LIST OF ABBREVIATIONS a ‘ampere(s) ib Jounal ABoc after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s} BBDC before bottom dead center Pa pascalls) BDC bottom dead center | PS horsepower BTDc before top dead center | psi pound(s) per square inch °c degree(s) Celcius ' revolution be direct current rpm revolution(s) per minute F farad(s) TDC top dead center a degree(s) Fahrenheit TIR total indicator reading ft foot, feet v volt(s) 8 gram(s) w watt(s) h hour(s) a ohm(s) He liter(s) U.K. model WARNING CONTAINS. ASBESTOS (searing anence ‘This warning may apply to any of the following components or any assembly containing one or ‘more of these components:— Brake Shoss or Pads Clutch Friction Material Gaskets Insulators ‘SAFETY INSTRUCTIONS Operate if possible out of doors or in @ well ventilated place. Preferably uso hand tools or low speed tools equipped, if necessary, with an appropriate dust extraction facility. If high speed tools are used, they should always be so equipped ‘lf possible, dampen before cutting or drilling. ‘eDampen dust and place it in properly closed receptacle and dispose of it safely. Read OWNER’S MANUAL before operating.Kawasaki KMX 125 Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or other- wise, without the prior written permission of Quality Assurance Department/Consumer Products & Components Group/Kawasaki Heavy Industries, Ltd., Japan, No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible, : The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. See your Motorcycle dealer for the latest information on product improvements incorporated after this publication. All information contained in this publication is based on the latest product information available at the time of publication, Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © Kawasaki Heavy industries, Lid. 1986, 1988 Second Edition ® : july 9, 1988 @)‘This quick reference guide will assist you in locating a desired topic or procedure. ‘Band the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page, ‘¢Refer to the sectional table of contents for the exact pages to locate the specific topic required. Quick Reference Guide Fuel System Eaiiietiielitesiicitslaed [Engine Fisnt Side] [Engine Removal/Instaliation id [Crankshaft/Transmission [fs] Suspension [Steering CUNOTE OThis note symbol indicates points of parti ular interest for more efficient and con- venient operation, indicates @ procedural step or work to be done. olndicates @ procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a WARNING, CAUTION, or NOTE. *Indicates a’ conditional step or what action to take based on the results of the test or ingpection in the procedural step or sub-step it follows. Indicates “2 conditional sub-step or what action to take based upon the results of the conditional step it follows In most chapters an exploded view illustre- tion of the system components follows the Table of Contents, In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or @ locking agent during assembly.Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic main- tenance and repair work, A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insu ficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thor- oughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean’ area, Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation. For the duration of your warranty period, especially, we recommend that all repairs and scheduled maintenance be performed in accord- ance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your Motor- cycle: Follow the Periodic Maintenance Chart in the Service Manual. Be alert for problems and nonscheduled maintenance. *Use proper tools and genuine Kawasaki Motorcycle parts. Special tools, gauges, and testers that are necessary when servicing Kewasaki motorcycles ate introduced: by the Special Tool Manual. Genuine parts provided as spare parts are listed in the Parts Catalog. *Follow the procedures in this manual care- fully. Don’t take