·m,25ft·lb)

SwingarmBearingRemoval

- Remove:

Swingarm(seethischapter)

Sleeve

GreaseSeals

- Removetheneedlebearings[A], using the oil seal & bearingremover[B].

SpecialTool-OilSeal&BearingRemover:57001-1058

SwingarmBearingInstallation

• Applyplentyofgreasetothenewneedlebearings, sleeve,andgreaseseallip.
• Positionthebushings[A]asshown, usingasuitablebearingdriverinthebearingdriverset.
  Besuretoinstalltheneedlebearingsothatthemanufacturer'smarksarefacedout. Thispreventsbearingdamage.

SpecialTool-BearingDriverSet:57001-1129

Mechanical assembly diagram showing springs and brackets with no visible text or symbols

Close-up of a mechanical assembly with springs and components, no visible text or symbols

Swingarm

SwingarmPivotCheck

- Remove:

RearWheel(seeWheels/Tireschapter)

RearShockAbsorberBolts

- Movetheswingarmupanddowntocheckforabnormal friction, and pushandpullittocheckforbushingsplay [A]. Asmallamountofplayonthepivotisnormalandno correctiveactionisneeded. However, if excessive play is felt, checktheswingarmbushingsforwearandreplace themifnecessary.

SwingarmBearing, SleeveInspection

CAUTION

Donotremovethebearingforinspection.Removal maydamagethem.

- Visuallyinspecttheswingarmneedlebearing[A].

○ Therollersinaneedlebearingnormallywearverylittle, andwearisdifficulttomeasure. Insteadofmeasuring, inspectthebearingintheswingarmforabrasion, color change, orotherdamage.

★ Ifthereisanydoubtastotheconditionofanyoftheneedlebearingsorsleeves[B],replaceallthesleeves,and needlebearingsasaset.

Steering

TableofContents

Exploded View 13-2

Special Tools 13-4

Steering 13-5

Steering Inspection 13-5

Steering Adjustment.... 13-5

Steering Stem.... 13-6

Steering Stem Removal 13-6

Steering Stem Installation 13-7

Steering Stem Warp 13-8

Steering Stem Bearing 13-9

Steering Stem Bearing Removal.... 13-9

Steering Stem Bearing Installation.... 13-9

SteeringStemBearingWear, Damage....13-9

Steering Stem Bearing Lubrication 13-9

Handlebar 13-10

HandlebarRemoval(BN125-A1/A2)....13-10

Handlebar Removal (BN125-A3 \~) 13-10

HandlebarInstallation(BN125-A1/A2)....13-10

Handlebar Installation (BN125-A3 \~ ) 13-11

RearViewMirrorRemoval(Europe)....13-11

Rear View Mirrors Installation (Europe).... 13-11

BN125-A1\~

ExplodedView

No.Fastener		Torque			Remarks
		N·mkgf·mft·lb
1SteeringStemHeadBolts444.533
2SteeringStemNutHand-tight		or4.9	Hand-tight or0.50	Hand-tight or43in·lb
3HandlebarNuts343.525
4	Handlebar Weight Screws	-	-	-	L
5	HandlebarSwitchHousingScrews	3.4	0.35	30in·lb
6	Front Fork Clamp Bolts (Lower)	34	3.5	25	S
7	Front Fork Clamp Bolts (Upper)	20	2.0	15	S
8	Handlebar holder clamp bolts	20	2.0	15	S

1. BN125-A3\~
   AD: Applyadhesive.
   G: Applygrease.
   L: Applyanon-permanentlockingagent.
   S: Followthespecifictighteningsequence.

SpecialTools

SteeringStemBearingDriver: 57001-137

Technical line drawing of a cylindrical mechanical component with a flanged end and internal features (no text or symbols)

SteeringStemBearingDriverAdapter,34.5:57001-1074

Simple line drawing of a cylindrical mechanical component (no text or symbols)

HeadPipeOuterRacePressShaft: 57001-1075

Technical line drawing of a mechanical component with threaded ends and a cylindrical shaft (no text or symbols)

HeadPipeOuterRaceDriver,51.6:57001-1076

Technical line drawing of a mechanical component with a flanged top and central hole (no text or symbols)

HeadPipeOuterRaceDriver,46.5:57001-1106

Technical line drawing of a mechanical component with a flanged top and circular base (no text or symbols)

SteeringStemNutWrench: 57001-1100

Line drawing of a mechanical wrench with a curved handle and two notches (no text or symbols)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

Steering

SteeringInspection

- RefertotheSteeringInspectioninthePeriodicMaintenancechapter.

SteeringAdjustment

- RefertotheSteeringAdjustmentinthePeriodicMaintenancechapter.

13-6STEERING

SteeringStem

SteeringStemRemoval

• Loosenthesteeringstemheadbolt[A].
• Opentheheadlightbodyandpullofftheconnectorsintheheadlightbody(seeElectricalSystemchapter).
• Removetheclutchcableupperendandleadconnector.
• Loosentheturnsignallightholderboltsandnuts[B].

- Removethenuts[A]andtakeofftheheadlightbody[B].

- Remove:

SteeringStemHeadBolt[A] SteeringStemHead[B] FrontForkC ○Removethesteeringstemheadwiththemeterunitand handlebarleftinstalled.

- Pushuponthestembase[A], andremovethestemnut [C] with thesteeringstemnutwrench[B], then remove thesteeringstem.

SpecialTool-SteeringStemNutWrench:57001-1100

- Remove:

LowerInnerRaceandSteelBalls(20)

SteeringStemCap[A]

UpperInnerRaceandSteelBalls(19)

Close-up of a motorcycle's head and side components, labeled A and B, with no visible text or symbols beyond labels.

Close-up of a person wearing a helmet and safety goggles, with no visible text or symbols

SteeringStem

SteeringStemInstallation

- Applygreasetotheupperandlowerouterracesintheheadpipesothathesteelballswillstickinplaceduringsteminsertion.Installtheuppersteelballs(23)[A]andlowersteelballs(23).Allthesteelballsarethesamesize.

• Putontheupperinnerraceandsteeringstemcap[A]and insertthesteeringstemintotheheadpipe.

• Installthestemnut[B]sothattherecessedside[C]faces down.

• Whentheracesarereplacedwithnewones,tightenthe stemnutto20N·m(2.0kgf·m,14.5ft·lb)oftorquewiththe stemnutwrench[A]tosettletheracesinplace.Totighten thestemnuttothespecifiedtorque,hookthewrenchon thestemnut,andpullthewrenchattheholewith108N (11kgf)offorce[B]inthedirectionshown.

• Loosenthestemnutandadjustthesteering(seethis chapter).

• Installtheturnsignallightunit.

○TheleftturnsignallightunithasanLmark[A]onit,andtherightturnsignallightunithasanRmark[B].

○Tighten:

Torque - Turn Signal Light Holder Nuts: 5.9 N·m (0.60 kgf·m, 52in·lb)

• Runthethrottlecables[A], clutchcable[B], andturnsignallightleads[C]asshown. Front[D]

Close-up of two black electronic components with labeled parts A and B, shown against a plain background (no readable text or symbols)

SteeringStem

• Installthefrontfork(seeSuspensionchapter).

NOTE

○ Installthefrontforkatthecorrectposition. Tightenthe forkupperclampbolts[A]first, nextthestemheadbolt [B], lasttheforklowerclampbolts.

Torque-FrontForkClampBolts(Upper):20N·m(2.0 kgf·m,15ft·lb)

SteeringStemHeadBolt:44N·m(4.5kgf·m,33ft·lb)

FrontForkClampBolts(Lower):34N·m(3.5 kgf·m,25ft·lb)

• Installtheremovedparts.

WARNING

Donotimpedethehandlebarturningbyroutingthe cables,harnessesandhosesimproperly(seeGeneralInformationchapter).

- Checkandadjustthefollowingitems.

ThrottleCables(seeFuelSystemchapter)

ClutchCable

RearViewMirrors

- Checkthefrontbrakeeffectiveness.

WARNING

Donotattempttoridethemotorcycleuntilafull brakeleverisobtainedbypumpingthebrakelever untilthepadsareagainstthedisc. Thebrakeswill notfunctiononthefirstapplicationoftheleverif thisisnotdone.

SteeringStemWarp

- Whenever the steering stem [A] is removed, or if the steering cannot be adjusted for smooth action, check the steering stem for straightness.

★Ifthesteeringstemisbent,replacetheeeringstem.

GN050101S1 C

SteeringStemBearing

SteeringStemBearingRemoval

★ Ifthebearingisdamaged,removeit.
- Toremovetheouterraces[A]pressedintheheadpipe, insertabar[C]intotheheadpipe[B], andhammerevenly around the circumference of the oppositer acetodriveit out.

• Hammerthebottom[A]ofthelowerinnerracewitha chisel.
  ○Usingasuitablebar, pryouttheinnerracefromthestem. GreaseSeal[B] LowerInnerRace[C]

SteeringStemBearingInstallation

• Replacethebearingouterraceswithnewones.
• Applygreasetotheouterraces, and drivetheminto the headpipeatthesametime.

SpecialTools-HeadPipeOuterRacePressShaft:57001 -1075[A]

HeadPipeOuterRaceDriver, 51.5:57001

-1076[C]

HeadPipeOuterRaceDriver, 46.5:57001

-1106[B]

• Replacethestembearinginnerracewithnewones.
• Applygreasetothelowerinnerrace[A], anddriveitonto thestem[B].

SpecialTools-SteeringStemBearingDriver:57001-137 [C]

Steering Stem Bearing Driver Adapter, 34.5:57001-1074[D]

SteeringStemBearingWear, Damage

• Removethesteeringstem(seethischapter).
• Usingahigh-flashpointsolvent, washthe bearings, clean of grease and dirt, and examinetheraces and balls.
• Visuallychecktheballsorraces.
  ★ Iftheballsorracesareworn, orifeitherraceisdented, replacebothracesandalltheballsforthatbearingasa set.

SteeringStemBearingLubrication

- RefertotheSteeringStemBearingLubricationinthePeriodicMaintenancechapter.

Handlebar

HandlebarRemoval(BN125-A1/A2)

- Remove:

ThrottleCablesA

BrakeMasterCylinderB

LeftHandlebarSwitchHousing[C]

ClutchCableUpperEnd[D]

SpeedometerUnitE

- Removethehandlebarnuts[A]andtakeoffthehandlebar.

HandlebarRemoval(BN125-A3 →)

- Remove:

BrakeMasterCylinderA

RightHandlebarSwitchHousing[B]withThrottleCables[C]

ClutchCableUpperEnd[D]

LeftHandlebarSwitchE

StarterLockoutSwitchLead[F]

- Removethecaps[A]andhandlebarholderclampbolts [B].

Close-up of mechanical components with no visible text or symbols

HandlebarInstallation(BN125-A1/A2)

- Tightenthehandlebarnuts.

Torque-HandlebarNuts:34N·m(3.5kgf·m,25ft·lb)

• Installtheremovedparts.

BrakeMasterCylinder(seeBrakeschapter).

Handlebar

• Thefronthalfotherightandleftswitchhousings[A]hasasmallprojection[B].Fittheprojectionintothesmallhole[C]inthehandlebar.
  • Installthehandlebarswitchhousing.
• Tighten:

Torque - Handlebar Switch Housing Screws: 3.4 N·m (0.35 kgf·m, 30in·lb)

HandlebarInstallation(BN125-A3 \~)

• Thereisagap[A]betweentheupperhandleholderand lowerhandleholdersothatthehandlebarshouldbeinstalledsecurely. Whentheupperholdershallbeinstalled, tightenthefronthhandlebarclampboltsfirstandthenrear boltwithspecifiedtorque.
• Tighten:

Torque-HandlebarHolderClampBolts:20N·m(2.0kgf·m, 15ft·lb)

• Installtheremovedparts.

RearViewMirrorRemoval(Europe)

- Loosenthelowerhexagonalarea[A]fortighteningtoremovetherearviewmirrorfromtheholder.

CAUTION

Donotforcetotightenand/orloosentheupper hexagonalarea(Adapter)[B]withapairofspanners.DisassemblyofthisareaisNotAvailable. Non-permanentlockingagent[D]isalreadyapplied tothethreadsofthisinnerarea.Forciblelooseningmaydamagetheadapterand/ortheturning mechanismofthestay[C].

RearViewMirrorsInstallation(Europe)

- Screwthemountingareaoftherightrearviewmirrorinto theholderalltheway,andtightenthelowerhexagonal areafortighteningsecurely.

[A]LowerHexagonalAreaforTightening

[B]UpperHexagonalArea(Adapter)

[C]RearViewMirror(Right)

Close-up of a robotic arm with visible joints and control buttons (no text or symbols)

Frame

TableofContents

Exploded View.... 14-2

Special Tool 14-6

Side Covers 14-7

Left Side Cover Removal 14-7

Left Side Cover Installation 14-7

Right Side Cover Removal.... 14-7

Right Side Cover Installation.... 14-7

Seat 14-8

Seat Removal 14-8

Seat Installation 14-8

Fenders 14-9

Front Fender Removal 14-9

Front Fender Installation 14-9

Rear Fender Rear Removal 14-9

Rear Fender Rear Disassembly.... 14-10

Rear Fender Front Removal 14-10

Frame 14-11

Frame Inspection 14-11

ExplodedView

No.Fastener	Torque			Remarks
	N·mkgf	mft·lb
1FrontFootpegBolts232.317

O:Applyoil.

ExplodedView

IT:Italy

SG:Singapore

US:UnitedStates(BN125-A4\~)

Jack: 57001-1238

Technical line drawing of a mechanical support structure (no text or symbols)

Technical line drawing of a mechanical support structure with springs and mounting brackets (no text or symbols)

SideCovers

LeftSideCoverRemoval

• Removethescrews[A].
• Pull[B]thefrontpartoftheleftsidecoveroutwardtoclear thestopper.
• Pull[C]thecoverrearwardtoclearthehook,andremove it.

LeftSideCoverInstallation

• Slipthestopper[A]oftheleftsidecoverontothehook[B].
• Pushthestopperofthecoverintothegrommet.
• Tightenthescrews.

