Мануал кавасаки kx 125

Quick Reference Guide

Read OWNER’S MANUAL before operating

Foreword

GENERAL INFORMATION 1-1

1-2 GENERAL INFORMATION

Before Servicing

Before starting to perform an inspection service or carry out a disassembly and reassembly operation 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 reinstallation or disassembly and reassembly of general parts.

Especially note the following:

(1) Dirt

Before removal and disassembly, clean the motorcycle. Any dirt entering the engine will 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

Disconnect the ground (–) cable from the battery before performing any disassembly operations on the motorcycle. This prevents the engine from accidentally turning over while work is being carried out, sparks from being generated while disconnecting the leads from electrical parts, as well as damage to the electrical parts themselves. For reinstallation, first connect the positive cable to the positive (+) terminal of the battery

(3) Installation, Assembly

Generally, installation or assembly is the reverse of removal or disassembly. However, if installation or assembly sequence is given in this Service Manual, follow it. Note parts locations and cable, wire, and hose routing during removal or disassembly so they can be installed or assembled in the same way. It is preferable to mark and record the locations and routing whenever possible.

(4) Tightening Sequence

When installing bolts, nuts, or screws for which a tightening sequence is given in this Service Manual, make sure to follow the sequence. When installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit, thus ensuring that the part has been installed in its proper location. Then, tighten them to the specified torque in the tightening sequence and method indicated. If tightening sequence instructions are not given, tighten them evenly in a cross pattern. Conversely, to remove a part, first loosen all the bolts, nuts, or screws that are retaining the part a 1/4-turn before removing them.

(5) Torque

When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a 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 removing screws held by non-permanent locking agent) in order to avoid damaging the screw heads.

(7) Edges

Watch for sharp edges, as they could cause injury through careless handling, especially during major engine disassembly and assembly. Use a clean piece of thick cloth when lifting the engine or turning it over.

(8) High-Flash Point Solvent

A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is standard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent.

(9) Gasket, O-ring

Replace a gasket or an O-ring with a new part when disassembling. Remove any foreign matter from the mating surface of the gasket or O-ring to ensure a perfectly smooth surface to prevent oil or compression leaks.

(10)Liquid Gasket, Locking Agent

Clean and prepare surfaces where liquid gasket or non-permanent locking agent will be used. Apply them sparingly. Excessive amount may block engine oil passages and cause serious damage.

GENERAL INFORMATION 1-3

Before Servicing

(11)Press

When using a press or driver to install a part such as a wheel bearing, apply a small amount of oil to the area where the two parts come in contact to ensure a smooth fit.

(12)Ball Bearing and Needle Bearing

Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any ball or needle bearings that were removed with new ones. Install bearings with the manufacturer and size marks facing out, applying pressure evenly with a suitable driver. Apply force only to the end of the race that contacts the press fit portion, and press it evenly over the base component.

(13)Oil Seal and Grease Seal

Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. Oil or grease seals should be pressed into place using a suitable driver, applying a force uniformly to the end of seal until the face of the seal is even with the end of the hole, unless instructed otherwise. When pressing in an oil or grease seal which has manufacturer’s marks, press it in with the marks facing out.

(14)Circlip, Retaining Ring, and Cotter Pin

When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. Install the circlip with its chamfered side facing load side as well.

Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while the motorcycle is driven, leading to a major problem.

(15)Lubrication

Engine wear is generally at its maximum while the engine is warming up and before all the sliding surfaces have an adequate lubricative film. During assembly, make sure to apply oil to any sliding surface or bearing that has been cleaned. Old grease or dirty oil could have lost its lubricative quality and may contain foreign particles that act as abrasives; therefore, make sure to wipe it off and apply fresh grease or oil. 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 intended.

(16)Direction of Engine Rotation

To rotate the crankshaft manually, make sure to do so in the direction of positive rotation. Positive rotation is counterclockwise as viewed from the left side of the engine. To carry out proper adjustment, it is furthermore necessary to rotate the engine in the direction of positive rotation as well.

(17)Replacement Parts

When there is a replacement instruction, replace these parts with new ones every time they are removed.

Replacement parts will be damaged or lose their original function once they are removed. Therefore, always replace these parts with new ones every time they are removed. Although the previously mentioned gasket, O-ring, ball bearing, needle bearing, grease seal, oil seal, circlip, and cotter pin have not been so designated in their respective text, they are replacement parts.

