KX125 KX250: Service Manual

KX125
KX250
Motorcycle
Service Manual
Quick Reference Guide
~G==e=n=e=ra=I=I=n=f=o=r=m=a=t=io=n==================~1IiII
Fuel System
Cooling System
Engine Top End
Engine Right Side
Engine Removal/Installation
Engine Bottom End/Transmission
Wheels/Tires
Final Drive
Brakes IIIJ
Suspension
Steering
Electrical System
This quick reference guide will assist you
in locating a desired topic or procedure.
- Bend the pages back to match the black Appendix
tab of the desired chapter number with
the black tab on the edge at each table
of content s page.
- Refer to the sectional table of contents for
the exact pages to locat e t he specific topic
required .
Supplement- 1991 Model
' ..1
•
KX125
Kawasaki KX250
Motorcycle
Service Manual
LIST OF ABBREVIATIONS
A ampere{s) Ib Pound!s)
ABOC after bottom dead center m meter!s)
AC alternating c urrent min minute(s)
ATOC after top dead center N newton!s)
BBOC before bottom dead center Pa Pascalls)
BOC bottom dead cen ter PS horsepower
BTOC 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) TOC top dead center
of degree(s) Fahrenheit TIR total indicato r reading
It foot, feet V vo lt(s)
g gram(s) W watt!s)
h houris ) 0 ohm!s)
L liter(s)
This warning may apply to any of the follow·

lng components or any assembly containing
one or more of these components:-
Brake Shoes or Pads

Clutch Friction Material
Gaskets
Insulators
WARNING SAFETY INSTRUCTIONS

CONTAINS
ASBESTOS
.Operate if possible out of doors or in 8 well
Breetl!lng albnla.
dull ;. dengerow
ventilated place.
10 heellt! ePreferably use 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 .
elf possible , dampen before cuning or drilling.
-Dampen dust and place it in property closed
receptacle and dispose of it safely.
Read OWNER'S MANUAL before operating.

Foreword
............. ............................ .... .................
This manual is designed primarily for use by
trained mechanics in a properly equipped shop .
However. it contains enough detail and basic
..How to Use this Manual
............ .... .............. ......................... .... .
information to make it useful to the owner In preparing this manual, we divided the
who desires to perform his own basic main - product into its major systems. These systems
tenance and repair work. A basic knowledge became the manual' s chapters . AU information
of mechanics. the proper use of tools, and for a particular system from adjustment
workshop procedures must be understood in through disassembly and inspection is located
order to carry out maintenance and repair in a single chapter.
satisfactorily. Whenever the owner has insuf- The Quick Reference Guide shows you all
ficient experience or doubts his ability to do of the product's system and assists in locating
the work, all adjustments , maintenance, and their chapters. Each chapter in turn has its own
repair should be carried out only by qualified comprehensive Table of Contents.
mechanics. The Periodic Maintenance Chart is located
In order to perform the work efficiently and in the General Information chapter. The chart
to avoid costly mistakes, read the text, thor- gives a time schedule for required maintenance
oughly familiarize yourself with the procedures operations .
before starting work, and then do the work If you want spark plug information, for ex·
carefully in a clean area. Whenever special ample, go to the Periodic Maintenance Chart
tools or equipment are specified , do not use first. The chart tells you how frequently to clean
makeshift tools or equipment. Precision meas· and gap the plug. Next, use the Quick Reference
urements can only be made if the proper instru· Guide to locate the Electrical System chapter .
ments are used, and the use of substitute tools Then, use the Table of Contents on the first page
may adversely affect safe operation. of the chapter to find the Spark Plug section .
We recommend that aU repairs and scheduled Whenever you see these WARNING and
maintenance be performed in accordance with CAUTION symbols, heed their instructions!
this service manual. Always follow safe operating and maintenance
To get the longest life out of your motor· practices.
cycle:
- Follow the Periodic Maintenance Chart in the AWARNING
Service Manual.
-Se alert for problems and non·scheduled This warning symbol identifies speciallnstruc·
maintenance. tions or procedures which, if not correctly
-Use proper tools and genuine Kawasaki followed, coukl result in personal injury. or
Motorcycle parts. Special tools, gauges, and loss of life.
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Special Tool Manual. Genuine parts provided
as spare parts are listed in the Parts Catalog .
CAUTION
-Follow the procedures in this manual care · This caution symbol identifies special instruc·
fully . Don't take shortcuts. tions or procedures which. if not strictty ob·
-Remember to keep complete records of main· served. could resun in damage to or destruc·
tenance and repair with dates and any new tlon of equipment.
parts installed.
This manual contains five more symbols (in
addition to WARNING and CAUTiON) which will
help you distinguish different types of
information.
NOTE
OThis note symbol indicatBs points of partic-

ular interest for more efficient and con-
venient operation.
-Indicate a procedural step or work to be
done.
olndicates a 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
inspection in the procedural step or sub-
step it follows .
-(( Indicates a conditional sub-step or what
action to take based upon the results of the
conditional step it follows.
In most chapters an exploded view illustra-

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 a locking agent during assembly.
GENERAL INFORMATION 1· 1
..
General Information
Table of Contents
Before Servi cing ................. ........ ..... ............ ... .. ... " .. ...... ....... ... 1-2
Model Identification ........ ... .... .. .... ....... .... .... ...... ... . "..... ... .. ........ ' -4
General Specifications .............. , ....•.•.......... ......... ..•• ......... " ...... 1-6
Periodic Maintenance Chart ............ ................... ",.. ......... ... ... .. , - '0
Torque and Locki ng Agent .... .. ..... .... ........ ............................... ,-"
Cable Routing ...... " ..... , .............. " ............. ...... .. .... .. ..... ... .. ... .... ' -'4
' ·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.
Especlaly not. the foIowing :

(1) Dirt
Before removal and disassembly. clean the motorcycle. Any dirt entering the engkle or other
parts will work as an abrasive and shorten the life of the motorcycle. For the same reason, before install-
ing 8 new part, clean off any dust or metal filings.
(2) 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 pattem. This
is to avoid distortion of the part andlor causing gas Of 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,
Of screws must be tightened in the order and method indicated.
(31 Torque
The torque values given in this Service Manual should always be adahered to. Either too
little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench .
(4) Force
Common sense should dictate how much force is necessary in assembly and disassem-
Iy. If a part seems especially difficult to remove or install, stop and examine w hat may be causing the
problem. Whenevar tapping is necessary, tap lightly using a wooden or plastic faced mallet. Use an im-
pact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid
damaging the screw heads .
(5) Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Pro-
tect your hands with gloves or a ptece of thick cloth when lifting the engine or turning it over.
(6) High Flash-point Solvent
A high flash-point solvent is recommended to reduce fire danger. A commercial solvent
commonly available in North America is Stoddard solvent (generic name) . Always follow manufacturer
and container directions regarding the use of any solvent.
(7) Gasket , O;ing
Do not reuse a gasket or O;ing 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 com-
pression leaks.
(8) l iquid Gasket, Non-permanent 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).
(9) Press
A part installed using a press or driver, such as a w heel bearing, should first be coated
with oil on its outer or inner circumference so that it will go into place smoothly.
(10) 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
(11) Oit Seal and Grease Seal
Replace any oil Of 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
the seal, until the face of the seal is even with the end of the hole.
('21 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.
(13) Circlip, Retaining Ring
Replace any 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.
(14) Cotter Pin
Replace any cotter pins that were removed with new ones, as removal deforms and breaks them.
(15) 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 intended. This manual
makes reference to molybdenum disulfide grease {MoS21 in the assembly of certain engine and chassis
parts. Always check manufacturer recommendatk>ns before using such special lubricants.
(16) 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 cotor. 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 "yel-
low/red" wire; it would be a "red/yellow" w ire 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
(17) 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.
(18) Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or other
damage. If there is any doubt as to their condition, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change Deterioration Seizure
(19) Service Data
Numbers of service data in this text have the 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
............................................................
KX125 -H1 Lett Side View
KX 125-H 1 Right Side View

GENERAL INFORMATION 1-S
KX2S0-H1 Left Side View
KX2S0-H1 Right Side View

General Specifications
Items KX12S -Hl

Dimensions:
Overall length 2135 mm
Overall width 815 mm
Overall height 1215 mm
Wheelbase 1445 mm
Road clearance 395 mm
Seat height 935 mm
Dry weight 86.5 kg
Curb weight: Front 45.5 kg
Rear 48.5 kg
Fuel tank capacity 8.5 L
Engine:
Type 2-5troke , single cylinder, crankcase reed valve
Cooling system Liquid -cooled
Bore and stroke 56 .0 x 50.6 mm
Displacement 124 mL
Compression ratio 8.2:1
Maximum horsepower 28 .5 kW 137.8PSI @11500 r/min Irpml
Maximum torque 24.5 N-m12.5 kg-m, 18.1 fi<bl @ 10500 rlmin Irpml
Carburetion system Carburetor, KEIHIN PWK 35
Starting system Primary kick
Ignition system CDI
Ignition timing 14 ° BTDC @11000r/minlrpml
Spark plug NGK B10EG OGllNGK 8R10EG
Port timing: Inlet Open Full open
Close
Scavenging Open 65.5° BBDC
Close 65.5° A8DC
Exhaust Open 93.5° 88DC
Close 93.5° ABDC
Lubrication system (GasoJine:oiJ) Petrol mix (32 : 1)
Drive Train:
Primary reduction system:
Type Gear
Reduction ratio 3.500163/ 181
Clutch type Wet, multi disc
Transmission : Type 6-speed, constant mesh, return shift
Gear ratios: 1st 2.142130/141
2nd 1.714124/141
3rd 1.400 128/201
4th 1.181 126/ 221
5th 1.041 125/241
6th 0 .920 123/251
Final drive system : Type Chain drive
Reduction ratio 4 .000 148/121
Overall drive ratio 12.880 @Top gear
Transmission oil : Grade SE class
Viscosity SAE 10W30 or 10W40
Capacity 0.7 L
(Con tinued on next page. ~
Item KX125 -H1

Frame :
Type Tubular, semi -double cradle
Steering angle 45 D to either side
Caster (rake angle) 25 .5 D
Trail lOB mm
Front tire : Make/ Type DUNLDP K490 It) DUNLDP D752
® <CI BRIDGESTONE M23, Tube type
Size 801100 - 21 51M
Rear tire: Makel Type DUNLOP K695 It) DUNLOP 0752
® <CI BRIDGESTONE M22, Tube type
Size 100190 - 19 57M
Front suspension : Type Te lescopic fork (up side down )
Wheel travel 310 mm
Rear suspension: Type Sw ing arm (Uni-trak)
Wheel travel 330 mm
Brake type : Front and Rear Single disc
Effective disc diameter:
Front 220 mm
Rear 190 mm
Specifications subject to change without notice, and may not apply to every country .
® : U.S model
() : Canadian model
<01 : U. K. model
() : European model
1·8 GENERAL INFORMATION
Items KX250·Hl
Olmensions:
OveraU width 815 mm
Overall height 1215 mm
Wheelbase 1480 mm
Road clearance 385 mm
Seat height 940 mm
Dry weight 96.5 kg
Curb weight: Front 50 kg
Rear 52 kg
Engine:
Type 2-stroke. single cylinder, piston reed valve
Cooling system Liquid-cooled
Bore and stroke 67.4 x 70.0 mm
Displacement 249 mL
Compression ratio 9.4: 1 Ihigh speedl. 10.8: 1 lIow speedl
Maximum horsepower 39.5 kW 152.5PSI @8000 rlmin Irpml
Maximum torque 47.6 N·m 14.85 kg·m. 35.1 h·lbl @7500 rlmin Irpml
Carburetion system Carburetor. KEIHIN PWK 38
Ignition system CDI
Ignition timing 14° 8TDC @6000 rl min Irpml
Spark plug NGK 89EG 00 NGK 8R9EG
Port timing : Inlet Open Full open
Close
Scavenging Open 60.5° 88DC
Close 60.5° A8DC
Exhaust Open 92° 88DC Ihigh speedl. 81.5° 88DC Ilow speed I
Close 92° A8DC Ihigh speedl. 81.5° ABDC lIow speedl
Lubrication system (Gasoline:oill Petrol mix (32:1)
Drive Train:
Primary redu ction system:
Type Gear
Reduction ratio 2.750 1551201
Clutch type Wet, multi disc
Transmission: Type 5-speed, constant mesh, return shift
Gear ratios: 1st 2.1331321151
2nd 1.6871271161
3rd 1. 3881251181
4th 1.136 1251221
5th 1.000 1241241
Final drive system : Type Chain drive
Reduction ratio 3.4281481141
Transmission oil: Grade SE class
Capacity 0.8 L
ICootinued on nexl page.!
Item KX2S0-Hl
Frame:
Type Tubu lar , sem i-double cradle
Steering angle 45 0 to either side
Caster (rake angle ) 26 .5 0
Trail 113 mm
Front tire : Make/Type DUNLOP K490 ® D752, Tube type
Size 80/100-21 51 M
Rear tire: Make/Type DUNLOP K695 ®D752, Tube type
Size 110/90-19 62 M
Front suspension: Type Telescopic fork (up side down)
Wheel travel 310 mm
Rear suspens ion : Type Swing arm (un i-trak)
Wheel travel 330 mm
Brake type : Front and Rear Single disc
Effective disc diameter: Front 220 mm
Rear 190 mm
Specifications subject to change without notice, and may not apply to every country .
©: Canadian Model
(Q): U.K. Model
®: European Model
1· 10 GENERAL INFORMATION
..... .... .... ...... ..... ...... ......... .... .... ..... ..•. .. ....
Periodic Maintenance Chart
........... ..... ..... .............. ....... .... ... ..... .... ....
The maintenance must be done in accordance with this chart to keep the motorcycle in
good running condition.
~
Each Every Every Every As
race 3 races 5 races '0 races required
OPERATION
Clutch ad 'ust •
Clutch and friction olates-check f • R
Throttle cable ad 'ust •
Spark pluq clean. Qap f • R
Air cleaner element-clean •
Air cleaner element reclace If dama ad
Carburetor inspect/ad 'usl •
Transmission oil change •
"'z Piston and piston rino-clean/check. f • R
a Cvlinder head. cvlindef and exhaust valves-insoect •
m Muffler clean/check f •
Silencer wool ChanQ8 •
Small end bearino-check f • R
Kick oedal and shift oedal clean •
Exhaust pipe D-rin re lace •
Enaine sprocket check f •
Coolant -check f • R
Radiator hoses connections-check •
Brake ad·ustment check f •
Brake wear check f •
Brake fluid level-check f •
Brake fluid-chanoe Every 2 vears
Brake master inder cu and dust seal reolace Everv 2 vears
Brake caliper piston seal and dust seal replace Eve 2 vears
Brake hose-replace Every 4 vears
Soake tiahtness and rim runout-check f •
Drive chain ad·ust •
Drive chain lubricate •
Drive chain wear check f •
ijl Chain sliaaer and ouide-reclace If damaaed
Front fork inspect/clean •
~u Front fork oil chanae 1SI time aher 2 races then every 5 races
Nuts bolts fasteners-check f • I
Fuel s'l'stem clean • I
Fuel hose-reclace Every 4 vears
Steerino plav · check f •
Sleerina stem bearina·-arease •
Rear sprocket check f •
General lubrication lubricate •
Wheel bearina-arease •
Swine arm and Uni-Trak linkaae Divots-crease •
S"Xi.og"arm and Uni-Trak linkaae aivots check f •
Rear shock oil -replace 1st time aher 2 races then every 5 races
f:RepIace, add, adjust, clean Of torque if necessary.
R:Replace
Torque and Locking Agent
Tighten all bolts and nuts to the proper torque using an accurate torque wrench. 1f insufficiently
tightened , a bolt or nut may become damaged or fall off. possibly resulting in damage to the
motorcycle and injury to the rid er. A bolt or nut w hich is overtightened 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.
W hen checking the tightening torque of the bolts and nuts , first loosen the bolt or nut by
half a turn and then ti ghten to specified torque .
Letter used in the " Rema rks" column mean:

L Apply a non-permanent locking agent to the threads .
LG Apply liquid gasket to the threads .
5 Tighten the fasteners fo llo wing the specified sequence.
.. Left-hand threads.
Torque
Fastener Remarks
N-m kg-m ft-Ib
Fuel System
Rear Frame Mounting Bolt s 26 2.7 20.0
Cooling System:
Water Pump Impelle r Bolt 6.9 0.7 61 in -Ib
Coolant Drain Plug:
Water Pump Cover 15 1.5 11
Cylinder (KX250) 9 0.9 78 in-Ib
Engine Top End:
Cylinder H ead Nuts 25 2.5 18.0
Cylinder Nuts: (KXI25) 25 2.5 18.0
(KX250) 34 3.5 25
Engine Bracket Nuts: Engine side 26 2.7 20.0
Frame side 34 3.5 25
Exhaust Va lve Operating
Lever Nut: (KXI25)' 8.3 0 .85 74 in-Ib
(KX250) 9.8 1.0 87 in- Ib
Operating Rod Left Side Plu g
(KX250) 15 1.5 11
Engine Right Side :
External Sift Mechanism
Return Sp ring Pin 22 2.2 16.0 L
Clutch Spring Bolts: (KX125) 9.3 0 .95 82 in-Ib
(KX250) 8.8 0.9 78 in -Ib
Clutch Hub Nut: (KX 1 251 88 9 65
(KX250) 98 10 72
Torque
Fastener Remarks
N-m kg-m ft-Ib
Primary_Gear Nut IKX125) 59 6.0 43
Kick Pedal Bolt IKX 125) 10 1.0 87 in-Ib
Kick Pedal Nut IKX250) 49 5 36
Exhaust Valve Advancer
Shaft Mounting Bolts 3.9 0.4 35 in-Ib
Exhaust Valve Operating
Shaft Lever Nut:
IKX125)' 8.3 0.85 74 in-Ib
IKX250) 9.8 1.0 87 in-Ib
Engine Removal/Installation:
Swing Arm Pivot Shaft Nut 7B 8.0 58
Engine Nuts 34 3.5 25
Engine Bra cket Nuts:
Frame side 26 2.7 20.0
Engine side 34 3.5 25
Engine Bottom EndfTransmission:
Transmission Oil Drain Plug 20 2.0 14.5
Shift Drum Operating Plate Bolt 22 2.2 16.0
Magneto Flywheel Bolt IKX125) 22 2.2 16.0
Magneto Flywheel Nut IKX250) 78 8.0 58
WheelsfTires:
Front Axle Clamp Nuts 9.3 0.95 82 in-Ib
Front Axle Nut 54 5.5 40
Rear Caliper Mounting Bolts 25 2.5 18.0
Rear Axle Nut 98 10 72
Spoke Nipples Not less Not less Not les s
than 1. 5 than 0.15 than 13 in -tb
Final Drive :
Rear Sprocket Bolts 29 3.0 22.0
Brakes:
Caliper Mounting Bolts(Front, Rear) 25 2.5 18.0
Brake Hose Banjo Bolts 25 2.5 18.0
Front Master Cylinder Clamp Bolts 8.8 0.9 78 in-Ib
Brake Disc Mounting Screws
(Fro nt, Rear) 9.8 1.0 87 in-Ib
Brake Pad Bolts 18 1.8 13.0
Caliper Bleed Valve (Front, Rear) 7.8 0 .8 69 in-Ib
Brake Pedal Mounting Bolt 8.8 0.9 78 in-Ib L
Torque
Fastener Remarks
N-m kg -m ft -Ib
Suspension:
Front Axle Clamp Nuts 9.3 0 .95 82 in-Ib
Front Fork Clamp Bolts (Upper, Lower) 20 2 .0 14.5
Front Fork Compression Valve Assembly 54 5.5 40 L
Front Fork Top Plug 29 3.0 22
Guide Stay Nut 27 2.8 20
Swing Arm Pivot Shaft Nut 78 8.0 58
Rear Spack Absoher Bracket Bolts 39 4.0 30
Rear Shock Absorber
Mounting Bolts 39 4.0 30
Tie-Rod Mounting Nuts (Front. Rear) 81 8 .3 60
Rocker Arm Bracket Mounting Bolts 81 8.3 60
Rocker Arm Nut 81 8.3 60
Steering:
Steering Stem Head Nut 44 4.5 33
Steering Stem locknut 3.9 0.4 35 in -Ib
Handlebar Clamp Bolts 25 2 .5 18.0
Front Fork Clamp Bolts (Lower) 20 2.0 14.5
Electrical System:
Flywheel Bolt IKX125) 22 2.2 16.0
Flywheel Nut IKX250) 78 8.0 58
Spark Plug 27 2.8 20.0
The table below, relating tightening torque to thread dia meter, lists the basic torque for the bolts
and nuts. Use this table for only the bolts and nuts which do not requ ire a specific torque value.
Al l of the values are for use with dry so lvent-c leaned threads.
General Fasteners
Threads diameter Torque
Imm) N-m kg-m ft-Ib

5 3.4 - 4 .9 0 .35 - 0 .50 30- 43 in-Ib
6 5.9 -7.8 0 .60 - 0 .80 52 - 69 in-Ib
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 - 23 125- 165
20 225 -325 23 - 33 165- 240
Cable Routing
KX125 : 1. Throttle Cable

2. Brake Hose
J Clutch Cable
4. Ignition Coil
5. Stator lead
=
•
•
KX250 :
1. Throttle Cable
2. Clutch Cable
3. Brake Hose
4. Stator Lead
S. Radiator Breather Hose
FUEL SYSTEM 2- 1
Fuel System
Table of Contents
Exploded View .. ......... ...... , .... .•_...........•. .......... , _.......... .•. .... 2-2
Spec ificat ions ............. , ... " ............................. _, _. ......... ..• ..... 2-4
Special Tools ..................................................................... 2- 5
Throttle Grip and Cable ................................... "......... . .••. .... 2-6
Throttle Grip Free Play Inspection .. .. ................ ... ... . ..... .. 2-6
Throttle Cable Adjustment "" ... ', ..... " ..... ... ". ...... ... ...... .. 2-6
Throttle Cable Install ation Notes ....... ........... ....... ........... 2-6
Throttle Cable Lubrication ." ........... "".. ..... .. ....... ..... .. .... 2-7
Throttle Cable Inspection ................ ..... .... .. . .. . ....... ..... ... 2-7
Carburetor . ..... ......... .. ........... ............ ........ ... ••........... .•....... 2-8
Idle Speed Inspection ...... .......... ........................•..... ..... 2-8
Idle Speed Adjustment .... ........ ........ .... .. .... ....... .•.......... . 2·8
Serv ice Fu el Level In spection ............... .......................... 2-8
Serv ice Fuel Level A djustment ..............•........... _............ 2-9
Fuel In spect ion .. ............................•.... ...... .• ................. 2- 10
Carburetor Remova l ..................... ... ... .... .............. ........ 2- 10
Carburetor In sta llation No t es .. ".. ..... ..... . ..... ......... ......... 2-10
Carburetor Disassemb ly ......... " .................................... 2·11
Carburetor Assembly Notes ..................... _.................... 2-12
Carburetor Cleaning .............................. .............. .. ....... 2-12
Carburetor Inspection ............ . ...... .. .... .............. .... ....... 2- 13
Air Cleaner ............ .. ... ..... .. .... .. .. ........ .. ....... .. ........ .... .. .. ..... 2· 14
Air Cleaner Housing Removal .... ....... .. .... ..... ......... ... ...... 2- 14
Air Cleaner Housing Installation Notes ................. .......... 2- 14
Air Cleaner Element Removal .... ...................... .. ...... ... ... 2- 14
Air Cleaner Element Installation Notes ......... ... .. .......... ... 2-14
Air Cleaner Element Cleaning and In spection ......... ......... 2- 14
Fuel Tank ................ ............... ........ ....... ...... .... .................. 2- 15
Fuel Tank Removal ...................... .. .......... .. ... ............... 2- 15
Fuel Tank Installation Notes .................... .. .................... 2- 15
Fue l Tap Removal .... .. ..... ... .. ........... .... ........ ................. 2- 16
Fuel Tap Installation Notes .............. ........ ... ... .. ... ..... ..... 2-16
Fuel Tap Inspection ... .. ............................ .......... .......... 2- 16
Fuel Tank Cap Inspection .. .... ..... .... .. ........ .. ... ............... 2- 16
Fuel Tank and Tap Cleaning ..... .. .. ... .... ... .. .. .................. 2-16
Reed Valve .......... ..... ....................... ....... ... ..... ..... ... ......... . 2- 17
Reed Valve Removal .............. ... .... ..... .......................... 2-17
Reed Valve In stallation .................... .. .......... .... .. .. .... .. ... 2- 17
Reed Valve Inspection ... ............................................... 2-17
2-2 FUEL SYSTEM
................................. ...........................
Exploded View
.. ........ ........ ... ........ .......... ....... ... ....... ....
©
KX250
,- _____ L ___ _ ,
o
~~
L __________ ...JI
I
, 6((J
r-
I
-------1
I
( , I
I!!l
~
~ @)-i •
I
I
I
I
I .. 7 ®-! 0
I L KX125
.,
i f'\
IV !
I
/.....®
~ Ie
0 ,
D
L __________ -.J ~
e
\ ---<D
,
2
, . Jet Needle Clip
2. Jet Needle "'® "1
3 , Throttle Valve
4 . Slow Jet
5. Main Jet
6. Idle Adjusting Screw
7. Air Screw
a : Oil
G : Grease
FUEL SYSTEM 2-3
® o
o : 2-stroke racIng
. . foam-air filter oil
oil or high -quality
G : Grease k m 20 ft-Ibl
T1 : 26 N-m 12.7 g- •
2-4 FUEL SYSTEM
Specifications
................ ..................................... ........
KX125 '
Item Standard Service limit
Throttle Grip Free Play 2 - 3 mm - - -
Carburetor Specifications:
Meke/type KEIHIN PWK35 - - -
Main jet 155 - - -
Throttle valve cu taway 6 - - -
Jet needle N84C - - -
Jet need le clip position 3rd groove from the top - - -
Slow jet 52 - - -
Air screw 11h (t urns out)
Service fuel level 1.0 ± 1 mm - - -
(below the bottom edge of the carb o body)
Bore Center 32 mm - - -
Float height 16 ± 1 mm - - -
Air Cleaner Element Oil: 2·st roke rac ing oil or high·
quality foam-a ir filter oil - --
Reed Valve:
Reed warp - -- 0 .2 mm
KX250 '
Throttle Grip Free Play 2 - 3 mm - - -
Meke/type KEIHIN PWK38 - - -
Main jet 175 - --
Throttle valve cutaway 7 - --
Jet needle N85C - - -
Jet needle clip pos ition . 3rd groove from the top - - -
Slow jet 55 - - -
Air screw , 1/2 (turns out) - --
Service fuel level 1.0 ± 1 mm - - -
(below the bottom edge of the carb o body)
Bore Center 34mm - - -
Float height 16 ± 1 mm - - -
Air Cleaner Element Oil: 2-stroke racing oil or high-
quality foam-a ir filter oil - --
Reed Valve :
Reed warp - -- 0 .2 mm
FUEL SYSTEM 2·5
Special Tools
Pressure Cable luber: K56019-021

Along with common hand tools, the fo11owing
more specialized too ls are requi red for comp lete
fuel system servici ng.
Fuel Level Gauge: 57001 -122