Close-up of mechanical components with labeled parts A and B, no readable text or symbols present

RightSideCoverRemoval

• Inserttheignitionswitchkeyintotherightsidecover.
• Turn[A]thekeyclockwise,andpull[B]thefrontpartof thecoveroutwardtoclearthestopper.
• Pull[C]thecoverrearwardtoclearthehook,andremove it.

RightSideCoverInstallation

• Slipthestopper[A]oftherightsidecoverontothehook [B].
• While turning the ignitions switch key clockwise, push the stopper of the cover into the grommet.
• Turnthekeycounterclockwise, andpulloutthekey.

14-8FRAME

Seat

SeatRemoval

• ForthemodelsotherthantheSingaporeandU.S.A.models,removethebolts[A]andloosenthebolts[B]onboth sides.
• Removethepadassembly[C].

- FortheSingaporeandU.S.A.modelsremovethebolts [A],cover[B],andcollar[C]onbothsides. Front[D]

- Removetheseatbolts[A]andtakeofftheseat[B].

SeatInstallation

• Slipthehook[A]oftheseatunderthebracket[B]onthe fueltank.
  • Installtheremovedparts.
  ○FortheSingaporeandU.S.A.models,installthecollar,notingitsdirection(seeabovefigure).

Fenders

FrontFenderRemoval

CAUTION

Becarefulnottoscratchthepainedsurfaceduring removalorinstallation.

- Removethemountingbolts[A]andtakeoffthefront fender[B].

FrontFenderInstallation

- Installthefrontfendersothatthenarrowside[A]faces forward[B].

RearFenderRearRemoval

• Removetheseat(seethischapter).
• Raisetherearwheelofftheground, using the jack (see Wheels/Tireschapter).
  SpecialTool-Jack:57001-1238
• Pulltheconnectors[A]oftherearturnsignallightand tail/brakelightleads.

- Removetherearfenderrearbolts[A].

- Pulltherearfenderrear[A]rearward. ○Therearturnsignallightandtail/brakelightleadscome off.

Close-up of a curved, smooth object with labeled points A and B, and an arrow indicating direction (no text or symbols on the object itself)

Close-up of a car's front wheel assembly with labeled parts and an arrow indicating direction (no readable text or symbols)

14-10FRAME

Fenders

RearFenderRearDisassembly

• Removethenuts[A]andtakeofftherearturnsignallight assembly[B].
• Removethenuts[C]andtakeoffthetail/brakelightassembly[D].

RearFenderFrontRemoval

- Remove:

RearFenderRear(seethischapter)

DriveChainClip

RearBrakeRodRearEnd

• Removetherearaxle, and movetherearwheel rearward for the accesstothebolts[A].
• Removetherearfenderfront[A].

Close-up of a mechanical component with coiled spring and labeled section A (no readable text or symbols)

Frame

FrameInspection

• Visuallyinspecttheframe[A]forcracks, dents, bending, orwarp.
  ★ Ifthereisanydamagetotheframe,replaceit.

WARNING

Arepairedframemayfailinuse,possiblycausing anaccident.Iftheframeisbent,dented,cracked,orwarped,replaceit.

Technical line drawing of a mechanical assembly with labeled component A (no text or symbols beyond label)

ElectricalSystem

TableofContents

PartsLocation....15-2

ExplodedView....15-4

Specifications....15-10

SpecialToolsandSealant......15-12

WiringDiagram....15-13

Precautions....15-24

Electrical Wiring....15-26

WiringInspection....15-26

Battery....15-27

BatteryRemoval/Installation.....15-27

ElectrolyteSpecificGravity Inspection....15-27

InitialCharging....15-28

OrdinaryCharging....15-29

ChargingSystem....15-31

AlternatorCoverRemoval.....15-31

AlternatorCoverInstallation......15-31

AlternatorRotorRemoval......15-31

AlternatorRotorInstallation......15-32

StatorCoilRemoval....15-32

StatorCoilInstallation....15-33

AlternatorInspection......15-33

Regulator/RectifierInspection.....15-34

ChargingVoltageInspection......15-35

IgnitionSystem....15-38

CrankshaftSensor Removal/Installation....15-38

CrankshaftSensorInspection.....15-38

CrankshaftSensorPeakVoltage Inspection....15-38

IgnitionTimingInspection......15-39

IgnitionCoilRemoval....15-40

IgnitionCoilInstallation....15-40

IgnitionCoilInspection......15-40

IgnitionCoilPrimaryPeak Voltage....15-41

SparkPlugRemoval....15-42

SparkPlugCleaning/Inspection...15-42

SparkPlugGapInspection......15-42

CDIUnitRemoval....15-42

CDIUnitInspection......15-43

ElectricStarterSystem....15-48

StarterMotorRemoval....15-48

StarterMotorInstallation......15-48

StarterMotorDisassembly......15-48

StarterMotorAssembly......15-49

BrushInspection......15-50

CommutatorCleaningand Inspection....15-50

ArmatureInspection......15-50

BrushLeadInspection......15-51

BrushPlateandTerminalBolt Inspection....15-51

StarterRelayInspection......15-51

StarterCircuitRelayInspection...15-52

LightingSystem....15-55

HeadlightBeamHorizontal/VerticalAdjustment....15-55

HeadlightBulbReplacement......15-55

ACLightingVoltageInspection....15-56

Tail/BrakeLightBulb Replacement.....15-58

TurnSignalRelayInspection......15-59

Meter,Gauge,IndicatorUnit....15-63

SpeedometerRemoval......15-63

SpeedometerDisassembly......15-63

IndicatorUnitRemoval/Installation....15-63

BulbReplacement....15-63

SwitchesandSensors....15-64

FrontBrakeLightSwitch Inspection.....15-64

RearBrakeLightTiming Inspection.....15-64

RearBrakeLightTiming Adjustment.....15-64

SwitchInspection....15-64

Fuse....15-65

MainFuse15ARemoval....15-65

MainFuse15AInspection......15-65

Fuse10ARemoval....15-65

Fuse10AInstallation....15-65

Fuse10AInspection....15-66

15-2 ELECTRICAL SYSTEM

PartsLocation

PartsLocation

1. Speedometer
2. Starterlockoutswitch
3. Ignitioncoil
4. Startermotor
5. Ignitionswitch
   6.Crankshaftsensor
6. Alternator
7. Neutralswitch
   9.Sidestandswitch
   10.Regulator/rectifier
   11.Fuseunit
   12.Startercircuitrelay
8. Starterrelay
   14.Turnsignalrelay
   15.Battery
   16.CDlunit
   17.Frontbrakelightswitch
9. Rearbrakelightswitch

ExplodedView

GP02242BW5 C

ExplodedView

No.F	Fastener	Torque			Remarks
		N·m	kgf·mft·lb
1	AlternatorCoverBolts	8.80.9	078in·lb
2	StarterMotorMountingBolts8.80.9078in·lb
3	StarterMotorTerminalLocknut6.90.7061in·lb
4	StarterMotorAssemblyBolts3.40.3530in·lb
5	Stator Coil Bolts	13	1.3	113 in·lb
6	Alternator Lead Holder Bolts (BN125-A1 ~ A2)	13	1.3	113 in·lb
	Alternator Lead Holder Bolts (BN125-A3 ~)	8.80.9	078in·lb
7	Alternator Rotor Nut (BN125-A1/A2)	69	7.0	51
	Alternator Rotor Nut (BN125-A3)	98	10.0	72
	Alternator Rotor Nut (BN125-A4 ~)	104	10.6	76
8	Crankshaft Sensor Screws	3.9	0.40	35 in·lb
9	IgnitionCoilBolt	6.90.7	061in·lb
10	SparkPlug	13	1.3	113 in·lb
11	Starter Relay Terminal Bolt	4.9	0.50	43 in·lb
12	Starter Motor Terminal Nut	4.9	0.50	43 in·lb
13	Alternator Cover Damper Bolts	8.8	0.90	78 in·lb	L
14	Starter Motor Clutch Bolts (BN125-A1)	34	3.5	25	L
15	Starter Motor Clutch Bolts (BN125-A2 ~)	12	1.2	104 in·lb	L
16	IgniterMountingScrews	4.90.5	043in·lb

1. Crankshaftsensor
2. Regulator/rectifier
3. Ignition coil
4. CDI unit
5. Battery
6. Starter relay
7. Starterclutch (BN125-A1)
8. OtherthanUnitedStatesandCanadaModels
   EO: Apply engine oil.
   L: Applyanon-permanentlocking agent.
   M: Applymolybdenumdisulfidegrease.
   Si: Applysilicone grease.
   SS: Apply silicone sealant (Kawasaki Bond: 56019-120).

ExplodedView

ExplodedView

No.Fastener		Torque			Remarks
		N·m	kgf·mft·lb
1	NeutralSwitch	151.51	1
2SidestandSwitchScrews3.90.4035in·lbL
3	Handlebar Switch Housing Screws	3.4	0.35	30 in·lb

1. Ignitionswitch
2. Turnsignal relay
3. Startercircuit relay
   7.Interlockdiode
   8.Fusecase (BN125-A1)
4. Rearbrake lightswitch
   10.Sidestandswitch
   11.Meter unit

L: Applyanon-permanentlockingagent.

ExplodedView

ExplodedView

No.Fastener		Torque			Remarks
		N·m	kgf·mft·lb
1	HeadlightBodyScrews	2.90.30	26in·lb
2	Turn Signal Light Holder Nuts	5.9	0.60	52 in·lb

3.Headlightunit
4. Turnsignallights
5. Tail/brakelight
6.CanadaandUnitedKingdomModels(BN125-A6\~ )
7. Other than Canada and United Kingdom Models
8. United Kingdom Model only (BN125-A6\~ )

Specifications

ItemStandardServiceLimit
BatteryCapacity12V9Ah-- --ElectrolyteLevelbetweenlevellines-- -SpecificGravityofElectrolyte1.280±0.01@20°C(68°F)-- --
ChargingSystemType:(BN125-A1/A2)Single-phaseAC-- -(BN125-A3 ~) Charging Voltage Stator Coil Resistance Regulator/rectifier:Type:(BN125-A1/A2)(BN125-A3 ~) Resistance Single-phase all wave rectifier Three-phase all wave rectifier in the text
ACLightingSystemAlternatorType:(BN125-A1/A2)Single-phaseAC(BN125-A3 ~) AC Lighting Voltage LightingCoilResistance:(BN125-A1/A2)(BN125-A3 ~)	Three-phase AC11 ~ 16 V @engine speed 4 000 r/min (rpm)	---
		---
		---
		---
		---
		---
IgnitionSystemCrankshaftSensorResistance:(BN125-A1/A2)(BN125-A3 ~) Crankshaft Sensor Peak Voltage IgnitionCoil:3 Needle Arcing Distance Primary Winding Resistance Secondary Winding Resistance Primary Peak Voltage SparkPlug:SparkPlugType:Standard Option Spark Plug Gap Spark Plug Cap Resistance	180 ~ 280 Ω (× 100 Ω)190 ~ 290 Ω (× 100 Ω)3.6 V or more6 mm or more0.09 ~ 0.13 Ω (× 1 Ω)3.8 ~ 5.8 kΩ (× 1 kΩ)110 V or moreNGK CR7ENGK CR8E or ND U24ESR-N0.7 ~ 0.8 mm (0.028 ~ 0.031 in.)3.75 ~ 6.25 kΩ (× 1 kΩ)	---
		---
		---
		---
		---
		---
		---
		---
		---
		---
		---
		---
		---
		---
		---
ElectricStarterSystemStarterMotor:BrushLength Commutator Diameter	9.5 ~ 10.5 mm (0.37 ~ 0.41 in.)27.95~ 28.05mm(1.10~ 1.11in.)	8 mm (0.31 in.)27mm(1.06 in.)

Specifications

ItemStandardServiceLimit
SwitchesRearBrakeLightSwitchTimingONafterabout10mm(0.39in.)pedaltravel	-- --

SpecialToolsandSealant

FlywheelPuller, M30×1.5: 57001-1191

Technical line drawing of a mechanical component with a hexagonal top and cylindrical base (no text or symbols)

RotorPuller, M16/M18/M20/M22×1.5: 57001-1216

Technical illustration of a mechanical assembly with threaded components and a cylindrical component (no text or symbols)

TimingLight: 57001-1241

Line drawing of a handheld electronic device with coiled cable and connector (no text or symbols)

Spark Plug Wrench, Hex 16: 57001-1262

Line drawing of a T-shaped tool with a cylindrical end and two protruding pins (no text or symbols)

FlywheelHolder: 57001-1313

Technical line drawing of a mechanical clamp or measuring tool (no text or symbols present)

HandTester: 57001-1394

Technical line drawing of a mechanical housing or enclosure with internal components and mounting holes (no text or symbols)

PeakVoltageAdapter: 57001-1415

Pure electrical circuit lines without any symbols

KawasakiBond(SiliconeSealant): 56019-120

WiringDiagram

DummyPage

BN125-A1

WIL1861AW5 C

W1R1661AW5 C

BN125-A2\~ (Singapore) and BN125-A4 (United States)

WiringDiagram

W1R1783CW5 C

BN125-A2\~ A5(Europe)

W1R1784CW5 C

BN125-A5(UnitedStatesandCanada)

BN125-A6\~ (US,CA,N,NU)

WiringDiagram

W2R0138AW5 C

Precautions

Thereare anumberofimportantprecautionsthatare mustswhenservicingelectricalsystems.Learnandobservealltherulesbelow.

○Donotreversethebatterycableconnections. This will burnoutthediodesontheelectricalparts.
○Alwayscheckbatteryconditionbeforecondemningother partsofanelectricalsystemAfullychargedbatteryisa mustforconductingaccurateelectricalsystemtests.
○Theelectricalpartsshouldneverbestrucksharply,as withahammer,orallowedtofallonahardsurface.Such ashocktothepartscandamagethem.

○Topreventdamagetoelectricalparts,donotdisconnect thebatterycablesoranyotherelectricalconnections whentheignitionswitchison,orwhiletheengineis running.

○Becauseofthelargeamountofcurrent,neverkeepthe starterbuttonpushedwhenthestartermotorwillnotturn over,orthecurrentmayburnoutthestartermotorwindings.

- Donotuseameterorindicatorilluminationbulbrated forotherthanvoltageorwattagespecifiedinthewiring diagram, asthemeterorindicatorpanelcouldbewarped byexcessiveheatradiatedfromthebulb.