shortcuts. ‘Remember to keep complete records of main: tenance and repair with dates and any new How to Use this Manual In preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product's systems and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you went spatk plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, 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 Spark Plug section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe opereting and maintenance practices. This warning symbol identifies special instruc- tions or procedures which, if not correctly followed, could result in personal injury, or loss of life, This caution symbol identifies special instruc- tions or procedures which, if not strictly ob- served, could result in damage to or destruc- tion of equipment. This manual contains five more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information,GENERAL INFORMATION 1-1 General Information Table of Contents Before Servicing ...., Model Identification . General Specifications Periodic Maintenance Chart Torque and Locking Agent Cable Routing ... Wire Routing . Hose Routing . 12 14 15 17 18 Vt 4-12 1141-2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle, careful reading of the applicable section is recommended to eliminate unnecessary work, Photographs, diagrams, notes, cautions, wamings, and detailed des- criptions have been included wherever necessary, Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is also required for successful work Especially note the following: (1) Dirt. Before removal and disassembly, clean the motorcycle, Any dirt entering the engine or other parts will work as an abrasive and shorten the life of the motorcycle, For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground Remove the ground (—) lead from the battery before performing any disassembly operations on the motorcycle. This prevents: {a) the possibility of accidentally turning the engine over while partially disassembled. {b) sparks at electrical connections which will occur when they are disconnected, {c)_ damage to electrical parts. (3) Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, they should all be started in their holes and tightened to a snug fit. Then tighten them evenly in'a cross pattern. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of tum and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or serews must be tightened in the order and method indicated, (4) Torque The torque values given in this Service Manual should always be adhered to. Either too little ‘or too much torque may lead to serious damage. Use 2 good quality, reliable torque wrench. (6) Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic faced mallet. Use an impact driver for screws (particularly for the ramoval of screws held by a locking agent) in order to avoid damaging the screw heads. (6) Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. (2) High Flashpoint Solvent A high flash-point solvent is recommended to reduce fire danger. A commercial solvent com- monly available in North America is Stoddard solvent (generic name). Always follow manufac- turer and container directions regarding the use of any solvent. (8) Gasket, O-ring Do not reuse a gasket or O-ring once it has been in service, The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks, (9) Liquid Gesket, Nonpermanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in North ‘America is Loctite Lock’n Seal (Blue). (10) Press A part installed using a press or driver, such 2s a wheel bearing, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly (11) Ball Bearing When installing a ball bearing, the bearing race which Is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented, Press a ball bearing until it stops at the stop in the hole or on the shaft,GENERAL INFORMATION 1.3 (12) Oil Seat and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals, When pressing in a seal which has manufacturer's marks, press it in with the marks facing out, Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. (13) Seal Guide A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips, Before a shaft passes through a seal, apply a little oil, preferably high temperature ‘grease on the lips to reduce rubber to metal friction. (14) Circlip, Retaining Ring Replace eny circlips and retaining rings that were removed with new ones, as removal weakens and deforms them, When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. (15) Cotter Pin Replace any cotter pins that were removed with new ones, as removal deforms and breaks them, (16) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is ‘more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don’t use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not in- tended. This manual makes reference to molybdenum disulfide grease (MoS; ) in the assembly of certain engine and chassis parts. Always check manufacturer recommendations before using such lubricants. (17) Electrical Wires All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a “yellow/red” wire; it would be a “ted/yellow” wire if the colors were reversed to make red the main color. Wire (cross-section) ‘Name of Wire Color Red Wire strands Yellow/red Yellow Red (18) Replacement Parts When there is a replacement instruction, replace these parts with new ones every time they are removed. These replacement parts will be damaged or lose their original function once removed. (19) Inspection When parts have been disassembled, visually inspect these parts for the following conditions or other damage, If there is any doubt as to the condition of them, replace them with new ones. Abrasion Crack Hardening Warp Bent Dent Scratch Wear Color change Deterioration Seizure (20) Service Data Numbers of service data in this text have following meanings: “Standards”: Show dimensions or performances which brand-new parts or systems have, “Service limits": Indicate the usable limits. If the measurement shows excessive wear or dete- riorated performance, replace the damaged parts.1-4 GENERAL INFORMATION ‘Model Identification KMX125-A1/B1 Left Side KMX125-A2/B2 Left Side View KMX125-A3/B3 Left Side ViewGENERAL INFORMATION 15 General Specifications KMX125-A1/B1/A2/B2 KMX125-03/B3 ‘Overall length 2.145 mm, (GA) 2 080 mm 2100 mm, $A) 2080 mm Overall width 840 mm WOEDO® 2745 mm Overall height 1.175 mm l<— Wheelbase 1375 mm <—_ Road clearance 295 mm <—_ Seat height 865 mm <— Dry weight 99 kg 97 kg Curb weight Front B4kg 53 kg Rear 62 kg 61 kg Fuel tank capacity 93L <— Performane Climbing | 32° auaaal Braking nce 12.5 m from 50 km/h. eet Minimum turning redius | 2.1'm <— Engine: . Type 2-stroke, single cylinder, piston reed valve <— Cooling system Liquid-cooled <—— Bore and stroke | 54.0 x 54,4 mm <—_ Displacement 124 mL <— Maximum horsepower 17.7 KW (24 PS) @9 500 r/min (rpm) eee 17 PS @B 500 r/min (rpm) [DIN] lk (S) 12.5 kW (17 PS) @8 500 r/min (rpm) <—— | ®_ 17.2 kW @9 600 r/min (rpm) [UTAC's norms] KMX125-81/B2 © _11.1 kW @8 800 r/min (rpm) [UTAC’s norms} 9.0 kW (12.2 PS) @8 800 r/min (rpm) Maximum torque 17.7 Nim (1.8 kgm, 13.0 ft-lb) @9 000 r/min (rpm) QO 1.5 kg-m @7 500 r/min (rpm) [DIN] © 14.7 Nem (1.5kg-m, 10.8 ft-1b) @7 700 r/min (cpm 125-83 z 3 x thttt KMX125-B1/B2 KMX125-B3 @ 11.8N-m (1.2kg-m, 8.7 ft-lb) @6 500 r/min (rpm) |<— Carburetion system Carburetor, Mikuni VM26SS <— Starting system Primary kick j<— Ignition system col —— Timing advance Electronically advanced <—_ Ignition timing 10.5° BTDC @1 300 r/min (rom) — 26.8" BTDC @3 000 r/min (rpm) eet Spark plug NGK BR8ES,(D(GA) NGK BBES —_— Port timing: Iniet: Open Full open <— Close - <—_ Scavenging Open —_| 61° BBDC <— Close | 61° ABDC <—_ Exhaust Open 88° BBDC fete Close | 88° ABDC <— (Continued on next pags.)1-6 GENERAL INFORMATION Item KMX125-A1/B1/A2/B2 KMX125-A3/B3 Lubrication systern Superlube (oil injection) <— Engine oil: Type 2-stroke oil for air-cooled engine <—_— Oil tank capacity 1.2L eo Drive Train: Primary reduction system: Type Gear <— Reduction ratio 3.272 (72/22) <_ Clutch type Wet, multi dise <_— Transmission: Type 6-speed, constant mesh, return shift | <— Gear ratios: 1st 3.100 (31/10) —_— 2nd 1,928 (27/14) —_— 3rd 1.411 (24/17) <_ 4th 1.090 (24/22) <— Bth 0.916 (22/24) — 6th 0.807 (21/26) <_ Final drive system: Type Chain drive << Reduction ratio 3.428 (48/18) <—_ ‘Overall drive ratio 9.062 @Top gear — Transmission oil: Grade SE class << Viscosity SAE 10W30 or 10W40 ie Capacity 0.75 L cana Frame: Type Tubular, semi-double cradle eee Caster (rake angle) 28° << Trail 11mm ae Front tire: Type DUNLOP K260, Tube type <— Size 2.75-21 4PR ES Reartire: Type DUNLOP K260, Tube type <_ Size 4,10-18 4PR < Front suspension: Type Telescopic fork <_ Wheel travel 230 mm ee Brake type: Front Single disc <—_ Rear Single disc <_ Electrical Equipment: Battery 12V 4 Ah eet Headlight: ‘Type ‘Semi-sealed beam <— Bulb 12.V 60/55 W (quartz-halogen) <_ GD 12 V 35/36.5 W (quartz-halogen) <_ Tail/brake light 12V 6/21 W, GD 12V 8/27 W —_— Alternator: Rated output 11.5 A @8 000 r/min (rpm), 14 V GB 9.5 A @8 000 r/min (rom), 14V St Voltage regulator: Type Short-ci it et Specifications subject to change without notice, and may not apply to every country. ® : U.K, Model © + French Model GB: Greek Model @ : Italian Model @® + Norwegian Mode! 1 Swiss Model South African Model : Swedish Model GG : West German ModelGENERAL INFORMATION 1.7 Periodic Maintenance Chart ‘The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition. Th { maintenance is vitally important and must not be neglected. ee ee ee “ODOMETER READING case FREQUENCY See SS, EF See OPERATION first even SS (See Spark plug ~ clean . ofe fey] 18 Spark plug ~ check epepepepele fe] E19 ‘ir cleaner element — clean : < . 216 ‘Air cleaner element ~ replace. B cleanings . 216 Throttle grip play ~ check + . we e235 Oil pump and carburetor synchronization ise ist tetlcetlceeioel wel tties! ~check + cee Tle speed ~ check elelelelelele! 28 Fuel system — check ¢ . ° ©) 210 Cylinder head boit tightness ~ check t . . ° e465 [ Coolant - change Z year eo) 36 Radiator hoses, connections ~ check > ear | @ e343 Transmission oil - change year | * as [67 replace 4 years = Clutch - adjust, wee ee ere 67 Drive chain wear check} epepeLete lel os Drive chain ~ lubricate 300. km. 10-6 Drive chain slack ~ check 800 km 10-4 Brake lining or pad wear ~ check e[elele ele) 118 Brake fluid level ~ check + month) e |e [e]e)e,e}e| ti Brake fluid ~ change 2 years ° 112, Brake hose ~ replace 4 years 11-14 Brake restr eying oS Bd HTH TD ars a Caliper piston seal and dust seal = replace _|2 years it7 Brake light switch ~ check + epee pe pe [16.27 ‘Steering — check + elepejfelelelel a4 Steering stem bearing lubricate ___| 2 years . 13:7 Front fork oil change Lop bet 35 | Tire wear - check + 7 Pee ele ele ele 98] Spoke tightness and rim runout ~ check epee te tele fe] 96 ‘Swing arm pivot, uni-trak linkage ] z a eae __= lubricate Battery electrolyte level ~ check months |e |e[+|+|e)]+| 69 General lubrication ~ perform efelefe lel} | 167 Nut, bolt, and fastener tightness ~ check + . ° wD Le bos * For higher odometer readings, repeat at the frequency interval established here, + + Replace, add, adjust, clean, or torque if necessary.18 GENERAL INFORMATION Torque and Locking Agent Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, 2 bolt or nut may become damaged or fall off, possibly resulting in damage to the motor- cycle and injury to the rider. A bolt or nut which is overtightening may become damaged, strip an internal thread, or break and then fall out. ‘The following table lists the tightening torque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket. When checking the tightening torque of the bolts and nuts, first loosen the bolt or nut by half & turn and then tighten to specified torque. Letters used in the “Remarks” column mean: L__: Apply a non-permanent locking agent to the threads. LG : Apply liquid gasket to the threads. S$ _: Tighten the fasteners following the