2-6 FUEL SYSTEM
.............................................................. -Turn the adjuster until the proper amount of throttle
Throttle Grip and Cable grip free play is obtained.
.......................... " ........................ ......... . - Tighten the locknut.
If the throttle grip has excessive free play due to

* If the throttle grip free play cannot be adjusted
with the adjuster at the upper end of the throttle
cable stretch or misadjustment, there will be a delay in cable use the cable adjuster at the carburetor.
throttle response. Also. the throttle valve may not open oPull the boot off of the carbu retor top. Make the
fully at full throttle. On the other hand, if the throttle necessary free play adjustment at the lower cable
grip has no play, the throttle will be hard to control, adjuster, tighten the locknut. and install the boot
and the idle speed will be erratic. Check the throttle
grip play periodically in accordance with the Periodic
Maintenance Chart. and adjust the play if necessary.
The throttle cable routing is shown in Cable Rout·
ing in the General Information chapter.
Throttle Grip Free Play Inspection

- Check throttle grip free play by lightly turning the
throttle grip back and forth .
A. l ocknut
B. Adjuster
- Turn the handlebar from side to side whi le idling the

engine. If idle speed varies, the throttle cable may
be poorly routed or it may be damaged.
A. Throttle Grip
B. Throttle Grip Free Play
AWARNING
Throttle Grip Free Play
Operation with an Improperty adjusted. incorrectly
2 - 3 mm routed. or damaged cable could result In an unsafe
* If the throttle grip free play is improper, adjust the riding condltkm.
throttle cable.
Throttle Cable Adjustment

-loosen the locknut at the upper end of t he throttle Throttle Cable Installation Notes
cable. -Install the throttle cable in accordance with the
Cable Routing section in the General Information
chapter.
- After the installation, adjust the cable properly.
AWARNING
Operation with an Incon'ectty routed or Improperly

adjusted cable could result In an unsafe riding con-
dition.
A. Adjuster C. Throttle Grip Free Play
B. l ocknut
FUEL SYSTEM 2-7
Throttle Cable Lubrication Throttle Cable Inspection
Whenever the cable is removed, and in accordance -With the throttle cable disconnected at both
with the Periodic Maintenance Chart (see General ends, the cable shou ld move freely within the cable
Informati on chapter), do the following. housing.
-Apply a thin coating of grease to the cable upper end.
Cabkt Lubrication
Cable Inspection
1. Apply grease.
- lubricate the cable with penetrating rust inhibitor

through the Pressure Cable Luber (special tool). 1. Cable
Cabkt Lubrication
* If cable movement is not free after lubricating. if
the cable is frayed. or if the housing is kinked,
replace the cable.
® ,
1. Cable 2. Pressure Cable Luber: K56019-021

2-8 FUEL SYSTEM
- After adjustment, tighten the locknut
Carburetor - Open and close the throttle a few times to make
.... ....... ... ... ...... ... ............ ...... .................. sure that the idle speed is as desi red. Readjust if
necessary.
Since the carburetor regu lates and mixes the fuel
and air going to the engine. there are two general
types of carbu retor trouble: too rich a mixture (too
much fuel), and too lean a mixture (too little fuel). Service Fuel Level Inspection
Such trouble can be caused by dirt. wear, maladjust-
ment, or improper fuel level in the float chamber.
A dirty or damaged air cleaner can also alter the fuel
to air ratio.
AWARNING
GasoNne is extremety flammable and can be axpk)-
Idle Speed Inspection s iva under certain conditions. Always s top the an-
- Start the engi ne and wa rm it up thoroughly. gine and do not smoke. Make sure the are8 is weD
- With the engine id ling, turn the handlebar to both vantiated and free from any source of flame or
sides. sparks; this Includes any appliance wtth a piat light .
• ,f handlebar movement changes the idle speed, the
throttle ca ble may be improperly adju sted or
incorrectly routed, or it may be damaged . Be sure - Tum the fuel tap to the OFF position.
to correct any of these conditions before riding (see - Remove the fuel tank.
Cable Routing in the Cenera llnformation chapter). - Remove the carburetor, and hold it in true vertical
position on a stand. The fuel hose and carburetor
cable do not have to be removed to inspect the fuel
level.
- Put the fuel tank on a bench, and connect the fuel
'~WARNING tap to the carburetor using a suitable hose.
- Remove the drain plug from the bottom of the
Operation with an Improperly adjust ed. incorrect - float bowl, and screw- a fuel level gauge (special
ly routed . or damaged cable could (esult In an un- tool) into the plug hole.
saf e riding condition . - Hold the gauge vertically against the side of car-
buretor body SO that the "zero" line is several milli-
meters higher than the bottom edge of the carburetor
- Check idle speed . body.
*Ad just it as needed. - Turn the fuel tap to the ON IX>sition to feed fuel to
the carburetor.
- Wait until the fuel level in the gauge settles.
Idle Speed A djustment - Keeping the gauge vertical, slowly lower the gauge
- Start the engine and warm it up thoroughly. until the "zero" line is even with the bottom edge
- First turn in the air screw- until it seats tightly, of the carburetor body.
and back it out 1 112 turns.
- loosen the locknut and tum the idle adjusting screw
to obtain the desired idle speed. If no idle is
preferred, tum out the screw- until the engine stops. NOTE
000 not lower the "zero" line below the bottom edge
of the carburetor body. If the gauge is lowered and
then raised again, the fuel level measure shows
somewhat higher than the actual fuel level. If the
gauge is lowered too far, dump the fuel out of it
into a suitAble container and stArt the procedure
over again.
- Read the fuel level in the gauge and compare it to

the specification.
_ Turn the fuel tap to the OFF position and remove
the fuel level gauge. Install the drain plug on the
bottom of the float bowl.
A. Idle Adjusting Screw C. Air Screw * If the fuel level is incorrect, adjust it.
B. l ocknut
FUEL SYSTEM 2-9
Service Fuel Level - Bend the tang on the float arm very slightly to
(below the bottom edge of the carb o body) change the float height. In crea si ng the float height
KX125 , 250 : 1.0 ± 1 mm lowers the fuel level and decreasing the float height
raises the fuel level.
Float Height
KXI25 . 26 0 : 16 ± 1 mm
1 , Fuel Level Cauge: 57001-122

2. Service Fuel Level
A. Tang
- Assemble the carburetor, and recheck the fue l
leve l.
Service Fuel Level Adjustment * If the fuel level cannot be adjusted by this method,
the float or the float valve is damaged.
AWARNING
Fbat Height Measurement
Gasoline is extremely flammable and can be ex-
plosive under certain conditions . Always stop the
engine and do not smoke . Make sure the area is
well ventilated and free from any source of flame
or sparks; this includes any appliance with a
pilot light.
- Remove the carburetor, and drain the fuel into a

suitable container.
- Remoye the float bowl.
- Drive out the pivot pin and remove the float.
1. Float Bowl Mating Surface

2. Float Valve Needle Rod (contacted but unloaded)
3. Float
- Place a suitable container beneath the carburetor.
NOTE
Ofloat height is the distance from the float bowl

mating surface of the carburetor body (with the
gasket removed) to the top of the float Measure
A. Pivot Pin B. Drive out the pin . the height with the carburetor upside down.
2-10 FUEL SYSTEM
Fuel Inspection
AWARNING
Gasoline I, extremely flammable and can be ex·
piosive under certain conditions . Always stop the
engine and do not smoke . Make SUf. the af88 Is
wen ventilated and free from any source of flame
or sparks: thl, Includes any appliance with 8
pilot light .
• Place a suitable conta iner beneath the ca rburetor.

-Turn the fue l tap to the O FF positio n.
-Remove the drai n plug from the bottom o f the A. Ca rburetor B. Throttle Va lve Assembly
float bowl and check for water or dirt in the f uel.
CAUTION
If the throttle valve Is not removed from the
cable , wrap It In e clean cloth to avoid damage.
- Afte r re movi ng the carburetor, push a clea n. lint-

free towel into the carbure tor ho lder and the a ir
cleaner du ct to keep d irt o r other fo reign material
fro m ente ring.
AWARNING
If dirt or dust la allowed to pass through Into the
A. Drain Plug
cerburetor, the throttle may become stuck. pos-
sibly causing an accident.
* If any water or d irt comes out, clean the carbure-
tor, fue l ta p and fuel ta nk (see Fuel Tank). CAUTION
• Insta ll t he dra in plug secu re ly,
If dirt gets through Into the engine. excessive en-
gine wear and possibly engine damage will occur.
Carburetor Removal
AWARNING Carburetor Installation Notes

-Insta ll ation is the reve rse of remova l.
Gasoline I. extremely flammable and can be ex· -Be ing ca reful not to be nd o r otherwise da mage the
plOsJV8 under certain condttlons . Always stop the jet needle. Check to see tha t the throttle valve goes
8ngine and do not amoke. Make SUfe the 8fe8 Is a ll the way down into the ca rburetor body. and
well ventilated and free from any source of flame slides smoothly.
or sparka; this Includes any appliance with a
pilot light.
-Tu rn the fue l tap to the OFF positio n and pull the
fuel hose off the ta p.
- Place a suitable conta iner be neath the ca rburetor.
- Dra in the fue l from the fl oat bowl by remove the
d rain plug. After dra ining, insta ll the dra in plu g
secu rely.
-loosen the clamps, and remove the carbureto r
from the end of the ai r c leaner duct, a nd the n pull
it o ut of the carbure to r ho lde r.
- Unsc rew the carburetor cap. a nd pull o ut the
throttle va lve assembly.
FUEL SYSTEM 2-11
- When installing the carburetor into the carburetor Carburetor Disassembly
holder, align the projection of the ca rburetor with - Remove the carburetor.
the groove on the carburetor holder. -Remove the throttle valve assembly and carburetor
cap from the ca rburetor cable lower end.
- Disassemble the throttle valve assembly; spring,
retainer, connector, clip, jet needle, circlip and
throttle valve.
KX250
A. Spring D. Clip
B. Retainer E. Jet Needle
C. Connector F. Throttle Valve
1. Adjuster
2. locknut
3. Cap
4. Casket
A. Projection of the carbu retor 5. Spring
B. Groove of the carburetor holder 6. Retainer
- Route the air vent hose properly. o-@ 7. Connector

8. Clip
9. Jet Needle
10. Throttle Valve
CAUTION I-®
Alwavs keep the air vent hoses free of obstruction,
and make sure they do not get pinched by the chain
, or shock absorber.
- After installing the carburetor, do the following.

oTum the fuel tap to the ON position, and check for fuel
leakage from the carburetor.
OAdjust the following items if necessary.

Throttle Cable
Idle Speed
2-12 FUEL SYSTEM
- Remove the choke knob/starter plunger assemb ly Carburetor Assembly Notes
from the carburetor. - Assembly is the reverse of disassembly,
- Clea n the disassembled pa rts before assembling.
- Replace the float bowl O-ring with a new one if it
is deteriorated or damaged.
- Turn in the air screw fu ll y but not tightly. and then
back it o ut 1'h: turns.
A. Choke knob/starte r plunger Assembly

B. Ca rburetor
-Remove the following parts from the ca rburetor

body. A. Air Screw
Carburetor Cleaning
AWARNING
Clean the carburetor In a w ...·ventilated area, and
take care that the,e Is no speak or flame any-
where near the working aree; this Includes any
eppliance wtth a pilot Nght . Because of the danger
of highly nammable IIqulds, do not use gasoline
or low flash -point lolvent to dean the carburetor.
-Make sure the fuel tap is in the OFF position .

-Drain the fue l in the carburetor.
8 -Remove the carburetor.
-Disassemble the carburetor.
CAUTION
00 not use compressed air on an assembled car-
buretor, the float may be deformed by the
pre88ure .
Remove as many rubber or plastic parts from the
carburetor as possible before cleaning the carbu-
1, Spring
retor with a cleaning solution . This will prevent
2. Air Screw
damage or deterioration of the parts.
3. locknut 00 not use a strong carburetor cleaning lolution
4. Idle Adjusting Screw
which could attack the pfastlc parts; instead. use
5. Slow Jet a mild high flash -point cleaning solution safe for
6. Main Jet plastic partl .
7. Float Va lve 00 not use wire or any other hard Instrument to
8. Float clean carburetor parts, .specially jets, as they
9. Pin may b. damaged.
10. O-ring
11 . Float Bowl
FUEL SYSTEM 2-13
- Immerse all the metal parts in a ca rburetor clean- - Remove the slow jet
ing solution . - Check the slow jet for any damage.
- Rinse the parts in water. * If the slow jet is damaged, replace it with a new one.
- When the pa rts are clean, dry them with com- - Remove the throttle valve and jet needle.
pressed air. - Inspect the outside of the throttle valve for
- Blow throu gh t he air and fuel passages with com- scratches and abnormal wear.
pressed air. * If it is badly sc ratched or worn, replace the throttle
- Assemble the carburetor, and install it on the motor- valve.
cycle. - Inspect the inside of the carburetor body for these
same faul ts.
* If it is badly scratched or worn, replace the entire
Carburetor Inspection carburetor.
- Check the jet needle for wear.
AWARNING
* A worn jet needle should be replaced.
• Disassemble the carbu retor, and clean the fuel and
air passages with a hign..flash point solvent and
Gasoline is extremely flammable and can be ex· compressed air.
plosive under certain conditions, Always stop the
engine and do not smoke , Make sure the erea is
wall·ventilated and free from any sourc e of flame
or sparks ; this includes any appliance with a
pilot light.
- Remove the carburetor.

- Before disassembling the carburetor, check the
f uel level (see Fuel level Inspection).
* If t he fue l level is in correct, inspect the rest of the
ca rburetor before correcting it.
- Pu ll the th rottle cable to check t hat t he throttle
va lve moves smooth ly and returns by spring pres-
sure.
* If the t hrottle valve does not move smoothly,
rep lace the ca rbu retor.
- Clean the carburetor.
- Remove the float valve needle.
- Check the float valve need le for wear.
* If the needle is worn as shown below, replace the
valve needle.
- Push the rod in the valve needle, then release it
* If the rod does not came out fu lly by spring tension,
replace t he valve needle.
Roat Valve Wear
Push and release
1. Rod 3. Va lve Needle Wear

2. Valve Needle
2- 14 FUEL SYSTEM
...............................................................
Air Cleaner Element InstalfBtion Notes
Air Cleaner
............................................................... - Installation is the reverse of remova l.
- When installing the element, coat the lip of the
Air Clesnar Housing Removal element with a thick layer of all purpose grease to
- loosen the air cleaner duct clamp. assure a complete seal against the air cleaner ele-
- Remove the following parts. ment base. Also, coat the base where the lip of the
Seat element fits .
Side Covers
Silencer
Rear Fender
Rear Flap
Rear Frame
- Remove the air cleaner housing.
Air Cleaner Housing InstaiJation Notes

-Insta ll ation is the reverse of removal.
-Tighten the rear frame mounting bolts to the speci-
fied torque.
Tightening Torque
26 N-m 12.7 kg·m. 20.0 ft-Ibl A. Crease
Air Cleaner Element Cleaning and Inspection
NOTE
Ofn dusty areas, the element should be cleaned more

frequently than recommended intetVa/.
oAfter riding through rain or on muddy roads, the
element should be cleaned immediately.
A. Rear Frame Mounting Bolts oSince repeated cleaning opens the pores of the ele-
ment, rep/ace it with a new one in accordance with
the Periodic Maintenance Chart. A/so, if there is a
Ai, Cleaner Element Removal break in the element material or any other damage
-Remove the seat. to the element, replace the element with a new one.
-Remove the wing bolt and pull out the element.
..WARNING
Oean the element In 8 wel-ventlated area, and take
care that there are no spIfks or ftame anywhenI near
the working area; tNs indudes any appiance with
• pilot light.
Because aI tho danger aI highly flammable lquids.
do not use gasoline or 8 low flash-point solvent to
clean the element.
A. Air Cleaner Element -Remove the air cleaner element, and separate the
B. Wing Bolt element from the element frame.
FUEL SYSTEM 2- '5
Fuel Tank
Fuel Tank Removal

-Remove the seat
-Remove the left and right radiator covers.
-Turn the fuel tap to the OFF position.
-Pull the fue l hose off the fuel tap.
AWARNING
Gasoine is axtremety flammable and can be explo-
A. Element B. Frame sive under certain conditions. Always stop the en·
gfne and do not smoke. Make sure the area is wei
ventilated and free from any source of flame or
sparks; this includes any appliance with a
- (lean the element in a bath of a high flash-point plot Ight .
solvent, a nd squeeze the element dry.
- Check all the parts of the element for visible damage. -Unhooks the rubber band. and remove the fuel tank
*I f any part of the element is damaged, replace it. mounting bolts.
- After cleaning. saturate the element with 2-stroke -Remove the fuel tank.
racing oil or high-qua lity foam-air-filter oil, squeeze
out the excess. then wrap it in a clean rag and
squeeze it dry as possible. Be careful not to tear
the element.
- Assemble the element.
- Install the element
A. Mounting Bolt B. Rubber Band
-Drain the fuel tank.
Fuel Tank Installation Notes

-Installation is the reverse of removal.
-Check the rubber dampers on the frame top-pipe and
fuel tank.
A. Dampers
2-16 FUEL SYSTEM
* If the dampers are damaged or deteriorated. replace * If the fuel tap screen has any breaks or deterioration,
them. it may allow dirt to reach the carburetor, causing
• Be sure the fue l hose is clamped to the fuel tap to poor running. Replace the fuel tap.
prevent leaks. * If the fuel tap leaks, or allows fuel to flow when it
• Insert the fuel tank breather hose outlet end into the is at OFF position, replace the damaged O-ring.
number plate hole.
Fuel Tank Cap Inspection

- Remove the fue l tank cap.
- Inspect the gasket on the tank cap for visible
damage.
* Replace the gasket if it is damaged.
- Remove the breather hose and check to see that
the hose is not clogged.
* If it is clogged, blow out the breather hose with
compressed air.
A. Fuel Tank Breather Hose

6. Number Plate Hole
Fuel Tank and Tap Cleaning

Fuel Tap Removal - Remove the fuel tank and drain it
• Remove the fuel tank and drain it - Pour some high flas~int solvent into the fuel tank
• Remove the mounting bolts and take out the fue l and shake the tank to remove dirt and fuel deposits.
tap_
Fuel Tap Installation Notes

• Insta llation is the reverse of removal.
• Be sure the O-ring is in good condition to prevent AWARNING
leaks.
• Be sure to damp the fue l hose to the tap to prevent Clean the tank in II wei ventlated area, and take
leaks. care that there is no sparks or flame anywhere near
the worUlg area . Because of the danger of highty
Fuel Tap Inspection flaf1"ll1lBlM liquids, do not use gasoIne or low flash-
• Remove the f uel lap. point sofvent to dean the tank .
• Check the fue l tap filter sc reen for any breaks or
deterioration.
Fuel Tap - Pour the solvent out of the tank.

- Remove the fuel tap from the tank by taking out the
bolts.
- Clean the fue l tap filter screen in a high fl ash-point
solvent
- Pour high f1ash-point solvent through the tap in all
lever positions.
- Dry the tank and tap with compressed air.
- Install the tap in the tank.
-Install the fuel tank on the frame.
-I nstall the parts removed.
1. O-ring 2. Filter Screen

FUEL SYSTEM 2-17
..•..••............ ....... .. .. .. .... ....•.•.••.•.•••....•.••.
Reed Valve
* If anyone of the clearance measurements exceeds
the service limit. replace the valve pa rt with a
new one.
Reed Valve Removal
-Remove the carburetor from the carbureto r holder Reed Warp
and air cleaner duct. SeNice Umit: 0 .2 mm
- Remove the carburetor holder mounting bolts. and
move the holder rearward .
-Take the reed valve out of the cy linder.
- For KX125 model ; remove the reed valve from the
crankcase .
Reed Valve Installation

- Installation is the reverse order of remova l (see car·
bu retor Instal lation Notes).
- Tighten the carburetor holder mou nting bo lts to
securely.
Reed Valve Inspection

- In spect the reeds for c racks, fo lds, o r othe r visible
d amage.
* If the re is any doubt as to the condi tion of a reed,
replace the reed va lve pa rt with a new o ne .
* If a reed becomes wavy, replace the valve part with
a new one even if its warp is less than the service
limit
- Measure the clearance between the reed and holder.
and check the reed warp as shown.
A. Reed C. Thickness Gauge

B. Reed Va lve Holder
COOLING SYSTEM 3-'
Cooling System
Table of Contents
Exploded View .. .............••........... ............•. ... ... ..... •.. ........ .. .. ..... 3-2
Specifications ............................... . __........................................ 3-4
Special Tool .... ............. .... ..... ....... ... .... ....•... .. ... .. .•. .. .... .... .... ..... 3-4
Coolant ..... ,,,....................... ................................... .. ..... .......... 3-5
Coolant In spection .. .... .......... .. .. .. ...... .. .. ................ .... .. ....... 3-5
Coolant Change ...... .. ........ .......... ,......... ....... _,_.. ...... ........... 3-5
Air Bleed ing ..................... ........ ...... .. _....................... __ _...... 3-7
Cooling System Pressure Testing ..... .... ....... ....•. .... .... .•• ..... ... 3-7
Cooling System Flushing ..... ', .......................... " ....... _._ ........ 3-7
Disassembly and Assembly Precautions ...... .... .. .... ........ .... .. .. .... .. 3-8
Water Pump ... ... ........... .............. ........... .... ... .... .•....... .. .. ... .... ... 3-8
Water Pump Cove r Removal .... .. ........ .. ....................... _........ 3-8
Water Pump Cover In st all ation Notes .. , .. . , .... ..• .. , ..... , .... ,....... 3-8
Impeller Removal ......................... ...... ,.. .... ............. .. .. ........ 3-8
Impeller Installation ... ,......... ....... ... ... .. .... ......... .. .. .. ... ...... .... 3-8
Impeller Inspection .... ............................ ....... ............... ....... 3-8
Water Pump Shaft Removal.. .. ... .. ...... .. ....... .... .... .... ............ 3-8
Water Pump Shaft Installation Notes .... ........ ........... ...... ....... 3-8
Oil Seal Removal .......... ............ .. ...... ...... .. ............ ............... 3-9
Oil Seal In stallation .. .. .... .............. ..................... ............... .. 3- 10
Radiator ................................................. .... .. ................ .. ........ . 3- 10
Radi ator Removal ......... .......... .. .... ....... ....... .... ........ ... . ,...... . 3-10
Radiator Installation ....................... .... .. .............................. 3- 10
Radiator In spection ....................................... ... ........ ,., ....... 3- 10
Radiator Cap Inspection .... .... ...... .. .. .. .......... ........ .......... .... .. 3- 11
Filler Neck Inspection .......................................... ............... 3- 12
, Cooling Hoses, Breather Hose Inspection ...... ........ ........ .. .... .. 3- 12
Cooling Hoses, Breather Hose Installation Notes ..... ............... 3·12
OOLING
3-2 C SYSTEM ........ .
................... ..... ......... .
.......................
Exploded View ... ................... .. . .... .........
KX125:
'r" .6. 9 N-m (110.7 -m, . "61 ;n-Ibl

kg-m
.5 kg
in·fb)
T2 : 15 N-m
COOLING SYSTEM 3·3
KX250 :
6 9 N-m (0. 7 kg -m' 61 in-Ib)

1 ft-Ib)
1
T1 : . N-m 11 .5 kg-m. 78In-lb)
.8 N· m {O .9 kg -m.
T2 : 815
T3:
3-4 COOLING SYSTEM
Specification s
Item Standard
Coolant:
Type Permanent type of antifreeze for aluminum
engines and radiators
Color Green
Mixed ratio Soft water 50% , Coolant 50%
Total amount: KX 125 0.96 l
KX250 1. 1l
Radiator:
Cap re lief pressu re 95 - 125 kPa 10.95 - 1.25 kg/cm2, 14 -
18 psi)
Special Tool
............................................................
Bearing Driver Set : 57001 · 1129

COOLING SYSTEM 3·5
Coolant
Check the coola nt level each day before riding the

motorcycle. and replenish coola nt if the level is low.
Change the coo lant in accordance with the Periodic
Maintenance Cha rt (see the General Information
chapter).
AWARNING
To avoid burns. do not remove the radiator cap
or try to inspect the coolant level or change the 1. Coolant Level 2. Breather Hose
coolant when the engine is still hot. Wait until it
cools down . * If the coolant level is low. add the correct amount
of coolant through the filler opening.
Coolant Inspecr;on
Coolant Level : Recommended coolant:
- Situ ate the motorcycle so that it is perpendicular to Permanent type of antifreeze (soft water and ethyl·
the ground . ene glycol plus corrosion and rust inhibitor chemi·
- Remove the radiator cap in two steps. First tu rn ca ls for aluminum engines and radiators)
the cap counterclockwise to the first stop and wa it Water and coolant mixture ratio:
there for a few seconds. Then push and turn it 1:1 (Water 50% , Coolant 50%)
further in the same direction and remove the cap. Total amount
KX125: O.96L
KX250: 1.1L
Coolant Deterioration:
- Visually inspect the o ld coolant.
* If whitish cotton-like wafts are observed, a lum inum
parts in the cooling system are corroded. If the cool-
ant 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 cooli ng system leak. It may be caused by ex-
haust gas leak ing into the cooling system.
Coolant Change
A, Radiator Cap
The coolant should be changed periodica lly to en·
su re long engine life.
- The coolant level should be at the bottom of the
Coolant Draining:
radiator fi ller neck.
AWARNING
NOTE Coolant on tires wi" make them slippery and can
cause an accident and injny. Immediately wipe up
OCheck the level when the engine is cold (room or wash away any coolant that Spills on the frame.
or ambient temperature). engine or other painted parts.
Since coolant is harmful to the human body. do not
use for drinking .
-Re move the radiator cap.

3·6 COOLING SYSTEM
. Place a container under the coolant drain plug, and -Inspect the old coolant for visual evidence of cor-
drain the coolant from the radiator and engine by rosion and abnormal smell (see Coolant Deterio-
removing the drain plug at the bottom of the water ration).
pump cover. Immediately wipe or wash out any
coolant that spills on the frame, engine. or wheel. Coolant Filling:
KX125
CAUTION
Use cootant 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 an-
tifreeze (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 consider-
ably reduces the efficiency of the cooling system.
A. Water Pump Cover B. Drain Plug
KX260 The coolant provided when shipping

Type : Permanent type antifreeze
for aluminum engines and
radiators
Cob' : Green
Mixed ratio : Soft water 50%.
coolant 50%
Freezing point : -35°C (_31°FI
Total amount : KX126 - 0 .96L
KX260 - 1.1L
-'nstall the drain plug. Always replace the gasket

with a new one. if it is damaged.
-Tighten the drain plug to the specified torque.
TIghtening Torque :
A. Water Pump Cover B. Drain Plug
KX125: Pump Cover-15N-m (1 .5kg-m.11ft-lhJ
KX250: Pump Cover-15N-m (1 .5kg-m.11ft-lbl
For KX260, Cyllnder - 8.8N-m (0.9kg-m,78in-lbJ
-Pl ace a container under the d ra in plug on the right
side of the cylinder and drain the coolant by re-
moving the drain plug.
-Fill the radiator up to the bottom of the radiator

filler neck with coolant, and install the cap. turning
it clockwise about 1..4 turn.
NOTE
OPour in the coolant slowly so that it can expel the

air from the engine and radiator.
oThe radiator cap must be instal/ed in two steps.
First turn the cap clockwise to the first stop. Then
A. Drain Plug push down on it and turn it the rest of the way.
COOLING SYSTEM 3-7
Radiator Fillar Neck -Build up pressure in the system carefully until the
pressure reaches 12S kPa (1 .25 kg/cm1 , 18 psi),
<D - Watch the gauge for at least 6 seconds. If the pres-
2 sure holds steady, the cooling system is all righl
1 . Breather Hose 2. Coolant level
- Check the cooling system for leaks.