(18)Electrical Leads

All the electrical leads are either one-color or two-color. A two-color lead is identified first by the primary color and then the stripe color. For example, a yellow lead with thin red stripes is referred to as a “yellow/red” lead; it would be a “red/yellow” lead if the colors were reversed. Unless instructed otherwise, electrical leads must be connected to leads of the same color.

Two-Color Electrical

1-4 GENERAL INFORMATION

Before Servicing

(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.

(20)Specifications

Specification terms are defined as follows:

“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 deteri-

orated performance, replace the damaged parts.

GENERAL INFORMATION 1-5

Model Identification

KX125-M1 Left Side View

KX125-M1 Right Side View

1-6 GENERAL INFORMATION

Model Identification

KX250-M1 Left Side View

KX250-M1 Right Side View

GENERAL INFORMATION 1-7

General Specifications

1-8 GENERAL INFORMATION

General Specifications

GENERAL INFORMATION 1-9

General Specifications

Specifications are subject to change without notice, and may not apply to every country. (EUR): Europe Model

1-10 GENERAL INFORMATION

General Specifications

GENERAL INFORMATION 1-11

General Specifications

1-12 GENERAL INFORMATION

General Specifications

Specifications are subject to change without notice, and may not apply to every country. (EUR): Europe Model

1-14 GENERAL INFORMATION

Technical Information

○This mechanism operates as follows:

1.Suppose the 1st gear position is set as shown. Neutral Detent [N]

2.Shift Up (for example: shift from 1st to 2nd) (→) : transmitting of shift force

The shift pedal is lifted. → The arm [G] turns counterclockwise until it stops at pin [L]. → ratchet [H] → lower pawl [M] → shift drum cam [J] → shift drum → The gear is shifted in 2nd position.

3.Ratchet Returns.

The arm [G] returns by force of spring [O]. →The ratchet

[H]disengages to be free by itself. → The set lever [K] holds the shift drum cam [J]. → The ratchet [H] returns (turns clockwise).

4.The 2nd Gear Position settles.

The upper and lower pawls [I], [M] catch the next teeth inside the shift drum cam [J] → The ratchet [H] settles in position. → The 2nd gear position settles.

5.Shift Down (for example: shift from 2nd to 1st)

The shift pedal is depressed. →The arm [G] turns clockwise until it stops at the pin [L]. → ratchet [H] → upper pawl [I] → shift drum cam [J] → shift drum → The gear is shifted into 1st position. → (continues to operate in the same way as Shift Up)

GENERAL INFORMATION 1-15

Technical Information

Chrome Composite Plating Cylinder (KX250M, KX125M)

○This new cylinder bore [A] has Kawasaki’s composite cylinder plating, which is used for the first time on two stroke engines. The composite plating includes a nickel-phosphorous alloy, inorganic materials like ceramic, silicone carbide and some organic materials.

○The treatment improves heat transfer of the cylinder for consistent power output, allows closer piston-to-cylinder clearances for more horsepower.

○The treatment is porous, so it holds lubrication well, and hard, so it resists abrasion and seizure.

○This plating gets on well even the chamfered edge of the cylinder top or port.

○This improves the surface of the chamber at the top of the cylinder, preventing hot spots, resultant pre-ignition and other abnormal combustion in the chamber.

Previous Cylinder [A] New Cylinder [B] Exhaust Port [C] Cylinder Top [D]

○This enables the top end of the exhaust port from round to straight in order to make gas flow smooth and improve mid-high performance and extending piston ring life.

Previous Cylinder [A] New Cylinder [B] Exhaust Port [C]

1-16 GENERAL INFORMATION

Technical Information

KIPS (Kawasaki Integrated Power Valve System, KX250M, KX125M)

○KIPS varies the exhaust port height to broaden the useful rpm range for low end and mid-range without sacrificing the top end power (see ’95 KDX200H Service Manual (Part No. 99924-1181-01) for basic information about KIPS).

○KIPS is 2-stage-3-way type: the main exhaust port is opened earlier than the sub-exhaust ports (2-stage) and they are opened differently in low, middle and high rpm (3-way).

