Eliminator 125 (1998) - Motorcycle MITSUBISHI - Free user manual and instructions

Product Type	Motorcycle
Brand	Mitsubishi
Model	Eliminator 125 (1998)
Engine Type	4-stroke, single cylinder, air-cooled
Displacement	124 cc
Bore x Stroke	56.5 x 49.5 mm
Compression Ratio	9.5:1
Maximum Power	11 hp at 9,500 rpm
Maximum Torque	9.5 Nm at 7,500 rpm
Ignition	CDI
Starting System	Electric and kick start
Transmission	5-speed manual
Front Suspension	Telescopic fork
Rear Suspension	Dual shocks
Front Brakes	Single disc
Rear Brakes	Drum
Front Tire	90/90-18
Rear Tire	110/90-16
Seat Height	735 mm
Fuel Capacity	13 liters
Dry Weight	130 kg
Overall Length	2,150 mm
Wheelbase	1,450 mm
Fuel System	Carburetor
Oil Capacity	1.2 liters (with filter)

Frequently Asked Questions - Eliminator 125 (1998) MITSUBISHI

How do I adjust the valve clearance on my Eliminator 125?

To adjust valve clearance, first remove the valve cover. Turn the engine to TDC on the compression stroke. Use a feeler gauge to check clearance between the valve stem and rocker arm. For intake, clearance is 0.05-0.08 mm; for exhaust, 0.08-0.12 mm. Loosen the locknut, adjust the screw, and retighten.

What type of engine oil should I use?

Use a high-quality 4-stroke motorcycle oil with viscosity SAE 10W-40 or 20W-50 depending on climate. Look for API classification SG or higher. Do not use car oil with friction modifiers. Capacity is approximately 1.2 liters with filter change.

Why won't my Eliminator 125 start?

Common causes: dead battery, clogged carburetor, faulty spark plug, or fuel supply issue. Check that the kill switch is in 'Run' position, ensure fuel tap is on, and try kick-starting if electric start fails. Inspect spark plug for fouling and clean or replace.

How to clean the carburetor?

Remove the carburetor from the engine. Disassemble carefully, noting jet positions. Soak all metal parts in carburetor cleaner. Use compressed air to blow out passages. Replace gaskets and O-rings. Adjust idle speed and mixture screws per manual.

What tire pressure is recommended?

Recommended tire pressures: Front 28 psi (1.9 bar), Rear 32 psi (2.2 bar) for solo riding. Adjust for load: increase rear to 36 psi when carrying a passenger or heavy load. Check pressures when tires are cold.

How often should I change the spark plug?

Replace the spark plug every 8,000 km (5,000 miles) or annually, whichever comes first. Use a NGK CR7HSA or equivalent. Check gap of 0.6-0.7 mm before installation. Torque to 20 Nm.

My brakes are squeaking, what should I do?

Squeaking often indicates glazed pads or contamination. Remove the brake pads and lightly sand the friction surface with fine sandpaper. Clean the disc with brake cleaner. Ensure pad pins are lubricated. If noise persists, replace pads.

How to adjust the chain tension?

Place the motorcycle on its center stand. Measure chain slack at the midpoint between sprockets; it should be 25-35 mm. Loosen the rear axle nut, adjust both chain adjusters equally. Tighten axle nut to 80 Nm. Check alignment using the markings.

What fuel octane rating should I use?

Use regular unleaded gasoline with a minimum octane rating of 91 RON (Research Octane Number) or 87 AKI (Anti-Knock Index). Higher octane is not necessary and may cause incomplete combustion.

Where is the VIN number located?

The vehicle identification number (VIN) is stamped on the right side of the steering head. It is also printed on a label located on the frame near the battery compartment. The engine number is on the left crankcase.

USER MANUAL Eliminator 125 (1998) 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 he very 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 it 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! Always follows safe operating and maintenance 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 otherforeignmaterialsenteringintosealedareasduringvehicledisassemblycancauseexcessivewearanddecrease performanceofthevehicle.

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

Illustration of a solvent tray with a flame and three small objects inside, no text or symbols present.

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 mechanical components including gears, gears, and a housing (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 ~
Maximumtorque9.7N·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)
CarburetionsystemCarburetorStartingsystemIgnitionsystemTimingadvanceIgnitiontimingFrom10°BTDC	,MIKUNIBS28ElectricstarterDC-CDIElectronicallyadvanced(analog)
	@1300r/min(rpm)to30°BTDC@4500r/min(rpm)		←From10°BTDC@1300r/min(rpm)to35°BTDC@4500r/min(rpm)(US,CA,CAL)
SparkplugNGKCR7E	←	NGKCR7EorU22ESR-N:(BN125-A4~, US, CA)
Valvetiming:Inlet:OpenCloseDurationExhaust:OpenCloseDurationLubricationsystemEngineoil: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)(whenengineiscompletelydry)
DriveTrainPrimaryreductionsystem:TypeReductionratioClutchtypeTransmission: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
    style_O["DC-DC Converter"] --> P["Oscillator"]
    P --> Q["Thyristor"]
    Q --> R["Ignition Timing Controller"]
    R --> S["Crankshaft Sensor"]
    S --> T["Spark Plug"]

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 thistext.

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