-I nsta ll the rad iator ca p.
A. Pressure Tester B. Adapter
Air Bleeding - Remove the pressure tester, replenish the coolant.
Before putting the motorcycle into operation, any and insta ll the radiator cap.
ai r t rapped in the cooli ng system must be removed
as fo llows.
* If the pressure drops and no external source is
found , check fOl' internal leaks. Check the cylinder
_ Start the engine, warm up the engine thoroughly, head gasket for leaks.
and then stop the engine.
• Remove the radiator cover.
• Remove the radiator cap.
- Check the coolant level after the engine cools
down.
* If the coolant level is low, add coolant up to the
rad iator filler neck. Cooling System Flushing
- Install the radiator cap. Over a period of t ime, the cooling system accu-
- Check the cooling system for leaks. mulates rust, scale, and lime in the water jacket and
- Install the radiator cover. radiator. When this accumu lation is suspected or ob-
served, flush the cooling system. If this accumula-
tion is not removed, it will clog up the water passages
and considerab ly reduce the efficiency of the cooling
Cooling System Pressure Testing system.
Any time the system slowly loses coolant, inspect - Drain the cooling system.
for leaks. -Fill the cooling system with fresh water mixed with
a flus hing compound.
CAunON CAunON
During pr8SSUf8 testng, do not exceed the pressU'8 Avoid the use of a flushing compound which is
for wt*=h the system is designed to work. The max- harmful to the aluminum engine and radiator. Care-
Imum pre..... is 125 kPa 11.25kg/cm'. 18 poil . fuly 1010.. the Instructions ... ppied by the
manufacturer of the cleaning product.
- Remove the radiator cover.

-Remove the radiator cap, and install a cooling sys- - Warm up the engine, and run it at normal opeating
tem pressure tester on the radiator filler neck. tempreature for about ten minutes.
- Stop the engine, and drain the cooling system after
the coolant cools down.
- Fill the system with fresh water.
NOTE - Wa rm up the engine and drain the system after the
coolant cools down.
oWet the adapter cap sealing surlaces with water -Repeat the previous two steps once more .
or coolant to prevent pressure leaks. - Fill the system with a permanent type coolant, and
bleed t he air from the system (see Air Bleeding).
3-8 COOLING SYSTEM
Water Pump Cover Installation Notes

Disassembly and assembly Precautions -I nstallation is the reverse of removal.
- Replace the pump cover gasket with a new one.
- Fill the cooling system (see Coolant Filling).
' Prior to disassembly of coo ling system parts (radi-
ator, pump, etc), wait until the coola nt cools down.
and then drain the coolant.
- After assembling and fill ing the system with coolant.
bleed any air from the system.
Impeller Removal
- Drain the coolant (see Coolant Draining).
- Remove the cover bolts and take out the water
pump cover from the right engine cover with the
Water Pump cooling hose(s) attached.
- Remove the impeller bolt, and pull out the impeller
and washer.
Watsr Pump Cover Removal
-Drain the coolant (see Coolant Draining).
' Loosen the cooling hose clamps, and disconnect the
cooling hoses on the water pump cover.
'Remove the water pump cover bolts. and remove
the water pump cover.
KX125:
A. Impeller B. Bo lt
A. Water Pump Cover B. Bolts

Impeller Installation
-I nsta ll the impeller onto the water pump shaft, and
tighten the impeller bolt to the specified torque.
KX250:
Tightening Torque:
8.9 N-m 10_7 kg-m. 81 in-fbi
A. Water Pump Cover B. Bolts

COOLING SYSTEM 3-9
Impeller Inspection Water Pump Shaft Insta llation
- Visually check the impeller.
,.. If the surface is corroded, or if the blades are dam-
1
aged. repla ce the impeller.
A. Impeller B. Blades
Water Pump Shaft Removal 1. Oil Sea l 3. Marked Side

- Remove the following parts. 2. Water Pump Shaft 4. Right Engine Cover
Impeller
Right Engine Cover (see Right Engine Cover in
the Engine Right Side chapter)
- Pull out t he water pump shaft toward inside of the
right engine cover.
CAUTION
CAUTION Be sure to apply a molybdenum disulfide grease
Be sure to pull out the shaft toward the Inside of to the water pump shaft when installing . If it is
the cover to prevent the oil s881 lips from peeling. installed dry . the seals may wear excessively.
Oil Seal Removal

- Remove the following part s.
Impeller
Right Engine Cover (see Right Engine Cover in the
Engine Right Side chapte r)
Water Pump Shaft
- Insert a bar into the wate r pump shaft hole from
the outside of the right engine cover, and remove
the bait bearing by tapping evenly around the bear-
ing inner race.
-I nsert a bar into the water pump shaft hole from
the inside of the right engine cover, and remove
the oi l seal by tapping evenly around the seal
lips.
A. Water Pump Shaft
Water Pump Shaft Installation Notes

- Insta ll ation is the re verse of removal.
- To prevent the oil sea l lips from peeling, apply a
molybdenum disu lfide grease to the water pump
shaft and insert it into the oil seal from the inside
of the right engine cover.
3-10 COOLING SYSTEM
..... . .. .. ....•.••••••••...•••....... .... . ...• . .. . ..• •••••••••• •
Oil Sea/Installation Radiator
Radiator Removal
- Remove the radiator covers.
- Drain the coolant (see Coolant Draining).
CAUTION - loosen the hose clamps, and pull off the cooling and
breather hoses.
If the all .eal or ball bearing I, removed. replace - Remove the mounting bolts, and take out the radiator.
all of them wfth new ones at the lame time .
-Apply plenty of high temperature grease to the oil

seal lips .
• Press the oil seal into the hole from the outside of
the right engine cover with a bearing driver set
special tool) so that the ma rked side faces toward
the inside of the cover.
CAUTION
U •• 8 bearing drive' larger In diameter than the
oil •••1. and pre•• the all ••• 1Into the hole until
the edge of tile 011 seal Is flush with the step for
the ball bearing.
0 11 Se.1 Instan.tlon
A. Radiator C. Cooling Hose

B. Mounting Bolts
Radiator Installation
-I nstallation is the reverse of removal (see Coolant
Filling).
Radiator Inspection
1. Oil Seal - Check the radiator core.
*If there are obstructions to air flow, remove them.
2. Apply High Temperature Grease
3. Bearing Driver Set: 57001·1129 * If the corrugated fins are deformed, carefully straight·
en them with the thin blade of a screwdriver.
4. Step
. Press the ball bearing into the hole with a bea ring CAUTION
driver set (specia l tool : 5700,.,129) until the bear-
Do not tear the radiator tubes whle straightening
ing is bottomed against the step. the fins .
COOLING SYSTEM 3 -11
Radiator Cap Inspection

- Check the condition of the valve spring, and the top
and bottom valve seals of the radiator cap.
* If anyone of them shows visible damage, replace
the cap.
A. Thin Screwdriver
* If the air passages of t he radiator core are blocked

more than 20% by unremovab le obstructions
or irreparab ly deformed fins, replace the radiator
with a new one.
1. Valve Spring 3. Bottom Valve Seal

2. Top Valve Seal
CAUTION - Wet the top a nd bottom valve sea ls with water or

When cleaning the radiator with compressed air, coolant to prevent pressure leaks.
be careful of the following to avoid damage to the -I nstall the ca p on a cooling system pressure tester.
fins . - Watching the pressure gauge, pump the tester to
Keep the air nozzle over 0 ,5 m (20 in.) away from build up the test pressure. The cap must open at the
the radiator. specified rel ief pressure (the gauge hand flicks down).
Blow air perpendicularly to the radiator core .
Never blow air at an angle against the fins but
straight through them in the direction of natural
air flow.
Never shake the air nozzle at a right angle against
the fins, be sure to move It at a level with the fins.
Radiator Cleaning
(obliquity)
(perpendicu lar)
1 . Pressure Tester 2. Rad iator Cap
OK
Radiator Cap Relief Pressure :
more t an 95 - 125kPa (0.95 - 1.25 kg/cm 2 , 14- 18 psI)
O.S m
o Also, the cap must hold t he re lief pressure for at
least 6 seconds.
* If the cap cannot hold the pressure, or if the relief
pressure is too high or too low, replace the cap with
a new one.
3-12 COOLING SYSTEM
Filler Neck Inspection

- Check the radiator fil ler neck for signs of damage.
- Check the conditio n of the top a nd bottom sea ling
seats in the fi lle r neck. They must be smooth a nd
dean for the radiatOl' cap to fu nction properly.
A. Breather Hose
A. Bottom Sealing Seat B. Top Sealing Seat
Cooling Hoses. Breather Hose Inspection

- In accordance with the Periodic Maintenance Chart,
visually inspect the hoses for signs of deteriorabon.
Squeeze the hose. A hose should not be hard and
brittle, nor should it be soft or swollen.
- Replace a ny damaged hose.
Cooling Hoses, Brea ther Hose

Installation Notes
- Install the cooling hoses or breather hose being
careful to follow the preformed bends (see Exploded
View and Cable Routing in the General Informat ion
chapter). Avoid sharp bending. kinking, flattening, or
twisting.
- Tighten the hose damps securely,
A. Cooling Hoses B. Breathe r Hose

ENGINE TOP ENO 4 -1
Engine Top End

Table of Contents
Exploded View .... ....... .•... ..... ... .. ......... _, _..... ... ............... .... ....... . 4-2
Specifications .. .... ... .. .. ... ........ ... ........ .... ....... .......... ....... ......... .. 4-4
Special Tools .................................... .. .... .. ... .. .......... ............... . 4-6
Cylinder Head .... . " .... , ... ...... . " .. , ..... ' ... .. , ..... , ...... ....... .. ,_ ......... .. .
Cylinder Compression Measurement .......... .. .. ......... ..... ....... . .
4-7
4-7
II
Cylinder Head Removal ........... .. .... .... ... ... ... ......... .. ... ... ....... . 4-7
Cylinder Head Installation Notes .......................... .............. .. 4-7
Cylinder Head Warp Inspection ..... ..... ... ... ..... ..... ..•• ... .. ... ..... . 4-8
Exhaust Valve IKIPS) .......... _.... _......... . _...... . _.. _._ ... _.. .. __ ...... _.. _._ .. 4-8
Exhaust Valve Removal .......................... ............ .. ...... ....... . 4-8
Exhaust Valve Insta llation Notes .. ............. ............. .... .. .. .. .. 4-10
Cylinder, Piston ...... ........ ..... .. .. .. ...... .. ...... .... ......................... .. 4-12
Cylinder Removal ................................................. ..... .. ... .. 4-12
Cylinder Installation Notes .. .... ........ .. .. ............ .. ........... ..... . 4- 12
Piston Removal .. ............ ....... ...... ............. ....................... . 4-12
Piston Installation Notes ............. ......................... _........... . 4-13
Cylinder Wear Inspection .................. ........ ........... ... .. ........ .. 4-14
Piston Diameter Measurement ..... ..... ................ ... ........... ... .. 4-14
Piston /Cylinder Clearance .... .. ................................ ............ .. 4-15
Piston Ring, Piston Ring Groove Inspection ......................... .. 4 -15
Piston Ring End Gap Inspection ........................... .. ... .. .. .. ... .. 4- 15
Piston, Piston Pin. Connecting Rod Wear Inspection ....... .... . .. 4-16
Muffler (Expansion Chamber, Silencer) .... ..... ... .. .. .. ......... ... ...... . .. 4-16
Expansion Chamber Removal ............ ...... ..... .......... ... ... .... .. . . 4-16
Expansion Chamber Installation Notes ....................... .. .. .. .. . .. 4-16
Sil ence r Packing Change ......... ... .................... _.................. .. 4-16
4-2 ENGINE TOP ENO
Exploded View
KX1 25:
o
~~
T1 : 25 N·m (2.5 kg ·m. 18 fHbl
T2: 8 .3 N·m (0 .85 kg·m. 74 In·lbl
T3: 26 N-m 12.7 kg -m. 20 fHbl
T4: 34 N-m (3.5 kg-m. 26 ft-Ibl
ENGINE TOP END 4-3
KX250 :
. /J
~C)
8 ~
C)
ij ~
~~ /'J~,.PJ
~v
~
T1 ." 25 N-m 126 k g m

T2: 26 N-m 12-7 k - , 18 ft-Ibl
T3: 9 .8 N-m (; 0 :-m, 20 fHb)
5.
T4: 34 N-m (3 k g-m . 87 In -Ibl
T5 : 16 N-m 115 g-m . 25 ft -Ib)
. kg-m. 11 ft-Ibl
4-4 ENGINE TOP END
Specifications
KX125 :
Cylinder Head:
Cylinder compression (usable range) ---
770 - 1200 kPa
17 .7 - 12 kg/em' , 109-171 psi)
Cylinder head warp --- 0 .03 mm
Cylinder, Piston :
Cylinder inside diameter 56.020 - 56.035 mm 56.10 mm
Piston diameter 55.935 - 55.950 mm 55.79 mm
Piston /cylinder clearance 0 .071 - 0 .091 mm ---
Piston ring /groove clearance 0 .04 - 0.08 mm 0 . 18 rnm
Piston ring groove width 0 .83-0.85 mm 0 .93 mm
Piston ring thickness 0.77 - 0.79 mm 0 .7 mm
Piston ring end gap 0 .15-0.35 mm 0 .7 mm
Piston pin diameter 15.995 - 1 6 .000 mm 15.96 mm
Piston pin hole diameter 16.000- 16.020 mm 16.07 mm
Small end inside diameter 21.003 - 21.014 mm 21.05 mm
ENGINE TOP END 4-5
KX250:
Cylinder Head:
Cylinder compression (usable range) ---

840 - 1300 kPa
18.4 - 13 kg/em ' . 119 - 185 psi)
Cylinder head warp - -- 0 .03 mm
Cylinder. Piston:
Cylinder inside diameter 67 .400-67.415 mm 67.48 mm

Piston diameter 67.336 - 67.351 mm 67.23 mm
Piston/cylinder clearance 0 .054 - 0 .074 mm ---
Piston ring/groove clearance 0 .04 - 0.08 mm 0 . 18 mm
Piston ring groove width 1.03 - 1.05 mm , . 10 mm
Piston ring thickness 0 .97 - 0 .99 mm 0.9 mm

Piston ring end gap 0 .15 - 0.35 mm 0 .7 mm
Piston Pin diameter 17 .995 - 18.000 mm 17.96 mm
Piston pin hole diameter 18 .000 - 18.020 mm 18.07 mm
Small End inside diameter 22.003 - 22.014 mm 22.05 mm
4-6 ENGINE TOP ENO
.............. ... ..... .... ........ ........ .................. .
Special Tool
.............................................................
Comprellion Gauge: 67001 ·221 Piston Pin PuMer Assembly : 57001 ·910
o
o
o
Adapter: 6700 ' · 1169 Pi, ton Ring Pllers: 57001 · 115
ENGINE TOP ENO 4-7
Cylinder Head Removal

Cylinder Head - Drain the coolant (see Coolant Change in the
Cooling System c hapter).
Cylinder Compression M easurem ent - Remove the fo llowi ng parts:
- Start the engine Radiator Covers
- Thoroughly warm up the engine so that the engine oil Side Covers
between the piston and cylinder wall will help seal Seat
compre§sion as it does during normal running. Fuel Tank
- Stop the engine. Muffler
- Remove the spark plug. and screw a compression Spark Plug
gauge (special tool) firmly into the spark plug hole. Water Hoses
- With the throttle fu lly open, tum the e ngine over
sharply with the kickstarte r several times until the
compression gauge stops rising; the compression is
the highest reading obtainable .
CytInde< Compression (Usable Rangel,

KX125 : 770 - 12OOkPa 17.7 - 12 kglcm 2 •
109- 171 pol)
KX250 : 840- 1300kPa 18.4 - 13 kglcm 2 •
119- 185 pol)
A. Spark Plug C. Engine Mounting Bracket

B. Water Hoses
- Remove the engine mounting brackets on the cylinder

head.
A. Compression Gauge: 57001-221

B. Adapter: 57001-11 59
* If cylinder compression is higher than the usable

range, check the following:
1. Carbon build-up o n the piston head a nd cylinder A. Engine Mounting Brackets
nead - clean off a ny carbon o n the piston nead and
cylinder head.
2. Cylinder head gasket, cylinder base gasket - use - Remo ve t he cylinder head nuts, and take
only the proper gaskets for the cylinder head a nd off the cylinder head and gasket
base. The use of gaskets of the incorrect thickness
will change the compression.
* If cylinder compression is lower than the usable
range, check the following: Cylinder Head Installation Notes
1. Pistonlcylinder clearance, piston seizure. -Installation is the reverse of removal.
2. Gas leakage around the cylinder head - replace - Replace the head gasket with a new one.
the damaged gasket and c heck the cylinder head - Scrape out any carbon and clean the head with
for warping. a high flas~ int solvent
3. Piston ring, piston fing groove . - Check fO/" a c rust of minerals and rust in the head
water jacket, and remove them if necessary.
4-8 ENGINE TOP END
.. ..................... ......... ... .............. .. ... ...... ...
- Tighten the cylinder head nuts to the specif ied
Exhaust Valve (KIPS)
torque. .............................................................. .
Tightening Torque :
Exhaust Valve Removal
25 N-m 12.6 kg-m. 18 ft - Ibl - Remove the cylinder head (see Cylinder Head Re-
- Tighten the engine mounting bracket nuts to the moval).
specified torque. - Remove the right cover at the cylinder.
- Remove the exhaust valve operating shaft lever nut,
T1ghtenlng Torque :
and take off the shaft lever.
Frame Side : 26 N-m 12.7 kg-m. 20 ft-Ib)
Engine Side : 34 N-m 13.5 kg-m. 25 ft-lb}
CAUTION
-Tighten the spark plug to the specified torque.
Exhaust valve operating shah lever nut for the
Tightening Torque :
KX126 Is leh-hand threads .
27 N·m 12.8 kg·m. 20 ft-Ibl
-Remove the exhaust valve operating rod retaining

Cylinder Head Warp Inspection screw .
• lay a straightedge across the lower surface of the
head at several different points. and measure wa rp KX126
by inserting a thickness gauge between the straight-
edge and the head.
* If warp exceeds the service limit. repair the mating
surface. Replace the cylinder head jf the mating
surface is badly damaged.
A. Shaft lever C. Retaining Screw

B. Shaft lever Nut
A. Straightedge B. Thickness Gauge KX250
Cylnder Head WIK9

Service Umit: 0 .03 mm
A. Shaft lever
B. Shaft lever Nut
C. Retaining Screw
- Remove the cylinder (see Cyli nder Removal).

ENGINE TOP END 4-9
KX125, - Remove the idle gear.
-Pull out the operatin g rod as far as it goes. - lift up the exhaust valves, and remove the O-rings
- Remove the idle gear. and va lve guides .
~---
A.Exhaust Valve
B.ldle Gear A. Exhaust Valve D. Valve Operating Rod
CExhaust Va lve Operating Rod B. D-Ring E. Id le Gea r
D .Retaining Sc rew C. Va lve Guide
-Remove the valve operating rod retaining sc rew. - Remove the valve operating rod retaining screw .
• Pull out the exha ust valve operati ng rod . - lift up the exhaust valves, and pull out the va lve
- Remove the right and left exhaust va lves. operating rod .
- Unbolt the resonator. -T ake out the exhaust valves.
- Remove the main exhaust valve cover bolts, and
remove the cover and gasket.
A, Resonator
KX250 ,
- Up side down the cylinder. A. Cover B. Gasket
- Remove the plug and gasket.
-Remove the mounting bolts, and remove the main
exhaust valve.
A. Plug B. Casket
. Push in the operating rod as far as it will go . This
cause to align the punch marks on the exhaust
valve with the notch on the operati ng rod (see A. Bolts B. Main Exhaust Valve
Exhaust Valve Installation Notes).
4-10 ENGINE TOP END
Exhaust Valve Installation Notes KX250

elnstallation is the reverse of removal.
- Scrape out any carbon and clean the valves with a
high fla sh-poi nt solvent.
-Check the exhaust valves and valve operating rod
for signs of damage. If necessary. replace them with
new ones.
- Check the gasket and oil sea l on the rod sea l plug
for signs of damage. If necessary. replace them with
new ones.
- Check the O-rings on the va lve guides for signs of
damage. If necessary. replace them with new ones.
- Be careful not to mix up the right and left exhaust
valves . The right valve has an identifing groove.
A. Groove
- Apply a 2-stroke engine oil to the following:

Exhaust Va lve Upper and lower Journa ls
Exhaust Valve Pinions
Va lve Guides (inside)
KX125 Valve Ope rating Rod Journals
Valve Operating Rod Rack
- Apply a high temperature grease to the oil sea l lip
on the operating rod .
- Adjust the exhaust valve position in accordance
with the following procedure.
oFor KX125 model; after installing the rod retaining
screw in the cylinder with the valve operating rod.
pull the rod to the right side as far as it will go.
oE ngage the left va lve pinion with the rod rack 50
that the punch mark on the pinion is positioned
toward the front of the engine. The punch mark
on the valve pinion should align with the groove on
the rod .
0ln5tall the id le gear 50 that the punch mark on
the idle gear pinion aligns with right valve pinion
A. Groove punch mark .
KX125 Model Exhaust Valve Operating Rod Installation
1. Exhaust Valve
2. Id le Gear
3. Punch Mark
4. Guide
ENGINE TOP END 4-11
aFar KX2S0 model; tighten the main exhaust valve OE ngage the va lve pinions w it h t he rod rack so t hat
bracket mounting bolts secu rely. Check th a t the re t he punch ma rks on t he pi n ions are posi t ioned to-
is no gap between the bracket and cyli nder. ward t he front of the engine. The ponc h marks on
the valve pinions should a lign with the groove on
the rod ,
1
NOTE
oTne marked tooth ;s identified by its shape also.
00
1. No Cap
2. Bracket 1. Ma rked tooth
3. Main Exha ust Valve 2. Ponc h Ma rk
KX250 Model Exhaust Valve Operating Rod Installation
4 1
4
o
3
1. Idle Gear
2. Right and l e ft Exhaust Va lve
3. Pu nch Ma rk
4. Groove
OCheck the gasket o n the left plug for signs of
damage. If necessary, replace it with a new one.
Olnstall the Jeft plug on t he cylinder, and t ighten
it to the specified torq ue .
Tightening Torque
15 N-m 11.5 kg-m. 11 ft-Ibl
4-12 ENGINE TOP END
............................................................... Cylinder Installation Notes
Cylinder. Piston -I nstallation is the reverse of remova l.
............................................................... - Scrape a ny carbon out of the ex hau st port.
- Check for a crust of minerals and rust in the cylinder
Cylinder Removal water jacket. a nd remove them if necessary.
- Drain the coolant - Replace the cylinder base gasket with a new one.
' Remove the following parts: - Apply engine oil to the piston surface, piston rings
Cylinder Head and cylinder bore.
Clutch Cable lower End (KX125) -Check to see that the pin in each piston ring groove
' l oosen the clamps, and pull the ca rburetor out of is between the ends of the piston ring, and fit the
the holder and the air cleaner duct (KX250). base of the cylinder over each ring, pressing in on
- Remove the carburetor holder mounting bolts, and oPfX>Site sides of the ring as necessary. Be certain that
pull the hol der out 1.0 the rear (KX250). the rings do not slip out of position.
- Remove the right cover at the cylinder. - Tighten the cylinder nuts to the specified torque.
- Remove the shaft lever mounting bolt or nut, and
take off the shaft lever. T.ghtenlng Torque :
KX125 : 25 N·m 12.6 kg-m. 18 fHbl
KX250 : 34 N·m 13.5 kg·m. 25 fHbl
- Tighten the shaft lever nut to the specified torque.

Tightening Torque
KX126: 8 .3 N-m 10.85 kg-m . 74 in-Ibl
KX260: 9 .8 N-m 11 .0 kg-m. 87 in-tb)
- Refer to Carburetor Insta llation Notes in the Fuel

System chapter for carburetor installation.
A. Shaft l eve r
CAUTION
Piston Removal
Exhaust valve operating shaft lever nut for the
- Remove the cylinder.
KX125 has left·hand threads.
- Stuff a clean cloth into the cra nkcase opening around
the connecting rod so that no parts will fall into the
crankcase.
' Remove the cylinder nuts . - Remove one o f the piston pin snap rings with needle
- lift off the cyH nder. and remove the cy linder base
gasket. If necessary, tap lightly around the base of nose pliers.
- Remove the piston by pushing the piston pin out the
the cyli nder with a plastic ma llet, taking ca re not side from which the snap ring was removed. Use a
to damage the cylinder.
piston pin pu ller assembly (special toot), if the pin
is tighl
A. Plastic Ma llet
- Re move the exhaust va lves from the cylinder.