specified sequence. Fastener | Remar Fuel System: | il Pump Cable Locknuts og 10 70 Cooling System: j Water Temperature Sensor 8 18 11.0 Ls Water Pump Impeller Nut se | 10 70 Coolant Drain Plug 6 | 18 11.0 Engine Top End: Cylinder Head Bolts 25 26 19.0 Spark Plug 25 26 18.0 Cylinder Head Bracket Nuts % | 28 18.0 Shaft Lever Mounting Bolt as | 09 78 in-Ib Cylinder Nuss 25 28 18.0 Engine Right Side: Water Pump Impeller Nut 98 10 70 Shaft Lever Mounting Bolt 88 08 7Bimlb Exhaust Advancer Lever Mounting ae i ee Allen Bolts Clutch Spring Bolts 93 0.95 82 int Shift Drum Cam Mounting Screw - - - L Gear Positioning Lever Mounting Nut 98 1.0 70 Return Spring Pin 20 20 145 L Primary Gear Nut 59 60 43 Kick Guide Mounting Bolt | - --- 7 LGENERAL INFORMATION 1.9 Poe Cece ce Steerer ed Torque Fastener Nm kgm Ftlb Remarks Engine Lubrication System: Oil Pump Hose Banjo Bolt 44 0.45 39 int | Oil Pump Cable Locknuts 9.8 1.0 7.0 Transmission Oil Drain Plug 20 2.0 145 Engine Removal/Installation: ‘Swing Arm Pivot Shaft Nut 98 10.0 72 e Mounting Nuts 29 3.0 22.0 Cylinder Head Bracket Nuts 29 3.0 22.0 Crankshaft/Transmission: ‘Shift Drum Cam Mounting Screw --- --- -<-- L Transmission Oil Drain Plug 20 20 145 Primary Gear Nut 59 6.0 43 Neutral Switch 15 15 11.0 Flywheel Nut 59 6.0 43 Wheels/Tires: Front Axle Nut 49 5.0 36 Rear Caliper Mounting Bolts 25 25 18.0 Rear Axle Nut 88 3.0 65 Spoke Nipple Not less Not less. Not less than 1.5 than 0.15 | than 13 in-Ib} Final Drive: Rear Axle Nut 88 9.0 65 Engine Sprocket Bolts 12 1.2 85 Rear Sprocket Nuts 27 28 20 Brakes: E Caliper Mounting Bolts (Front, Rear) 25 25 18.0 Brake Hose Banjo Bolts 25 25 18.0 Front Brake Hose Clamp Bolts 78 08 69 in-Ib Front Master Cylinder Clamp Bolts 8.8 09 78 in-lb s Brake Lever Pivot Locknut 5.9 06 52 in-Ib Rear Master Cylinder Mounting Bolts 25 25 18.0 Reservoir Mounting Bolt (Rear) 5.9 06 52 in-lb Brake Pedal Adjuster (Adjusting Nut, Locknut) 172 1.78 182 in-Ib Breke Disc Mounting Bolts (Front) 23 23 | 16.5 Brake Disc Mounting Bolts (Rear) 15 15 11.0 l1-10 GENERAL INFORMATION Fastener Torque ! Remerks Nm | kgm fel | a t ee Caliper Bleed Valves (Front, Rear) 78 08 69 in-Ib Brake Pedal Mounting Bolt 98 1.0 7.0 L Suspension: Front Fork Clamp Nuts 2 pee ate (Upper, Lower) Front Fork Bottom Allen Bolts 20 2.0 14.5 L Swing Arm Pivot Shaft Nut 98 10.0 2 Rear Shock Absorber 59 60 43 Upper Mounting Bolt | Rear Shock Absorber Lower | | Mounting Nut Pee) ane il Tie-Rod Front Mounting Nut | 98 10.0 72 ‘Tie-Rod Rear Mounting Nut | 5o 6.0 a Rocker Arm Pivot Shaft Nut 98 10,0 | 72 Steering: | Steering Stem Head Nut 44 45 | 33 Steering Stem Locknut 3.9 04 36 in-lb Handlebar Clamp Bolts 24 | 24 17.6 Electrical System; Magneto Cover Damper Mounting Screws ae Ste spk Flywheel Nut 59 6.0 43 Spark Plug 25 25 18.0 Neutral Switch 15 15 | 11.0 Water Temperature Sensor 15 16 | 11.0 LG Gen The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Torque ae ee only, neta be mnie do bn (mm) ma kg- ft: 10, 25 ~ 34 26-35 | 190-25GENERAL INFORMATION 1-11 Cable Routing Run behind the bracket | andin frontofits mount, a Run the carburetor and cll pump cables between the brackets. ® € Run in front of the bracket. ©. Run through the clamps. Run to the left side of the right fork leg, Run between the shaft Da not run the and the hose tachometer cable between the brackets Run ‘the only. tacho- meter cable through the clamp, never the throt: the cable, Fit the junction case in the clamp. Do not run the tachometer cable through the clamp, Run behind the bracket for headlight beam ad: justment. Run under the radiator Run to the’left side of the bracket. Clutch Cable Throttle Cable Carburetor Cable Oil Pump Cable >. Tachometer Cable Speedometer Cable Choke Cable | CD! Unit Cylinder Head Bracket . Lever Shaft + Water Pump Hose Front Fork Horn Heed Light2 GENERAL INFORMATION Run the left grip lead in front of the bracket, Guteh Cable Champ Moser // Run the rahe gp / | cad in the rear of CS US teetaty mate te eo Ignition Switch