(In low rpm)

resonator: open to fully, sub-exhaust ports and main exhaust port: close (In middle rpm)

resonator: close, main exhaust port: open to fully, sub-exhaust ports open to halfway (In high rpm)

resonator: close, main exhaust port and sub-exhaust ports open fully. ○The KIPS valve is now made of aluminum instead of steel to save weight.

○The KIPS main valve holder shape is modified to match the straightened exhaust port, and timing for the main and sub-valves is changed to deliver more power in the low to mid-range.

○The main valve end is changed from thick end to thin end, reducing exhaust pressure on the valve and making valve operation smooth.

(KX250M)

A.Previous KIPS

B.New KIPS

GENERAL INFORMATION 1-17

Technical Information

(KX125M)

A.Previous KIPS

B.New Model

C.Full Opened Position

D.Low Speed Position

E.Straightened Exhaust Passage

○The KIPS governor is modified so that the exhaust valves operate over a wider rpm range to improve low and mid -range power and smooth the power delivery.

○The KX250’s governor inside is changed from straight to concave in order to move the balls smoothly.

Previous Governor [A] New Governor [B]

Carburetor (KX250M)

○The 38.7 mm (1.524 in.) Keihin PWK 38S carburetor helps boost mid-range and top-end power.

1-18 GENERAL INFORMATION

Technical Information

○The crescent shaped slide [A] enables the needle to sit closer to the intake ports for quicker throttle response.

○Large bores in the front and back of the carburetor and a smoother shape (38 to 40 mm-tapered bore [B]) boost mixture flow for more mid-range and top-end power.

○The semi air bleed needle jet [C] improves throttle response in the very low and low range.

Front [D]

○The air baffle forms vacuum, the stop narrows the outlet and speeds up outflow from the needle jet, improving atomization.

○The new main air inlet tends to take in static pressure and to exclude dynamic pressure and vortexes, making the main air flow stable.

GENERAL INFORMATION 1-19

Technical Information

A.Previous Carburetor

B.New Carburetor

C.Jet Needle

D.Air Baffle

E.Main Air

F.Needle Jet

G.Engine Inlet

Carburetor (KX125M)

○The 38 mm (1.496 in.) Mikuni TMX 38-27 carburetor helps boost mid-range and top-end power.

○The arched slide [A] improves throttle response in the very low and low ranges.

○Large bores in the front and back of the carburetor and a smoother shape (38 to 40 mm-tapered bore [B]) boost mixture flow for more mid-range and top-end power.

○The semi air bleed needle jet [C] improves throttle response in the low range and provides proper mixture from the low to top range.

Front [D]

1-20 GENERAL INFORMATION

Technical Information

○In low range, fuel drops in the fuel/air mixture is larger and tends to stick to the carburetor wall. The arched slide deflects fuel/air mixture flow from the wall to the middle of the carburetor for better atomization and better throttle response.

A.Previous Carburetor

B.New Carburetor

C.Flat Slide (piston valve)

D.Arched Shape Slide (piston valve)

E.Engine Intake

○The semi air bleed hole is positioned at the side of the needle jet, where fuel mixes with air well (due to enough fuel and faster air flow than in main bore), resulting in better atomizing. The air screen suppresses dynamic pressure around the main air inlet.

A.Previous Carburetor

B.New Carburetor

C.Jet Needle

D.Air Baffle

E.Main Air

F.Needle Jet

G.Engine Intake

H.Semi Air Bleed Hole

I.Air Screen

Units of Temperature:

PERIODIC MAINTENANCE 2-1

Periodic Maintenance

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-3

Periodic Maintenance Chart

The maintenance must be done in accordance with this chart to keep the motorcycle in good running condition.

2-4 PERIODIC MAINTENANCE

Periodic Maintenance Chart

†: Replace, add, adjust, clean or torque if necessary. R: Replace

PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently tightened, a bolt or nut may become damaged, strip an internal thread, or break and then fall out. The following table lists the tightening toque for the major bolts and nuts, and the parts requiring use of a non-permanent locking agent or liquid gasket.

When checking the tightening toque of the bolts and nuts, first loosen the bolt or nut by half a 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.