A. Piston Pin Pu ller Assembly: 57001-910
ENGINE TOP ENO 4- 13
' Remove the piston ring(s) with piston ring pliers - When installing the piston ring on the piston, note
(special tool). If the special tool is not available, the following:
carefully spread the ring opening with you r thumbs o lf installi ng the piston ring by hand. first fit one
and then push up on the opposite side of the ring to end of the piston ri ng agai nst t he pin in the ring
remove it. groove, spread the ring opening with the other
hand and then slip the ring into the groove.
o The piston ring ha ve a mark on its upper surface.
o lnstalJ the ring so t ha t the pin in the piston ring
groove is between the ends of the piston ring.
Piston Ring Position
A. Piston Ring Pliers: 57001 -115
1. Pin
Piston Installation Notes

- Installation is the reverse of removal.
- Apply 2-stroke engine oil to the connecting rod nee-
- Stuff a dean cloth into the crankcase opening
dle bea ring and the piston pin .
around the connecting rod so that no parts will fall
-I nstall the piston and piston pin . The arrow on the
into the crankcase.
top of the piston mu st point toward the front.
- Scrape any ca rbon off of the piston, then lightly
- When insta lling a piston pin snap ring, compress it
polish the piston with fine emery cloth .
on ly enough to install it and no more.
- Clean ca rbon and dirt out of the piston ring grooves
using a su itable tool .
CAUTION CAUTION
Carbon particles can be very abrasive to piston 00 not reuse snap rings. as removal weakens and
rings. Don ' t allow such particles to fall onto the deforms them . They could fall out and score the
cylinder walls . cylinder wall.
4-14 ENGINE TOP ENO
- Fit a new piston pin snap ri ng into the side of the Cylinder InskSe Diameter
piston so that the ring opening does not coincide 10(126,
with the notch in the edge of the piston pin hole. Standard: 56.020-56 .035mm. and less
than O.Olmm difference between
any two meast.r8ments.
SetvIce Umit, 56.1Omm, Of more than O.05mm

diffefence between any two
measurements.
KX250,
Standard, 67 .400 - 67 .415mm. and less
than O.Olmm difference between
any two I1"Ie8SW8ments.
Servtce Umit: 67 .48mm. Of more than O.05mm

dlffefence between any two
A . Arrow C. Ring Opening measments.
B. Snap Ring D. Notch
Piston Diameter Measurement

• Measure tile outside diameter of the piston 16 mm
Cylinder Wesr Inspection (KX125) or 20.5 mm (KX250) up from the bottom of
the piston at a right angle to the direction of the
piston pin.
NOTE * If the measurement is under the service limit re-
place the piston.
oMeasu re the cylinder inside diameter when the
cylinder is cold (room or ambient temperature). PIston Diameter
- Inspect the inside of the cylinder for scratches and 10(125,
abnormal wear. Standard, 65.935-65.960 nvn
* If the cylinder is damaged or badly worn, replace it SetvIce Umit, 55.79 mm
with a new one.
- Since there is a difference in cylinder wear in 10(260,
different directions, take a side-to-side and a front- Standard, 67 .336- 67 .351 mm
to-back measurement shown in the figure. Service Umtt: 67.23 mm
* If any of the cylinder inside ' diameter measure-
ments exceeds the service limit, the cylinder must
be replaced with a new one since the ELECTRO- Piston Obimeter Measurement
fUS ION cylinder cannot be bored or honed.
CyInder Inside Diameter Measurement
c,..<J.-+ ®
® : KX125 - 18 mm ® ' KX125 - 16 mm

KX250 - 30 mm KX250 - 20.5 mm
ENGINE TOP END 4- 15
Piston/Cylinder Clearance
The piston-to-cylinder clea ra nce is measured
whenever a piston or cylinder is replaced with a new
one. The standard piston-to-cylinder clearance must
be adhered to whenever the cylinder is replaced.
If only a piston is re placed, the clearance may ex-
ceed the standard slightly. But it must not be less
than the minimum, in order to avoid piston seizure.
The most accurate way to find the piston clearance
is by making separate piston and cylinder diameter
measurements and then computing the difference
between the two values. Measure the piston diameter
as just described, and measure the cylinder diameter
at the very bottom of the cylinder.
A. Thickness Gauge
Plstonl~ Clearance
10(125: 0 .071 - 0 .091 mm
Piston Ring End Gap Inspection
KX250: 0 .059 - 0 .079 mm • Place the piston ring inside the cylinder, using the
piston to locate the ring SQuarely in place.
• Set it close to the bottom of the cylinder. where cyl-
Piston Ring, Piston Ring Groove Inspection inder wear is low.
• Visually inspect the piston rings and the piston • Measure the gap between the ends of the ring with
ring grooves. a thickness gauge.
* If the rings are wom unevenly or damaged. they * If the gap is wider t han the service limit. the ring is
must be replaced. overworn and must be replaced.
* If the piston ring grooves are wom unevenly or
Piston Ring End Gap
damaged, the piston must be replaced and fitted with
neYI rings. Standard: 0 .15- 0 .35 mm
• Check for uneven groove wear by inspecting the ring Service Umtt: 0 .70 mm
seating.
* The rings should fit perfectly parallel to the groove Ring End Gap Measurement
surfaces. If not, the piston must be replaced.
• With the pistoo ring in its groove. make several
measurements with a thickness gauge to determine
piston ringlgroove clearance.
*If the clearance exceeds the service limit, measure
the th ickness of the piston ring.
o ,
* If the ring has wom down to less t han the service
limit, replace the ring; if the groove width exceeds
the service limit, replace the piston.
Piston Ring/Groove Clearance

Standard: 0.04 - 0 .08 mm
Service Limit: 0.18 mm
Piston Ring Thickness
Standard: KX125: 0 .77 - 0.79 mm 00
KX250: 0 .97 - 0.99 mm
Service Umit: KX125: 0.7 mm
KX250: 0 .9 mm
Piston Ring Groove Width
Standard: KX125: 0.83-0.85 mm
KX250: 1.03 - 1.05 mm
Service Umit: KX125: 0.93 mm 1. Piston Ring 3. Thickness Gauge
KX260: 1. 10 mm 2. Cylinder Block
4 · 16 ENGINE TOP END
Pis ton, Piston Pin,

Connecting Rod Wea r Inspec tion Muffler (Expansion Chamber. Silencerl
• Visually inspect the snap ring still fitted in place.
* If the ring shows weakness or deformation. replace Expansion Chamber Removal
the ring. Also if the pin hole groove shows exces-
- Remove the right side cover.
sive wear, replace the piston.
- Remove the silencer.
• Measure the diameter of the piston pin with a micro-
meter.
* 11 the piston pin d iameter is less than the service
limit at any point, replace the piston pin.
• Using a cylinder gauge, measure the diameter of
both of piston pin holes in the piston and the in-
side diameter of the connecting rod small end.
* If either piston pin hole diameter exceeds the
service limit. replace the piston.
* If the connecting rod small end inside diameter ex-
ceeds the service limit. replace the crankshaft as-
sembly.
Piston PIn Diameter

KX125: A. Silencer B. Mounting Bolts
Standard: 15.995- 16.000 mm
Senllce Umk : 15.96 mm
KX250: - Remove the exhaust pipe holding springs.
- Remove the muffler damper mounting bolt, and
Standanl: 17.99 5- 18.000 mm
pull off the expansion chamber toward the front
SenllceUmk: 18.96 mm
PIston PIn Hole Diameter

KX125:
Standard: 16.000 - 16.020 mm
SenllceUmk: 16 .07 mm
KX250:
Standard: 18.000 - 18.020 mm
Smal End Inskte DIameter

KX1 25 :
Standard: 21 ,003 - 21.014 mm
Service lintt: 21.06 mm A. Muffler Damper Mounting Bolt
KX250: B. Exhaust Pipe Holding Springs
Standard: 22.003 - 22.014 mm
Expansion Chamber Installation Notes

- Scrape any carbon out of the expansion chamber.
- Check the exhaust ().rings for signs of damage. If
necessary, replace them with new ones.
Silencer Packing Change

Replace the silencer packing if the exhaust noise
becomes too loud or the engine performance drops.
- Remove the inner pipe mounting bolts, and pull the
inner pipe out toward the rear.
A. Snap Ring B. PistCKl Pin
ENGINE TOP END 4-17
A. Mounting Bolts B. Inner Pipe
. Pull off the o ld silencer packing, and install the new

silencer pack ing into the si l encer.
A. Silencer Packing
- Instal l inner pipe into the silencer.

-I nstall the silencer.
ENGINE RIGHT SIDE 5-1
Engine Right Side

Table of Contents
Exploded View ............ .. ........•............. •...... ... .•.. ..... .....•.......... .. 5-2
Specifications ... ........ .... ....... ...•••. ......... _,_........ .••... ....... .... ........ 5-4
Specia l Tool s .......................... ........ .. .. .......... .......... .. .. ............. 5-4
Right Engine Cover ....... .. ...... ............ _, ..... ,......... ,_.,.... ............... 5-5
Right Engine Cover Removal ... .. ... ..... .... ..... ...... ... .•• ... ....... ... 5-5
Right Engine Cover Installation Notes ........ .... ..................... ,. 5-5
Right Engine Cover Disassembly ................. ,_ .. _, .... _,............. 5-6
Exhaust Advancer Assemb ly Disassembly/Assembly Notes.. .. ... 5-7
Right Eng ine Cover A ssembly Notes .... .. ........... ...... ............. 5-8
Clutch .... ... ............. ....................................•..................... ..•.... 5-9
Clutch Adjustment ............. ..... .... .•........ . .•.... ..... .••... .... ... .... 5-9
Clutch Removal /Disassembly ........................................... ... . 5-9
Clutch Installation Notes .. ............... ......................... .. .... .. . 5- 11
Friction and Steel Plate Wear, Damage Inspection ................. 5- 12
Friction and Steel Plate Warp Inspec tion .. .. ............ ... .. .... ...... 5- 12
Clutch Spring Free length Measurement .. .. .. ... ..... ................. 5- 12
Clutch Plate/Clutch Housing Clearan ce ................ ................. 5- 13
Clutch Hub Spline Inspection .......... .. ...... ......... ..... .. .. .. ......... 5- 13
External Shift Mechanism ... ....... ....... .. .. .. ... ... .... .......... ............... 5-13
External Shift Mechanism Removal ... .. ....................... ... ....... .. .. .. . 5- 13
External Shift Mechani sm Install ation Notes ............ ... .••. ... ... .. ..... 5- 13
External Shift Mechanism Inspection ... .......... .......... .. ... .. ............ 5- 14
Primary Gear ............................ ....... .......... ....... ....... ................. 5- 14
Primary Gea r Removal ... .. .......... .......... .............. ................. 5-14
Primary Gear Installation Note s ..... .......... ............ ................. 5- 15
Kick Starter ................................................. ,....... ... ...... ....... ... . 5-15
Kick Shaft Assembly Removal ...... .. .... ........ ... ..... ..... .......... .. 5-15
Kick Shaft Assembly Installation Notes ....... ...... .. .. ... ........ .. ... 5-15
Kick Shaft Assembly Disassembly/Assembly Notes ....... ......... 5- 16
Kick Starter Idle Gear Removal Notes ........ ..... ............. .. ..... .. 5- 16
Kick Starter Idle Gear Installation Notes ... .. ....... .... .. .. .. .......... 5- 16
5-2 ENGINE RIGHT SIDE
.............................................................
Exploded View
.............................................................
KX125 :
c/J
V
~~
04
0 %$% _ 1
~t#. V.../l.X~
o.
AOo ~
o ~ ~~
~ ~
~~ ©
T1 :
~~
9 .8 N-m (1.0 kg-m. 87 In-Ib) T7 : 22 N-m {2 .2 kg-m. 16.0 ft-Ibl
T2: 9.3 N-m 10.96 kg-m. 82 In-Ibl L: Appty 8 non-permanent locking agent to
T3: 88 N-m 19 kg-m. 86 ft-Ibl the threads.
T4: 8.3 N-m 10 .86 kg-m. 74 In-Ibl M: Apply molybdenum disulfide gr88s8 .
T6: 3 .9 N-m 10.4 kg-m. 35 In-Ib) G: Apply high temperature grease .
T6 : 69 N-m {6.0 kg-m. 43 ft-Ibl 0: Apply transmission 011.
ENGINE RIGHT SIDE 5 -3
KX250 :
l: Apply a non-permanent locking agent to the

threads .
M : Apply molybdenum disulfide grease .
G: Apply high temperature grease .
0 : Apply transmission oil.
T1 : 8.8 N-m (0.9 kg-m. 78 in-Ibl
T2: 9 .8 N-m (1.0 kg-m . 87 In-Ib)
T3: 98 N-m 110 kg-m. 72 ft-Ibl
T4: 3.9 N-m (0 .4 kg-m . 35 In-Ibl
T5: 22 N-m 12.2 kg-m . 16 ft -Ibl
Specifications
Item Standard Service Limit
Clutch:
Clutch lever free play 2 - 3 mm ---
Clutch spring free length: KX125 37.5 mm 36.1 mm
KX250 40 .7 mm 39.0 mm
Steel plate thickness 1.41 - 1.59mm 1.31 mm
Friction plate thickness: KX125 2.92 - 3.08 mm 2.7 mm
KX250 2.92-3.08 mm 2.8mm
Friction plate tang width: KXl 25 11.8 - 12.0 mm 11 .3 mm
KX250 13.6 - 13.8 mm 13. 1 mm
Friction plate/clutch housing clear- 0.35 - 0.60 mm 0 .9 mm
ance
Friction and steel plate warp not more than 0 . 15 mm 0 .3 mm
Special Tools
Clrclip Pliers: 57001-144 Flywheel Holder: 57001-1313
Kick Sh.ft 011 Se.1 Guide: 57001-263 Clutch Holde r: 57001-1243
Shift Sh.ft Oil Se.1 Guide: 57001-264

Right Engine Cover - For KX125 model; turn the clutch release lever
toward the rea r and free the release shaft f rom t he
dutch spring plate pusher.
Right Engine Cover Removal - Take off the oil f iller ca p and remove the right
- Drain the transmission oil (see Transm ission O il engine cover.
Change in the Engine Bottom End{Transmission
chapter),
- Drain the coolant (see Coolant Cha nge in the Cool-
ing System chapter).
- Remove the following parts .
Kick Peda l Right Engine Cover Installation Notes
Clutch Cable lower End (KX125 only) -I nsta llation is the re verse of remova l. Note the
Brake Pedal following.
Wa ter Pump Cover - There are two knock pins on the mating surfaces of
Impeller the cra nkcase and right engi ne cover.
- Remove the KIPS cover f rom the right side of the -I n case the exhaust advancer assembly has been
cyli nder. removed, install it and turn the gea r so as to level
-Remove the exhaust valve operating shaft lever the gear drive pin.
nut, and take off the shaf t lever.
CAunON
CAUTION
Exhaust valve operating shaft lever nut for the
KX125 Is leh-hand threads . If the gear drive pin Is not positloned ~vel. it may
fallout when installing the right engine cover.
KX125
A. Shaft lever B. Nut A. Gear Drive Pin (level position)
KX250
- For KX125 model; turn the clutch release lever to-
ward the rear.
- Install the right engine cover using t he kick shaft
oil sea l gu ide (s peci al tool) to protect the cover
oil seal.
A. Shaft lever B. Nut

5·6 ENGINE RIGHT SIDE
- Apply grease to the inside of the brake pedal boss.
- Tighten the brake pedal mounting bolt to the speci-
fied torque.
Tightening Torque
8 .8 N-m (0.9 kg-m. 78 in-Ib)
- Fill the cooling system with coolant (see Coolant

Filling in the Cooling System chapter).
- Fill the transmission with oil (see Transmission Oil
Change in the Engine Bottom End{Transmission
chapter).
- Adjust the fo llowing parts.
Clutch Ca ble (KX125)
A. Kick Shaft Oil Sea l Guide: 57001·263 Rear Brake
-F it the shaft lever boss in the groove of the valve Right Engine Cover Disassembly
operating rod coliar, and insta ll the shaft lever on - Remove the right engi ne cover.
the lever shaft. Tighten the shaft lever nut to the - Turn the lever shaft to the right, and remove the ex·
specified torque. haust advancer assembly.
- Remove the Allen bolts, and take off the advancer
lever.
TIghtening Torque
KX125
• KX126 : : 8 .3 N-m 10.85 kg-m. 74 in-Ib)
KX250 : : 9 .8 N-m 11 .0 kg-m. 87 In-Ib)
it: left-hand threads
NOTE
OTighten the shaft lever nut while holding the valve

operating rod all the way in.
A. l ever Shaft
B. Exhaust Advancer Assembly
C. Allen Bolts
KX250
A. Shaft lever C. Collar

8. Boss D. Valve Operating Rod
-T ighten the water pump impeller bolt to the speci- A. lever Shaft
fied torque. B. Exhaust Adva ncer Assembly
6 .9 N-m fO .7 kg-m . 61 In-Ib) C. Al len Bolts
- Remove the plug screw and take out the position'
ing pin.
- Pull the lever shaft out of the right e ngine cover.
A. Clutch Re lease Shaft
A. Plug Screw C. l ever Shaft

B. Positioni ng Pin
Ex haust Advancer Assembly

Disassem bl y/Assembly No tes
- The exhaust advancer assembly consists of the
- Pull off the water pump shaft (see Water Pump following parts.
Shaft Removal in the Coolin g System chapter).
Exhaust Advancer Assembly
KX125 :
CAUTION
Do not remove the clutch release shaft unless ft
Is absolutely necessary. If removed . you must
replace the 011 88al with a new one .
A. Exha nst Adva ncer Assembl y
A. Clutch Release Shaft B. O il Seal

10(126 - Check the exhaust adva ncer assembly parts for

damage. Any damaged parts should be replaced
with new o nes.
- When assembling, apply molybdenum disulfide
grease between the rod and holder.
Right Engine Cover AssembJy Notes

- Assembly is the reverse of disassembly.
- For KX125 model; in case the clutch release
shaft has been removed, be sure to replace the
oif sea l with a new one.
- Apply high temperature grease to the oil sea l lips
before inserting the lever shaft.
- Apply molybdenum disulfide grease to the su rfa ce
of the lever shaft. a nd insert the lever shaft into
the right engin e cover hole.
- Tighten the advancer lever mounting Allen bolts
to the speci fied torque.
KX250 Tig htening Torque
3.9 N-m 10 .4 kg·m. 35 in-Ib)
- Fit the advancer lever pin into the groove on the
exhaust advancer assembly. and install the as-
sembly in the e ngine cover while turning the lever
shaft to the left,
1. Pins 7. Need le Bearing

2. Rod 8. Spacer
3. Guide 9. Col lar A. Exhaust Advancer Assembly C. Pin
4. O-ring 10. Spring B. Advancer lever D. Groove
5. Steel Balls '1 , Washer
6. Holder 12. Gea r
- Tighten the exhaust va lve advancer shaft plug

screw securel y_
ENGINE RIGHT SIDE 5 -9
Clutch
Proper clutch lever play between the clutch lever

and the clutch lever holder is 2-3 mm. Pl ay in-
crease with cable stretch and friction plate wea r,
necessitating adjustment. When there is too much
lever play, first try adjusting the cable at the clutch
lever.
AWARNING A. Adjusting Nut B. l ocknut
To a void a serious burn , naver touch the hot - Tighten the lock nut.
- Slide the dust cove r ba ck into place.
eng ine or exhau st c ha mbe r during clutch - After the adjustment is made, sta rt the engine and
adjustment.
check that th e clutc h does not slip and that it re-
leases properl y.
Clutch Adjustmen t
- Slide the clutch lever dust cover out of pla ce. Clutch Removal/Disassembly
-loosen the knurled locknut. turn the adjuster to -For KX125 model; remove the dutch cable.
obta in the proper amount of lever play, and tight- - Remove the cl utch cover.
en the locknut
A. Cl utch l ever A. Clutch Cover B. Clutch Cable (KX125)

B. Knurled l ock nut
C. Adjuster - Remove the ma gne to cover.
D. Clutch l ever Free Play 2 - 3 mm - Unscrew the pickup coil mounting sc rews and
remove the pickup coil.
- Slide back the clutch lever dust cover. KX125: KX250 :
* If the adjuster at the clutch lever has reached its
limit, adjust the cable with the ad justing nut at
the upper of the clutch cable.
- l oosen the knurled lock nut at the clutch lever.
- Turn the adjuster in all the way, then tighten the
knurled locknut
- l oosen the locknut at the upper of the cable, and
turn the adj usting nut so that dutch lever has
2 - 3 mm of play.
A. Pickup Coil B. Mounting Screws

- Use the flywheel holder{spec iaJ tooll to prevent the
clutch from rotating, loosen the cl utch hub nut.
A. Needle Bearings C. Thrust Washer

B. Sleeve
A. Flywheel Holder: 57001·131 3
KX250:
- Using the flywh ee l holder (specia l tool) to prevent
KX1 25 the clutch from rota ti ng, remove the dutch spring
- Remove the f lat was her (if provided), clutch pusher
bolts and sp rings.
and spring plate pusher in the clutch hub.
A. Clutch Pu sher A. Clutch Spring Bolts B. Clutch Pressure Plate

B. Flat Washer (If provided)
C. Spring Plate Pusher
O. Sprin g Plate - Remove the clutch pressure plate, push rod holder,
f lat was her (if provided), friction plates, steel plates,
- Re move the clutch hub nut. and push rod .
A. Clutch Hub Nut

A. Pu sh Rod Holder C. Pu sh Rod
- Remove the cl utch assembly. needle bea rings, B. Flat Washer (If provided)
sleeve and thrust was her.
ENGINE RIGHT SIDE 5·"
- Use the clutch holde r (specia l tool) to prevent t he - For KX125 model, repla ce the clutcn hub nut with
clutch hub from rotatin g. a new one.
- Tighten the clutch hub nut to the specified torque .
Tightening Torque
KX1 25: 88 N-m (9 kg -m , 65 ft -Ib)
KX250 : 98 N-m (10 kg-m , 72 ft -Ib)
- For t he KX250 model ; set the pu sh rod bushing

as the following procedures.
a Mea s u re the he ight CD which the bushing
protrudes from the shaft e nd.
A. Clutch Holde r: 57001-1243

B. Clutch Hub Nut
- Remove the clutc h hub nut and washer.

- Remove the d utch assembly, needle bearing. 1. Bushing
sleeve, and th rust washer. 2 2. Pu sh Rod
a lf the height is 1.5 mm or less than it, investigate other

cause than the bu sh ing.
olf the height is more than 1 .5 mm, press the bus hing
into the t ransmission shaft by lightly tapping the
bush ing with a brass hammer until the height is 1.5
mm . Be ca reful not to deform the bu sh ing end.
CAUTION
If the bushing is pressed in so f ar that the height
reduces less than 1.5 mm , the inner c hamfered
end of bushing rides over the stepped portion of
A. Needle Bearing C. Thrust Washe r the drive shaft and the inside diameter of bush-
B. Sleeve ing reduces. In this case the push rod cannot be
inserted into the bushing or slides with dragging .
Clutch Installation Notes

- In st allation is the reverse of removal.
- Appl y molybdenum d isulfide grease to the outside 0After pressing into the bush ing. insert the push rod
of the sleeve. into the drive shaft. Check if the p us h rod can s lide
- Apply tra nsmission oil to the inside of t he clutch smoothly. light dragging can be cured by sanding the
housing gear and kick sta rte r drive n gear. push rod su rface by sand paper.
- Install the frictio n plates and steel plates, starting
with a friction plate a nd alte rnat ing them Finish
with a friction plate. - Apply molybden um disulfide grease to the clutch
spring plate pusher.
- Tighten the clutc h spring bolts to the specified
torque.
CAUTION
If dry steel plates and friction plates are installed.
Tightening torque
apply transmission 011 to the surfaces of each
plate to avoide clutch plate seizure . KX125 : 9 .3 N-m (0.95 kg-m . 82 in-fbi
KX250 : 8.8 N -m (0.9 kg-m . 78 in-lbJ
5· 12 ENGINE RIGHT SIDE
Friction Bnd Steel Plate Wear, Friction ptate Tang Width

Damage Inspection
• Visually inspect the friction and steel plates to see if
they show any signs of seizure, or uneven wear.
*If any plates show signs of damage, replace the fric-
tion plates and steel plates as a set
• Measure the thickness of tile friction and steel plates
with vernier calipers.
ef.Masure the width of the friction plates tangs with
vernier calipers.
*If they have wom past the service limn. replace them
with new ones.
A. Friction Plate Tang
Friction ptate Thickness Friction and Steel Plate Warp Inspection

Standard : 2 .92 - 3.08 mm • Place each fri ction plate or steel plate on a surface
SeMce Umlt: KX125 2.7 mm plate. and measure the gap between the surface
plate and each friction plate or steel plate. The
KX250 2 ,8 mm gap is the amount of friction or steel plate warp.
Steel Plate Thickness * If any plate is warped over the service limit. re-
place it with a new one.
Standanl: 1.41 - 1.59 mm
SeMce UmIt: 1.31 mm
Friction and Steel Plate Warp
Friction Plate Tang Width
StItndard : not more than 0 .15 mm
Standard: KX125 11.8 - 12.0mm
SeMce UmIt: 0.3 mm
KX250 13.6 - 13.8 mm
Friction and Steel Plate Warp Measurement
SeMce UmIt : KX125 13.3 mm
KX250 13.1 mm
CD
Frk:don Pilte 11lk:kneu Measurement
1. Plate 3. Surface Plate

2. Thickness Gauge
Clutch Spring Free Length Measurement

• Since the spring becomes shorter il5 it weakens,
check its free length to determine its condition.
* If any of the springs is shorter than the service
limit, it must be replaced.
1. Friction Plate Clutch Spring Free length

Standard : KX126 37 .6 mm
KX250 40 .7 mm
Service limit: KX125 36 . 1 mm
KX250 39.0 mm
External Shift Mechanism

............. ... ... ....... ............. .. ....... .... .. ........ .
External Shih Mechanism Removal
- Remove the following parts.
Shift Peda l
Magneto Cover
Right Engine Cover
Clutch Housing
- Putt out the external shift mechanism.
A. Clutch Spring
Friction Plate/Clutch Housing Clearance

- Measure the clearance between the tangs on the
friction plate and the fingers of the clutch housing.
* If this dearance is excessive, the clutch will be noisy.
*If the clearance exceeds the service limit, replace
the friction plates.
Friction Plate/Chrtch Housing Clearance

Standard: 0 .35 - 0.60 mm
A. External Shift Mechanism C. Spring
B. Neutral Set Lever O. Bolt
- Remove the bolt, and take off the neutral set

lever.
External Shih Mechanism Installation Notes

-I nsert the shift shaft into the crankcase using the
Clutch Hub Spline Inspection shift shaft oil seal guide (special tool) on the oil seal
-Visually inspect where the teeth on the steel plates in the left crankcase half to protect the seal.
wear against the splines of the clutch hub. oBefore installing the shift shaft, apply high temper-
* If there are notches worn into the splines, replace ature grease to the oil seal lips.
the clutch hub. Also, replace the steel plates if their
teeth are damaged.
A. Clutch Hub Spline A. Shift Shaft Oil Seal Guide: 57001 -264
.... ..... ........ .. .... ..... ........ .. .......... .... ..... ..... .
External Shift Mechanism Inspec tion Primary Gear
• Examine the shift shaft for any damage. .. .. ...... ................ .......................... .......... .
o Check the shift shaft for bending or damage to the
splines. Primary Gear Removal
'fl It the shaft is bent. straighten or replace it If the - Remove the right engine cover (see Right Engine
splines are damaged, replace the external shift Cover Removal).
mechanism. - Remove the clutch (see Clutch Removal).
oCheck the return spI'ing and arm spring for cracks - For KX125 model ; remove the primary gea r nut,
or distortion. spring washer, woodruff key. primary gea r, and
11 If the springs are damaged in any way, replace them. O -ring.
o Check the shift mechanism arm for distortion.
'* If the shift mechanism arm is damaged in any way.
replace the external shift mechanism.
A. Primary Gea r Nut

A. Sh;ft Shaft C. Ann Spring B. Primary Gear
B. Retum Spring O. Shift fv\echa nism Arm
• Check that the retum spring pin is not loose.