○Takecarenottoshorttheleadsthataredirectlyconnectedtothebatterypositive(+)terminaltothechassis ground.

○Troublesmayinvolveoneorinsomecasesallitems. Neverreplaceadefectivepartwithoutdeterminingwhat CAUSEDthefailure.Ifthefailurewascausedbysome otheritemoritems,theytoomustberepairedorreplaced, orthenewreplacementwillsoonfailagain.

○Makesureallconnectorsinthecircuitarecleanandtight, andexaminewiresforsignsofburning,fraying,etc.Poor leadsandbadconnectionswillaffectelectricalsystem operation.

○Measurecoilandwindingresistancewhenthepartiscold (atroomtemperature).

○ColorCodes:

BK:Black

BL:Blue

BR:Brown

CH:Chocolate

DG:Darkgreen

G:Green

GY:Gray

LB:Lightblue

LG:Lightgreen

O:Orange

P:Pink

PU:Purple

R:Red

W:White

Y:Yellow

Precautions

ElectricalConnectors Connectors[A]

Technical line drawing of two electronic components with labeled terminals (no text or symbols beyond labels)

Connectors[B]

• Visuallyinspectthewiringforsignsofburning,fraying, etc.
  ★Ifanywiringispoor,replacethedamagedwiring.
• Pulleachconnector[A]apartandinspectitforcorrosion, dirt,loosenessanddamage.
  ★ Iftheconnectoriscorrodedordirty, cleanitcarefully. Ifit isdamaged, replace it.
• Checkthewiringforcontinuity.
  ○Usethewiringdiagramtofindtheendsoftheleadwhich issuspectedofbeingaproblem.
  ○Connectthehandtesterbetweentheendsoftheleads.

SpecialTool-HandTester:57001-1394

○Setthetestertothe×1Ω range,andreadthetester.

★If the tester does not read 0 Ω, the lead is defective. Re-placetheleadorthewiringharness[B]ifnecessary.

graph TD
    A["Device 1"] --> B["Component B"]
    B --> C["Device 2"]
    C --> D["Component D"]
    D --> E["Device 3"]
    E --> F["Component F"]
    F --> G["Device 4"]
    G --> H["Component H"]
    H --> I["Device 5"]
    I --> J["Component J"]
    J --> K["Device 6"]
    K --> L["Component L"]
    L --> M["Device 7"]
    M --> N["Component N"]
    N --> O["Device 8"]
    O --> P["Component P"]
    P --> Q["Device 9"]
    Q --> R["Component R"]
    R --> S["Device 10"]
    S --> T["Component T"]
    T --> U["Device 11"]
    U --> V["Component V"]
    V --> W["Device 12"]
    W --> X["Component X"]
    X --> Y["Device 13"]
    Y --> Z["Component Z"]

Battery

BatteryRemoval/Installation

- Remove:

RightSideCover(seeFramechapter) BatteryHolder

- Disconnectthebatterynegative(−)cable[A]first,and then the positive(+)cable[B]. Front[C]

- Wheninstallingthebattery,connectthepositive(+)cable [A]firstandthenthenegativecable[B].

CAUTION

If the batterycable is not correctly disconnected or connected, sparkscanariseate electrical connections, causing damage to electrical parts.

ElectrolyteSpecificGravityInspection

- Checkbatteryconditionbytestingthespecificgravityof theelectrolyteineachcellwithahydrometer[A].

○Readtheleveloftheelectrolyte[B]onthefloatingscale.

★ If the specific gravity is below 1.200, the battery need to be charged.

NOTE

○ Thespecificgravityoftheelectrolytevarieswith changesintemperature, sothespecificgravityreading mustbecorrectedforthetemperatureoftheelectrolyte.

○Celsius:Add0.007pointstoreadingforeach10°C (50°F)above20°C(68°F)orsubtract0.007pointsfor each10°Cbelow20°C(68°F).

○Fahrenheit:Add0.004pointstoreadingforeach-12°C (10°F)above10°C(68°F)orsubtract0.004pointsfor each-12°C(10°F)below10°C(68°F).

★ If the specific gravity of any of the cells is more than 0.050 away from any other reading, the battery will probably not accept a charge. It is generally best to replace the battery in this condition.

★ If the specific gravity of all the cells is 1.280 or more, the battery is fully charged.

When using the hydrometer, read the electrolyte level at the bottom of themeniscus (curved surface of the fluid).

Battery

InitialCharging

WARNING

Keepthebatteryawayfromsparksandopenflames duringcharging,sincethebatterygivesoffanexplosivegasmixtureofhydrogenandoxygen.When usingabatterycharger,connectthebatterytothe chargerbeforeturningonthecharger.Thisprocedurepreventssparksatthebatteryterminalswhich couldigniteanybatterygases.

• Removethebattery(seethischapter).
• Filleachcelltotheupperlevellineonthebatterycasewith freshelectrolyte(specificgravity:1.280)atatemperature of 30^(86^) orless.Letthebatterystandforabout30 minutesbeforecharging.

NOTE

○ Iftheelectrolyteleveldrops, addelectrolytetotheupper levellinebeforecharging.

- Setthechargingrateat1/10thebatterycapacity,and chargeitfor10hours.Thebatteryisratedat9Ah,and therecommendedchargingrateis0.9A.

CAUTION

Ifthebatteryisnotgivenafullinitialcharging, it willdischargeinafewweeks. Afterthatitcannot bechargedbysupplementalcharging. Alwaysremovethebatteryfromthevehiclefor charging. Ifthebatteryischargedwhilestillinstalled, batteryelectrolytemayspillandcorrode theframeorotherpartsofthevehicle. Donotuseahighratebatterycharger, asistypicallyemployedatautomotiveservicestations, unlesssthechargerratecanbereducedtothelevelrequired. Chargingthebatteryataratehigherthan specifiedmayruinthebattery. Chargingatahigh ratecausesexcessheatwhichcanwarptheplates andcauseinternalshorting. Higher-than-normal chargingratesalsocausetheplatestoshedactive material. Depositswillaccumulate, andcancause internalshorting. Ifthetemperatureoftheelectrolyterisesabove 45°C(113°F)duringcharging, reducethecharging ratetolowerthetemperature, andincreasechargingtimeproportionately.

• Turnthechargeroff, thendisconnectitfromthebattery.
• Checkbatteryvoltage.Batteryvoltageshouldbe12\~ 13 V.

Battery

OrdinaryCharging

• Removethebattery(seeBatteryRemoval).
• Ifanyofthecellsarelow,fillthemtotheLOWERlevel linewithdistilledwateronly.Theelectrolytewillexpand duringcharging,andthelevelwillrise.

WARNING

Keepthebatteryawayfromsparksandopenflames duringcharging,sincethebatterygivesoffanexplosivegasmixtureofhydrogenandoxygen.When usingabatterycharger,connectthebatterytothe chargerbeforeturningonthecharger.Thisprocedurepreventssparksatthebatteryterminalswhich couldigniteanybatterygases.

• ConnectachargertothebatteryBEFOREpluggingitinorturningiton.
• Setthechargingrateandtimeaccordingtothebattery conditionpreviouslydetermined,usingtheBatteryChargingRate/TimeTable.
• Checktheelectrolytelevelaftercharging.

CAUTION

Alwaysremovethebatteryfromthevehiclefor charging. If the battery is charged while still installed, battery electrolyte may spill and corrode the frame or other part of the vehicle. Donot use a high rate battery charger, asistypically employed data automotiveservices stations, unless the chargerrate can be reduced to the level required. Charging the battery at a rate higher than specified may ruin the battery. Charging at a high rate causes excess heat which can warp the plates and cause internal shorting. Higher-than-normal charging rates also cause the plate tested active material. Deposits will accumulate, and can cause internal shorting. If the temperature of the electrolyterises above 45°C (113°F) during charging, reduce the charging rate to lower the temperature, and increase charging time proportionately.

• Turnthechargerofforunplugit, thendisconnectit from thebattery.
• Checkbatterycondition.
  ★ If the battery condition indicates that it is not fully charged, additional charging time is necessary.

Battery

BatteryChargingRate/TimeTable(12V9Ah)

GP08017BW2 C

ChargingSystem

AlternatorCoverRemoval

• Draintheengineoil(seeEngineLubricationSystem chapter).
• Remove: EngineSprocketCover(seeFinalDrivechapter) AlternatorLeadConnector[A]

- Remove: AlternatorCoverBolts[A] AlternatorCover[B]

- Removethetorquelimiter[A].

Close-up of a car's engine compartment with labeled component A (no readable text or symbols beyond label)

Close-up of a mechanical component with labeled parts A and B, showing internal structure and wiring (no readable text or symbols)

Close-up of a mechanical assembly with gears and springs, no visible text or symbols

AlternatorCoverInstallation

• Install:
  DowelPins[A]
  NewGasket[B]
• Applymolybdenumdisulfidegreasetothestarterpinion gear[C]andtorquelimitershaft[D].
• Routetheleadscorrectly(seeAppendixchapter).
• Tighten:

Torque-AlternatorCoverBolts:8.8N·m(0.90kgf·m,78 in·lb)

- Pourtheengineoil(seeEngineLubricationSystemchapter).

AlternatorRotorRemoval

• Removethealternatorcover(seethischapter).
• Wipeoilofftheoutercircumferenceoftherotor.
• Holdthealternatorrotor[A]steadywiththeflywheel holder[B],andremovetherotornut[C].

SpecialTool-FlywheelHolder:57001-1313

CAUTION

Donotholdthetimingplate[D]ofthealternator rotor. This candamagethetimingplate.

ChargingSystem

- Usingtheflywheelpuller[A]androtorpuller[B],remove thealternatorrotor[C]fromthecrankshaft. SpecialTools-FlywheelPuller,M30×1.5:57001-1191 RotorPuller,M16/M18/M20/M22×1.5:57001 -1216

○Holdingtheflywheelpuller, screwintherotorpullerwhile tappingtheheadoftherotorpullerwithahammerand removethealternatorrotor.

- Removethestartergear[D].

AlternatorRotorInstallation

• Applyoiltothecrankshaftjournal[A].
• Usingacleaningfluid,cleanoffanyoilordirtonthefollowingportionsanddrythemwithacleancloth. CrankshaftTaperedPortion[B] AlternatorRotorTaperedPortion[C]

• Installthestartergear[A].
- Installthewoodruffkey[B]securelyintheslotofthe crankshaft.
- Installthealternatorrotor[D]sothatthewoodruffkeyfits inthegroove[C]oftherotor.
- Tighten:

Torque-AlternatorRotorNut (BN125-A1/A2):69N·m(7.0kgf·m,51ft·lb) (BN125-A3):98N·m(10.0kgf·m,72ft·lb) (BN125-A4\~):104N·m(10.6kgf·m,76ft·lb)

SpecialTool-FlywheelHolder:57001-1313

• Installthealternatorcover(seethischapter).

StatorCoilRemoval

- Remove: AlternatorCover(seethischapter) StatorCoilBolts[A] CrankshaftSensorScrews[B] Holders[C]

- Removethestatorcoil[D]andthecrankshaftsensorE fromthealternatorcover.

ChargingSystem

StatorCoilInstallation

- Tighten:

Torque-StatorCoilBolts[A]:13N·m(1.3kgf·m,113in·lb)

CrankshaftSensorScrews[B]:3.9N·m(0.40 kgf·m,35in·lb)

AlternatorLeadHolderBolts

(BN125-A3\~):8.8N·m(0.90kgf·m,78in·lb)

(BN125-A1\~A2):13N·m(1.3kgf·m,113in·lb)

- Applysiliconesalanttothecircumferenceofthealternatorleadgrommet[C],andfitthegrommetintothenotch ofthecoversecurely.

Sealant-KawasakiBond(SiliconeSealant):56019-120

AlternatorInspection

Therearethreetypesofalternatorfailures:short,open (wireburnedout),orlossinrotormagnetism.Ashortor openinoneofthecoilwireswillresultineitheralowoutput, ornooutputatall.Alossinrotormagnetism,whichmaybe causedbydroppingorhittingthealternator,byleavingit nearanelectromagneticfield,orjustbyaging,willresultin lowoutput.

• Tocheckthealternatoroutputvoltage,dothefollowing procedures.
  ○ Disconnectthealternatorconnector[A]. Usinganauxiliarywires, connectthefollowingleadsintheconnectors forengineoperation.

L/G←→ L/G

W/Y←→ W/Y

G/W←→ G/W

○Connectthehandtesterasshowninthetable.
○ Starttheengine.
○Runitat4000r/min(rpm)oftheenginespeed.
○Notethevoltagereadings.

SpecialTool-HandTester:57001-1394

AlternatorOutputVoltage(BN125-A1/A2)

Meter Range	Connections		Reading @4000rpm
	Meter (+) to	Meter (-) to
50VAC	Pink lead	Engine ground	37 V or more

AlternatorOutputVoltage(BN125-A3\~)

Meter Range	Connections		Reading @4000rpm
	Meter (+) to	Meter (-) to
250 V AC	Yellow lead	Yellow lead	38 V or more

★If the output voltage shows the value in the table, the alternatoroperatesproperly.Amuchlowerreadingthanthe valueinthetableindicatesthatthealternatorisdefective.

ChargingSystem

• Checkthestatorcoilresistanceasfollows.
  ○Stoptheengine.
  ○Connectthehandtesterasshowninthetable.
  ○Notetheresistancereadings.

StatorCoilResistance(BN125-A1/A2)

Tester Range	Connections		Reading
	Meter(+)toMeter(-) to
× 1	PinkleadEngineground		0.1~0.8Ω

StatorCoilResistance(BN125-A3\~)

Tester Range	Connections		Reading
	Meter(+)toMeter(-) to
×1Ω	YellowleadYellowlead		0.3~0.9Ω

★Ifthereismoreresistancethanshowninthetable,orno handtesterreading(infinity),thestatorhasanopenlead andmustbereplaced.Muchlessthanthisresistance meansthestatorisshorted,andmustbereplaced.

★If the stator coil has normal resistance, but the voltage check showed the alternator to be defective, then the rotor magnetshaveprobablyweakened,andtherotor mustbe replaced.