Lead Connector . (6P) @ ee @ dota Drawing Run between the brackets, Pall he hanes tbe frontvard from te clamp under the mete. 6P Connector with water proof boot. i, Earth lead (BK/Y) ison the lef. the aluminum part of the acon? clamp with the leads @ arow View © Arrow View Run around the pyrifera pine, 4 Run upward along the : right crankcase surface p— Install from the right side.part of the clamp with the | lead. GENERAL INFORMATION 1-13 Run the hose and leads through the clamps. Fit the sensor so that its leads come out (ip toward the rear Jy (D Battery terminals are to the front. Cover the (+) terminal with the rubber cap. Run along the frame pipe rear side, and between the pipe and the fender. Run over the diode, ‘Clamp the connector under the main pipe. | Under the reservoir Run ty the inside of the bracket. Mount together Install the clamp per- pendicular to the frame Pipe. |. Horn 8. Regulator/Rectifier 15, Neutral Switch Main Harness 9. Side Stand Switch 16. Oil Tank Breather Hose | Turn Signal Relay 10, Magneto Lead 11. Oil Level Sensor Diode 11. Pickup Coil Lead 18, Fuse - Cylinder Head Bracket 12, Side Stand Switch Lead 19. Battery CDI Unit, 13. Flywheel Magneto 20, Brake Light Switch + Ignition Coil 14, Pickup Coil 21, Earth Terminal1-14 GENERAL INFORMATION Hose Routing Battery Vent Hose Fuel Tank Breather Hose (kit 25.41 /92/81/82] [kMx125-43/83), Ansert into the steringstemole. — Ciayp Ka = Run to the right side of ey O engine Breather Hose the ar cleaner duct. ‘Through the footpeg bracket holes. conamranvernes i ; Trouth the clanp on th svog am with the eng Carburetor Overt Tbe reat hos caret aye ee Rsnrslr Tan Hoe pearics ae avon teas ppg ia ihn the brackets. ® * Through the oil pump bracket bole Run the oi tank hose tothe lf side of thea vent and oerlow tubes ~ 1, Fuel Tank Breather Hose a % 2. Steering Stem Head Nut a 3, Reservoir Tank Hose : = 4. Reservoir Tank Air Vent Hose 5. Cylinder Head Bracket 6, Battery Vent Hose 7. Engine Breather Hose 5 8. Carburetor Air Vent and Overflow Tubes 9. Air Cleaner Housing 10. Oil Pump Hose Ss a 11, Flap seo 12, Oil Tank am cara 13. Oil Tank Breather Hose ‘Mounting angle \\ 14, Rear Fender 16. Reservoir 17. Master Cylinder 18. Head Light Cover 19. Brake Hose 20. Caliper 21. Reservoir Hose of thehesweeg\\a_ Run othe let sde J CRORE gO att tame ie 15, Swing ArmFUEL SYSTEM 24 Fuel System Table of Contents Exploded View... 6... 66e see sees eens 22 Specifications... .. ‘| ood Special Tools... 2.2. e eee eee OH ‘Throttle Control Cable cab: ‘Throttle Grip Free Play Inspection 25 ‘Throttle Cable Adjustment 25 Carburetor Cable Adjustment 25 Oil Pump Cable Adjustment . 26 ‘Throttle Control Cable Installation Notes... 02.0228. 26 ‘Throttle Control Cable Lubrication..... 26 Throttle Control Cable Inspection ..... 26 Choke Cable... ... ee 27 Choke Cable Free Play Inspection 27 (Choke Cable Adjustment . 27 Choke Cable Installation Notes ....... 27 Choke Cable Lubrication ........... 27 Choke Cable Inspection . 28 Carburetor... 28 {dle Speed Inspection. 28 Idle Speed Adjustment... .. 28 Service Fuel Level Inspection... . 28 Service Fuel Level Adjustment........ 28 Fuel System Cleanliness Inspection. .... 210 Carburetor Removal....... 6... 2... 240 Carburetor installation Notes. ........ 2411 (Carburetor Disassembly coves 2M2 Carburetor Assembly Notes. 0... 4.4 243 Carburetor Cleaning. 243 Carburetor Inspection . 24 Air Cleaner... 6... a 24 Air Cleaner Housing Removal we 214 Air Cleaner Housing Installation Notes .. 2-415 Air Cleaner Eloment Removal ......., 246 Air Cleaner Element Installation Notes .. 2-46 Air Cleaner Element Cleaning and Inspection... 6... 246 Fuel Tank... 7 Levees 247 Fuel Tank Removal . 247 Fuel Tank Installation Notes 247 Fuel Tap Remove i 218 Fuel Tap Installation Notes 218 Fuel Tap Inspection. ... 0.0.02... 248 Fuel Tank Cap inspection.........., 248 Fuel Tank and Tap Cleaning ......... 218 Reed Valve. . Reed Valve Removal . Reed Vaive Installation. Reed Valve Inspection .