2-6 PERIODIC MAINTENANCE

Torque and Locking Agent

PERIODIC MAINTENANCE 2-7

Torque and Locking Agent

2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

PERIODIC MAINTENANCE 2-9

Torque and Locking Agent

Basic Torque for General Fasteners

2-10 PERIODIC MAINTENANCE

Specifications

PERIODIC MAINTENANCE 2-11

Specifications

2-12 PERIODIC MAINTENANCE

Specifications

2-14 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Fuel System

Fuel Hose and Connections Inspection

○The fuel hoses are designed to be used throughout the motorcycle’s life without any maintenance, however, if the motorcycle is not properly handled, the inside the fuel line can cause fuel to leak [A] or the hose to burst. Remove the fuel tank and check the fuel hose.

Replace the fuel hose if any fraying, cracks [B] or bulges

[C] are noticed.

•Inspect that the hoses are securely connected and clamps are tightened correctly.

•When installing, route the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.

•When installing the fuel hoses, avoid sharp bending, kinking, flattening or twisting, and route the fuel hoses with a minimum of bending so that the fuel flow will not be obstructed.

Replace the hose if it has been sharply bent or kinked.

Throttle Cable Inspection

Throttle Grip Free Play Inspection

•Inspect throttle grip free play [B] by lightly turning the throttle grip [A] back and forth.

If the free play is improper, adjust the throttle cable.

Throttle Grip Free Play

Standard: 2 3 mm (0.08 0.12 in.)

•Inspect that the throttle grip moves smoothly from full open to close, and the throttle closes quickly and completely in all steering positions by the return spring.

If the throttle grip does not return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable.

•Run the engine at the idle speed, and turn the handlebar all the way to the right and left to ensure that the idle speed does not change.

If the idle speed increase, check the throttle cable free play and the cable routing.

Throttle Grip Free Play Adjustment

•Loosencable. the locknut [A] at the upper end of the throttle

•Turn the adjuster [B] until the proper amount of throttle grip free play is obtained.

•Tighten the locknut.

PERIODIC MAINTENANCE 2-15

Periodic Maintenance Procedures

If the throttle grip free play cannot be adjusted with the adjuster at the upper end of the throttle cable, use the cable adjuster [A] at the carburetor.

•Free the fuel cut valve connector from the frame.

•Pull the boot off of the carburetor top. Make the necessary free play adjustment at the lower cable adjuster, tighten the locknut [B], and install the boot.

•Turn the handlebar from side to side while idling the engine. If idle speed varies, the throttle cable may be poorly routed or it may be damaged.

WARNING

Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an unsafe riding condition.

Carburetor Inspection

Idle Speed Inspection

•Start the engine and warm it up thoroughly.

•With the engine idling, turn the handlebar to both sides. If handlebar movement changes the idle speed, the throttle cable may be improperly adjusted or incorrectly routed, or it may be damaged. Be sure to correct any of these conditions before riding (see Cable, Wire, and Hose Routing in the Appendix chapter).

WARNING

Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an unsafe riding condition.

•Check idle speed. Adjust it as needed.

Idle Speed Adjustment

•First turn in the air screw [A] until it seats lightly, and back it out the specified number of turns. (see specifications in the Fuel System chapter)

•Start the engine and warm it up thoroughly.

•Turn the idle adjusting screw [B] to obtain desired idle speed. If no idle is preferred, turn out the screw until the engine stops.

•Open and close the throttle a few times to make sure that the idle speed is as desired. Readjust if necessary.

Air Cleaner Element Cleaning and Inspection

NOTE

○In dusty areas, the element should be cleaned more frequently than recommended interval.

○After riding through rain or on muddy roads, the element should be cleaned immediately.

○Since repeated cleaning opens the pores of the element, replace it with a new one in accordance with the Periodic Maintenance Chart. Also, if there is a break in the element material or any other damage to the element, replace the element with a new one.

2-16 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

WARNING

Clean the element in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean the element.

•Remove the air cleaner element, and separate the element [A] from the frame [B].

•Clean the element in a bath of a high-flash point solvent using a soft bristle brush. Squeeze it dry in a clean towel. Do not wring the element or blow it dry; the element can be damaged.

•Inspect all the parts of the element for visible damage. If any of the parts of the element are damaged, replace them.

•After cleaning, saturate the element with a high-quality foam-air-filter oil, squeeze out the excess, then wrap it in a clean rag and squeeze it as dry as possible. Be careful not to tear the sponge filter.

•Assemble the element.