Regulator/RectifierInspection

- Remove: RightSideCover(seeFramechapter) Regulator/Rectifier[A]

- Disconnecttheconnector[B]fromtheregulator/rectifier.

- Set the hand tester to the × 1 kΩ range and make the measurementsshowninthetable.

SpecialTool- HandTester: 57001-1394

★If the tester readings are not as specified, replace the regulator/rectifier.

CAUTION

UseonlyHandTester57001-1394forthistest.A tester other than the Kawasaki Hand Tester may showdifferentreadings. Ifamuggerorameterwithalarge-capacitybattery isused,theregulator/rectifierwillbedamaged.

Regulator/RectifierInternalResistance(BN125-A1/A2)
Unit:kΩ

(-)*: Tester(-)LeadConnection

Charging Voltage Inspection

• Check the battery condition (see Battery section).
• Warm up the engine to obtain actual alternator operating conditions.
• Check that the ignition switch is turned off, and connect the hand tester as shown in the table.

Special Tool - Hand Tester: 57001-1394

Charging Voltage

Tester Range	Connections		Reading
	Tester (+) to	Tester (−) to
25 V DC	Battery (+)	Battery (−)	14 ~ 15 V

• Turn on the ignition switch and start the engine, and note the voltage readings at various engine speeds with the headlight turned on and then turned off. The readings should show nearly battery voltage when the enginespeedislow,andastheenginespeedrises,the readingsshouldalsorise. Buttheymustbekeptunder thespecifiedvoltage.
• Turn off the ignition switch to stop the engine, and disconnectthehandtester.
  ★ If the charging voltage is kept between the values given in the table, the charging system is considered to be working normally.
  ★ If the output voltage is much higher than the values specified in the table, theregulator/rectifier is defective or the regulator/rectifier leads are loose or open.
  ★If the charging voltage does not rise as the engine speed increases, then the regulator/rectifier is defective or the alternatoroutputisinsufficientforthe loads. Checkthe alternatorandregulator/rectifiertodeterminewhichpart isdefective.

ChargingSystemCircuit(BN125-A1/A2)

graph TD
    A["①"] --> B["BR W"]
    B --> C["BR W"]
    C --> D["②"]
    D --> E["③"]
    E --> F["④"]
    F --> G["P Y"]
    G --> H["⑤"]
    H --> I["+"]
    I --> J["⑥"]
    J --> K["⑦"]
    K --> L["BR R/W"]
    L --> M["⑧"]
    M --> N["R/W"]
    N --> O["⑨"]
    O --> P["BK/Y"]
    P --> Q["-"]
    Q --> R["⑤"]
    R --> S["⑥"]
    S --> T["W"]
    T --> U["BK/Y"]
    U --> V["W"]
    V --> W["BK/Y"]
    W --> X["BK/Y"]
    X --> Y["BK/Y"]
    Y --> Z["BK/Y"]
    Z --> AA["BK/Y"]
    AA --> AB["BK/Y"]
    AB --> AC["BK/Y"]
    AC --> AD["BK/Y"]
    AD --> AE["BK/Y"]
    AE --> AF["BK/Y"]
    AF --> AG["BK/Y"]
    AG --> AH["BK/Y"]
    AH --> AI["BK/Y"]
    AI --> AJ["BK/Y"]
    AJ --> AK["BK/Y"]
    AK --> AL["BK/Y"]
    AL --> AM["BK/Y"]
    AM --> AN["BK/Y"]
    AN --> AO["BK/Y"]
    AO --> AP["BK/Y"]
    AP --> AQ["BK/Y"]
    AQ --> AR["BK/Y"]
    AR --> AS["BK/Y"]
    AS --> AT["BK/Y"]
    AT --> AU["BK/Y"]
    AU --> AV["BK/Y"]

1. Ignitionswitch
2. Alternator
3. Regulator/rectifier
4. Controller
   5.Battery
   6.Mainfuse15A
5. Starterrelay
   8.Lightfuse10A
   9.Load

ChargingSystem

ChargingSystemCircuit(BN125-A3\~)

1. Ignitionswitch
2. Alternator
3. Regulator/rectifier
   4.Battery
   5.Mainfuse30A
4. Starterrelay
   7.Lightfuse15A
   8.Load

IgnitionSystem

CDIUnitConnectors[A]

CAUTION

Donotdisconnectthebatterycablesoranyother electricalconnectionswhentheignitionswitchis on,orwhiletheengineisrunning. This is to prevent CDlunitdamage.Donotinstallthebatterybackwards.Thenegativesideisgrounded.This is to prevent damage to the diodes and CDlunit.

WARNING

Theignitionsystemproducesextremelyhighvoltage.Donottouchthesparkplug,ignitioncoilwhile theengineisrunning,oryoucouldreceiveasevere electricalshock.

CrankshaftSensorRemoval/Installation

- RefertotheStatorCoilRemoval/InstallationintheElectricalSystemchapter.

CrankshaftSensorInspection

• Removethealternatorleadconnector[A].
• Setthehandtestertothe×100Ω rangeandmeasure theresistancebetweentheG/WandW/Yleadterminals inthefemaleconnector.

SpecialTool-HandTester:57001-1394

★ Ifthereismoreresistancethanthespecifiedvalue,the coilhasanopenleadandmustbereplaced.Muchless thanthisresistancemeansthecoilisshorted,andmust bereplaced.

CrankshaftSensorResistance BN125-A1/A2:180\~280Ω

BN125-A3\~:

190\~290Ω

• Using the highest resistance range of the tester, measure the resistance between the G/Wand W/Y lead in the female connector and chassis ground.
  ★Any tester reading less than infinity ( ) indicates a short, necessitating replacement of the crankshaft sensor assembly.

CrankshaftSensorPeakVoltageInspection

NOTE

○Besurethebatteryisfullycharged.
○ Usingthepeakvoltageadapterisamorereliableway todeterminetheconditionofthecrankshaftsensorthan crankshaft sensorinternal resistancemeasurements.

• Remove:
  RightSideCover(seeFramechapter)
• Disconnectthe crankshaftsensorconnector[A].

Close-up of an electronic device with visible components and wiring (no readable text or symbols)

Close-up of a mechanical engine component with labeled parts (A) and no visible text or symbols beyond the label.

Close-up of a car engine bay with visible wiring and battery (no text or symbols)

IgnitionSystem

• Setthehandtester[B]tothe×25VDCrange, and connectittothepeakvoltageadapter[C]asshowninthe diagram.
• ConnecttheblackleadoftheadaptertoW/Yleadandred leadtoG/Wleadinthecrankshaftsensorconnector[A].
• Turntheignitionswitch.
• Pushingthestarterbutton,turntheengine4\~5 secondswiththetransmissiongearinneutraltomeasurethe crankshaftsensorpeakvoltage.
• Repeatthemeasurement5ormoretimes.

CrankshaftSensorPeakVoltage

Standard: 3.6Vormore

SpecialTools-HandTester:57001-1394

PeakVoltageAdapter:57001-1415

Type: KEK-54-9-B

★ Ifthetesterreadingisnotspecifiedone, checkthecrank-shaftsensor.

CAUTION

Donotdisconnectthebatterycablesoranyother electricalconnectionswhentheignitionswitchis on,orwhiletheengineisrunning. Thisoprevent CDlunitdamage.Donotinstallthebatterybackwards.Thenegativesideisgrounded.Thisisto preventdamagetothediodesandCDlunit.

WARNING

Theignitionsystemproducesextremelyhighvoltage. Donottouchthesparkplug,ignitioncoil,or sparkplugleadwhiletheengineisrunning,oryou couldreceiveasevereelectricalshock.

IgnitionTimingInspection

• Removethecamshaftchaincover(seeEngineTopEnd chapter).
• Attachthetiminglight[A]inthemannerprescribedbythe manufacturer.
  SpecialTool- TimingLight:57001-1241
• Starttheengineandaimthetiminglightattheignition timingmarkonthecamshaftsprocket[B].
• Runtheengineatthespeedspecifiedandnotethealignmentoftheignitiontimingmarks.

IgnitionSystem

IgnitionTiming

EnginespeedHeadtiming	mark[A]alignswith:
1 300 ±100 r/min (rpm)	“T” mark [B] on camshaft sprocket

★Iftheignitiontimingisincorrect,inspecttheCDlunitand thecrankshaftsensor.

IgnitionCoilRemoval

• Removethefueltank(seeFuelSystemchapter).
• Disconnecttheprimarywindingleadsfromtheignition coil.
• Removethemountingbolt[A].
  • Takeofftheignitioncoil[B].

IgnitionCoilInstallation

- Tightentheignitioncoilbolt.

Torque-IgnitionCoilBolt:6.9N·m(0.70kgf·m,61in·lb)

○Installtheignitioncoilnotingthepositionoftheground terminal[A],andprimarywindingleads.

(+) Terminal[B] BL/BKLead
(-) Terminal [C] → BK/Y Lead

IgnitionCoilInspection

• Removetheignitioncoil(seethischapter).
• Measure the arcing distance with the suitable commercially available coil tester [A] to check the condition of the ignition coil [B].
• Connecttheignitioncoil(withthesparkplugcapleftattachedattheendofthesparkpluglead)tothetesterin themannerprescribedbythemanufacturerandmeasure thearcingdistance.

WARNING

Toavoidextremelyhighvoltageshocks, donot touchthecoilbodyorleads.

★If the distance reading is less than the specified value, the ignitioncoilorsparkplugcapsdefective.

IgnitionCoilArcingDistance:6mmormore

• Todeterminewhichpartisdefective,measurethearcing distanceagainwiththesparkplugcapremovedfromthe ignitioncoil.Removethecapbyturningitcounterclockwise.
  ★Ifthearcingdistanceissubnormalasbefore,thetrouble iswiththeignitioncoilitself. Ifthearcingdistanceisnow normal,thetroubleiswiththesparkplugcap.

IgnitionSystem

★ Ifthecolltesterisnotavailable, thecoilcanbechecked forabrokenorbadlyshortedwindingwiththehandtester.

NOTE

○Thehandtestercannotdetectlayershortsandshorts resultingfrominsulationbreakdownunderhighvoltage.

- Measure the primary winding resistance as follows.

○Connectthehandtesterbetweenthecoilterminals.

- Measurethesecondarywindingresistanceasfollows.

○Removetheplugcap.

○Connectthetesterbetweenthesparkplugleads.

Measureprimarywindingresistance[A]. Measuresecondarywindingresistance[B]. IgnitionCoil[C]

★ Ifthetesterdoesnotreadasspecified, replacethecoil.

IgnitionCoilWindingResistance

Primary Windings:	0.09 ~ 0.13 Ω (× 1 Ω)
Secondary Windings:	3.8 ~ 5.8 kΩ (× 1 kΩ)

- Visually inspect these secondary winding lead.

★ Ifitshowsanydamage, replacethecoil.

IgnitionCoilPrimaryPeakVoltage

NOTE

○Besur ethebatteryisfullycharged.

• Removethefueltank(seeFuelSystemchapter).
• Removethesparkplugcap.
• Measuretheignitioncoilprimarypeakvoltageasfollows;
• Installthenewsparkplug[A]intotheremovedsparkplug cap[F]andgrounditontotheengine.
• Connectthepeakvoltageadapter[B]intothehandtester [C]andsetittothe×250VDCrange.

Adapterblacklead→ Ignitioncoilprimaryleadterminal [D]

Adapterredlead→ Ignitioncoilgroundterminal IgnitionCoilE

Battery[G]

CDIUnit(ICIgniter)[H]

WARNING

To avoid extremely high voltage shock, do not touch the spark plugort ester connection.

IgnitionSystem

• Turntheignitionswitchandenginestopswitchon.
• Pushing the starter button, turn the engine 4 \~ 5 seconds with the transmission gear in neutral to measure the ignition coil primary peak voltage.
• Repeatthemeasurement5ormoretimes.

IgnitionCoilPrimaryPeakVoltage

Standard: 110Vomore

SpecialTools-HandTester:57001-1394

PeakVoltageAdapter:57001-1415

Type:KEK-54-9-B

★Ifthereadingislessthanthespecifiedvalue,checkthe following; IgnitionCoil(seeIgnitionCoilInspection) CrankshaftSensor(seeCrankshaftSensorInspection) CDIUnit(seeCDIUnitInspection)

SparkPlugRemoval

• Removethesparkplugcap.
• Removethesparkplugusingthe16mmplugv
  SpecialTools-SparkPlugWrench,Hex16:57001-1262or
  Owner's Tool:92110-1172

SparkPlugCleaning/Inspection

- RefertotheSparkPlugCleaning/InspectioninthePeriodicMaintenancechapter.

SparkPlugGapInspection

- RefertotheSparkPlugGapInspectioninthePeriodic Maintenancechapter.

CDIUnitRemoval

ThehandtestercanchecktheCDIunitforabrokenor badlyshortedwinding, butitisashortcutmethodwhich cannot inspect the precise condition of the CDIunit.

- Remove: FuelTank(seeFuelSystemchapter) CDIUnitscrews[A]andBolts[B] CDIUnit[C]

- DisconnecttheconnectorsfromtheCDlunit.

IgnitionSystem

CDIUnitInspection

CAUTION

When inspecting the CDIUnit[A], observethefollowing to avoid damage to the CDIUnit. Donot disconnect the CDIUnit with the ignition switch on. This may damage the CDIUnit. Donot disconnect the battery leads while the engine is running. This may damage the CDIUnit.

CDIUnitOperationCheck

• Removethefueltank(seeFuelSystemchapter).
• Disconnecttheconnectors[A]fromtheCDIUnit.
• Setthehandtester[B]tothe25VDCrange,andconnect ittotheconnectorcomefromharnesssideasfollows.

Tester(+)terminal[D]→ Rlead Tester(-)terminal[C]→ BK/Ylead

SpecialTool-HandTester:57001-1394

- Turntheignitionswitchon, andreadthevoltage.

CDIUnitOperationVoltage:BatteryVoltage

★ If the tester reading is not specified one, check the battery voltage, ignition switch and ignition fuse.

- Setthehandtestertothe×1kΩ rangeandmakethe measurementsshowninthetable.

SpecialTool-HandTester:57001-1394

★ Ifthetesterreadingsarenotasspecified, replacetheCDI unit.