* If it is loose, unscrew it, apply a non-pennanerJt
locking agent to the threads. and tighten it to the
specified torque. -Fo r KX250 model; remove the circlip, and take off
the water pu mp drive gea r and primary gea r.
Tightening Torque
22 N-m 12.2 kg-m, 16.0 ft-Ibl
KX250:
• Check the neutral set lever and its spring for
cracks or distortion.
* If the lever or spring is damaged in a ny way,
replace them .
A. Ci rcl ip
B. Water Pump Drive Gea r
C. Primary Gear
ENGINE RIGHT SIDE 5· 15
Primary Gear Installa tion No tes Kick Starter

. lnstalfation is the reverse of removal.
. for the KX125 model ; do the following.
of it the woodruff key on the crankshaft groove. Kick Shaft Assembly Removal
olnstalf the sprin g washer so that concave side faces . Remove the following parts .
inward. Right Engine Cover
Clutch Housi ng
. Pull the end of the kick spring out of the hole in
the crankcase .
KX125:
A. Concave Side B. Woodruff Key
oTighten the primary gear nut to the specified torque. A. Spring

B. Kickstarter Assembly
Tightening Torque
59 N·m 16.0 kg·m , 43 ft-Ib) KX250 :
. For KX250 model; install the primary gear so that

chamfered side faces outward.
A. Kick Spring C. Ratchet Guide

B. Kickstarter Assembly D. Bolt
. Remove the kickstarter assembly .

• Remove the ratchet guide and bo lts.
A. Chamfered Side B. Primary Gear Kick Shaft Assembly Installation Notes

.lnstaiJation is the reverse of removal.
. For KX250 model; replace the old circl ip with a new • Applya non-permanent locking agent to the threads
one. of the ratchet guide bolts.
Kickstarter Assembly
Disassembly/Assembly Notes CAUTION
eThe kickstarter assembly consists of the following
parts. When assembling the ratchet gear onto the kick
- Check the kickstarter assembly parts for damage. Any shaft. align the punch mark on the ratchet gear
damaged parts should be replaced with new ones. with the punch mark on the kick shaft.
KX125:
A. Kick Shaft C. Punch Marks

B. Ratchet Gear
KX260 : - App ly molybdenum disulfide grease to the inside

of the kick gear and ratchet gear.
- Replace the circlips that were removed with new
ones.
Kickstarter Idle Gear Removal Notes

- Remove the right engine cover and clutch housing
before idle gear removal (see Right Engine Cover
Removal and Clutch Removal).
- Remove the idle gea r circlip and pull off the idle
gear.
1. Idle Gear 6. Kick Gear

2. Circlip 7. Kick Shaft
3. Washer 8. Kick Spring
4. Spring 9. Spring Guide
5. Ratchet Gear
A. Idle Cea r B. Ci rclip
Kick Starter Idle Gear Instalfation Notes

-I nstallation is the reverse of removal (see Right
Engine Cover Installation Notes and Clutch Installa-
tion Notes).
- Apply molybdenum disulfide grease to the inside of
the idl e gear.
- Replace the circlip that was removed with a new one.
ENGINE REMOVAL/INSTALLATION 6· '
Table of Contents
Exploded View .. ........ .. ..... ... .. .. ....... .... , ........ ' •.. ........... ' ........ 6-2
Engine Removal/ Installation .... .. ........... ' " ............. ,. , .......... ,.,.. 6-3
Engine Removal .. ... ...... ... ....................... .................... , .. 6-3
Engine Installation Notes ... " ......... .......... ............ ........... . 6-3
6-2 ENGINE REMOVAL/INSTALLATION
.. ... .... .......... ........ .. ... ........ ..... .. .... ......... .
Exploded View
.. ....... ........ ........... ... .... .......... ... ... .. ........
T1 : 26 N-m 12.7 kg-m . 20 ft-Ibl

T2: 34 N-m 13.6 kg-m. 25 ft~bl
T3: 78 N-m 18.0 kg-m. 58 ft~bl
ENGINE REMOVAL/INSTALLATION 6 -3
- Remove the engine mounting bolts.

Engine Remova l/Installation
- Pull out the swing arm pivot shaft
- Uft the engine out to the right.
Engine Removal
-Drain the transmission oil (see Transmission Oil
Change in the Engine Bottom End/Transmission chap-
ter).
- Drain the coolant (see Coolant Change in the Cool-
ing System chapter).
- Remove the following parts.
Right and left Side Covers
Right and left Radiator Covers
Seat
Fuel Tank
Expansion Chamber
Spark Plug
Cooling Hoses
Carburetor (with Cables and Hoses)
Clutch Cable lower End
Drive Chain
Engine Sprocket A. Engine Mounting Bo lts
Shift Pedal B. Swing Arm Pivot Shaft
Brake Pedal C. Jack (57001-1238)
- Disconnect the magneto output lead, and free the

leads from the frame.
- Remove the engine brackets and mounting bolts.
Engine Installation Notes

- Engine installation is the reverse of removal.
- Tighten the nuts to the specified torque.
Tightening Torque
Engine Mounting Nuts :
34 N-m (3 .5 kg-m. 25 ft-lbJ
Engine Bracket Mounting Nuts:
Frame side: 26 N-m (2. 7 kg-m . 20 ft-Ib)
Engine side: 3 5 N-m (3.5 kg-m . 2 5 ft -Ibl
Pivot Shaft Nut :
A. Magneto lead 78 N-m 18.0 kg-m. 58 ft-lbJ
B. Engine Brackets
C. Engine Bracket Mounting Bolts
- To route the leads, cables and hoses, refer to the

- Place a jack under the frame to lift the motorcycle off General Information chapter.
the ground, and put blocks under the front and rear tires - To install parts removed, refer to the appropriate
to steady the motorcycle. chapters.
- Fill the cooling system with coolant (see Coolant Change
in the Cooling System chapter).
- Fill the engine with transmission oil (see Transmission
AWARNING Oil Change in the Engine Bottom End[Transmission
chapter).
The sw ing ann pivot shaft also serves as the en- - Adjust the following parts;
gine mounting bott. Take precautjons to insure the Throttle Cable
frame Is wei supported. and that the motorcycle wi Clutch Cable
not tal over when the pivot shaft is removed. Drive Chain
Rear Brake
ENGINE BOTTOM ENO/TRANSMISSION 7-1

Table of Contents
Exploded View ............... .............. _. _........••......... . ' ............••... ... 7-2

Specifications .................... .. ,' ...................•• •........ _._ ........... _._ .. . 7-4
Special Tools ........ ......... .... .... ..... ............................................ . 7-5
Transmission Oil .. .. .... ....... .... .... ........ ................. .. ........... .. " ..... . 7-6
Oil Level Inspection ............. ... ......... _,_ ........ ......... ... _._ ..... .. . . 7-6
Oil Change ................ ................................. .. .......... .......... . 7-6
Crankcase Splitting ...... , ....... ..... . _. .......... ......... ..... .... ...... ........ .. . 7-7
Crankcase Splitting ............ .. .......... .................................. .. 7-7
Crankcase Assembly ........... .. ............ ..... .... ........... ... .... ..... .
Crankshaft. Connecting Rod ..... ... ....................... ......... ............. .
Crankshaft Removal ... .... .. .......... ... ...................... ............. . .
7-7
7-9
7-9
D
Crankshaft Installation Notes .......... ....................... ........ , .... . 7-9
Crankshaft Disassembly Note ......... .. ................................. .. 7-9
Crankshaft Assembly Notes ... , ............. .. ...... ....... .... ......... .. . 7-10
Connecting Rod Big End Radial Clearance .... ... ......... .. ......... .. 7-10
Big End Seizure ., ........................................ .... .. .. .... .......... . 7- 10
Connecting Rod Big End Side Clearance ........... ... .. ............. .. 7- 10
Crankshaft Runout , ............................................... ............ . 7- 10
Crankshaft Alignment ...... ...... ......... ...... ..... ...... ... ......... ...... . 7- 11
Tran smiss ion , ..................... ...... , ............................................ . . 7- 12
Transmission Shaft Removal ......................................... , .... . 7- 12
Transmission Shaft Installation Notes ................................. .. 7-12
Transmission Shaft Disassembly Notes ............................... .. 7-12
Transmission Shaft Assembly Notes .................................. .. 7-12
Shift Drum and Fork Installation Notes ............ ... ................. . 7-13
Shift Fork Bending ...................................... .... .. ..... .. ... ... ... . 7- 14
Shift Fork/Gear Groove Wear ...................... ........ .. .. ... ....... .. 7- 14
Shift Fork Guide Pin/Shift Drum Groove Wear ................ . .... .. 7- 15
Gear Damage ..................... .. .......... , ............. .................... . 7-15
Gear Dog/Gear Dog Hole Damage ........ ........ .. ... .. ........ .. . ..... . 7-15
Ball Bearing Wear ., .... , ........ , ........... ,., .... .. ... ... ... . , ...... , .•. , ... . 7-16
7· 2 ENGINE BOTTOM END{TRANSMISSION
........ .............. ............ ...........................
Exploded V iew
... ............... .. ........ ......•... ......... .... ..........
KX125 :
ENGINE BOTTOM ENDITRANSMISSION 7-3
KX250 :
T1 : 20 N-m {2 .0 kg -m. 14.5 ft-Ibl

T2: 22 N-m 12.2 kg -m. 16.0 ft-Ibl
7·4 ENGINE BOTTOM ENO/TRANSMISSION
Specifications
Transmission Oil :
Grade SE class ---
Viscosity SAE lOW 30 or lOW 40 ---
Amount : KX 125 0 .7 L ---
KX250 0.8 L ---
Crankshaft, Connecting Rod :

Connecting rod:
Bend and twist not more than O.03mml 0 .20mm / l00mm
100mm
Big end radial clearance :
KX125 0.026 - 0.043 mm 0.10 mm
KX250 0.037 -0.049 mm 0.10 mm
Big end side clearance :
KX125 0.40-0.50 mm 0.70 mm
KX250 0.45-0.55 mm 0.70 mm
Crankshaft runout: KX125,250 under 0.03 mm 0.05 mm
Transmission:
Gear backlash : KX125 0.06 - 0.23 mm 0.33 mm
KX250 0 .02 - 0 .19 mm 0.26 mm
Shift fork finger thickness: KX125 3.9 - 4 .0 mm 3.80 mm
KX250 4.4 - 4.5 mm 4.30 mm
Gear shift fork groove width: KX125 4 .05 - 4. 15 mm 4.25 mm
KX250 4.55-4.65 mm 4 .75 mm
Shift fork guide pin diameter 5.90-6.00 mm 5.80 mm
Shift drum groove width 6.05 - 6.20 mm 6.25 mm
ENGINE BOTTOM END/TRANSMISSION 7-5
Special Tools Shift Shaft Ojl Seal Guide: 57001 -264
Along with common hand tools and precision

instruments, spec ialized tools are required for com-
plete crankshaft/tra nsmission servicing.
Circlip Pliers : 57001 -144
Bearing Puller: 57001 -158
Crankshaft Jig : 57001 -1174
Crankcase Splitting Tool Set : 57001 -1098
Bearing Driver Set : 57001 -1129
Kick Shaft Oil Seal Guide: 57001 -263 Adapter: 57001 - 136
7-6 ENGINE BOTTOM END/TRANSMISSION
.......................................................... '"
Transmission Oil
* If the oil leve l is too high, remove the excess oil
.. ............... .. .. ............ ...... .......... .... .. ...... using a syringe or some other suitable device .
* If the oil level is too low, add the correct amount
In order for the transmission and clutch to function of oil through the oil filler opening. Use the same
properly. always maintain the transmission oil at the type and make of oil that is already in the engine.
proper level and change the oil periodically.
NOTE
o ff the transmission oil type and make are unknown,
AWARNING use any brand of the specified oil to top up the level
in preference to running the engine with the oil level
Motorcycle operatlon with Insufficient. deterio- low. Then at your earliest convenience, change the
rated. or contaminated t,ansmlssIon oil will cause
oil completely.
accelerated wear and may result In transmission
salzure, accident. and Injury.
Oil Change
. Warm up the engine thoroughly so that the oi l will
pick up any sediment and drain easily. Then stop
Oil Leve/ln spection t he engine.
- Situate the motorcycle so that it is perpendicu la r . Place an oil pan beneath the engine.
to the ground. . Remove the transmission oil drain plug on the bottom
-I f the motorcycle has just been used, wait several of the engine, and let the oil drain completely.
minutes un til the oil settles .
- Check that the oil level comes up between the upper NOTE
and lower levels through the oi l level gauge on the
clutch cover. OHoid the motorcycle upright so that the oil may
drain completely.
KX125
C. lower leve l A. Transmission Oil Draim Plug

A. Oi l level Cauge
B. Upper l evel
• Check the gasket at the drain plug for damage.
KX250
*Replace the gasket with a new one if it is damaged.
• After the oil has completely drained out, install the
drain plug with the gasket. and tighten it to the
specified torque.
Tightening torque:
20 N-m (2.0 kg-m. 14.5 fHb)
• Fill the engine with a good quality motor oil
specified.
• Check the oil level.
Transmissbl 01
Grade: SE class
ViscosIty: SAE 10W30 or 10W40
Amount: KX126 0.7 L
A. Oil level Cauge C. lower l evel
B. Upper level 10(250 0 .8 L
ENGINE BOTTOM ENDITRANSMISSION 7 -7
-I nstall the crankcase splitting tool and adapter

Crankcase Splitting (special tools) into the left side of the crankcase.
Be certain to screw the tool in a ll the way.
Crankcase Splitting
- Remove the engine (see the Engine Removal/Instal·
lation chapter),
- Set the engine on a clean surface while parts are
being removed.
- Remove the fo llowing parts from the engine:
Magneto Cover
Output Shaft Sleeve and O-ring
Cylinder Head
Cylinder
Piston
Right Engine Cover
Clutch
Primary Gear
Kickstarter Assembl y
Kickstarter Idle Gear A. Crankcase Splitting Too l Set: 57{X)1·1098
Neutral Set lever B. Adapter: 57001-136
Magneto Flywheel and Stator
Reed Va lve (KX125) - Tighten the bolt on the c ra nkcase splitting tool
to split the crankcase halves.
- Remove the c ra nkcase bolts. - Once the cra nk case is split, remove the crank case
splitting tool, and lift off the left crankcase ha lf .
-Remove the shift rods, shift forks , shift d ru m, and
KX125: output and drive shaft assemblies.
A. Crankcase Bolts A. Drive Shaft D. Shift Drum

B. Output Shaft E. Shift Forks
C. Shift Rods
KX260 :
-Remove the breather hose from the right crank-

case half .
-Remove the crankshaft from the right crankcase
half using a press.
Crankcase Assembly
- Before fitting the left crankcase on the right crank-
case, note the fo llowing.
OChip off the old gasket from the mating surfaces of
the crankcase ha lves, a nd clean off the cra nkcase
with a high fla sh-point solvent. After cleaning,a pply
transmission oil to the transmission gears, shift
A. Crankcase Bolts drum, shift forks and so on .
7-8 ENGINE 80TTOM ENDITRANSMISSION
CBe sure to replace any oil sea l removed with a new - Check to see that the crankcase knock pins are in
one. Press in the new oil sea t using a press and place on the right crankcase half. If any of them has
suitable tools so that the seal surface is flu sh with been removed, replace it with a new one.
the su rface of the crank case. - Apply liquid gasket to the mating surface of the left
oAppJy high temperature grease to the oil seal lips. crankcase half.
oPress in the ball bearings using the bearing driver - Using a suitable tool on the left crankcase to press
set (specia l tool: 57001-1129) until the bearing is around the hole for the crankshaft, fit the crankcase
bottomed. halves together with a press on the tool.
aFor KX125 model; insta ll the bearing for the output
shaft into the left crank case half so that stepped
side faces inside.
NOTE
OConstanrly check the alignment of the two crankcase

halves, and the position of the transmission shafts,
and shift drum. The front and rear of the crankcase
must be pushed together evenly.
1. Stepped Side
NOTE
000 not remove the bearings unless it ;s necessary.

Removal may damage them.
O/nstall the bearings for the crankshaft in the right
and left crankcase so that their sealed sides face
toward the oil seal side.
o Tighten' the output and drive shaft bearing re-

taining bolts securely.
* If the crankshaft bearings stay on the crankshaft
when splitting the crankcase, remove the bearings
from the crankshaft and reinstall them in the
crankcase, and then assemb le the crankcase (see A. Press
Crankshaft Removal and Insta ll ation Notes).
- Turn the crankshaft to BDC, and insta ll the crank-
shaft jig (special tool) between the flywheels
opposite the connecting rod big end to protect
flywheel alignment as shown. • Remove the cra nkshaft jig (special tool) from the
o If the crankshaft has been removed from the flywheels.
crankcase, install the crankshaft jig (specia l tool) - Tighten the crankcase bolts securely starting with
between the crankshaft flywheels before pressing the ones around the crankshaft, and then the
the crankshaft into the right crankcase half. farther ones.
- Check to see that the crankshaft, drive shaft, and
output shaft all turn (reely (in the neutral position).
* If the crankshaft will not turn, probably the crank-
shaft is not centered; tap the appropriate end of
the crankshaft with a mallet to reposition it.
- Spinning the output shaft, shift the transmission
through all the gears to make certain there is no
binding and that all the gears shift properly .
• Install the parts removed in the reverse order of
remova l, and refer to the appropriate chapters.
o Replace the O-ring on the output shaft with a new
one.
A. Crankshaft Jig: 57()()1 -1174

ENGINE BOTTOM END/TRANSMISSION 7-9
Crankshaft. Connecting Rod
Crankshaft Removal
- Split the crankcase (see Crankcase Splitting).
-Remove the transmission shafts (see Transmission
Shaft Removal).
- Using a press, remove the crankshaft from the right
crankcase.
- If the bearings stay on the crankshaft when splitting
the crankcase or removing the crankshaft from the
right crankcase, remove the bearings from the crank-
shaft with a bearing puller and adapter (special tools).
A. Bearing Driver Set: 57001-1129
- Insert the crankshaft jig lspedal tool) between the

crankshaft flywheels opposite the connecting rod
big end to protect flywheel alignment as shown, and
press the crankshaft into the right crankcase.
oWhen pressing, position t~ jig in the crankcase
opening so the jig does not hit the crankcase.
A. Bearing Puller. 57001-158

B. Adapter: 57001-136
Crankshah Installation Notes

- Insta llation is the reverse of removal (see Transmission
Shaft Installation Notes and Crankcase Assembly).
- When insta lling the crankshaft bearings, apply high
temperature grease to the outer sides of the bearings, A. Crankshaft Jig: 57001-1174
and then press them into the crankcase using the
bearing driver set (special tool) until the bearing
bottoms against the step.
- Apply 2-stroke oil to the connecti ng rod big eod
bearing.
Crankshaft Disassembly Note

Since assembly of the crankshaft demands exacting
tolerances, the disassembly and reassembly of the
crankshaft can only be done by a shop having the
necessary tools and equipment
- If it should be necessary to disassemble the crank-
A. Bearing Driver Set: 57001-1129 shaft, use a press to remove the crankpin.
7-10 ENGINE BOTTOM ENOITRANSMISSION
Crankshah Assembly Notes Big End Seizure
Since the assembly of the crankshaft demands ex- * In case of serious seizure with damaged flywheels,
acting tolerances, the disassembly and reassembly of the crankshaft must be replaced.
the crankshaft can only be done by a shop having * In case of less serious damage, disassemble the
the necessary tools and equipment. crankshaft and replace the crankpin, needle bearing.
- Reassemble the crankshaft according to the standard side washers, and connecting rod.
tolerances in Specifications.
o(onnecting rod bend, twist
OConnecting rod big end radial clearance.
OColcf..fitting tolerance between crank pin and fly-
wheels.
OSide clearance between the connecting rod big
end and one of the flywheels.
OCranluhaft runout Connecting Rod Big End Side Clearance
- Measure the side clearance of the connecting rod
with a thickness gauge.
* If the clearance exceeds the service limit. replace
the c rankshaft
Connecting Rod Big End Radial Clearance

• Set the crankshaft in a flywheel alignment jig Of on Coonectlng Rod BIg End Side Ciearanc:e
V blocks, and place a dial gauge against the connect- Standard, 10(125 0.40 - 0.60 mm
ing rod big end.
• Push the connecting roo first towards the gauge and 10(250 0 .45- 0 .55 mm
then in the opposite direction. The difference be- Service Umit: 0 .70 mm
tween the two gauge readings is the radial clearance.
* If the radial clearance exceeds the service limit.
the crankshaft should be either replaced or disas- Side Ciearanc:e
sembled and the crank pin, needle bearing, and con-
necting nxI big end examined for wear.
I Side Oearance
r-T---T-'
Connoc1ing Rod BIg End _ Clearance

Standard,
10(125 0.026 - 0 .043 mm
10(250 0 .037 - 0 .049 mm
Service Uml" 0.1 mm
Crankshaft Runout
- Set the crankshaft in a flywheel alignment jig or on
V blocks, and place a dial gauge against the points
indicated.
- Tum the crankshaft slowly. The maximum difference
in gauge readings is the crankshaft runout.
Crankshaft Runout
Standard: Not more than 0 ,03mm
Service Umit: 0 .05 mm
ENGINE BOTTOM ENO/TRANSMISSION 7 -"
Crankshaft Runout
CAUTION
Don't hammer the flywheel 8t point " A",
®
Vertical Misalignment
Turn the crankshaft

slowly.
r r ¢
u...J 1-1-'
®: KX12S-7.S mm
KX2S0-S.S mm
Q '- \:J
D
*If the runout at either point exceeds the service limit,
align the flywheels so that the runout falls within
!-
the service limit
Jl
t-
Crankshaft Alignment
• In the case of horizontal misalignment, which is the
most common, strike the projecting rim of the fly-
A <:><- '-- ¢
wheel with a plastic, soft lead, or" brass hammer as
indicated in the figure .
• Recheck the runout with a dial gauge, repeating the
process until the runcut fall s within the service limit
o Vertical misalignment is corrected either by driving
a wedge in between the fl ywheels or by squeezing
the flywheel rims in a vise, depending on the nature
of the misalignment In cases of both horizontal and
vertical misalignment, correct the horizontal mis-
alignment first
* If flywhee l misalignment cannot be corrected by
the above method, replace the crankpin or the
crankshaft itself.
Horizontal Misalignment
7-12 ENGINE BOTTOM ENO/TRANSMISSION
..... ......... ..... ......... ..... .. ........ .... ........ .......
Transmission Transmission Shaft Assembly Notes
........ ..... ....... ...... ..... .. ......... .. .................. - Assembly is the reverse of removal.
- Apply transmission oil liberally to the transmission
Transmission Shaft Removal shaft, gears and bearings.
- Split the crankcase (see Crankcase Splitting), - Replace any ci rclips that were removed with new
. Pull out the shift rod, and disengage the shift fork ones.
guide pins from the shift drum grooves. oAlways install circlips so that the opening is aligned
- Remove the shift drum. with a spline groove, and install toothed washers so
- Remove the shift forks from the transmission gears. that the teeth are not aligned with the circlip open-
- Take out the drive shaft and output shaft together, ing. To install a circlip without damage, first fit the
with their gears meshed. circlip onto the shaft expanding it just enough to
install it, and then use a suitable gear to push the
circlip into place.
Clrclip and Toothed Washer Installation
A. Drive Shaft D. Shift Drum

B. Output Shaft E. Shift Forks
C. Shift Rods
1. Teeth of Toothed Washer 4. Opening of Circlip
Transmission Shaft Installation Notes 2. Toothed Washer 5. Circlip
- Installation is the reverse of remova l. 3. Groove of Shaft 6. Shaft
- Hold the drive shaft and output shaft together, with
their gears meshed, and fit them into the right - The drive shaft gears can be identified by size; the
crankcase half. smallest diameter gear is 1st gear, and the largest is
5th (KX250) or 6th (KX125). Be sure that a ll parts are
put back in the correct sequence, facing the proper
direction, and that all circlips and the washer are
properly in place.
Drive Shaft Gears

KX125,
1. 1st gear (14T; part of drive shaft)
2. 6th gear (25T; plain side faces right)
3. 3rd/4th gear (20T/22T; larger gear faces right)
4. 5th gear (24T; has an identifyling groove)
5. 2nd gear (14T; chamfered side faces right)
A. Drive Shaft B. Output Shaft
-To instal l the shift forks and shift drum, see the Shift
Drum and Fork Installation Notes.
5
Transmission Shaft Disassembly Notes
- Us ing circlip pliers (specia l tool: 57001-144) to re-
move the circlips, disassemble the transmission
shaft.
ENGINE BOTTOM ENOITRANSMISSION 7-13
KX250 , KX250,
1. 1st gear (15T; part of drive shaft) 1. 2nd gear (27T; plain side faces left)
2. 5th gear (24T; dog recesses face left) 2. 4th gear (25T; fork groove goes to the right
3. 3rd gear (18T; fork groove goes to the left side of the gear teeth)
side of the gear teeth) 3. 3rd gear (25T; dog recesses face left)
4. 4th gear (22T; dog recesses face right) 4. 5th gear (24T; dogs fa ce right)
5. 2nd gear (16T; either side may face in) 5. 1st gear (32T; dog recesses face left)
5 4
eThe output shaft gears can be identified by size; - Check that each gear spins or slides freely on the
the largest diameter gear is 1st gear, and the transmission shaft without binding after assembly.
smallest is 5th (KX250) or 6th (KX125). Be su re that
all parts are put back in the correct sequence and
facing the proper direction, and that all cirdips Shift Drum and Fork Installation No tes
and washers are properly in place. - Apply a little transmission oil to the shift fork
fingers, and fit the shift fork s into the gear grooves.
Output Shaft Gears
KX125 ,
Shift Fork Ide ntification
1. 2nd gear (241; dog recesses face right)
2. 5th gear (25T; fork groove goes to the right KX125:
side of the gear teeth)
3. 3rd gear (28T; dog recesses face left) Drive shaft 3rd and 4th fingers are shorter than
4. 4th gear (26T; dog recesses fa ce right) gear shift fork those of the other two
5. 6th gear (23T; fork groove goes to the left side shift fo rks
of the gear teeth)
6. 1st gear (30T; plain side faces right) Output shaft 5th gear guide pin goes to left
shift fork side of the fingers
Output shaft 6th gear guide pin goes to right
® ©
7-14 ENGINE BOTTOM ENOITRANSMISSION
- Tighten the shift drum bearing retaining bolts se-

curely _
- Fit the shift fo rk guide pins into the corresponding
® ® © shi ft drum grooves.
- Tighten the sh ift d rum operating plate bolt to the
specified torq ue.
Tightening Torque
22 N-m (2 .2 kg ·m . 16 ft ·lbl
eApply a little transmission oi l to the shift rod, and

slide it into the shift fo rks.
A. Drive Shaft 3rd a nd 4th Gear Shift Fork

B. O utput Shaft 5th Gear Sh ift Fork Shift Fork Bending
C. Output Shaft 6th Gea r Sh ift Fork
- VisuaJJ y inspect the shift fork s, and replace any
KX250: fork that is bent. A bent fork cou ld cause d ifficulty
in shifting, or a llow the transmission to jump out
Drive shaft 3,d gear fingers are shorter t han of gear when under power.
shift fork those of the other two
shift forks
Output shaft 4th gear guide pin goes to left
Output shaft 5th gear guide pin goes to center
shift fork
A.90°
® ® © Shift Fork/ Gear Groove Wear

• Measure the thickness of the s hift fork fingers,
a nd measure the width of the shift fo rk grooves
in the t ransmission gea rs.
* If the thickness of a shih fork fi nger is less than
the service li mit, the shift fork must be replaced.
Shift Fork Finger Thickness

Standard :
KX125 3 .9 - 4 .0 mm
KX250 4 .4 - 4 . 6 mm
Service Limit :
KX125 3 .8 mm
® ® © KX250 4 .3mm
A. Drive Shaft 3rd Gea r Sh ift Fork

