Eliminator 125 (2000) - Motorcycle MITSUBISHI - Free user manual and instructions

Product Type	Motorcycle
Brand	Mitsubishi
Model	Eliminator 125
Year	2000
Overall Length	2150 mm (84.6 in)
Overall Width	780 mm (30.7 in)
Overall Height	1020 mm (40.2 in)
Wheelbase	1470 mm (57.9 in)
Seat Height	680 mm (26.8 in)
Ground Clearance	145 mm (5.7 in)
Dry Weight	128 kg (282 lb)
Fuel Tank Capacity	13 L (3.43 US gal)
Engine Type	4-stroke, SOHC, single-cylinder, air-cooled
Displacement	124 cm³ (7.6 cu in)
Bore x Stroke	55 x 52.4 mm
Compression Ratio	9.6:1
Maximum Power	8.8 kW (12 PS) @ 9500 rpm
Maximum Torque	9.7 N·m (7.2 ft·lb) @ 8000 rpm
Carburetor	Mikuni BS28
Ignition System	DC-CDI
Starting System	Electric
Transmission	5-speed, constant mesh
Final Drive	Chain
Front Suspension	Telescopic fork, 130 mm travel
Rear Suspension	Swingarm, 60 mm travel

Frequently Asked Questions - Eliminator 125 (2000) MITSUBISHI

What type of engine oil should I use for the Mitsubishi Eliminator 125?

Use API SE, SF or SG grade oil for early models (BN125-A1~A3) or API SH, SJ or SL with JASO MA for later models. Recommended viscosity is SAE 10W-40. Capacity is 1.4 L when engine is completely dry.

What is the recommended spark plug for this motorcycle?

The standard spark plug is NGK CR7E. For some models (BN125-A4~, US, CA), either NGK CR7E or U22ESR-N can be used. Gap should be 0.7-0.8 mm.

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

Valve clearance must be checked when the engine is cold. Inlet clearance: 0.08-0.12 mm, exhaust: 0.15-0.19 mm. To adjust, loosen the locknut and turn the adjusting screw until correct clearance is achieved, then tighten locknut to 15 N·m.

What tire pressure should I use?

For loads up to 185 kg (408 lb): Front 150 kPa (21 psi), Rear 175 kPa (25 psi). For loads up to 155 kg (342 lb): Front 150 kPa (21 psi), Rear 175 kPa (25 psi). Check when tires are cold.

How do I adjust the drive chain slack?

Drive chain slack should be 25-40 mm (0.98-1.57 in). Adjust by loosening the rear axle nut and turning the chain adjusters on both sides equally. Tighten axle nut to 98 N·m after adjustment.

What is the correct idle speed?

The standard idle speed is 1300 ± 50 rpm. Adjust using the idle adjusting screw on the carburetor after the engine is thoroughly warmed up.

How do I change the engine oil?

Warm up the engine, then remove the oil drain plug (torque 18 N·m) to drain old oil. Replace the oil filter if needed. Refill with 1.1 L (filter not removed) or 1.2 L (filter removed) of recommended oil. Check level after running and waiting 2-3 minutes.

What brake fluid is required?

Use DOT4 brake fluid. Check level periodically and change every 2 years. Bleed the brake line if air is present.

How do I clean the air filter element?

Remove the air filter element, clean it in a high-flash-point solvent, dry it, then saturate with SAE 30 oil (SE, SF, or SG grade) and squeeze out excess. Replace if damaged.

What is the fuel tank capacity?

The fuel tank capacity is 13 liters (3.43 US gallons).

USER MANUAL Eliminator 125 (2000) 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.

2. 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.

3. 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! 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.
  ★Indicates a conditional step or what action to take based on the result of the test or inspection 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 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 tight them to as nugfit. Thentight them 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, tight the 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 flange components with a sun symbol above (no text or symbols)

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.

Mechanical assembly diagram showing hands assembling a mechanical component with a tool and a labeled block (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 wheels (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): No Catalytic Converter

(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 ignition 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"]

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 --> Capacitor["Capacitor (+)"]
    Capacitor --> IgnitionCoil["Ignition Coil (-)"]
    IgnitionCoil --> Discharging["Discharging"]
    Discharging --> PrimaryWinding["Primary Winding"]
    PrimaryWinding --> SparkPlug["Spark Plug"]
    SparkPlug --> SecondaryWinding["Secondary Winding"]
    SecondaryWinding --> Drone["Drone"]
    Drone --> SparkPlug
    Battery --> Battery
    DC-DC_Converter --> Battery
    style DC-DC_Converter fill:#f9f,stroke:#333
    style Battery fill:#ccf,stroke:#333
    style DC-DC_Converter fill:#cfc,stroke:#333
    style Transformer fill:#fcc,stroke:#333
    style Battery fill:#ffc,stroke:#333
    style Crankshaft fill:#cfc,stroke:#333
    style PrimaryWinding fill:#fcc,stroke:#333
    style SparkPlug fill:#ffc,stroke:#333
    style SecondaryWinding fill:#fcc,stroke:#333

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)
Operation
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]arenoticed.
- 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 grille and engine compartment, showing a black head with circular features and a labeled component 'A' (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.
  ★ Ifthereisanydoubtastotheconditionofthereed,replace theairsuctionvalveasanassembly.
• Checkthereedcontactareas[B]ofthevalveholderfor grooves,scratches,anysignsofseparationfromthe holder,orheatdamage.
  ★ If thereisanydoubtastotheconditionofthereedcontact areas,replaceheairsuctionvalveasanassembly.
  ★ 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 beyond labels)

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

PeriodicMaintenanceProcedures

ValveClearanceAdjustment

★ If the valve clearance is not within the specified range, adjust the clearance by loosening the lock nut and turning the adjustingscrew.
- 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 pipe 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)