CAUTION

UseonlyHandTester57001-1394forthistest.A testerother thantheKawasakiHandTestermay showdifferentreadings.

Ifameggerormeterwithalarge-capacitybatteryis used,theCDIunitwillbedamaged.

Close-up of a motorcycle's internal electronic component with visible wiring and connectors (no readable text or symbols)

GP100627S1 C

GP100102S1 C

CDIUnitInternalResistance(BN125-A1/A2)Unit:kΩ

(-)*: Tester(-)LeadConnection

CAUTION

UseonlyHandTester57001-1394forthistest. A tester other than the Kawasaki Hand Tester may showdifferentreadings. If a megger or meter with a large-capacity battery is used, the CDlunitwillbedamaged.

CDI Unit Internal Resistance (BN125-A3 \~)
Unit: kΩ

Tester(+)LeadConnection

Terminal

1

2

3

4

5

6

7

8

9

10

(-)*

1

-

30~150

92.5~370

30~150

80~320

32.5~160

55~220

67.5~270

30~150

6.5~26

2

∞

-

24~96

0

8~38

0.5~2

3.3~13

7~28

0

4.5~18

3

∞

24.5~98

-

24.5~98

47.5~190

25~100

26.5~106

40~160

47.5~198

33~132

4

∞

0

24~96

-

9.5~38

0.5~2

3~12

7~28

0

4.5~18

5

∞

∞

∞

∞

-

∞

∞

∞

∞

∞

6

∞

0.5~2

24.5~98

0.5~2

10~40

-

6.5~26

7.5~30

0.5~2

5.3~21

7

∞

5~20

26.5~106

5~20

18.5~74

5.5~22

-

12~48

5~20

11~44

8

∞

500~2000

500~2000

500~2000

750~3000

500~2000

500~2000

-

500~2000

500~2000

9

∞

0

24~96

0

9.5~38

0.5~2

3.5~14

7~28

-

5~20

10

∞

20~96

70~280

20~92

55~220

20~96

20~130

45~180

19.5~92

-

(-)*: Tester(-)LeadConnection

IgnitionSystem

IgnitionSystemTroubleshooting

graph TD
    A["Faulty Ignition (Malfunctioned engine)"] -->|Good| B["Ignition System Wiring and Connector Inspection"]
    B -->|No Good| C["Repair or Replace"]
    B -->|Good| D["Crankshaft Sensor Inspection"]
    D -->|No Good| E["Replace"]
    D -->|Good| F["Crankshaft Sensor Peak Voltage Measurement"]
    F -->|No Good| G["Replace Faulty Parts"]
    F -->|Good| H["Ignition Coil Inspection"]
    H -->|No Good| I["Replace"]
    H -->|Good| J["Ignition Coil Peak Voltage Measurement"]
    J -->|No Good| K["Adjust or Replace"]
    J -->|Good| L["Spark Plug Gap Inspection"]
    L -->|No Good| M["Adjust or Replace"]
    L -->|Good| N["CDI Unit Inspection"]
    N -->|No Good| O["Replace CDI Unit"]
    N -->|Good| P["CDI Unit Operation"]
    P -->|No Good| Q["Replace Faulty Parts"]
    P -->|Good| R["Inspect: 1. Peak Voltage Adapter\n2. Crankshaft Sensor Connector\n3. Battery Voltage"]
    R -->|No Good| S["Replace Faulty Parts"]
    R -->|Good| T["Inspect: 1. Peak Voltage Adapter\n2. Ignition Coil Connector\n3. Battery Voltage"]
    T -->|No Good| U["Replace Faulty Parts"]
    T -->|Good| V["Inspect: 1. Battery Voltage\n2. Ignition Switch\n3. Ignition Fuse"]
    V -->|No Good| W["Replace CDI Unit"]

IgnitionSystemCircuit(BN125-A1/A2)

graph TD
    A["①"] --> B["②"]
    B --> C["③"]
    C --> D["④"]
    D --> E["⑤"]
    E --> F["⑥"]
    F --> G["⑦"]
    G --> H["⑧"]
    H --> I["⑨"]
    I --> J["⑩"]
    J --> K["⑪"]
    K --> L["⑫"]
    L --> M["⑬"]
    M --> N["⑭"]
    N --> O["⑮"]
    O --> P["⑯"]
    P --> Q["⑰"]
    Q --> R["⑱"]
    R --> S["⑲"]
    S --> T["⑳"]
    T --> U["㉑"]
    U --> V["㉒"]
    V --> W["㉓"]
    W --> X["㉔"]
    X --> Y["㉕"]
    Y --> Z["㉖"]
    Z --> AA["㉗"]
    AA --> AB["㉘"]
    AB --> AC["㉙"]
    AC --> AD["㉚"]
    AD --> AE["㉛"]
    AE --> AF["㉜"]
    AF --> AG["㉝"]
    AG --> AH["㉟"]
    AH --> AI["㉟A"]
    AI --> AJ["㉟B"]
    AJ --> AK["㉟C"]
    AK --> AL["㉟D"]
    AL --> AM["㉟E"]
    AM --> AN["㉟F"]
    AN --> AO["㉟G"]
    AO --> AP["㉟H"]
    AP --> AQ["㉟I"]
    AQ --> AR["㉟J"]
    AR --> AS["㉟K"]
    AS --> AT["㉟L"]
    AT --> AU["㉟M"]
    AU --> AV["㉟N"]
    AV --> AW["㉟O"]
    AW --> AX["㉟P"]
    AX --> AY["㉟Q"]
    AY --> AZ["㉟R"]
    AZ --> BA["㉟S"]
    BA --> BB["㉟T"]
    BB --> BC["㉟U"]
    BC --> BD["㉟V"]
    BD --> BE["㉟W"]
    BE --> BF["㉟X"]
    BF --> BG["㉟Y"]
    BG --> BH["㉟Z"]

1. Neutralswitch
2. Interlockdiodes
   3.Sidestandswitch
3. Starterlockoutswitch
   5.Enginestopswitch
   6.Ignitionfuse10A
4. Ignitionswitch
5. Regulator/rectifier
   9.Crankshaftsensor
   10.CDlunit
   11.Ignitioncoil
   12.Sparkplug
   13.Battery
   14.Mainfuse15A

IgnitionSystem

IgnitionSystemCircuit(BN125-A3\~)

graph TD
    A["①"] --> B["BR W GY"]
    B --> C["BR W GY"]
    C --> D["BR W GY"]
    D --> E["②"]
    E --> F["BK/Y Y/G BK"]
    F --> G["BK"]
    G --> H["G/W W/Y"]
    H --> I["Y/G G/W LG"]
    I --> J["G/BK G/BK"]
    J --> K["③"]
    K --> L["G/W W/Y"]
    L --> M["④"]
    M --> N["G/W LG"]
    N --> O["G/BK G/BK"]
    O --> P["⑤"]
    P --> Q["BK G"]
    Q --> R["G/W"]
    R --> S["⑥"]
    S --> T["BR BL/W R BL/W"]
    T --> U["R BL/W"]
    U --> V["⑦"]
    V --> W["⑧"]
    W --> X["LG"]
    X --> Y["⑨"]
    Y --> Z["⑩ BL/BK BK/Y"]
    Z --> AA["⑪"]
    AA --> AB["⑫"]
    AB --> AC["W"]
    AC --> AD["⑭"]
    AD --> AE["⑮"]
    AE --> AF["⑯"]
    AF --> AG["⑪"]
    AG --> AH["W"]
    AH --> AI["⑭"]
    AI --> AJ["⑮"]
    AJ --> AK["W"]
    AK --> AL["⑭"]
    AL --> AM["⑮"]
    AM --> AN["W"]
    AN --> AO["⑭"]
    AO --> AP["W"]
    AP --> AQ["⑭"]

1. Ignitionswitch
2. Starterlockoutswitch
   3.Crankshaftsensor
   4.Interlockdiodes
   5.Sidestandswitch
   6.Ignitionfuse15A
   7.Enginestopswitch
3. Neutralswitch
   9.CDlunit
   10.Ignitioncoil
   11.Sparkplug
   12.Mainfuse30A
   13.Battery
   14.Regulator/rectifier

ElectricStarterSystem

StarterMotorRemoval

CAUTION

Donottapthestartermotorshaftorbody. Tapping theshaftorbocoulddamagethemotor.

• Remove:
  OilPipe(seeEngineLubricationSystemchapter)
• Slidebacktherubbercap.
• Removethestartermotorterminalnut[A].
• Removetheartermotormountingbolts[B].
• Pulloutthestartermotor[C].

StarterMotorInstallation

CAUTION

Donottapthestartermotorshaftorbody. Tapping theshaftorbody could damage themotor.

- Wheninstallingthestartermotor,cleanthestartermotorlegs[A]andcrankcase[B]wherethestartermotoris grounded.

• ReplacetheO-ring[A]withanewone.
• ApplyasmallamountofengineoiltotheO-ring.
  • Installthestartermotor.
• Tighten:

Torque-StarterMotorMountingBolts:8.8N·m(0.90kgf·m, 78in·lb)

StarterMotorTerminalNut:4.9N·m(0.50kgf·m, 43in·lb)

StarterMotorDisassembly

• Removethestartermotor(seethissection).
• Takeoffthestartermotorassemblybolts[A]andremove bothendcovers[B]andpullthearmatureoutoftheyoke.

Close-up mechanical assembly showing a component with labeled parts A and B, no readable text or symbols present.

Close-up of a mechanical component with labeled section A (no readable text or symbols beyond label)

ElectricStarterSystem

- Removetheterminallocknut[A]andterminalbolt[B], and thenremovethebrushwiththebrushplatefromtheyoke.

StarterMotorAssembly

• ReplacetheO-ringswithnewones.
• Applyathincoatofgreasetotheoilseal[A]andneedle bearing[B].
• Fitthetoothedwasher[C]intotheendcover.

- Installthebrushplate[A]andtightentheterminallocknut [B].

Torque-StarterMotorTerminalLocknut:6.9N·m(0.70 kgf·m,61in·lb)

- Fitthetongue[C]onthebrushplateintotheendcover groove.

- Insertthearmature[A]betweenthebrushes.

Close-up of hands assembling a mechanical component with a labeled section (A), no visible text or symbols.

• Alignthemarks[C]ontheyoke[B]andendcovers[A].
• Tightenthestartermotorassemblybolts.

Torque-StarterMotorAssemblyBolts:3.4N·m(0.35 kgf·m,30in·lb)

ElectricStarterSystem

BrushInspection

• Measurethelength[A]ofeachbrush.
★Ifanyisworndowntotheservicelimit, replacethecarbon brushholderassembly[B].

StarterMotorBrushLength

Standard: 9.5 \~ 10.5 mm (0.37 \~ 0.41 in.)

ServiceLimit:8mm(0.31in.)

CommutatorCleaningandInspection

- Smooththecommutatorsurface[A]ifnecessarywithfine emerycloth[B],andcleanoutthegrooves.

- Measurethediameter[A]ofthecommutator[B].

★ If the commutator diameter is less than the servicelimit, replace the starter motor with anewone.

CommutatorDiameter

Standard: 27.95 \~ 28.05 mm (1.10 \~ 1.11 in.)

ServiceLimit:27mm(1.06in.)

ArmatureInspection

- Usingthe×1Ω handtesterrange,measuretheresistancebetweenanytwocommutatorsegments[A].

SpecialTool-HandTester:57001-1394

★Ifthereisahighresistanceornoreading(∞)betweenany twosegments, awindingisopenandthestartermotor mustbereplaced.

- Using the highest and test range, measure the resistance between these segments and the shaft [B].

★ If there is any reading at all, the immature has a short and the starter motorm must be replaced.

NOTE

Eveniftheforegoingchecksshowthearmaturetobe good,itmaybedefectiveinsomemannernotreadily detectablewiththehandtester.Ifallotherstartermotor andstartermotorcircuitcomponentscheckgood,but thestartermotorstilldoesnotturnoveroronlyturns overweakly,replacetheartermotorwithanewone.

ElectricStarterSystem

BrushLeadInspection

- Usingthe×1Ω handtesterrange,measuretheresistanceasshown.

TerminalBoltandPositiveBrush[A]

BrushPlateandNegativeBrush[B]

SpecialTool-HandTester:57001-1394

★ If there is not closeto 0Ω, the brush has an open. Re-placetheterminal bolt assembly and/or the brush holder assembly.

BrushPlateandTerminalBoltInspection

- Using the highest and testerrange, measure the resistance as shown.

TerminalBoltandBrushPlate[A]

TerminalBoltandNegativeBrushHolder[B]

TerminalBoltandEndCover[C]

SpecialTool-HandTester:57001-1394

★ Ifthereisanyreading, thebrushholderassembly and/or terminalboltassembly haveashort. Replacethebrush holderassembly and theterminalboltassembly.

StarterRelayInspection

- Remove:

RightSideCover(seeFramechapter)

StarterCircuitRelay

- Connectthehandtester[A]and12Vbattery[B]tothe starterrelay[C]asshown.

SpecialTool-HandTester:57001-1394

★ Iftherelaydoesnotworkasspecified,therelayisdefective.Replacetherelay.

TestingRelay

TesterRange: ×1Ω range

Criteria: When battery is connected → 0Ω

When battery is disconnected → ∞ Ω

ElectricStarterSystem

StarterCircuitRelayInspection

- Remove:

RightSideCover(seeFramechapter)

StarterCircuitRelay

- Connectthehandtester[A]and12Vbattery[B]as shown.

RelayCoilTerminal[1]and[2]

RelaySwitchTerminal[3]and[4]

★Iftherelay[C]doesnotworkasspecified,therelayis defective.Replacetherelay.