B. Output Shaft 4th Gear Shift Fork
C. Output Shaft 5th Gea r Shift Fork
ENGINE BOTTOM ENOITRANSMISSION 7-15
* If any shift d rum groove is worn over the service

limit, the drum must be replaced.
Shift Drum Groove Width

Standard: 6 .05 - 6 .20 mm
Service limit: 6 ,25 mm
A. Shift Fork Finger
* If a gear shift fork groove is worn over the serv-

ice limit, the gear must be replaced .
Gear Shift Fork Groove Width

Standerd:
KX125 4 .05 - 4 .15 mm A. Shift Fork Guide Pin B. Shift Fork Finger
KX250 4 .55 - 4 .65 mm
Service limit:
KX125 4 .25 mm
KX250 4.75 mm
A. Shift Drum Groove
Gear Damage
• Visually inspect the gear teeth on the transmission
A. Gear Shift Fork Groove gears.
* Repair lightly damaged gear teeth with an oilstone.
The gear must be replaced if the teeth are bad ly
damaged .
* At t he same tim e that a gea r is repaired or re-
Shift Fork Guide Pin/Shift Drum Groove Wear placed, t he driving gea r shou ld also be inspected
• Measure the diameter of each shift fork guide pin, and repai red or replaced if necessary .
and measure the width of eac h shift drum groove.
* If the guide pin on any shift fork is less than the
service lim it, the fork must be replaced .
Shift Fork Guide Pin Diameter Gear Dog/Gear Dog Hole Damage
• Visua lly inspect the gear dogs and gear dog holes.
Standard: 5.98 - 6 .00 mm * Replace any damaged gears or gears with exces·
Service limit : 5.88 mm sively worn dogs o r dog holes.
7-16 ENGINE BOTTOM ENO/TRANSMISSION
A. Dog Hole B. Dog
Ball Bearing WeBr

• Check the ball bearing on both sides of the shift
drum, drive shaft and ou tput shaft.
o Since the ball bearings are made to extremely
close tolerances, the wear must be judged by feel
rather than measu rement. Clean each bearing in a
high flash-point solvent. dry it (do not spin the
bearing while it is dry), and oi l it with transmission
oil.
o Spin the bearing by hand to check its cond ition.
* If the bearing is noisy. does not spi n smoot hly, o r
has any rough spots, replace it.
WHEELSITIRES 8 -1
Wheels/Tires
Table of Contents
Exploded View . ......... ... ...... ...... ... _, ........... ... .. ...... ............... ..... . 8-2
Specific ations .......................................................................... 8-3
Special Tools ..... .......... ........ .... ..... ... .. ..... ...... ... ... .... .... .... ... ..... . 8-4
Wheels ... .... ....... ... ..... ... ... ... .... ........... ..... .. .. .. .. .... ....... ... .......... . 8-5
Front Wheel Remova l ....... ......... ...... ........ .... ..... ... .... _. _....... . 8-5
Front Wheel Installation Notes ........... ................... .... _...... " .. 8-5
Rear Wheel Removal ............... , ................... .................. ... . . 8-5
Rear Wheel Installation Notes .... .... ... ........... ..... ..... .. ........... . 8-6
Wheel Alignment In spection .............. ................................. . 8-7
Wheel Alignment Adjustment .. .. ........• ...... ...... ..... ... .. ..•.. ...... 8-7
Wheel In spection
Spoke Inspection ...... ...... ....... ................. .... ... .............. ..... .
Rim Inspection ... .... .... ............................. .. ......... ..... ..... ... . ..
8-7
8-7
8-7
m
Axle Inspection ... .. ......... ... .. .. ... .... .... .... .. .... ...................... .. 8-8
Tires ......... .. ..................... .. ............................................... .... . . 8-8
Tire Removal ................................................................... .. 8-8
Tire Installation Notes ............... ..... .. ...... .... .. ..... ..... ..... ..... .. 8-9
Tire Pressure Inspection/Adju stment ...... ..... .... ............. ....... .. 8-9
Tire Inspection ... ...... .. .. .................................................... .. 8-10
Hub Bearing .. ..... ... .. ... .... ..... ... .. .......................... .............. .. ... . .. 8-10
Hub Bearing Removal Notes ...................... .. .... ........... ........ . 8 -10
Hub Bearing Installation Notes .. .. .......... .. .. ..... .... ....... ... .. .. ... . 8-11
Hub Bearing Inspection and Lubrication ... ..... ... ... .............. .. .. 8-11
Grease Seal Inspection and Lubrication .. ..... ...... .......... .. ...... .. 8-11
8 -2 WHEELSITIRES
... .......... .... ......... ... .... .... ....... .. ......... .... ..
Exploded View
.............................................................
T1 : 54 N-m 15.6 kg-m. 40 ft-Ibl

T2: 9 .3 N·m (0.95 kg-m. 82 in-Ibl
T3: 98 N-m 110 kg-m. 72 ft-Ibl
T4: 1.5 N·m (0 ,15 kg-m, 13 in-Ibl
WHEELSITIRES 8-3
..••... .... . .. ...... . ... ..........•.•. .. .. ... . .. . ...•..•.... ••
Specifications
.... ......... .... ......... .... ............ ..... ....... ........

Wheels :
Rim runout : Axial Under 0 .5 mm 2 mm
Radial Under 0 .8 mm 2 mm
Axle runout! 100 mm Under O. , 0 mm 0 .2 mm
Tires:
KX125:
Front: Size 80/100 - 21 51M ---
Make , type DUNLOP K490 IE) DUNLOP D752 ---
@ <0 BRIDGESTONE M23 ---
Rear : Size 100/90 - 1957M ---
Make, type DUNLOP K695 IE) DUNLOP D752 ---
@<O BRIDGESTONE M22 ---
KX250:
Front: Size 80/ 100 - 2 1 51M ---
Make , type DUNLOP K490 i£) DUNLOP K752 ---
Rear : Size 110/90 - 19 62M -- -
Make , type DUNLOP K695 i£) DUNLOP K752 ---
Air pressure 100 kPal1.0 kg/em ', 14 psil ---
@ : U.S model
C : Canadian model
(£) : European model
8-4 WHEELS/TIRES
Special Tools
Bearing Driver Set: 57001 -1'29 Rim Protector: 5700',' 063
Circlip Pliers : 57001 -143
Bead Breaker Ass'V : 57001 · 1072 Jack: 67001-1238

WHEELSITIRES 8-5
Wheels - The arrow mark on the front axle clamps must point
upward .
-T ighten the upper clamp nuts first, and then tighten
Front Wheel Removal the lower clamp nuts to the specified torque.
- Place a jack or block under the motorcycle so tha t the
front wheel is raised off the ground. rtghtening Torque
- Remove the front disc cover. 9.3 N-m 10.96 kg-m. 82 in-Ib)
- Loosen the left axle clamp nuts, remove the axle, and
pull out the wheel.
A. Axle C. Cap A. Arraw Mark C. low-er Clamp Nuts

B. Collar D. Axle Clamp Nuts B. Upper Clamp Nuts
-I nsert a wood wedge between the disc brake pads.
This prevents them from being moved out of their - Check the front brake for weak braking power and
proper position, should the brake lever be squeezed brake drag.
accidentally.
-Take off the collar and cap from the each side of the .aWARNING
front hub
Do not attempt to drive the motorcycle until a fuI
CAUTION brake tever is obtained by pumping the brake lever
unti the pads are against the disc. The brake wi!
00 not lay the wheel on the ground with the disc not function on the first application of the lever tf
facing down. This can damage or warp the disc . this is not done.
Place blocks under the wheel SO the disc does not
touch the ground. Rear Wheel Removal
- Place a jack or block under the motorcycle so that the
rear wheel is raised off the ground.
Front Wheel Installation Notes
-Remove the ca liper cover, unscrew the caliper
-I nstallation is the reverse of removal. mounting bolts, and remove the caliper from the disc.
-Fit the projection on the cap to the groove on the
collar.
A. Rea r Caliper B. Mounting Bolts

A. Projection C. Colla r
8. Cap D. Groove -Insert a wood wedge between the brake pads this
prevents them from being moved out of their proper
-Tighten the axle to the specified torque. position, shou ld the brake pedal be squeezed
Ttghtening Torque accidentally.
-Re move the clip from the master link using pliers,
54N-m (5.5 kg-m, 40 ft-lb) and free the drive chain from the rear sprocket
8-6 WHEELS/TIRE
Rear Wheel Installation Notes

-Installation is the reverse of remova l.
- Fit the brake holder stop agai nst the swi ng arm stop.
A. Drive Chain B. Clip
-Remove the cotter pi n and axle nut.
A. Brake Holder C. Swing Arm

B. Stop (Brake Holder) D. Sto p (Swi ng A rm)
- Fit the projection on the cap to the groove on the

collar.
A. Axle Nut B. Axle

B. Cotter Pin
.Pull out the ax le, and remove the chai n adjuster,

brake holder, and rear whee l.
-Take off the coll ar and cap from the each side of
the rear hub.
A. Ca p C. Collar
B. Projection D. Groove
-Install the drive chain. Insta ll the master link clip so

that the closed e nd of the "u" points in the direc-
tion of chain rota tion.
..,
rt.
-
.
••
(J
A. Collar B. Cap
-
CAUTION t ~
.'
"- .....
Do not lay the wheelan the ground with the disc
facing down . This can damage or warp the disc . , ,
Place blocks under the wheal so the disc does not
touch the ground . ......... ~ "-,v'
.
~
A. Master link Clip B. Direction of Chain Rotation
WHEELSITIRES 8-7
- Adjust the drive chain slack (see Drive Chain Slack
Inspection in the final Drive chapter).
- Tighten t he axle nut to the specified torque.
AWARNING
Tightening Torque If any spoke breaks. it should be replaced immedi-
98N-m (10 kg-m . 72 h -Ib) ately . A missing spoke places an additional load
on the other spokes. which will eventually cause
- Replace the cotter pin wit h a new one. other spokes to break.
- The caliper mounting bo lts to the specified to rque .
Tightening Torque
25N-m 12.5 kg-m . 18 h-Ib) Rim Inspec tion
- Inspect the rim for sm all cracks, de nts, bending, or
- Check the rear brake fo r weak braking power a nd warping.
brake drag. * If t here is any dam age to the rim . it mu st be re-
pla ced .
- Set a dial gauge agai nst the side of t he rim. and
rotate the rim to measure the axial runou t. The dif·
AWARNING ference between t he highest and lowest d ial
read ings is the a mount of (Unout.
Do not attempt to drive the motorcycle until a full - Set a d ial gauge aga inst the outer circumference of
brake pedal is obtained by pumping the brake pe- the rim,and rotate the rim to measure radial runout.
dal until the pads are against the disc . The brake The difference between the highest and lowest dial
will not function on the first application of the pe- read ings is the amou nt of runout.
dal if this is not done. * If rim runout exceeds the service limit, check the
wheel bea rings firs t. Replace them if they a re
damaged. If the problem is not due to the bearings.
correct the rim warp (runout). A certain amount of
rim warp can be corrected by recente rin g the rim.
l oosen some spokes and tighten others within the
Wheel Alignment Inspection standa rd torque to c ha nge the position of different
- Refer to Wheel Alignm ent Inspection in the final parts of the rim . If the rim is bad ly bent, however.
Drive chapter. it must be replaced .
Wheel A lignment Adjustment Rim Runout Iwlth tire Installed)

-Refer to Wheel Align ment Adjustment in the Final
Drive chapter. Standard Service limit
Axial und er 0.5 mm 2 mm
Radial under 0.8 mm 2 mm
Wheel Inspection
- Place a Jack or block under the motorcycle so that
the fron t/rea r wheel is raised off the ground .
- Spin the wheel lightly. and check for roughness or
binding.
*If roughness or binding is found. replace or lubri-
cate the hub bearings.
- Visually inspect the front and rear axles for damage.
* if an axle is damaged or bent. replace it.
Spoke Inspection
- Check that a ll the spokes a re tightened evenly.
* If spoke tightness is uneven or loose, tighten the
spoke nipples to the specified torque evenl y.
A. Ax ial Rim Ru nou t
Tightening Torque :
1.5N-m {0 ,15 kg-m. 13 in-Ibl
(not over 3N-m (0 .3 kg-m. 26 in-lblJ
- Check the rim runout.
8-8 WHEELSITIRES
Tires
Tire Removal
CAUTION
Do not lay the whee lan the ground with the disc
facing down . This can damage or warp the disc.
ptace block. under the wheel so the disc does not
touch the ground .
A. Radial Rim Runout
- Remove the wheel from the motorcycle (see Wheels).
-To maintain wheel balance, mark the valve stem
Axle Inspection position on the tire with chalk so that the tire can be
• Place the axle in V b locks that are 100 mm apart, reinstalled in the same position.
and set a dial gauge on the axle at a point ha lfway - Take out the valve core to let out the air.
between the blocks. Turn the axle to measure the
runout. The difference between the highest and
lowest dial readings is the amount of runout.
*If runout exceeds the repair limit, replace it.
* If runout only exceeds the service limit. stra ighten
the axle.
* If the axle cannot be straightened to within the
service limit. replace the axle.
Axle Runout/ 100 mm

Standard : under 0 . 10 mm
Service Limit : 0 .2 mm
A. Unscrew valve core. B. Mark valve stem position.

Axle Runout
oWhen handling the rim, be careful not to damage

the aluminum rim flanges.
- loosen the bead protector nul
100.
A. Bead Protector Nut

WHEELSITIRES 8-9
elubricate the tire beads and rim flanges on both Tire Installation Notes
sides with a soap and water solut ion o r rubber lubri- e ln stallation is the reverse of remova l (see Wheels).
cant. This helps the tire beads slip off the rim ePosition the tire on the rim so that the valve is at the
flanges . tire ba lance mark (the cha lk mark made during
removal or the ye llow paint mark on a new tire).
CAUTION
Never lubricate with mineral oil (engine oil) or
gasoline because they will cause deterioration of
the tire.
eBreak the beads away from both sides of t he rim

with the bead breaker (special tool).
A. Balance Ma rk
e Tighten the bead protector nut securely.

e Check and ad just t he air pressure after installi ng.
Tire Pressure Inspection/Adjustment

e Using a tire pressure gauge, measure the tire pressure
when the tires are cold .
* Adjust the tire pressure to suit track conditions and
rider preference, but do not stray too far from the re-
commended pressure.
A. Bead Breaker: 57001-1072
Track Condition Tire Pressure
ow...., ,.... track w., muddy. sandy eo kPa (0.8
epry the tire off the rim wi th tire iron portion of the slippery, reduce" ,.... tire "",,"" '0 kglcm z, 11 psi)
bead breaker (specia l too l) protecti ng the rim wi th
rim protecto rs (specia l tool).
~
increase ,.... ti re tread surface 0' ,h,

ground.
oWhen <h. track
" pebbly 0' ha rd,
Increase <h. tire pressure '0 preven t
damage 0' punctures, though ,h.
1
100 kPa (1.0
lire!; will skid more easily. kglcm 2, 14 psi)
/
A. Rim Protectors: 57001-1063
B. Tire Iron Portion of the Bead Breaker: 57001-1072
A. Tire Pressure Gauge

8- 10 WHEELSITIRE
.................. .............................................
Tire Inspection Hub Bearing
As the tire tread wears down, the tire becomes ... .......... ...... .......................... ..................
more susceptible to puncture and failu re.
- Remove any imbedded stones or other foreign pa rti-
cles from the tread.
- Visually inspect the tire for cracks and cuts, replacing
the tire in case of bad damage. Swelling or high
spots indicate interna l damage. requiring tire replace-
ment. CAunON
Do not lay the wheel on the ground with the disc
facing down . This can damage or warp the disc.
Place blocks under the wheel so the disc does not
touch the ground .
AWARNING
To ensure aafe handling and stability, use only the
recommended atandard tires for replacement. in-
flated to the standard pressure .
Hub Bearing Removal Notes

NOTE - Remove the hub beari ng by t apping evenly around
the bearing inner race as shown .
OCheck and balance the wheel when a tire i, replaced
with a new one.
Standard Tire
KX125 ,
Front : Size 80/100 - 21 S1M
Bearing Removal
Make, Type DUNLOP K490
iEl DUNLOP K752
o C BRIDGESTONE
M23
Rear: 51,. 100/90 - 1957M
Make, Type DUNLOP K695
iEl DUNLOP K752
o C BRIOGESTONE
M22
KX250,
Front : 51,. 80/ 100 - 21 51M
Make , Type DUNLOP K490
iEl DUNLOP K752
Rear: Size 110/90 - 1962M
Make . Type DUNLOP K695
iEl OUNLOP K752
® : US model
Cl: Canadian model 1. Ba r
(l: European model 2. Dista nce Coll ar
3. Hub Bea ri ng
WHEELSITIRE 8 -"
Hub Bearing Ins tallation Notes Hub Bearing Inspection and Lubricar;on
- Before installing the wheel bearings, blow any dirt or Since the wheel bearings are made to extremely
foreign particles out of the hub with compressed air close tolerances, the clearance cannot normally be
to prevent contamination of the bearings. measu red.
- Inspect the bearings and replace them if necessary. - For front hub bearing. tum each bearing back and
Lubricate them and install them using the bearing forth while c hecking for roughness or binding.
driver set (special tool) so that the marked or shielded * If roughness or binding is found, replace the bearing.
sides face out - For rear hub bearing. wash the bearing with a high
ftash-point solvent, dry it (do not spin it while it is
dryl and oil it Spin it by hand to check its condition.
* If it is noisy, does not spin smoothly, or has any
Front Hub Bearing rough spots, it must be replaced.
* If the bearing is to be used again, rewash it with a
quality high fl ash-point solvent Dry it and pack it
with good bearing grease, turning it by hand a few
times to make sure the grease is distributed uni-
formly inside the bearing. and wipe the old grease
out of the hub before bearing installation. Clean
and grease the wheel bearings in accordance with
the Periodic Maintenance Chart.
1 NOTE
oSince the bearings on the rear wheel hub are

pa cked with grease and shielded, they have not to
be lubricated.
Rear Hub Bearing
.~.
.---.,..
- ~
I
A. Crease
, . -- 1
- Examine the bearing seal for tears or leakage.
....
,
<' * If the seal is torn or is leaking. replace the bearing.
A. Bearing Driver Set: 57001-1129 2. Bearing Driver

1. Bearing Driver Holder 3. Bearing Driver
Grease Seal Inspection and Lubrication
If the grease seals are exami ned without removing the
seals themselves, look for discoloration (indicating the
rubber has deteriorated), hardening. damage to the
intemal ribbing. or other damage. If the seal or intemal
ribbing has hardened, the clearance between the seal
and the axle sleeve will not be taken up, which will
allow dirt and moisture to enter and reach the bear-
-I nspect the grease seal and replace if necessary. ing. If in doubt as to its condition and whenever a
Press it in until it stops at the circlip in the hole using seal is removed for greasing the bearing. the seal
the same special tools used for bearing installation. should be replaced. The seals are generally damaged
upon removal.
FINAL DRIVE 9-1
Final Drive
Table of Contents
Exploded View ........ .. , ... .•.... ".,,' " ..... .. .. ...••. ........ _. _..........• .•. ,.. ,. 9-2
Specifi cations 9-3
Special Tool s 9-3
Drive Chain .. .. ........ .............. ..... ... .... ..... •.... ....... _. _... ..... _, _., . ..... . 9-4
Drive Cha in Slack Inspection ..... .. ... . _. _... ..... .... .. ... ...... ...... ... . 9-4
Drive Chain Slack Adjustment ........... .......... ...... .... .. .... ...... .. 9-4
Wheel Alignment Inspection .... .... ..... .......... .............. .......... . 9-5
Wheel A lignment Adjustment .......... ......... , .... .... , .....•. ... ...... . 9-5
Drive Chain Wear Inspection ..... ... ... ......... ..... ........ .... ... ...... . 9-5
Drive Chain Lubrication .. ... .. ...... ... .... .. ........... .... ... ... ......... .. . 9-6
Drive Chain Removal ................ ...... ......... ... .... ..... .. ... ... ...... . 9-6
Drive Ch ain Installation Notes ....... ...................................... .
Sprocket ....... .......... ............ .. ... .... .. ..... ..... ..... ..... ... ... ..... .... ..... .
Engine Sprocket Removal ............ .. ............ ....... .. ... .. ..... .... .. .
9-6
9-7
9-7
m
Engine Sprocket In stallation Notes ............. ... ..................... .. 9-7
Rear Sprocket Rem oval ............... ......... , .. , ............ .. .. . , ........ . 9-7
Rear Sprocket Installation Not es ... .. ..... .. ... ........... ... .. .. ....... .. 9-7
Sprocket Wear Inspect ion 9-7
Sprocket Warp Inspection ....... ...
,", ,", .. ., ... , .. ,",., ....... " .. ,.,.,' 9-8
9 -2 FINAL DRIVE
......... . " ... .... ...... .. ........•. .............. .... ......
Exploded View
............. ............ ..... ....... ..... .. ........... .... ..
T1 : 29 N-m 13.0 kg-m. 22 ft-Ibl

T2: 98 N-m 110 kg-m . 72 ft-Ibl
FINAL DRIVE 9-3
Specifications

Drive Chain:
Make Daido ---
Type : KX125 0 _1.0 520 08-6 ---
KX250 0 .1.0 520 08-5 - --
Length : KX125 '12 Link - --
KX250 114 Link ---
Chain slack 50 - 60 mm Less than 50mm , or
more than 65mm
20·link length 3 17 . 5 mm 323 mm
Sprockets:
Engine sprocket diameter: KX125 50.98 - 51.18mm/ 12T 50 .7 mm
KX250 60 .99 - 61 . 19mm / 14T 60.7 mm
Rear sprocket diameter 232 .62 - 233.12mm/48T 232 .1 mm
Rear sprocket warp Und er 0.4 mm 0 .5 mm
Special Tools
Bearing Driver Set : 57001-' 129

9-4 FINAL DRIVE
* If the chain is too tight, back out the left and right
Drive Chain chain adjusting bolts evenly, and kick the wheel
fOlWard until the chain is too loose.
Drive Chain Slack Inspection * If the chain is too loose, turn both chain adjusting
- Support the motOfcycie on its side stand. bolts evenly until the drive chain has the correct
- Check the wheel alignment (see Wheel Alignment amount of slack. To keep the chain and wheel
Inspection), and adjust it jf necessary (see Wheel properly aligned, the notch on the left chain adjuster
Alignment Adjustment). shou ld align with the same swing arm mark as the
right chain adjuster notch.
NOTE - Check the wheel alignment
- Tighten both chain adjuster locknuts securely.
o Clean the drive chain if it is dirty, and lubricate it if - Tighten the axle nut to the specified torque.
it appears dry.
Tightening T0<qUe
• Rotate the rear wheel to find the position where the
98 N-m 110 kg-m. 72 ft-lb)
chain is tightest
• Measure the vertical movement as shown.
*If the drive chain slack exceeds the standard, adjust - Rotate the wheel, measure the chain slack again
;l at the tightest position, and readjust if necessary.
-I nstall a new cotter pin through the axle nut and
Drive Chain Sieck Inspection axle, and spread its ends.
AWARNING
If the axle nut is not S8CU"efy tightened or the
cottef pin Is not instaIed. an unsafe riding condition
may resuk.
- Check the rear brake for weak braking power, and

brake drag (see the Brakes chapter).
NOTE
A. Drive Chain Slack oJn wet and muddy conditions, mud sticks to the
chain and sprockets resulting in an overly tight
chain, and the chain may break. To prevent thiS,
Drive Chain Slack adjust the chain to 55 - 65 mm of slack whenever
Standard : 50 - 60 mm necessary.
Drive Chain Slack Adjustment

- Loosen the left and right chain adjuster locknuts. Wheel Alignment Inspection
- Remove the cotter pin and loosen the axle nul -Check that the notch on the left chain adjuster aligns
with the same swing arm mark as the right chain
adjuster.
A. Axle Nut D. Marks

B. Adjusting Bolt E. Notch
C. locknut F. Cotter Pin A. Marks B. Notches
FINAL ORIVE 9-5
NOTE
oWheel alignment can also be checked using the

straightedge or string method.
AWARNING
Misalignment of the wheel will resutt In abnormal
wear. and may resutt in 8n unsafe riding con-
dition .
A. Weight B. Measure
Wheel Alignment Adjustment
This procedure is the same as Drive Chain Slack
Adjustment. Drive Chain 20-link Length
Standard: 317.5 mm
DrivB Chain Wear Inspection Service Limit: 323 mm

• Rotate the rear wheel to inspect the drive chain fo r
damaged ro llers. and loose pins and links.
* If there is any irregularity. replace the drive c hain .
* Lubricate the drive chai n if it appears dry.
• Stretch the chain taut by hanging a 10 kg (20 Ib)
weight on the chai n. AWARNING
• Measure the length of 20 links on the straight pa rt of
the chain from the p in center of the 1st pin to the If the drive chain wear exceeds the service limit,
pin center of the 21 5t pin. Since the chain may wear replace the chain or an unsafe riding condition
uneven ly, take meas urements at several pla ces. may result. A chain that breaks or jumps off the
... If any measurements exceed the se rvi ce li mit, re- sprockets could snag on the engine sprocket or
place the chain . Also, re pla ce the front and rea r lock the rear wheel, severely damaging the motor-
sprockets when the drive chain ;s repla ced. cycle and causing It to go out of control.
Drive Chain Wear Inspection
Bushing
RoHer
II
~ \ Pin Link RoHer Li nk
C::O)( G)_ 10
lst 2nd 3rd 4th 20th 21st
I..:::E-----
I- Measure this length - --->>11
9-6 FINAL DRIVE
Drive Chain Drive Chain Installation Notes

·' nsta llation is the reverse o f remova l.
Make Daido - Fit the drive chain ba ck onto the sprockets with the
TVpe : KX 125 0 .1.0 52005-6 ends at the rea r sprocket .
KX250 0 .1.0 520 05-5 - Insta ll the master link from the frame side.
· 'nsta ll the clip so that the closed end of the " U"
links : KX125 112
points in the d irection of, chain rotation.
KX250 114
Drive Chain Lubrication

- If the chain appears especia lly dirty, it should be
cleaned before lubrication with high fla sh point sol-
vent
- Apply oil to the sides of the rollers so that oil wi ll
penetrate to the rolle rs and bushings.
- Wipe off any excess oil.
Drive Chain Lubrication
A. Clip
B. Direction of Drive Chain Rotation
- Adjust the drive chain slack (see Drive Chain Slack

Adjustment).
- Check the brake for weak braking power, and brake
drag (see the Brakes chapter).
_ : Apply oil.
Drive Chain Removal

- Remove the engine sprocket cover
- Remove the clip from the master link using pliers,
and free the drive chain from the rear sprocket.
A, Clip
-Remove the drive chain from the chassis.