•Remove the towel from the carburetor.

•Install the element.

Fuel Tank and Tap Cleaning

WARNING

Clean the fuel tank in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point solvent to clean the tank.

•Remove the fuel tank and drain it.

•Pour some high-flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits.

•Pour the solvent out of the tank.

•Remove the fuel tap from the tank by taking out the bolts.

•Cleanvent. the fuel tap filter screen in a high-flash point sol-

•Pour high-flash point solvent through the tap in all lever positions.

•Dry the tank and tap with compressed air.

•Install the tap in the fuel tank.

•Install the fuel tank.

Cooling System

Check the coolant level each day before riding the motorcycle, and replenish coolant if the level is low. Change the coolant in accordance with the Periodic Maintenance Chart.

WARNING

To avoid burns, do not remove the radiator cap or try to inspect the coolant level or change the coolant when the engine is still hot. Wait until it cools down.

PERIODIC MAINTENANCE 2-17

Periodic Maintenance Procedures

Coolant Inspection

Coolant Level Inspection

NOTE

○Inspect the level when the engine is cold (room or ambient temperature).

•Situateground.the motorcycle so that it is perpendicular to the

•Remove the radiator cap [A].

NOTE

○Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop and wait there for a few seconds. Then push down and turn it further in the same direction and remove the cap.

•Inspect the coolant level. The coolant level [A] should be at the bottom of the filler neck [B].

If the coolant level is low, add coolant through the filler opening to the bottom of the filler neck. Install the cap.

Recommended coolant:

Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)

Water and coolant mixture ratio:

1:1 (water 50 %, Coolant 50 %) Total amount:

KX125: 0.97 L (1.02 US qt.) KX250: 1.20 L (1.27 US qt.)

Coolant Deterioration Inspection

•Visually inspect the coolant.

If whitish cotton-like wafts are observed, aluminum parts in the cooling system are corroded. If the coolant is brown, iron or steel parts are rusting. In either case, flush the cooling system.

If the coolant gives off an abnormal smell, check for a cooling system leak. It may be caused by exhaust gas leaking into the cooling system.

Coolant Draining

The coolant should be changed periodically to ensure long engine life.

WARNING

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still hot. Wait until it cools down.

Coolant on tires will make them slippery and can cause an accident and injury. Immediately wipe up or wash away any coolant that spills on the frame, engine or other painted parts. Since coolant is harmful to the human body, do not use for drinking.

2-18 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

•Remove the radiator cap.

NOTE

○Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop and wait there for a few seconds. Then push down and turn it further in the same direction and remove the cap.

•Place a container under the coolant drain plug (KX125)

[A]or plugs (KX250) [B], and drain the coolant from the radiator and engine by removing the drain plug on the water pump cover and the cylinder (KX250). Immediately wipe or wash out any coolant that spills on the frame, engine, or wheel.

•Inspect the old coolant for visual evidence of corrosion and abnormal smell (see Coolant Deterioration Inspection).

Coolant Filling

CAUTION

Use coolant containing corrosion inhibitors made specifically for aluminum engines and radiators in accordance with the instruction of the manufacture’s. Soft or distilled water must be used with the antifreeze (see below for antifreeze) in the cooling system. If hard water is used in the system, it causes scale accumulation in the water passages, and considerably reduces the efficiency of the cooling system.

Recommended Coolant

Type: Permanent type antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)

•Install the drain plug.

○Replace the gasket with a new one.

•Tighten:

Torque — Coolant Drain Plug on Water Pump Cover: 8.8 N·m (0.9 kgf·m, 78 in·lb)

Coolant Drain Plug on Cylinder (KX250): 8.8 N·m (0.9 kgf·m, 78 ft·lb)

2-20 PERIODIC MAINTENANCE

Periodic Maintenance Procedures

Cylinder Wear Inspection

NOTE

○Measure the cylinder inside diameter when the cylinder is cold (room or ambient temperature).

•Visually Inspect the inside of the cylinder for scratches and abnormal wear.

If the cylinder is damaged or badly worn, replace it with a new one.

•Since there is a difference in cylinder wear in different directions, take a side-to-side and a front-to back measurement shown in the figure.

If any of the cylinder inside diameter measurements exceeds the service limit, the cylinder must be replaced with a new one since the PLATING cylinder cannot be bored or honed.