SpecialTool-HandTester:57001-1394

TestingRelay

TesterRange:×1Ω range

Criteria: When battery is connected → 0Ω

When battery is disconnected → ∞ Ω

StarterCircuitRelay[A]

StarterRelay[B]

InterlockDiodes[C]

ElectricStarterSystem

ElectricStarterCircuit(BN125-A1/A2)

1. Ignitionswitch
   2.Enginestopswitch
2. Starterbutton
3. Startercircuitrelay
4. Ignition fuse 10A
5. Starterlockoutswitch
   7.Interlockdiodes
   8.CDlunit
6. Startermotor
7. Starterrelay
   11.Mainfuse15A
   12.Battery
   13.Neutralswitch

ElectricStarterCircuit(BN125-A3\~)

1. Ignitionswitch
   2.Enginestopswitch
2. Starterbutton
3. Startercircuitrelay
4. Ignitionfuse15A
5. Starterlockoutswitch
   7.InterlockDiodes
   8.CDlunit
6. Startermotor
7. Starterrelay
   11.Mainfuse30A
   12.Battery

LightingSystem

HeadlightBeamHorizontal/VerticalAdjustment

• Turnthehorizontaladjuster[A]ontheheadlightwitha screwdriverinoroutuntilthebeampointsstraightahead.
  ○Turnthehorizontaladjusterclockwisetofacethehead-lightleft.
• Turntheverticaladjuster[B]ontheheadlightinoroutto adjusttheheadlightvertically.
  ○Turntheverticaladjusterclockwisetofacetheheadlight up.

NOTE

○Onhighbeam, the brightestpointsshouldbeslightly below horizontal with themotorcycleonitswheels and theriderseated. Adjust the headlight to the proper angle according to local regulations.

HeadlightBulbReplacement

• Removetheheadlightrimscrews[A].
• Pulltheheadlightunit[B]anddropitout.

- Remove: BulbSocket[A] DustCover[B]

- Removethehook[A].

Close-up of a motorcycle's headlight with labeled points A and B (no text or symbols beyond labels)

Close-up of mechanical components with labeled parts A and B, no readable text or symbols present

Close-up of a mechanical component with circular features and labeled parts (no readable text or symbols)

LightingSystem

- Replacetheheadlightbulb[A].

CAUTION

Whenhandlingthequartz-halogenbulb,never touchtheglassportionwithbarehands.Always useacleancloth.Oilcontaminationfromhandsor dirtyragscanreducebulblifeorcausethebulbto explode.

NOTE

○ Cleanoffanycontaminationthatinadvertentlygetson thebulbwithalcoholorsoapandwatersolution.

- Fitthedustcover[A]withthe"TOP"mark[B]upwardonto thebulbfirmlyasshown.

- Installtheheadlightunit[B]withthe"TOP"mark[A]upward. - Afterinstallation,adjusttheheadlightaim(seethischapter).

ACLightingVoltageInspection

• Removetheheadlightunit(seethischapter).
  ○Donotremovethebulbsocket.
• Connectthehandtester[A]totheR/BKandBK/Yleads inthesocketasshowninthetable.
• PushtheheadlightswitchtoONanddimmerswitchtoHI.
• Runtheengineat4000r/min(rpm)andmeasurethe voltage.

ACLightingVoltage

Tester Range	Connections		Rearing @4000rpm
	Tester(+)oTester(-)b
25 V AC	R/BK lead	BK/Y lead	11~ 16V

• Stoptheengine.
  ★If the voltage is kept between the values given in the table, thelightingsystemisconsideredtobeworkingnormally.
  ★Ifthevoltageismuchhigherthanthevaluesspecifiedin thetable,theregulator/rectifierisdefectiveortheregulator/rectifierleadsarelooseoropen.
  ★ If the voltage is much lower than the value specified in the table, theregulator/rectifier is defective or alternator output is insufficient. Check theregulator/rectifier and alternator to determine which part is defective.

Close-up of a hand adjusting a mechanical component with a labeled section (A), no visible text or symbols.

Close-up of mechanical components with labeled parts A and B, no readable text or symbols present

LightingSystem

HeadlightCircuit(BN125-A1/A2)

1. Highbeamindicatorlight
   2.Headlight

2. Dimmerswitch

3. Alternator

4. Regulator/rectifier
   6.Headlightswitch

HeadlightCircuit(BN125-A3\~A5)

1. Highbeamindicatorlight
   2.Headlight

2. Dimmerswitch
   4.Headlightswitch

3. Alternator

4. Regulator/rectifier
5. Ignitionswitch
   8.Headlightfuse15A

LightingSystem

HeadlightCircuit(BN125-A6\~)

1. Highbeamindicatorlight
   2.Headlight
   3.Dimmerswitch
2. Alternator
3. Regulator/rectifier
4. Ignitionswitch
   7.Headlightfuse15A

Tail/BrakeLightBulbReplacement

- Removethetail/brakelightlens[A].

- Pushthebulb[A]inthesocket,turnitcounterclockwise [B],andpullitout.

Close-up of a mechanical component with mesh grille and labeled point A (no readable text or symbols)

LightingSystem

• Withthefrontpin[A]down,insertthenewbulbbyaligning thefrontpinwiththegroove[B]inthewallsofthesocket.
• Pushthebulbin, turnitclockwise, andreplaceit. It should lockinposition.
• Tightenthelensscrews.Becarefulnottovertighten them.

TurnSignalRelayInspection

• Removetherightsidecover(seeFramechapter).
• Connectone12Vbatteryandturnsignallightsasindicatedinthefigure,andcounthowmanytimesthelights flashforoneminute.

TurnSignalRelay[A]

TurnSignalLights[B]

12VBattery[C]

★ Ifthelightsdonotflashasspecified, replacetheturnsignalrelay.

TestingTurnSignalRelay

Load		Flashingtimes (c/m*)
TheNumberofTurn SignalLights	Wattage(W)
1**	23or21	Lightstayson or 140~250
242or4675~95

*:Cycle(s)perminute

**:Correspondto"onelightburnedout"

TurnSignalLightCircuit(BN125-A1/A2)

graph TD
    A["1 ⑧ GY G"] --> B["6P"]
    B --> C["GY G"]
    C --> D["2 P R/W"]
    D --> E["BR"]
    E --> F["3 S"]
    F --> G["6 GY"]
    G --> H["8 BK/Y"]
    H --> I["9 P"]
    I --> J["8 L"]
    J --> K["+"]
    K --> L["10 BK/Y"]
    L --> M["11 W"]
    M --> N["12 + -"]
    N --> O["11"]
    style A fill:#f9f,stroke:#333
    style B fill:#ccf,stroke:#333
    style C fill:#cfc,stroke:#333
    style D fill:#fcc,stroke:#333
    style E fill:#cff,stroke:#333
    style F fill:#ffc,stroke:#333
    style G fill:#fcf,stroke:#333
    style H fill:#cff,stroke:#333
    style I fill:#cfc,stroke:#333
    style J fill:#cfc,stroke:#333
    style K fill:#cfc,stroke:#333
    style L fill:#cfc,stroke:#333
    style M fill:#cfc,stroke:#333
    style N fill:#cfc,stroke:#333
    style O fill:#cfc,stroke:#333

1. Turnsignalindicatorlight
2. Turnsignalrelay
3. Ignition fuse 10A
4. Frontrightturnsignallight
   5.Frontleftturnsignallight
5. Rearrightturnsignallight
6. Rearleftturnsignallight
7. Turnsignalswitch
8. Ignitionswitch
9. Starterrelay
   11.Mainfuse15A
   12.Battery

GP12121BW3 C

LightingSystem

TurnSignalLightCircuit(BN125-A3\~A5)

graph TD
    A["①"] --> B["②"]
    B --> C["③"]
    C --> D["④"]
    D --> E["⑤"]
    E --> F["⑥"]
    F --> G["⑦"]
    G --> H["⑧"]

    subgraph Terminal 1
        I["GY G"] --> J["6P"]
        K["GY G"] --> L["6P"]
    end

    subgraph Terminal 2
        M["BL/W"] --> N["2P"]
        O["BR"] --> P["BR"]
    end

    subgraph Terminal 3
        Q["BL/W"] --> R["BR"]
    end

    subgraph Terminal 4
        S["G BK/Y"] --> T["GY BK/Y"]
    end

    subgraph Terminal 5
        U["G BK/Y"] --> V["G BK/Y"]
    end

    subgraph Terminal 6
        W["GY BK/Y"] --> X["G BK/Y"]
    end

    subgraph Terminal 7
        Y["G BK/Y"] --> Z["G BK/Y"]
    end

    subgraph Terminal 8
        AA["GY BL/W"] --> AB["9P"]
        AC["GY BL/W"] --> AD["9P"]
        AE["GY BL/W"] --> AF["9P"]
        AG["GY BL/W"] --> AH["9P"]
        AI["GY BL/W"] --> AJ["9P"]
        AK["GY BL/W"] --> AL["9P"]
        AM["GY BL/W"] --> AN["9P"]
        AO["GY BL/W"] --> AP["9P"]
        AQ["GY BL/W"] --> AR["9P"]
        AS["GY BL/W"] --> AT["9P"]
        AU["GY BL/W"] --> AV["9P"]
        AW["GY BL/W"] --> AX["9P"]
        AY["GY BL/W"] --> AZ["9P"]
        BA["GY BL/W"] --> BB["9P"]
        BC["GY BL/W"] --> BD["9P"]
        BE["GY BL/W"] --> BF["9P"]
        BG["GY BL/W"] --> BH["9P"]
        BI["GY BL/W"] --> BJ["9P"]
        BK["GY BL/W"] --> BL["9P"]
        BM["GY BL/W"] --> BN["9P"]
        BO["GY BL/W"] --> BP["9P"]
        BQ["GY BL/W"] --> BR["9P"]
        BS["GY BL/W"] --> BT["9P"]
        BU["GY BL/W"] --> BV["9P"]
        BW["GY BL/W"] --> BX["9P"]
        BY["GY BL/W"] --> BZ["9P"]
        CA["GY BL/W"] --> CB["9P"]
        CC["GY BL/W"] --> CD["9P"]
        DD["GY BL/W"] --> DJ["9P"]
        DK["GY BL/W"] --> DL["9P"]
        DV["GY BL/W"] --> DW["9P"]
        DX["GY BL/W"] --> DXB["9P"]
        DXB --> DXC["9P"]
        DXC --> DXD["9P"]
        DXD --> DXE["9P"]
        DXE --> DXF["9P"]
        DXF --> DXG["9P"]
    end

    subgraph Terminals
    H
    I
    J
    K
    L
    M
    N
    O
    P
    Q
    R
    S
    T
    U
    V
    W
    X
    Y
    Z
    AA
    AB
    AC
    AD
    AE
    AF
    AG
    AH
    AI
    AJ
    AK
    AL
    AM
    AN
    AO
    AP
    AQ
    AR
    AS
    AT
    AU
    AV
    AW
    AX
    AY
    AZ
    BA
    BB
    BC
    BD
    BE
    BF
    BG
    BH
    BI
    BJ
    BK
    AL
    AM
    AN
    AO
    AP
    AQ
    AR
    AS
    AT
    AU
    AV
    AW
    AX
    AY
    AZ
    BA
    BB
    BC
    AD
    AE
    AF
    AG
    AH
    AI
    AJ
    AK
    AL
    AM
    AN
    AO
    AP
    AQ
    AR
    AS
    AT
    AU
    AV
    AW
   AX
   AB
   AC
    AD
    AE
    AF
    AG
    AH
    AI
    AJ
    AK
    AL
    AM
    AN
    AO
    AP
    AQ
    AR
    AS
    AT
    AU
    AV
    AW
   AX
   AB
   AC
   AD
    AE
    AF
    AG
    AH
   AI
    AJ
    AK
   AL
    AM
    AN
    AO

1. Turnsignalindicatorlight
2. Turnsignalrelay
3. Ignitionfuse15A
   4.Frontrightturnsignallight
   5.Frontleftturnsignallight
4. Rearrightturnsignallight
5. Rearleftturnsignallight
6. Turnsignalswitch
7. Ignitionswitch
8. Starterrelay
   11.Mainfuse30A
   12.Battery

TurnSignalLightCircuit(BN125-A6\~)

graph TD
    A["IGNITION"] --> B["BATTERY"]
    B --> C["BR W"]
    C --> D["BR W"]
    D --> E["BR W"]
    E --> F["BL/W"]
    F --> G["BL/W"]
    G --> H["BR W"]
    H --> I["3"]
    I --> J["BR"]
    J --> K["BR"]
    K --> L["BL/W"]
    L --> M["BL/W"]
    M --> N["2"]
    N --> O["BL/W"]
    O --> P["BR W"]
    P --> Q["BR W"]
    Q --> R["1"]
    R --> S["GY G"]
    S --> T["GY G"]
    T --> U["GY"]
    U --> V["GY"]
    V --> W["GY"]
    W --> X["GY"]
    X --> Y["GY"]
    Y --> Z["GY"]
    Z --> AA["GY"]
    AA --> AB["GY"]
    AB --> AC["GY"]
    AC --> AD["GY"]
    AD --> AE["GY"]
    AE --> AF["GY"]
    AF --> AG["GY"]
    AG --> AH["GY"]
    AH --> AI["GY"]
    AI --> AJ["GY"]
    AJ --> AK["GY"]
    AK --> AL["GY"]
    AL --> AM["GY"]
    AM --> AN["GY"]
    AN --> AO["GY"]
    AO --> AP["GY"]
    AP --> AQ["GY"]
    AQ --> AR["GY"]
    AR --> AS["GY"]
    AS --> AT["GY"]
    AT --> AU["GY"]
    AU --> AV["GY"]
    AV --> AW["GY"]
    AW --> AX["GY"]
    AX --> AY["GY"]
    AY --> AZ["GY"]
    AZ --> BA["GY"]
    BA --> BB["GY"]
    BB --> BC["GY"]
    BC --> BD["GY"]
    BD --> BE["GY"]
    BE --> BF["GY"]
    BF --> BG["GY"]
    BG --> BH["GY"]
    BH --> BI["GY"]
    BI --> BJ["GY"]
    BJ --> BK["GY"]
    BK --> BL["GY"]
    BL --> BM["GY"]
    BM --> BN["GY"]
    BN --> BO["GY"]
    BO --> BP["GY"]
    BP --> BQ["GY"]
    BQ --> BR["GY"]
    BR --> BS["GY"]
    BS --> BT["GY"]
    BT --> BU["GY"]
    BU --> BV["GY"]
    BV --> BW["GY"]
    BW --> BX["GY"]
    BX --> BY["GY"]
    BY --> BZ["GY"]
    BZ --> CA["GY"]
    CA --> CB["GY"]
    CB --> CC["GY"]
    CC --> CD["GY"]
    CD --> CE["GY"]

1. Turnsignalindicatorlight

2. Turnsignalrelay

3. Ignition fuse 15A

4.Frontrightturnsignallight

5.Frontleftturnsignallight

1. Rearrightturnsignallight

2. Rearleftturnsignallight

3. Turnsignalswitch

4. Ignitionswitch

5. Starterrelay

11.Mainfuse30A

12.Battery

Meter, Gauge, IndicatorUnit

SpeedometerRemoval

• Removethespeedometercableupperend[A].
• Removethemeterunit[C]bytakingoffthemountingbolts [B].