FINAL DRIVE 9-7
Rear Sprocket Ins tallation Notes

Sprocket - Insta ll ation is the reverse of removal.
- Insta ll the rear sprocket so that t he marked side
faces out .
Engine Sprocket Removal - Tighten the rear sprocket bolts to the specified
- Remove the following parts. torque.
Engine Sprocket Cover
Drive Chai n(f ree of engine sprocket)
- Remove the cirdip, and pull off t he engine sprocket.
Tightening Torque
Engine Sprocket Installa tion Notes 29 N-m (3 .0 kg-m . 22 ft -Ibl
- Insta llation is the reverse of re mova l.
A. Rear Sprocket C. Rear Sprocket Bolt

A. Engine Sprocket B. Circl ip B. Ma rk
-For KX125 model; insta ll t he sprocket so that the
cha mfered side faces in .
Sprocket Wear Inspec tion

- Visually inspect the front and rear sprocket teeth
for wear and damage.
* If they are worn as illustrated or damaged , rep lace
the sprocket.
Sprocket Wear Inspection
Worn Tooth Worn Tooth

(Engine Sprocket) (Rear Sprocket)
A. Chamfered Side
Rear Sprocket Removal ,

,, \ ,,,
- Remove the rea r wheel (see Rear Wheel Removal in
•, , .... __ . -' ,
the Wheel sfTires c hapter). ,
I ~ •,,
'-- -' to a
CAunON
Do not lay the wheel on the ground with the disc Direction of rotation
facing down . This can damage or warp the disc .
Place blocks under the wheel so that the disc
does not touch the ground .
- Measu re the diameter of the sprocket at the base of
the teeth.
- Unscrew the rea r sprocket bolts, and remove the * If the sprocket is worn down to less than the
rear sprocket. service limit, replace the s procket.
9-8 FINAL DRIVE
Sprocket Diameter Rear Sprocket Warp

Engine : Standard : Under 0 .4 mm
KX125 Service limit: 0 .5 mm
Standard: 50.98 - 51 . 18 mm
Service limit : 50.7 mm
KX250
Standard: 60.99 - 61.19 mm
Service Limit: 60.1 mm
Rear;
Standard: 232.62-233 . 12 mm
Service limit: 232. 1 mm
NOTE
clf a sprocket requires replacement, the chain

;s probably worn also. Wh en replacing a
sprocket. inspect the chain.
Sprocket Warp Inspection

• Elevate the rear wheel so that it will turn freely.
and set a dial gauge against the rear sprocket near
the teeth as shown. Rotate the rear wheel . The
difference between the highest and lowest dial
gauge read ings is the amount of run out (wa rp).
* If the runout exceeds the service limit, replace the
rear sprocket.
Sprocket Warp Inspection
1. Dial Cauge 3. Rotate

2. Rea r Sprocket
BRAKES 10-1
Brakes
Table of Contents
Exploded View .......... .......... ..... , ..... ... .......... ...... , ................... . 10-2
Specifications .. .. ....... _•.. ........•.... ..... .. , ..... .....•..........••• ..... ....... 10-4
Special Tool ...... ................. ... ............................................... .. 10-4
Brakes ........... " ...... " ............. ........... " .......... , ......... ......... .••.... 10-5
Brake Adjustment ... ......... ........... ....................... ...... .......... .. 10-5
Brake Lever/Pedal Free Play/Adjustment ...... , ..... ............ .... . 10-5
Front Brake Lever Play Adjustment ................... ................ . 10-5
Rear Brake Pedal Position Adjustment ..... ........... ....... .. ...... . 10-5
Rear Brake Pedal Play Adjustment ............................ .. ....... . 10-6
Caliper ................................... , .. ........................... ... .... ...... . 10-6
Caliper Removal ............. .. , ................... ........................... . 10-6
Caliper Installation Notes ........ .................................... .... .. 10-7
Caliper Disassembly .......... ............................. .. .............. .. 10-7
Caliper Assembly Notes ..................... .. ........ ................... .. 10-7
Fluid Seal Damage .......................................................... . 10-8
Dust Seal, Cover and Shaft Rubber Fiction Boot Damage ..... . 10-8
Piston and Cylinder Damage ........ ......... .. ......... ... .. ........... .. 10-8
Caliper Holder Shaft Wear .......... .. .............................. ..... .. 10-9
Brake Pads ............. ............. .................................... ......... . . 10-9
10-9
Pad Removal .. ......... ... ...... .... .. ........ ...... .......................... .
Pad Installation ............................................ .... ........... .... .
Pad In spection ... ...... .............. ..... .... ............................. ... .
10-9
10-9
1m
Master Cylinder ...................................... ....... .... ... ..... ......... . 10-9
Front Master Cylinder Removal ......................... ...... ......... .. 10-9
Front Master Cylinder Installation Notes .............. ............. .. 10-10
Rear Master Cylinder Removal .......... ............. ... ...... ......... .. 10-10
Rear Master Cylinder Installation Notes ................. .......... .. .. 10- 1 1
Front Master Cylinder Disassembly ............... ................ .... . 10- 1 1
Rear Master Cylinder Disassembly ....................... .. ........... .. 10- 1 1
Master Cylinder Assembly Notes ..................................... .. 10-12
Master Cylinder Inspection (Visual Inspection) .................... . 10-12
Brake Disc ..................... , ............ .. .......... ...... ........ .. ........... . 10-13
Disc In spection .................... ........ ............................. ...... . 10-13
Brake Fluid .................. ..... ................................................ .. 10-13
Brake Fluid Requirement , ............... ................. .. ...... ... ...... . 10-13
Brake Fluid Level Inspection ......... .................................... . 10-14
Brake Fluid Change .................... ........ ............ ... .... ......... .. 10- 14
Bleeding the Brake Line ................................................... . 10-15
Brake Hose .... ............................... ..... ... ... ..... .................... .. 10-16
Brake Hose Removal/Installation Notes ............... .. .. .......... .. 10-16
Brake Hose Inspection ............... ......... ...... ...................... .. 10- 16
10-2 BRAKES
.............
_~_~~Iod.d ~-I~~-- - - - ----··· .... · ................ .. .... ·
............
Front OTIc Br~~~ " "" " .................... ..... .
o
o
T1 , 25N-m125k
T2 , 8.8 N-m 10 9 :-m.
gm
18 ft-Ib}
T3 , 7 .8 N.m 10'S k · • 781n-lbl
9 .8 N.m '10 kg-m. 69 In-Ibl
T4, 18 N.m 11
T5 ,
8k g-m. 87 In-Ib)
. g-m. 13 ft-Ib}
BRAKES 10·3
Rear D'ose Brake
25 N·m 12.5 kg-m , 18

78 It·lbl
~~ ~ k9~::
in-Ib)
8.8 N-m (O .g 69 In-Ib)
1 8 N·m (0 .8 kg 87 in-Ibl
T3 : 9 ' S N'm (1 .0 kg-m. 13 ft-Ib)
T4
T5 :
: .
1SN-m '1 .8 kg-m.
10-4 BRAKES
........ ......... ........ ........... ........... ... ......... ..
Specifications
... .. ..... ........ .... .. ... ... .... ... ... ..... ................

Brake Adjustment :
Brake lever play Adjustable (to suit rider) ---
Brake pedal position Adjustable (to suit rider) ---
Brake pedal play Adjustable (to suit rider) ---
Brake Pads:
Pad lining thickness: Front 4.5 mm 1 mm
Rear 4 .7 mm 1 mm
Brake Discs:
Disc thickness : Front 2.85 - 3.15 mm 2.5 mm
Rear 4.35-4.65 mm 3.8mm
Disc runout not more than 0.12 mm O.3mm
Brake Fluid:
Recommended disc brake fluid :
Grade D.D.T.3 ---
Brand Atlas Extra Heavy Duty ---
Sheil Super Heavy Duty ---
Texaco Super Heavy Duty ---
Wagner Lockheed Heavy Duty ---
Castrol Girling -Universal ---
Castrol GT ILMAI ---
Castrol Disc Brake Fluid ---
.............................................................
Special Tool
Clrcllp Pliers: 57001 · 143

BRAKES 10-5
From Brake Lever Play Adjustment

Brakes - Adjust the fro nt brake lever to suit you .
- loosen the adjuster locknut and turn the adjuster
to either side.
- After adjustment, tighten the locknut securely.
AWARNING
When working with the disc brake, observe the
precautions listed below .
1. Never reuse o ld brake fluid .

2. Do not use fluid from a container that has been
left unsealed or that has been open for a long time.
3. Do not mix two types and brands of fluid for use
in the brake. This lowers the brake fluid boi li ng
point and cou ld cause the brake to be ineffective.
It may a lso cause the rubber brake parts to dete-
riorate.
4. Don't leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid . A. Brake Lever C. locknut
5. Don' t change the fluid in the rain or when a strong B. Adjuster
wi nd is blowing.
6. Except for the disc pads and di scs, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, motor oil, or any
other petroleum distillate will cause deterioration
of the rubber parts. Oil spit led on any part will be
difficult to wash off completely and will eventu-
ally rea ch and break down the rubber used in the
disc brake.
7. When handling the disc pads or disc, be careful
that no disc brake fluid or any oi l gets on them .
Clea n off any fluid or oil that inadvertently gets Rear Brake Pedal Position Adjustment
on the pads or disc with a high flash point solvent. - Adjust the rear brake pedal position to su it you.
Do not use one which will leave an oily resid ue . -Loosen the locknut, turn the adjusting bolt. and then
Replace the pads with new ones if they cannot be tighten the locknut.
cleaned satisfactorily.
8. Brake fluid quickly ruins painted surfaces; any
spi lled fluid should be completely wiped up imme-
diately.
9. If any of the brake line fittings or the bleed va lve
is opened at any time, the AIR MUST BE BLED
FROM THE BRAKE.
Brake Adjustment :
Brake Lever/ Pedal Free Pla y/Adjustment
Disc and disc pad wear is automatically compen-
sated for and has no effect on brake lever/pedal ac-
tion. So there are no parts that require adjustment on
the brakes except brake lever play, brake pedal posi- A. locknut B. Adjusting Bah
tion and pedal play.
If the brake leve r/peda l has a soft, or "spongy feel·
ing", check the brake flu id level in the reservoir and
bleed the air from the brake line (see Bleeding the
Brake line).
10-6 BRAKE S
Rear Brake Pedal Play Adjustment - loosen the banjo bolt at the brake hose lower end,
- Adjust the rear brake pedal play to suit you. and tigh ten it loosely.
- loosen the adjuster locknut and turn the adjuster on - Loosen the brake pad bolts before calipe r
the rear master cylinder. remo val if the caliper is to be disassembled .
- After adjustment, tighten the lock nut securely. - Unscrew the mounting bolts. and remove the caliper
from the disc.
NOTE
off the ca liper is to be disassembled after removal and

compressed air is not available, disassemble the
caliper before brake hose removal (see Disassembly).
-Unscrew the banjo bolt and remove the brake hose

from the caliper (see Brake Hose RemovaVlnstalla-
tion).
oThere is a f lat washer on each side of the hose fitting.
A. Ad juster C. Brake Pedal NOTE

B. Re"ar Master Cylinder D. locknut
olmmeciiately wipe up any brake fluid that spiffs.
Caliper:
Caliper Removal
- Remove the front disc cover and rear calipe r cover.
A. Front Caliper D. Brake Hose

B. Caliper Mounting Bolts E. Brake Pad Bolts
C. Brake Disc F. Banjo Bolt
A. Front Disc Cover B. Mounting Bolts
- Remove the front brak e hose ho lder mounting bolts.
A. Caliper Cover E. Brake Disc

B. Mountins Bolts F. Brake Hose
A. Brake Hose Holder C. Rear Caliper C . Banjo Bolt
B. Mounting Bolts D. Caliper Mounting Bolts H. Brake Pad Bolts
BRAKES 10-7
Caliper Installa tion Notes NOTE
-I nstallation is the reverse of removal.
- Tighten the brak e pad bol ts to the specif ied torque olf the caliper is to be disassembled after removal
if it was removed. and compressed air is not available, remove the
piston(s} using the following three steps before
Tightening Torque :
disconnecting the brake hose from the caliper.
18 N-m (1.8 kg-m. 13 ft -Ib) oPrepare a suitable container for brake fluid, and
perform the work above it.
-Tighten the caliper mounting bolts to the specified
oRemove the pads and spring (see Pad Removal).
torque.
oPump the brake lever or pedal to remove the
Tightening Torque : ca liper piston(s).
25 N-m (2.5 kg-m, 18 ft -Ib)
- Use a new flat washer on each side of the brake hose CAUTION
fitting, and tighten the ban jo bolt to t he specifi ed
torque. Immediately wipe up any brake fluid that spills.
It may ruin painted or plated surfaces.
Tightening Torque :
25 N-m {2 .5 kg-m , 18 ft -Ibl
-Change the brake fluid (see Brake Fluid Change).

-Check the brake fo r weak braking power. brake drag, Caliper Assembly
and fluid leakage by operating the brake lever/pedal. - Clean the cali per parts except for t he pads.
CAUTION
For cleaning the parts , usa only disc brake fluid ,
Caliper Disassembly
isopropyl alcohol, or ethyl alcohol.
- Remove the fr ont I rea r ca liper.
-Remove t he pads and spring (see Pad Removal).
- Remove the caliper holder, shaft rubber friction boot
and dust cover. - Tighten the bleed valve to the specified torque.
- Using compressed a ir, remove the piston(s).
OCover the ca liper openi ng with a clean, hea vy cloth . Tightening Torque :
oRemove the piston{s) by lightly applying compressed 7.8 N-m 10.8 kg-m, 69 in-Ib)
ai r to where the brake line fits into the caliper.
- It is recommended that the fluid seal which is
removed, be repla ced wi th a new one.
- Repla ce the dust seal if it is damaged.
- For the front and rear calipers, do the followin g.
AWARNING OApply brake fluid to the fl uid sea l(s) and dust seal(sJ,
and install them into the cyl inders by hand.
To avoid serious injury, never place your fingers OA pply brake fluid to the outside of the pistons, and
or palm inside the cali par opening. If you apply push them into each cy linder by hand .
compressed air into the caliper, the pistonfs) may
crush your hand or fingers.
A. Fluid Sea ls C. Piston

A. Apply compressed air. B. Cloth B. Dust Seals
, 0-8 FINAL DRIVE
- Re place the shaft rubber fri c tion boot and dust cover Fluid Seal Damage
if they are damaged . The fluid sea l a round the piston maintains the
- Apply a thin coat of PBC (Poly Butyl CuprysiJ) grease proper pad/disc clearance. If this seal is not in good
to the caliper ho lder shafts and holder holes (PBC condition, pad wear will increase, and constant pad
is a specia l high temperature, water-resistant grease). drag on the disc will raise brake and brake fluid
temperatu re.
Cali per
A. Shaft Rubber Friction Boot ',' ::: .::

B. Dust Cover
C. Caliper Ho lder Shafts 1. Caliper
2. Piston
3. Fluid Sea l
4. Dust Sea l
-I nstalr the anti-rattle spring in the cali pe r as shown.
Re pla ce the flu id seal under a ny of the following

cond itions: (a) fluid leakage around the pad; (b) brakes
overheat; (cl there is a large difference in left and
right pad wear; (d) the sea l is stuck to the piston. If
the fluid sea l is replaced, re place the dust seal as well .
Also, rep lace al l sea ls every other time the pads a re
chan ged.
Dus t Seal, Cover and Sha ft Rubber

Fric tion Boot Damage
- Check that the dust sea ls, covers and shaft rubber
A. Anti-Rattle Spring
frict ion boots are not cracked, worn, swo llen, or
otherwise damaged .
- Install the pads (see Pad Insta llation).
* If they show any damage, replace them.
Piston and Cylinder Damage

- Visua lly inspect the piston and cylinder surfa ces.
* Re pl ace t he piston and cylinde r if they are badly
scored or rusty.
BRAKES 10-9
Caliper Holder Shaft Wear Pad Inspec tion
The caliper body must slide smoothly on the caliper - Check the lining thickness and condition of the pads
holder shafts. If the body does not slide smoothly, in each ca li per.
one pad will wear more than the other, pad wear will * If either pad is damaged, replace both pads in the
increase, and constant drag on the disc will raise calipe r as a set.
brake and brake fluid temperature . * If the lining thickness of either pad is less than the
- Check to see if the caliper holder shafts are not service li mit, replace both pads in the caliper as a
badly worn or stepped, or the rubber friction boot set.
is not damaged.
* If the shafts or rubber fr iction boot are damaged, Lining Thickness Measuremant
replace the rubber friction boot and t he caliper
holder.
Brake Pads:
Pad Removal
- Remove the front disc cover or rear ca li per cover.
- Remove the caliper from the disc, and take out the
piston side pad from the ca liper holder.
-Push the caliper holder towa rd the piston, and then
remove the pad from the caliper holder shaft.
A. lining Thickness B. Service limit
Pad Lining Thickness (mm)
Front Rear
Standard 4.5 4.7
Service limit 1 1
Master Cylinder:
CAUTION
A. Pads B. Caliper Holder Brake fluid quickly ruins painted or plated sur-
faces ; any spilled fluid should be completely
wiped up immediately with 8 damp cloth .
Pad Installation
- Push the caliper piston in by hand as far as it will go. Front Master Cylinder Removal
- Insta ll the anti-rattle spring. -Remove the banjo bolt to disconnect the upper brake
- Install the piston side pad first, and then install the hose from the master cylinder. There is a flat washer
remaining pad. on each side of the hose fitting.
-Tighten the brake pad bolts to the specified torque.
TIghtening Torque:
18 N-m (1 .8 kg-m , 13 ft -Ib)
AWARNING
Do not attempt to drive the motorcycle until a full
brake lever or pedal is obtained by pumping the
brake lever or pedal until the pads are against the
disc . The brake will not function on the first ap-
plication of the lever or pedal if this is not done .
A. Banjo Bolt C. Reservoir

B. Master Cylinder
10-10 BRAKES
- When removing the brake hose, temporarily secure - Use a new flat washer on each side of the brake
the end of the brake hose to some high place to hose fitting, and tighten the banjo bolt to the speci-
keep fluid loss to a minimum . fied torque.
- Unscrew the clamp bolts, and take off the master
cylinder as an assembly with the reservoir and brake
lever. Tightening Torque :
25 N-m 12.5 kg-m. 18 h~bl
- Bleed the brake line after master cylinder installation

(see Bleeding the Brake line).
- Check the brake for weak braking power, brake drag.
and fl uid leakage.
Rear Master Cylinder Removal

- Remove the reservoir cover.
A. Clamp Bolts
Front Master Cylinder Installation Notes

-Installation is the reverse of removal.
-The master cylinder damp must be installed with the
arrow mark pointing upward.
A. Reservoir Cover B. Mounting Screw
- Remove the reservoir mounting bolt

- Remove the cotter pin, and pull out the joint pin.
- Unscrew the banjo bolt to disconnect the brake hose
from the master cylinder. There is a flat washer on
each side of the hose fitting.
A. ArrcHi Mark
- Tighten the upper damp bolt first and then tighten

the lower clamp bolt to the specified torque. There
will be a gap at the lower part of the damp after
tightening. A. Cotter Pin
B. Joint Pin
C. Master Cylinde r Mounting Screws
TIghtening Torque : D. Banjo Bolt
8 .8 N-m (0.9 kg-m, 78 in-lb) E. Master Cylinder
BRAKES '0- "
- When removing the brake hose, temporarily secure Front Master Cylinder
~!~~
the end of the brake hose to some high place to
keep fluid loss to a minimum.
- Unscrew the master cylinder mounting screws, and
8
remove the master cyli nder with the reservoir.
- Unscrew the reservoir cap screws, take off the
reservoi r cap (the diaphragm comes off with the
reservoir cap) and pour the brake fluid into a container. G'~ ® 5 1. Dust Cover
- Remove the reservoir and its hose from the master 2. Cl rcll p
cylinder. 3. Washer
4. Piston
5. Secondary
Cup
6. Primary Cup
7. Retum Spring
8. Reservoir
Rear Master Cylinder Installation Notes Rear Master Cylinder Disassembly

-I nsta llation is the reverse of removal. - Remove the rear master cylinder (see Rear Master
-Tighten the master cylinder mounting screws securely. Cyl inder Removal).
- Use a new flat washer on each side of the brake - Slide the dust cover on the push rod out of place, and
hose fitting, and tighten the banjo bolts to the using circlip pliers (special tool: 57001 -143), remove
specified torque. the circlip.
- Pull out the push rod with the piston stop.
- Take off the piston, secondary cup, primary cup, and
Tightening Torque retu rn spring.
25 N-m 12.5 kg-m , 18 ft-Ibl
-Tighten the reservoir mounting bolt securely. CAUTION

- Sleed the brake line after master cylinder install ation
(see Bleeding the Brake Lin e~ Do not remove the secondary cup from the piston
-Check the brake for weak braking power, brake drag. since removal will damage it.
and fluid leakage,
-Check the brake pedal position.
- Remove the cirdip, and take off the connector
and O-ring.
Rear Master Cylinder
Front Master Cylinder Disassembly

- Remove the front master cylinder (see Front Master
Cylinder Removal) 9
- Remove the reservoir cap and diaphragm, and pour
the brake flu id into a container.
- Unscrew the locknut and pivot bolt, and remove the
brake lever.
- Push the dust cover out of pla ce, and using circlip
pliers (special tool: 57001-143), remove the circlip. 1. Push Rod
- Remove the washer, and pullout the piston, 2. Dust Cover
secondary cup, primary cup, and retum spring. 3. Piston Stop
4. Cird ip
5. Piston
6. Secondary Cup
7. Primary Cup
CAUTION 8. Return Spring
9. Master Cylinder
Do not remove the secondary cup from the piston 10. O-Ring
since removal wHI damage it. 11 . Cirdip
12. Connector
10-12 BRAKES
Master Cylinder Assembly Notes Front and Rear Master C~

- Clean all parts with brake fluid or alcohol, and apply
brake fluid to the inner surface of the cylinder before
assembly.
CAUTION
Except for the disc pads and disc , usa only disc
brake fluid , Isopropyl aIcoho'. or ethyl alco~ . for
cleaning brake parts . 00 not usa any other flukf for
cleaning these part • . GasoIne, e ngine oil, or any
other petroteum distllate wi cause deterioration of
the rubber parts. 011 spilled on any part will be
dlfficuh to wash off comjMtely. and will eventual-
ty deteriorate the rubber used in the disc brake.
-Take care not to damage the inner surface of the

cylinder, or the piston.
-Tighten the brake lever pivot bolt locknut securely,
Master Cylinder Inspection

(Visual Inspection)
• Disassemble the front and rear master cylinders.
• Check that there are no scratches, rust or pitting
on the inside of each master cylinder and on the
outside of each piston.
* If a master cylinder or piston shows any damage,
replace them.
• Inspect the primary cups and secondary cups.
* If a cup is worn, damaged, softened (rottedl or
swollen, the piston assembly should be replaced to
renew the cups.
* If fluid leakage is noted at the brake lever, the piston 1. Reservoir
assembly shou ld be replaced to renew the cup. 2. Diaphragm
• Check the dust covers for damage. 3. Relief Port
* If they are damaged, replace them. 4. Supply Port
• Check that the relief and supply ports are not 5. Cylinder
plugged. 6. Return Spring
* If the small relief port becomes plugged, the brake
pads will drag 00 the disc. Blow the ports clean
7. Primary Cup
8. Piston
with compressed air. 9. Secondary Cup
• Check the piston return springs for any damage. 10. Washer
* If a spring is damaged, replace the piston assembly. 11 . Circlip
• Check the O-ring in the rear master cylinder for 12. Oust Cover
damage. 13. Brake lever
* If a CHing is damaged, replace it 14. Push Rod
BRAKES 10-13
Brake Disc: Disc Runout Measurement
Disc Inspection
• Visually inspect the disc.
* If disc is scratched at damaged, replace the disc.
• Measure the thickness of each disc at the point where
it has worn the most
* Replace the disc if it has worn past the service limit.
Disc Thickness Measurement
1. Disc
2. Measuring Area
Disc Runout
1. Disc Standard: under 0 .12 mm

2. Measuring Area Service Limit: 0.3 mm
Disc Thickness
Standard: Front: 2.85 - 3.15 mm
Rear : 4.35 - 4.65 mm Brake Fluid:
Service Umit: Front : 2.5 mm
Rear: 3 .8 mm Brake Fluid Requirement
Recommended fluids a re given in the table belO'N.
If none of the recommended brake fluids are available,
• Using the jack (special tool: 57001·12381 raise the use extra heavy-duty brake fluid only from a coo-
front/rear wheel off the ground. tainer marked D.O .T.3.
• Set up a dial gauge against the disc as illustrated.
o For the front disc, tum the handlebar fully to one side.
• Rotate the wheel to measure disc runout The dif- Recommended Disc Brake Ftukl
fere nce between the highest and lowest d ial readings
is t he amount of runcut Grade: O.O .T.3 .
* If disc runout exceeds the service limit, replace the Brand : Attas Extra Heavy Duty
disc. Sheal Super Heavy Duty
Texaco Super Heavy Duty
Wagner Lockheed Heavy Duty
Castrol Giriing-Universal
Castrol GT ILMAI
Castro! Disc Brake Auld
10-14 BRAKES
Brake Fluid Level Inspection Brake Fluid Change
Inspect the brake fluid level in the front and rear Change the brake fluid periodically. The brake fluid
brake fluid reservoirs periodically. should also be changed if it becomes contaminated
- Check the brake fluid level in the reservoir. with dirt or water.
Changing Bnlk. Auid :

NOTE - level the brake reservoir.
- Remove the reservoir cap.
o Hold the reservOIr horizontal when checking - Remove the rubber cap on the bleed valve.
brake fluid level.
* The front and rear reservoirs must be kept more

than half full with brake fluid . If the amount of
brake fluid is insufficient, add brake fluid .
AWARNING
Do not mix two brands of fluid . Change the brake
fluid in the brake line completely If the brake fluid
must be refilled but the type and brand of the
brake fluid that is already In the reservoir are A. Bleed Valve
unidentified.
- Attach a clear plastic hose to the bleed valve on the
caliper, and run the other end of the hose into a
container.
- Open the bleed valve (counterclockwise to open).
-Pump the brake lever or pedal. until all the fluid is
drained from the line.
- Close the bleed valve.
- Fill the reservoir with fresh specified brake fluid .
AWARNING
Do not mix two brands of fluid . Change the brake
fluid in the brake line completely H the brake fluid
must be reflled but the type and brand of the brake
fluid that is already In the reservoir are unidentified.
A. Front Reservoir
- Install the reservoir cap.
- Open the bleed valve, apply the brake with the brake
lever or pedal.
- Close the valve with t he brake held applied, and then
quickly release the lever or pedal.
- Repeat this operation until the brake line is filled
and fluid starts coming out of the plastic hose.
NOTE
OReplenish the fluid in the reservoir as often as
necessary to keep it from running completely out
- Bleed the air from the lines (see Bleeding the Brake
A. Rear Reservoir C lower level line).
B. Upper Level
BRAKES 10- 15
Filling up the Brake line NOTE
oTap the brake hose lightly from the caliper to the

reservoir for easier bleeding.
-Install the reservoir cap, and connect a clear plastic

hose to the bleed valve at the caliper.
- Run the other end of the plastic hose into a container.
-Pump the brake lever or pedal a few times until it
becomes hard and then, holding the lever or pedal
squeezed, quickly open (turn counterclockwise) and
close the bleed valve.
-Release the brake.
-Repeat this operation until no more air can be seen
coming out into the plastic hose.
-Remove the clear plastic hose.
-Tighten the bleed valve to the specified torque, and
install the rubber cap.
Tightening Torque
7 .8N-m (0.8 kg-m, 69 in-lb)
-Check that the brake fl uid is fi lled to the upper level
line marked in the reservoir (with the master cylinder
held level).
- After bleeding is done, check the brake for weak
1. Open the bleed valve . braking power, brake drag, and fluid leakage.
2. Apply the brake and hold it.
3. Close the bleed valve with the brake held applied. Bleedtng the Brake Une
4. Then quickly release the brake.
~
Bleeding the Brake Line
The brake fluid has a very low compression coef-
ficient so that almost all movement of the brake lever (
or pedal is transmitted directly to the caliper fo r brak- o
ing action . Ai r, however, is easily compressed. When
air enters the brake lines, brake lever or pedal move-
ment wi ll be partially used in compressing the air.
This will make the lever or peda l feel spongy, and
there will be a loss in braking power.
Bleed the air from the brake whenever brake lever
or pedal action feels soft or spongy, after the brake
fluid is changed, or whenever a brake line fitting has
been loosened for any reason .
- Remove the reservoir cap, and check that there is
plenty of flu id in the reservoir.
NOTE
oThe fluid level must be checked often during the bleed-

ing operation and replenished as necessary.
olf the fluid in the reservoir runs almost out any time
during bleeding, the bleeding operation must be done
over again from the beginning since air wiIJ have
entered the line.
- With the reservior cap off, slowly pump the brake 1. Pump the brake lever or pedal until it becomes hard,
lever or pedal several times until no air bubbles can and hold the brake applied.
be seen rising up through the fluid from the holes 2. Quickly open and close the bleed valve with the
at the bottom of the reservoir. This bleeds the air from brake held applied.
the master cylinder end of the line. 3. Release the brake.
10-16 BRAKES
Brake Hose:
Brake Hose Removal/Installation Notes