CAUTION

Placethemetersothatthefaceisup.lfameteris leftupsidedownorsidewaysforanylengthoftime, itwillmalfunction.

SpeedometerDisassembly

• Remove:
  Speedometer(seethischapter)
  Screws[A]
  Screw[B]andKnob[C]

- Toremovethewedge-basetypebulb[A], thenpullthe bulboutofthesocket.

CAUTION

Donotturnthebulb.Pullthebulbouttoprevent damagetothebulb.Donotusebulbratedforother thanvoltageorwattagespecifiedinthewiringdiagram.

IndicatorUnitRemoval/Installation

• Removethebolts[A]andindicatorunit[B]fromthefuel tank.
• Wheninstallingtheindicatorunit,tightenthefrontbolt first.

BulbReplacement

- Toremovethewedge-basetypebulb[A], pullthebulbout ofthesocket[B].

CAUTION

Donotturnthebulb.Pullthebulbouttoprevent damagetothebulb.Donotusebulbratedforother thanvoltageorwattagesspecifiedinthewiringdiagram.

Mechanical assembly diagram showing a cylindrical component with labeled parts A and B, and a dial indicator (no readable text or symbols)

Close-up of hands assembling a mechanical component with a labeled part (A), no visible text or symbols beyond the label.

SwitchesandSensors

FrontBrakeLightSwitchInspection

- RefertotheFrontBrakeLightSwitchInspectioninthe PeriodicMaintenancechapter.

RearBrakeLightTimingInspection

- RefertotheRearBrakeLightTimingInspectioninthe PeriodicMaintenancechapter.

RearBrakeLightTimingAdjustment

- RefertotheRearBrakeLightTimingAdjustmentinthe PeriodicMaintenancechapter.

SwitchInspection

- Usingthehandtester, checktoseethatonlytheconnectionsshowninthetablehavecontinuity(about0Ω).

○Forthehandlebarswitchesandtheignitionswitch, refer tothetablesintheWiringDiagram.

★ Iftheswitchhasanopenorshort,repairitorreplaceit withanewone.

SpecialTool-HandTester:57001-1394

Rear Brake Light Switch Connections
Color	BR	BL/W
When brake pedal is pushed down	○	○
When brake pedal is released

Sidestand Switch Connections
Color	BK	G
When sidestand is down
When sidestand is up	○—	○

Neutral Switch Connections
Color	SW.Terminal	Ground
When transmission is in neutral	○—	○
When transmission is not in neutral

Fuse

MainFuse15ARemoval

• Removetherightsidecover(seeFramechapter).
• Disconnectthestarterrelayconnector.
• Pulloutthemainfuse[B]fromthestarterrelay[A]with needlenosepliers.

MainFuse15AInspection

• Removethefuse(seeFuseRemoval).
• Inspectthefuseelement.
  ★ Ifitisblownout, replacethefuse. Before replacing a blownfuse, always check the amperage in the affected circuit. If the amperage is equal to greater than the fuserating, check the wiring and related components for ashort circuit.
  Housing[A]
  FuseElement[B]
  Terminals[C]
  BlownElement[D]

CAUTION

Whenreplacingafuse,besurethenewfuse matchesthespecifiedfuseratingforthatcircuit. Installationofafusewithahigherratingmaycause damagetowiringandcomponents.

Fuse10ARemoval

• Removetherightsidecover(seeFramechapter).
• Openthefusecase[A]andremovethefuses[B].

Fuse10AInstallation

★ Ifafusefailsduringoperation,inspecttheelectricalsystemtodeterminethecause,andthenreplaceitwitha newfuseorproperamperage.

CAUTION

Thefusecasehas10Afusesonly.Donotusethe fuseotherthan10Afuse.

Fuse

Fuse10AInspection

• Inspectthefuseelement.
  ★Ifitisblownout, replacethefuse.

FuseElement[A]

BlownElement[B]

Appendix

TableofContents

Cable, Wire, and Hose Routing 16-2

Troubleshooting Guide 16-32

BN125-A1\~

Cable, Wire, and HoseRouting

1. CrankshaftSensor
   2.OilPipe
2. Clamp
3. Runthealternatorleadundertheoilpipe.
4. AlternatorLead
5. Runtheneutralswitchleadsothatitshallnotoutofguiderib.
6. GuideRib
7. NeutralSwitch
8. TurnSignalRelay
9. EngineGroundLead
   11.Holder
   12.CarburetorDrainHose
   13.BatteryVentHose

BN125-A1\~

Cable, Wire, and HoseRouting

1.CDIUnit
2. Ignition Coil Lead
3. EngineBreatherHose
4. ToFuelTap
5. Insulator
6. Runtheignitioncoilleadundertheenginebreatherhose.
7. Clamp
8. Install the hose as shown.
9. Other than AT, DE, SG, CH Models

AT:Austria

CH:Switzerland

DE:Germany

SG:Singapore

CleanAirSystem

Cable, Wire, and HoseRouting

1. VacuumHose
2. Three-way Joint
3. ToFuelTap
   4.AirHose
   5.AirPipe
4. EngineBreatherHose
5. AirCleanerDuct
   8.AirCleanerHousing
6. VacuumSwitch
7. Carburetor
   11.AirSuctionValve
8. Insulator
9. Run the vacuum hose onto the left side of the duct (7), and then behind the hose (6) and carburetor (10).
10. Themarkfacesupward.
    15.PositioningMark
11. ArrowMark(facestowardthevacuumhose)
12. Clamp

Note: The position mark(15), arrowmark(16) and vacuum hose(1) shall be inline as shown.

BN125-A1\~A4

Cable, Wire, and HoseRouting

1. IgnitionSwitch
2. Runtheignitionswitchleadtotheright.
   3.SidestandSwitchLead
3. Runthesidestandswitchleadtotheright.
   5.BodyGround
   6.IgnitionCoil
4. Alternator Lead Connector
   8.SidestandSwitch
5. Clamp
   10.Band

BN125-A5\~

Cable, Wire, and HoseRouting

1. IndicatorLightConnector(Moveittotherightsideafterconnected.)
   2.Horn
2. Sidestandswitchconnector
3. Ignitioncoil
4. Regulator/Rectifier
   6.GroundLead
5. AlternatorLead
6. Puttheconnectorsintothegussetafterconnectingthem.
   9.SidestandSwitch
   10.Band
   11.LeftHandlebarSwitchConnector
7. Connectitinthefueltankcover.
   13.RightHandlebarSwitchConnector
8. California Model
9. EuropeModel

BN125-A1\~

Cable, Wire, and HoseRouting

1. RearLeftTurnSignalLight
2. Tail/BrakeLight
3. RearRightTurnSignalLight
   4.RearFenderRear
4. RearFenderFront
   6.ThrottleCables
5. CarburetorAirVentHose
6. EngineBreatherHose
   9.RightHandlebarSwitch
   10.BrakeHose
   11.ClutchCable
   12.RearBrakeLightSwitch
   13.BatteryVentHose
   14.Clamp
   15.Holder
   16.Band
7. Runthethrottlecablesinsidetherighthandlebarswitch.
   18.Runtheleft/rightrearturnsignallight,tail/brakelightleadsbetweentheststayandtherearfender.

BN125-A1\~

Cable, Wire, and HoseRouting

1. ThrottleCables
2. ClutchCable
3. Speedometer Cable
   4.LeftHandlebarSwitchHarness
   5.RightHandlebarSwitchHarness
   6.SidestandSwitch
   7.Holder
   8.Band
4. Clamp
   10.BN125-A3\~

BN125-A1\~A2

Cable, Wire, and HoseRouting

1. Tail/BrakeLightConnector
2. RearLeftTurnSignalLightConnector
3. White Tape
4. Ignition Coil Connector
   5.BodyGround
   6.FrontLeftTurnSignalLightConnector
5. FrontRightTurnSignalLightConnector
6. Joinconnectorsintheheadlightunit.
7. SpeedometerLightConnector
   10.HeadlightConnector
   11.RearRightTurnSignalLightConnector
   12.InterlockDiodes
   13.StarterCircuitRelayConnector
   14.StarterRelayConnector
   15.Regulator/RectifierConnector
   16.FuseBoxConnector
8. TurnSignalRelayConnector
   18.BatteryNegativeLead
9. AlternatorConnector
   20.CDIUnit
   21.LeftHandlebarSwitchConnector
   22.RightHandlebarSwitchConnector
   23.RearBrakeLightSwitchConnector
   24.IgnitionSwitchConnector
   25.IndicatorLightConnector
   26.SidestandLightConnector
   27.HornConnector
   28.BatteryPositiveLead
   29.CDIUnitConnector
   30.Battery
   31.RightHandlebarSwitchLeadConnector
   32.CityLightConnector(EuropeModel)
   33.Band
   34.Clamp
   35.StarterLead
   36.RearBrakeLightSwitch
   37.TurnSignalRelay

BN125-A3\~A4

Cable, Wire, and HoseRouting

1. RearLeftTurnSignalLightConnector
2. Tail/BrakeLightConnector
   3.Band
   4.GroundLead
3. Ignition Coil Lead
   6.Regulator/RectifierConnector
   7.CDIUnitConnector
   8.LeftHandlebarSwitchConnector
   9.HornConnector
   10.IndicatorLightConnector
   11.SidestandSwitchConnector
   12.HeadlightConnector
   13.FrontRightTurnSignalLightConnector
   14.FrontLeftTurnSignalLightConnector
   15.RearRightTurnSignalLightConnector
   16.DiodeConnector
   17.StarterCircuitRelayConnector
   18.StarterRelayConnector
   19.FuseBoxConnector
   20.AlternatorConnector
   21.IgnitionSwitchConnector(CaliforniaModel)
   22.BatteryNegativeLead
   23.TurnSignalRelayConnector
   24.RightHandlebarSwitchConnector
4. IgnitionSwitchConnector(OtherThanCaliforniaModel)
   26.RearBrakeSwitchConnector
   27.BatteryPositiveLead
   28.Runthethrottlesensorleadtoleftside.
   29.Turnsignalrelay
   30.Runtheindicatorlightleadfromleftside.
   31.StarterLead
   32.SpeedometerConnector
   33.CityLightConnector(EuropeModel)
   34.Clamp
   35.Putthemintothegussetafterconnected.
5. Connect them in the headlighthousing.

BN125-A5\~

Cable, Wire, and HoseRouting

1. RearLeftTurnSignalLightConnector
2. Tail/BrakeLightConnector
   3.Band
3. White Tape
   5.GroundLead
   6.Regulator/RectifierConnector
4. Ignition Coil Lead
   8.LeftHandlebarSwitchConnector
   9.HornConnector
   10.IndicatorLightConnector
   11.SidestandSwitchConnector
   12.FrontLeftTurnSignalLightConnector
   13.FrontRightTurnSignalLightConnector
   14.HeadlightConnector
   15.SpeedometerConnector
   16.CityLightConnector(EuropeModel)
5. IgnitionSwitchConnector
   18.RearBrakeSwitchConnector
   19.RightHandlebarSwitchConnector
   20.CDIUnitConnector
6. AlternatorConnector
   22.BatteryNegativeLeadConnector
   23.TurnSignalRelayConnector
   24.FuseBoxConnector
   25.StarterRelayConnector
   26.StarterCircuitRelayConnector
   27.DiodeConnector
   28.RearRightTurnSignalLightConnector
7. Tiewiththestaybythebandafterconnected.
   30.CaliforniaModel

BN125-A5\~

Cable, Wire, and HoseRouting

1. DiodeConnector
   2.FuseBoxConnector
   3.BatteryPositiveLead
2. Clamp
3. TurnSignalRelay
4. Alternator Connector
   7.BatteryNegativeLead
   8.Band
   9.CDIUnitConnector

10.IgnitionCoilLead

11.Runtheindicatorlightleadfromleftside.
12. Connect them in the headlighthousing.
13.CityLightConnector(EuropeModel)

1. IgnitionSwitchConnector

15.Putthemintothegussetafterconnected.

16.RearBrakeSwitchConnector

17.RightHandlebarSwitchConnector

18.StarterLead

19.Battery

20.StarterCircuitRelay

21.CaliforniaModel

Evaporative Emission Control System (BN125-A5 \~ : California Model)

Cable, Wire, and HoseRouting

1.FuelTank
2.Separator
3.Canister
4. VacuumSwitchValve
5.AirCleanerHousing
6.Label(Blue)
7.Label(Red)
8.Hose(withbluestripe)
9.Hose(withbluestripe)
10.Hose(withredstripe)
11.Hose(withwhitestripe)
12. WhitePaintMark
13. WhitePaintMark

Evaporative Emission Control System (BN125-A5 \~ : California Model)

Cable, Wire, and HoseRouting

1. VacuumSwitchValve
2. Gotothefueltap
3. CarburetorHolder
   4.Separator

Evaporative Emission Control System (BN125-A5 \~ : California Model)

Cable, Wire, and HoseRouting

1. Runtheignitioncoilprimaryleadunderthethrottlecables, secondaryairhoseandbreather hose.
   2.GoToLeftSide
   3.Separator
   4.GoToTheFuelTank
   5.BreatherHose
2. SecondaryAirHose
   7.AirVentHose
   8.ThrottleCables
3. VacuumSwitchValve
4. CarburetorHolder
   11.Canister
   12.GoToLeftSide
5. Clamp
   14.Knobofclipshallbeinstalleddownward.

Evaporative Emission Control System (BN125-A5 \~ : California Model)

Cable, Wire, and HoseRouting

1.MainHarness
2.BreatherHose
3. SecondaryAirHose
4. AirVentHose
5. Gotothefueltank
6.Separator
7. Gotothecanister
8. Clamp
9.Front

TroubleshootingGuide

NOTE

○ Thisisnotanexhaustivelist, giving every possible cause foreach problem listed. It is meant simply as a rough guideto assist the troubleshooting for some of them more common difficulties.

EngineDoesn'tStart, Starting Difficulty:

Startermotornotrotating:

Starterlockoutswitchorneutralswitchtrouble Startermotortrouble Batteryvoltagelow Starterrelaynotcontactingoroperating Starterbuttonnotcontacting Wiringopenorshorted Ignitionswitchtrouble Enginestopswitchtrouble Fuseblown

Startermotorrotatingbutenginedoesn't turnover:

Startermotorclutchtrouble Torquelimitertrouble

Nofuelintank Fueltankairventobstructed Fueltapvacuumhoseclogged Fueltapclogged Fuellineclogged Floatvalveclogged

Engineflooded:

Fuellevelincarburetorfloatbowltoohigh Floatvalvewornorstuckopen Startingtechniquefaulty(Whenflooded, cranktheenginewiththethrottlefully openedtoallowmore air toreach the engine.)

Nospark;sparkweak:

Batteryvoltagelow Ignitionswitchnoton Enginestopswitchturnedoff Clutch lever not pulled in or gear not in neutral Sparkplugdirty, broken, orgapmaladjusted

Sparkplugcaporhightensionwiringtrouble Sparkplugcapshortedornotingoodcontact Sparkplugincorrect CDlunittrouble Neutral, starterlockoutswitch, or sidesta switchtrouble Crankshaftsensortrouble Ignitioncoiltrouble Ignitionorenginestopswitchshorted Wiringshortedoropen Fuseblown

Fuel/airmixtureincorrect:

Pilot screw and/or idle adjusting screw mal-adjusted Pilotjet, orairpassage clogged Air cleaner clogged, poorly sealed, or missing Starterjet clogged

CompressionLow:

Sparkplugloose Cylinder head not sufficiently tightened down Novalveclearance Cylinder, pistonworn Piston ringbad (worn, weak, broken, or sticking) Pistonring/grooveclearanceexcessive Cylinderheadgasketdamaged Cylinderheadwarped Valve spring broken or weak Valve not seating properly (valve bent, worn, orcarbonaccumulationonthe seatingsurface)

PoorRunningatLowSpeed:

Sparkweak:

Batteryvoltagelow Sparkplugdirty, broken, orgapmaladjusted Sparkplugcaporhightensionwiringtrouble Sparkplugcapshortedornotingoodcontact Sparkplugincorrect CDlunittrouble Crankshaftsensortrouble Ignitioncoiltrouble

Fuel/airmixtureincorrect:

Pilotscrewmaladjusted Pilotjet, orairpassageclogged Needlejetbleedholes orneedlejetclogged Pilotpassageclogged Air cleaner clogged, poorly sealed, or missing Starterplungerstuckopen

TroubleshootingGuide

Fuellevelincarburetorfloatbowltoohigh ortoolow

Fueltankairventobstructed

Carburetorholderloose

Aircleanerductloose

Fueltapclogged

AircleanerO-ringdamaged

Compressionlow:

Sparkplugloose

Cylinderheadnotsufficientlytightened down

Novalveclearance

Cylinder, pistonworn

Pistonringbad(worn,weak,broken,or sticking)

Pistonring/grooveclearanceexcessive

Cylinderheadwarped

Cylinderheadgasketdamaged

Valvespringbrokenorweak

Valvenotseatingproperly(valvebent, worn,orcarbonaccumulationonthe seatingsurface)

Other:

CDlunittrouble

Carburetorvacuumpistondoesn'tslide smoothly

Carburetorvacuumpistondiaphragmdamage

Engineoilviscositytoohigh

Drivetraintrouble

Brakedragging

Overheating

Clutchslipping

Airsuctionvalvetrouble(AT,DE,SG,CH)

Vacuumswitchvalvetrouble(AT,DE,SG,CH)

Castingenrichertrouble

PoorRunningorNoPoweratHigh Speed:

Firingincorrect:

Spark plug dirty, broken, or gap maladjusted

Sparkplugcaporhightensionwiringtrouble

Sparkplugcapshortedornotingoodcontact

Sparkplugincorrect

CDlunittrouble

Crankshaftsensortrouble

Ignitioncoiltrouble

Fuel/airmixtureincorrect:

Starterplungerstuckopen

Mainjetcloggedorwrongsize

Jetneedleorneedlejetworn

Airjetclogged

Fuellevelincarburetorfloatbowltoohigh ortoolow

Needle jet bleed holes or needle jet clogged

Aircleanerclogged,poorlysealed,ormissing

Aircleanerductloose

Fueltocarburetorinsufficient

Waterorforeignmatterinfuel

Carburetorholderloose

Fueltankairventobstructed

Fueltapclogged

Fuellineclogged

Compressionlow:

Sparkplugloose

Cylinderheadnotsufficientlytightened down

Novalveclearance

Cylinder, pistonworn

Pistonringbad(worn,weak,broken, or sticking)

Pistonring/grooveclearanceexcessive

Cylinderheadgasketdamaged

Cylinderheadwarped

Valve spring broken or weak

Valvenotseatingproperly (valvebent, worn, orcarbonaccumulation on the seatingsurface.)

Knocking:

Carbonbuiltupincombustionchamber

Fuelpoorqualityorincorrect

Sparkplugincorrect

CDlunit

Miscellaneous:

Throttlevalvewon'tfullyopen

Carburetorvacuumpistondoesn't slide smoothly

Carburetorvacuumpistondiaphragmdamaged

Brakedragging

Clutchslipping

Overheating

Engineoilleveltoohigh

Engineoilviscositytoohigh

Drivetraintrouble

Airsuctionvalvetrouble(AT,DE,SG,CH)

Vacuumswitchvalvetrouble(AT,DE,SG,CH)

Balancermechanismmalfunctioning

Coastingenrichertrouble

Overheating:

Firingincorrect:

Spark plug dirty, broken, or gap maladjusted

Sparkplugincorrect

CDlunittrouble

TroubleshootingGuide

Fuel/airmixtureincorrect:

Mainjetcloggedorwrongsize

Fuellevelincarburetorfloatbowltoolow

Carburetorholderloose

Aircleanerductloose

Aircleanerpoorlysealed,ormissing

AircleanerO-ringdamaged

Aircleanerclogged

Compressionhigh:

Carbonbuiltupincombustionchamber

Engineloadfaulty:

Clutchslipping

Engineoilleveltoohigh

Engineoilviscositytoohigh

Drivetraintrouble

Brakedragging

Lubricationinadequate:

Engineoilleveltoolow

Engineoilpoorqualityorincorrect

ClutchOperationFaulty:

Clutchslipping:

Noclutchleverplay

Clutchinnercablecatching

Clutchcableunadjusted

Frictionplatewornorwarped

Steelplatewornorwarped

Clutchspringbrokenorweak

Clutchreleasemechanismtrouble

Clutchhuborhousingunevenlyworn

Clutchnotdisengagingproperly:

Clutchleverplayexcessive

Clutchplatewarpedortoorough

Clutchspringcompressionuneven

Engineoildeteriorated

Engineoilviscositytoohigh

Engineoilleveltoohigh

Clutchhousingfrozenondriveshaft

Clutchreleasemechanismtrouble

Clutchhubnutloose

Clutchhubsplinedamaged

GearShiftingFaulty:

Doesn'tgointogearshiftpedaldoesn't return:

Clutchnotdisengaging

Shiftforkbentorseized

Gearstuckontheshaft

Gearsetleverbinding

Shiftreturnspringweakorbroken

Shiftreturnspringpinloose

Shiftmechanismarmspringbroken

Shiftmechanismarmbroken

Shiftpawlbroken

Jumpsoutofgear:

Shiftforkearworn,bent

Geargrooveworn

Geardogsand/ordogholesworn

Shiftdrumgrooveworn

Gearsetleverspringweakorbroken

Shiftforkguidepinworn

Driveshaft, outputshaft, and/orgear splinesworn

Overshifts:

Gearsetleverspringweakorbroken

Shiftmechanismarmspringbroken

AbnormalEngineNoise:

Knocking:

CDlunittrouble

Carbonbuiltupincombustionchamber

Fuelpoorqualityorincorrect

Sparkplugincorrect

Overheating

Pistonslap:

Cylinder/pistonclearanceexcessive

Cylinder, pistonworn

Connectingrodbent

Pistonpin, pistonpinholeworn

Valvenoise:

Valveclearanceincorrect

Valvespringbrokenorweak

Camshaftbearingworn

Rockerarmworn

Rockershaftworn

Othernoise:

Connectingrodsmallendclearanceexcessive

Connectingrodbigendclearanceexcessive

Pistonringworn,broken,orstuck

Pistonseizure,damage

Cylinderheadgasketleaking

Exhaustpipeleakingatcylinderheadconnection

Crankshaftrunoutexcessive

Enginemountsloose

Crankshaftbearingsworn

Primarygearwornorchipped

Camshaftchaintensionertrouble

Camshaftchain,sprocket,guideworn

Airsuctionvalvedamaged(AT,DE,SG,CH)

Vacuum switch valve damaged (AT, DE, SG, CH)

Balancergearwornorchipped

Balancershaftgearpositionmaladjusted

Balancerbearingworn

Alternatorrotorloose

TroubleshootingGuide

AbnormalDriveTrainNoise:

Clutchnoise:

Clutchrubberdamperweakordamaged

Clutchhousingfinger/frictionplatetang clearanceexcessive

Clutchhousinggearworn

Metalchipsjammedinclutchhousinggear

Transmissionnoise:

Bearingsworn

Transmissiongearswornorchipped

Metalchipsjammedingearteeth

Engineoilinsufficient

Drivechainnoise:

Drivechainadjustedimproperly

Drivechainworn

Rearand/orenginesprocketworn

Chainlubricationinsufficient

Rearwheelmisaligned(Rightwheelbearingsarenotbottomedout)

AbnormalFrameNoise:

Frontforknoise:

Oilinsufficientortoothin

Springweakorbroken

Rearshockabsorbernoise:

Shockabsorberdamaged

Springweakorbroken

Discbrakenoise:

Padinstalledincorrectly

Padsurfaceglazed

Discwarped

Calipertrouble

Mastercylinderdamaged

Drumbrakenoise:

Brakeliningsoverwornorwornunevenly

Drumwornunevenlyorscored

Brakespringsweakorbroken

Foreignmatterinhub

Brakenotproperlyadjusted

Othernoise:

Bracket, nut, bolt, etc. not properly mountedortightened

ExhaustSmokesExcessively:

Whitesmoke:

Pistonoilringworn

Cylinderworn

Valveoilsealdamaged

Valveguideworn

Engineoilleveltoohigh

Blacksmoke:

Aircleanerclogged

Mainjettoolargeorfallenoff

Starterplungerstuckopen

Fuellevelincarburetorfloatbowltoohigh

Brownsmoke:

Mainjettoosmall

Fuellevelincarburetorfloatbowltoolow

Aircleanerductloose

AircleanerO-ringdamaged

Aircleanerpoorlysealedormissing

Handling and/or Stability Unsatisfactory:

Handlebarhardtoturn:

Cableroutingincorrect

Hoseroutingincorrect

Wiringroutingincorrect

Steeringstemnuttootight

Steeringstembearingdamaged

Steeringstembearinglubricationinadequate

Steeringstembent

Tireairpressuretoolow

Handlebarshakesorexcessivelyvibrates:

Tireworn

Swingarmpivotbearingsworn

Handlebarnutloose

Rimwarped,ornotbalanced

Wheelbearingworn

Spokesloose

Steeringstemheadboltloose

Front, rearaxlerunoutexcessive

Handlebarpullstooneside:

Framebent

Wheelmisalignment(Rightwheelbearings arenotbottomedout)

Swingarmbentortwisted

Swingarmpivotshaftbent

Steeringmaladjusted

Frontforkbent

Rightandleftfrontforkoilleveluneven

Rightandleftshockabsorberadjustment uneven

Shockabsorptionunsatisfactory:

(Toohard)

Frontforkoilexcessive

Frontforkoilviscositytoohigh

Rearshockabsorberadjustmenttoohard

Tireairpressuretoohigh

Frontforkbent

(Toosoft)

Tireairpressuretoolow

Frontforkoilinsufficientand/orleaking

Frontforkoilviscositytoolow

Rearshockadjustmenttoosoft

Frontfork, rearshockabsorberspringweak

Rearshockabsorberoilleaking

BrakeDoesn'tHold:

Discbrake:

Airinthebrakeline

Padordiscworn

Brakefluidleakage

TroubleshootingGuide

Discwarped

Contaminatedpad

Brakefluiddeteriorated

Primaryorsecondarycupdamagedinmastercylinder

Brakemastercylinderscratchedinside

Drumbrake:

Brakemaladjusted

Brakeliningsordrumworn

Overheated

Waterinbrakedrum

Brakecam, camshaftworn

Oilonbrakelinings

BatteryTrouble:

Batterydischarged:

Batteryfaulty(e.g., platessulphated, shortedthroughsedimentation, electrolyteinsufficient)

Batteryleadsmakingpoorcontact

Loadexcessive(e.g.,bulbofexcessive wattage)

Ignitionswitchtrouble

Alternatortrouble

Wiringfaulty

Regulator/rectifiertrouble

Batteryovercharged:

Regulator/rectifiertrouble

Batteryfaulty

MODELAPPLICATION

YearModel	BeginningFrameNo.
1998BN1	25-A1	BN125A000001orJKABN125AAA000001
1999BN1	25-A2	BN125A016001orJKABN125AAA016001
2000BN1	25-A3JKABN125AAD	A00001
2001BN1	25-A4JKABNRA1□1	DA00574
2002BN1	25-A5	JKABNRA1□2DA04626orJKABN125AADA04626
2003BN1	25-A6	JKABNRA1□3DA08070orJKABN125AADA08170
2004BN1	25-A7	JKABNRA1□4DA09073orJKABN125AADA09929
2005BN1	25-A8	JKABNRA1□5DA11506orJKABN125AADA11856
2006BN1	25A6F	JKABNRA1□6DA13459orJKABN125AADA13359
2007BN1	25A7F	JKABNRA1□7DA17901orJKABN125AADA17951

□: Thisdigitintheframenumberchangesfromonemachinetoanother.