- When removing the brake hose, take care not to spill
the brake fluid on the frame or other painted parts.
- When removing the brake nose, temporari ly secure
the end of the brake hose to some high place to keep
fluid loss to a minimum.
CAUTION
Brake fluid quickly ruins painted or plated surfaces;
any spilled fluid should be completefy wiped up im-
mediatety with 8 damp cloth.
- There is a flat washer on each side of the brake hose

fitting. Replace them with new ones when installing it
- When installing the hoses, avoid sharp bending, kink-
ing, flattening or twisting. and route the hoses accord-
ing to the Hose Routing section in the General
Information chapter.
- Tighten the banjo bolts at the hose fittings to the
specified torque.
Togtttening T"""""
25N-m (2.S kg..." . 18 ft-IJ)
- Change the brake fluid and bleed the brake line after
installing the brake hose (see Bleeding the Brake li ne~
Brake Hose Inspection

• The high pressure inside the brake line can cause
fluid to leak or the hose to burst if the line is not
properly maintained. Bend and twist the rubber hose
while examining it
* Replace it if any cracks or bulges are noticed.
SUSPENSION 11 - 1
Suspension
Table of Contents
Exploded View ...... ' ... _. _..... ... .•.. ....... .. ......... . _. _... ..... .... ......... .... 11-2
Specifications .. ...... .. ... ............ .............. ,",." ............. ". ....... .... 11 -3
Spec ial Tools .. ....... ............. ............ .... ....... ....... ...... .. .............. 11 -4
Front Fork ........ ,....... ... .... ... ......... ... ... ........ ............ ......... .. .. .... 11 -5
Front Fork Adjustment ............... ... ............ , .......• .. ... .. ,. ....... 11 -5
Front Fork Removal .... ...... ... ... .... ... ... .... _,_ .... .... .•• .. ..... .. ..... . 1 1-9
Front Fork Installation Notes ..... _, _......... .... .... ...••• •..... . ... .. ... 11 -9
Front Fork Disasse mbly ..... ...... ... .. .......... ........... ... ............. 11 - 10
Front Fork Assem bly Note s ....... ........................ ...... .. ..... .. .. 11 -12
Inner Tube Inspection ................ .. ........................ ........ ...... 11 - 14
Guide Bushing Inspection ........ .. .. .. ... ...... .... ..... ... ... ............. 11 -14
Oil Seal and Oust Seal Inspection ................ " .... .... ... .. ..... ... 11 -15
Spring Tension .. .. ........................................... ....... ... .... .... 11 -15
Rear Suspension IUni-trakl ...... ........ ... ...... ................ ................ 11 -15
Rear Shock Absorber ......................... .................... .... ... .. .... .. 11 -15
Shock Damping Adjustment ..... ..... ..... ............... ............... .. J-
1 15
Spring Preload Adjustment .............. ... ..... ... ... .......... .. ...... .. 11-17
Rear Shock Absorber Removal ................................. .. ........ . 1 1- 17
Rear Shock Absorber Installation Note s .................... ...... ... .. 1 1- 18
Rear Shock Abso rber Spring Replacement ........................... . 1 1- 18
Rear Shock Absorber Disassembly ................................. ... ..
Rear Shock Adsorber A sse mbly Notes ......... .. .. .. ............... ..
1 1- 19
11-20
01
Spring Tension ........... ............. ................ .... .. .... ... ...... ... .. 11 -22
Scrapping ...................... . _. ......... ..... ...... ............. .. ......... .. 11-22
Swing Arm ...... ... ................ _......... .. ..... .. ..... .. .. ... .. .. .. ... ......... 11 -23
Swing Arm Remov al ... ... ............. .. .................... ........ .. ... ... . 11 -23
Swing Arm Installation Notes ....... ............ ... .... .. .. ............... 11-23
Tie-rod , Rocker Arm .......... .. ... .. ..... ... ................................ .... 11 -23
Tie -rod Remova l .. ... ...... ... ....................... ...... ....... ..... .. ...... 1 1-23
Tie-rod In stallation Notes ............ .......... .. ........................... 11 -23
Rocker Arm Removal .......................... ... .... ..... .. ... .... ... ....... 11-23
Rocker Arm In stallation Notes ............... ........ ... .................. 11 -24
Uni-trak Maintenance ..... .. .......... .... .................. ....... .. .. ............. 1 1-24
Sleeve .......................................... .. ............................... .... .. 11 -24
Rocker Arm ...... .......... ................... .... ...... .... ... .. ... ..... ........... 11 -25
Mounting Bolt Bend ..... ... ..... .......................... ... .. ... .. ... ... ... 11 -25
11 -2 SUSPENSION
•.•.••. .. . .•......... ... . .••.•• •••• .. .. .............•...... •.
Exploded View
... ....... ................ ... .... ........ ....................
L.-----1
e
.. 0
0 0
~
0
e 0
•
EO)
L : Apply a non*permanent locking agent to the threads.

T1 , 20 N-m 12.0 kg-m. 14.5 ft-Ibl
T2 , 29 N-m 13 .0 kg-m. 22 ft-Ibl
T3 , 27 N-m 12 .8 kg-m. 20 ft-Ibl
T4 ; 9.3 N-m (0 .95 kg-m. 82 In-fbI
T5 , 54 N-m 15 .5 kg-m. 40 ft-Ibl
T6 , 81 N-m 18.3 kg-m. 60 ft-Ibl
T7 , 39 N-m 14.0 kg-m. 29 ft-Ibl
SUSPENSION 11-3
......... .. ................ ................... ...............
Specifications
............................. ... ........ .. . ........... . . .....
Front Fork:
Air pressure Atmospheric pressure
Rebound damping adjustment 8 clicks counterclockwise (from the (adjustable range)
seated position adjuster turned fully 16 clicks
ck>ckwise) (adjustable range)
16 clicks
Compression damping adjustment 8 clicks counterclockwise (from the
seated position adjuster turned fully
clockwise)
Oil viscosfty KAYABA 01 or SAE 5W

Oil amount (per side)
When changing oil: approx . 375 mL
After disassembly and dry
completely KX125: 439 ± 4 mL
I[) 443 ± 4 mL
KX250: 439 ± 4 mL
I[) 447 ± 4 mL (adjustable range)
Oil level: KX125: 100 mm 1[)95 mm 70 - 120mm
KX250: 100 mm 1[) 90 mm
( fuUY compressed, )
spring removed
Fork spring free length 533 mm 522 mm
Rear Suspension:
Rear Shock Absorbe<: (adjustable range)
Rebound damping Adjuster turned fully clockwise 16 turns
(counterclockwise)
Spring preload:
adjusting nut position from the )
( center of the upper mounting
hole
KX125 119.5mm 109 - 132 mm
KX250 119.5 mm 109 - 130 mm
Spring free length 275 mm 270 mm
Gas Reservoir : (adjustable range)
Compression damping Adjuster turned fully clockwise 16 tums
(counterclockwise)
Gas pressure 1200 kPa 112 kg/em', 170 psi) 1000- 1 500 kPa
110- 1 5kg/em',
142-213 psi)
(): European model

" ·4 SUSPENSION
.............................................................
Special Tools
... .... ... ...... ............ ...... ................ .......... .
Fork Push Rod Puller: 57001 · 1289

Fork Spring Holder: 67001 · 1286
Rubber Plug : 92066· 1189
Hook Wrenches : 57001 · 1101

Oil Syringe: 57001 -1290
Fork Cylinder Holder: 67001 -1287 Jack: 67001 -1238
Fork OU Seal Driver: 57001 -1288

SUSPENSION 11-5
·.......................• .........••...........••............
Front Fork
Front Fork Adjustment

The front fork should always be adjusted for the
rider's weight and track conditions by using one or
more of the following methods.
Basically, there are five adjustments you can make
to the front fork .
oAir pressure -Air pressure acts as a progressive spring
and affects the entire range of fork travel. The air
pressure in the fork increases as the fork heats up, so
the fork action on your KX will get stiffer as the race
progresses. Because of this, we don't recommended
using air pressure for additional springing. Your KX A. Screw
forks are designed to work without adding any air
0Rebound damping adjustment - This adjustment Rebound Da m ping Adjustment
affects how Quickly the rebound . The fork rebound - To adjust rebound damping, turn the adjuster on the
damping adjuster has 16 clicks. The seated position front fork top plugs with the blade of a screwdriver
(full clockwise until the adjuster stops) is full hard. until you feel a dick. Adjust the rebound damping to
From the point, 8 clicks counterclockwise is the suit your preference under special conditions.
standard setting, and 16 clicks (full counterclockwise
until the adjuster stops) is full soft Softer Harder
OCompression damping adjustment- This adjustment
affects how quickly the fork compresses. The fork
compression damping adjuster has 16 clicks. The seat-
16 0 • ®
ed position (full clockwise until the adjuster stops) is
full hard. From that point, 8 clicks counterclockwise
,. 2
is the standard setting, and 16 clicks (fu ll counter-
clockwise until the adjuster stops) is full soft.
OOillevel ad justment - The effects of higher or lower
12
10 8 6
•
fork oil level are only felt during the final 100 mm
of fork travel. A higher oil level (more oil) will make
the fork rebound more Quickly. A lower oil level LStandard
(less oil) will make the fork rebound more slowly. Number of turns counterclockwise
oFork springs -Optional springs are available that usable range- 1 6 clicks
are softer and stiffer than standard.
oFork clamp position -Steering qualities are greatly
A. Seated position with adjuster turned fully clockwise.
affected by the fork clamp position (If amount of
the outer tube projecting above the steering stem
head). When the fork tube height is smaller, the CAUTION
front e nd become lighter due to the change in
The left and right fork tubes must have same shock
weight bias. Also, it tends to understeer in turns
and · wash out". When the height is greater, the damping.
results are opposite.
A.- Pressure
The standard air pressure in the fork legs is
atmospheric pressure. The air pressure in the fork legs
increases as the fork heats up, so the fork action will
get stiffer as the vehicle operation progresses.
- Park the vehicle on level ground.
- Remove the screws at the top of the front fork top
plugs.
A. Adjuster
11 -6 SUSPENSION
Compression Damping Adjustment OR level Adjustment
- Clean the bottom of the fork tubes. - Using the jack stand (special tool: 57001·1238) under
- Remove the caps on the bottom of the fork tubes. the frame, stabilize the motorcycle.
- To adjust compression damping. tum the adjuster on - Place a stand or block under the engine so that the
the front fork cylinder valve with the blade of a front wheel is raised off the ground.
screwdriver until you feel a click. Adjust the com-
pression damping to suit your preference under special
condition.
AWARNING
Uft the front w.... before oosct8wing both top
plugs. or the front forte tubes compress al the way
and hazard can occur.
-Remove the following:

Front Disc Cover
Brake Hose Holder
Front Fork Protector
A. Adjuster
Softer Harder
16 o ....- 0
14 2
12 4 A. Brake Hose Holder B. Front Fork Protector

10 B 6
Front Fender
LStandard Handleber (place on one side)
Number of turns counterclockwise Front Fork Top Plugs (unscrew)
usable r8nge· 16 clicks
CAUTION
The .tt and right forte tubes must have the same
shock damping .
- Put the caps into the bottom of the fork tubes.
A. Front Fork Top Plug

SUSPENSION 11-7
- Slowly compress the front forks fully while pushing - Remove t he top plug .
up the inner tube lower ends (touch the stepped - Remove the spring seats.
portions of the inner tube to the outer tube dust seal - Remove the fo rk spring holder (special tooll. and pu ll
lower end s), and place a stand or other suitable out the fork spring.
support under the front wheel.
A. Top Plug C. Spring Seats

B. O-ring D. Spring
- Adjust the oi l leve l with the oi l syringe (special tool).

oSet the oil syringe stopper so t hat its lower side shows
t he oil level d istance specif ied.
NOTE
oThe ga uge tube is graduated in 1 em division.

o Th e syringe body is graduated in 10 m L
division, excluding the gauge tube of abou t-5
mL capacity.
Oil Level (fuliV compressed , without spring)

A. Inner Tube C. Dust Sea l Standard : KX125 : 100 mm
B. Outer Tube
(£) 95 mm
KX250 : 100mm
- Pu ll down the fork spring and insert the fork spring (£J 90 mm
holder (special tool) under the push rod nut. Adjustable Range : 70 - 120 mm
~: European model
OWith the fork fully com pressed, insert the gauge

tube into the outer tube and position the stopper
across the o uter tube top end .
NOTE
OPosition the stopper so that the gauge tube is a t the

line of outer tube diameter in the direction of the
handlebar, or the specified oil level can not get cor-
rectly.
A. Spring C. Fork Spri ng Holder: o Pull t he handle slowly to pu mp out t he excess oil
B. Push Rod Nut 57001-1286 until t he oi l comes out no longer.
* If no oil is drawn out, there is insufficient oil in the
fork tube. Pour in enough oil, then draw ou t the
excess o il as show n above.
11 -8 SUSPENSION
A. Oi l Syringe: 57001-1290 C. Stopper A. Spring C. Fork Spring Holder:

B. Handle B. Pu sh Rod Nut 57001-1266
·Pu ll up the push rod with the fork push rod pul ler
(spec ia l tool). -Remove the fo rk push rod puller (special too ll. and
put the spring seats as shown o nto the fork sprin g.
NOTE
oPufi up the push rod slowly so as not to spi/J the fork

oif out of the fork tube.
A. Spring Seats
- Check the O-rin g of the top plugs for damage. 1f

necessary, replace it with a new one.
-Insta ll the top plug on the push rod.
A. Push Rod
B. f ork Push Rod Puller: 57001-1289
- Put the fork spring onto the push rod .
A. Top Plu g C. O-rin g

b. Push Rod
A. Fork Spring B. Push Rod - Remove the fo rk sp ri ng holder (special tool).

- Remove the stand o r other suitable means under the
- Pull down the fo rk spring and insert the fo rk spring front wheel. and slowly extend the front forks to put
holder (specia l toof) under the push rod nut. the top plugs onto the o uter tubes.
SUSPENSION 11 -9
- Tighten the top plugs to the specified torque.
Tightening Torque
29 N-m (3 .0 kg-m, 22 ft -Ib)
- Install the parts removed .
Fork Spring
Different fork springs are available to achieve
suitable front fork action in accordance with the
riders weight and track condition.
- Harder springs make the fork stiffer. and rebound
action quicker.
- Softer springs make the fork softer. and rebound
action slower. A. Upper Fork Clamp Bolts
B. l ower Fork Clamp Bolts
Fork Clamp Position
- With a twisting motion, work the fork tube down
Steering qua lities are greatly affected by the
and out.
fork clamp position (the amount of the outer tube
projecting above the steering stem head). When
the fork tube height is smaller. the front end be- Front Fork Installation Notes
comes lighter due to change in weight bias. Also. -I nsta ll ation is the reverse of removal.
it tends to understeer in turns and " wash out". -I f the fork tube was disassembled, check the fork
When the height is greater. the results are opposite. oil level.
Be sure the front tire doesn' t rub the fender - Route the cables and hose according to the Cable
when the fork tubes compress fully. Make this and Hose Routing section in the General Information
adjustment in 5 mm increments. chapter.
- Tighten the lower and upper fork clamp nuts to the
specified torque.
CAUTION
The fork tubes. both right and left. should be Tightening Torque
adjusted evenly.
20N -m (2.0 kg-m . 14.5 ft -Ib)
- Tighten the axle to the specified torque.
TIghtening Torque
54 N-m (5 .6 kg-m . 40 ft -Ib)
- Mount the axle damps, and tighten t he clamp

nuts, fi rst tighten t he upper damp nuts and then
the lower clamp nuts to the specified torque. The
arrow mark on the axle clamp must point upwards.
A. Standard Fork Tube Height
Front Fork Removal

- Remove the front disc cover.
- Remove the left and right fork protectors.
- Remove the caliper from the fork tube to be
removed, and rest the caliper on some kind of stand
so that it doesn' t dangle .
- Remove the front wheel (see Front W heel Removal A. Arrow Ma rk
in the Whee lsfT ires chapter). B. Upper Clamp Nuts
- Loosen the upper and lower fork clamp bolts. C. l ower Clamp Nuts
11 -10 SUSPENSION
-R emove t he spring sealS .

Tightening Torque
- Pull off the fork spring holder (specia l tool).
9 .3 N-m 10 .96 kg-m. 82 in-Ibl - Take out the fork spring .
- Take the rebou nd damping adjuster rod (short) out
- Tighten the caliper mounting bolts to the speci- of the push rod .
fied torq ue.
Tlghtening Torque
26N-m 12.6 kg-m. 18 f1-lbl
- Check the front brake operation after insta llation.
Front Fork Disassembly fail Change)

· Place the hand lebar on one side. and loosen the fork
top plug.
- Remove the front fork .
-H old the outer tube in a vise.
- Unscrew the top plug out of the outer tube.
- Slowly compress the front fork f ull y wh ile pushing
up the inner tube lower end (touch the stepped A. Rebound Damping Adj uster Rod (short)
portion of the inner tube to the outer tube dust B. Push Rod
seat lower end). and place a stand or other
suitable support under the inner t ube lower end. -Pour t he fork oil into a container.
· Pull down the fork spring and insert the fork spring oTurn the fork upside down and pump the push rod .
holder (special tool) under the push rod nut. In this time, rebound damping adjuster rod (long) may
be come ou t of the push rod.
A. Spring C. Fork Spring Holder:

B. Push Rod Nut 57001-1286 A. Pu sh Rod
B. Rebound Damping Adjuster Rod (long)
-H oldind the push rod nut with a wrench, remove the
- Remove the push rod nut, and take out the collar and
top plug.
..orin" ollirip
A. Top Plug C. Spring A. Push Rod Nut C. Spring Gu ide

B. Spring Seats B. Co ll ar
SUSPENSION 11 -11
- Clean the bottom of the inner tube.

- Remove the cap on the bottom of the inner tube.
- Hold the front fork in a vise.
- Stop the cylinder unit from turning by using the fork
cylinder holder (special tool). Unscrew the compres-
sion valve assembly, and take the compression
valve assembly and gasket out of the bottom of the
inner tube.
A. a-ring D. Oil l ock Piston

B. Guide Stay Nut E. Piston Ho lder
C. Sp lit Ring Keepers
1. Fork Cylinder Holder: 57001-1287
2. Cyli nder Unit
3. Compression Valve Assembly -Pull the push rod assembly out o f the bottom of the
inner cy linder.
A. Inner Tube C. O-ring

B. Compression Va lve Assemb ly D. Gasket
A. Push Rod Assembly B. Inner Cylinder
- Pull the push rod and cylinder unit assembly out
of the top of the outer tube.
- Separate the inner tube from the outer tube as
follows:
oSlide up the spring band .
oS lide up the dust seal.
A. Push Rod C. Outer Tube

B. Inner Cylinder
- Unscrew t he guide stay nut out of the piston holder,
and remove the split ring keepers. A. Spri ng Ba nd B. Dust Sea l
- Remove the a-ring, guide stay nut, oil lock piston
and piston holder from the top of the push rod . oRemove the reta ining ring from the outer tube.
11 -12 SUSPENSION
- When assembling the new outer tube gu ide bushing,

hold the washer agai nst the new one. and tap the
washer with the front fork oil sea l driver (special
tool) until it stops.
A. Retaining Ring
OHolding the inner tube by hand in a vertica l position,

stroke the o uter tube up and down seve ra l times and
pull it down. This shock to fork tube sepa rates t he
outer tube from the inner tube. A. Guide Bushing C. Front Fo rk Oil Sea l Driver:
B. Washer 57001-1288
- After insta ll ing the washer. insta ll the oil seal by

using the fork oi l sea l driver (special tool: 57001-1288).
- Install the oi l lock piston on the piston holder so that
the notched side faces to the bottom .
- Tighten the guide stay nut to the specified to rque.
Tightening Torque
27 N-m 12.8 kg-m . 20 ft-Ibl
- Remove the gUide bushing, washer, oi l sea l, retain-

in g ring, dust seal from the inner tube. - Check the O-ring on the guide stay nut . and replace
it with a new one if da maged.
A. Guide Bushing C. Oi l Sea l

B. Washer
A. Piston Ho lder D. Guide Stay Nut
B. Oi l Lock Piston E. O-ring
Front Fork Assembly (Oil Change) Netes
C. Notched Side
- Replace the following with new ones.
Dust Sea l - Check the O-ring on the compression va lve assembly,
Retaining Ring and re place it with a new one.
Oil Sea l . - Replace the gasket with a new o ne.
Gu ide Bushing
SUSPENSION 11 - 13
. Applya non-permanent locking agent to the threads Recommend Oil

of the com pression valve assembly.
KAYABA 01 or SAE 5 W
Oil Amount (per side)
When changine oil: approx . 375 mL
Aher disassembly and completely dry :
KX125 : 439 ± 4 mL (£> 443 ± 4 mL
KX2 50: 439 ± 4 mL (£> 447 ± 4 mL
Oil Level (fully compressed . without spring)
Standard :
KX125: 100 mm ~ 95 mm
KX250 : 100 mm ~ 90 mm
Adjustable Range : 70 - 120 mm
A. Compression Va lve Assemb ly C. Gasket
B. O-ring D. Threads !II: European model
. Using the fo rk push rod pu ller (special tool), bleed

· Stop the cy linder unit from turning by using the fork the ai r in the fork o il by pumping the push rod .
cylinder holder (specia l tool : 57001-1287). Tighten the
compression valve assembly to the specified torque .
NOTE
Tightening Torque o To prevent the fork oil from welling out of the top
of the fork push rod puller (special tool) while
54 N-m (5 .5 kg-m . 40 ft -Ib )
pumping. plug the hole in the puller with the rubber
plug (special too/) at the position shown in the figure
• ln5tall the spring guide so that the more tapered before installing the puller.
portion faces to the bottom . aSlowly pump the push rod several times without
· Screw in the push rod nut so that the chamfered side spilling the fo rk oil, and bleed the air completely.
is down.
oPosi tion the push rod nut at 18.5 mm or more from
the top of the push rod .
}0
A. Fork Push Rod Pu ller: 57001-1289

B. Rubber Plug: 92066-1189
1. 18.5 mm 4 . Chamfered Side

2. Push Rod Nut 5. Spring Guide
3. Collar
. Insert the rebound damping adjuster rod (long) into

the push rod if it has been removed .
• Insert the rebound damping adjuster rod (short) into
1 . Fork Push Rod Puller: 57001-1289
the push rod so that the holder portion faces to the
adjuster pipe. 2. Rubber Plug: 92066-1189
. Pour in the type and amount of fork oil specified. 3. 18 mm
and adjust the oil level.
11-14 SUSPENSION
- Check the O-ring on the top plug, and replace it with

a new one if damaged .
-H olding the top plug with a wrench, tighten the push
rod nut against the top plug to the specified torque.
Tightening Torque
20 N·m 12.0 kg-m . 14.5 ft-Ibl
- After installing the front fork, tighten the top plug

to the specified torque.
TIghtening Torque
29 N-m 13.0 kg-m. 22 ft-Ibl
A. Fork Push Rod Pull er: 57001·1269
B. Push Rod
Inner Tube Inspection
• Pull up the push rod with the fo rk push rod pulle r - Visually inspect the inner tube, repai r a ny damage .
(specia l tool), - Nicks or rust damage can sometim es be repaired
by usi ng a wet-stone to remove sha rp edges or
NOTE raised areas which cau se seal damage.
* If the d amage is not repa irable, replace the inne r
oPuJl up the push rod slowly so as not to spill the fo rk tube. Since damage to the inner tube damages t he
oil out of the fork tube. oil seal, replace the oi l seal whenever the inner
tube is repai red or replaced .
• Put the fork spring onto the push rod . - Temporarily assemble the inner and outer tubes•
-Pull down the fork spring and insert the fork spring and pump them back and fort h manua lly to check
holder (special tool) under the push rod nut. for smooth operation ,
CAUTION
If the Inner tube is badly bent or creased , replace
It. Excessive bending. followed bV subsequent
straightening, can weaken the inner tube.
Guide Bushing Inspection

- Visually inspect the guide bushings, and replace them
A. Fork Push Rod Puller: 57001 -1289 if necessary.
B. Fork Spring Holder: 57001·1286
-Remove the push rod puller (special tool).
- /nstall the spring seats as shown.
A. Spring Seats A. Guide Bus hings

SUSPENSION 11 -15
.......... ...... .. .......... ............... .... ...............
Oil Seal and Dust Seal Insp ection
• Inspect the dust seal for any signs of deterioration Rear Suspension IUni·Trak)
or damage .
.... ............ .... ......... ................ .................
*Replace them if necessary.
Rear Shock Absorber:
• Replace the oi l sea l with a new one whenever it
has been removed . The rear suspension system of t his motorcycle is
Uni-trak . It consists of a rear shock absorber, swing
arm, tie rod and roc ker arm .
To su it to va rious riding conditions, the spring
preload of the shock absorber ca n be adjusted or
the spr ing can be replaced with an optional one.
Also the damping force can be ad justed eas ily so
changing oil viscosity is unnecessary.
Shock Damping Adjustment

Reaf Shock Absorber
Rebound Damping A djustment
To adjust shock rebound damping, turn the reo
bound damping adjuster on t he rear shock absorber
A. Oil Sea l B. Dust Sea l lower end with the blade of a screwd river until you
feel a click .
If the damper setting feels too soft or too stiff,
adjust it in accorda nce with the following table:
Spring Tension Rebound Damping Adjustment

Since a spri ng becomes shorter as it weakens,
check its free length to determine its condition . Softer Harder
* If the spring of either fork leg is shorter than the
service limit, it must be replaced. If t he length of 16 0 <e--®
<
a replacement spring and that of the remaining
spring vary greatly, the remaining spring shou ld 14
also be repla ced in o rder to keep the fork tubes 2
balanced for motorcycle stability.
12 4
10 B 6
L Standard
Fork Spring Free Length Number of turns counterclockwise
usable range-16 clicks
Standard: 533 mm A. Seated position with adjuster turned fully clockwise.

Service Limit: 522 mm
A . Rebound Damping Adjuster

B. Mark
11 - 16 SUSPENSION
Gss Pressure Adjustment

Gas Reservoir The gas pressure in the gas reservoir can be ad-
Compression Damping Adjustment justed for different course and loading conditions.
To adjust compression damping. turn the compres- The following table shows an example of gas
sion damping adjuster on the gas reservoir with the pressure adjustment. To obtain stable handling or
blade of a screwdriver until you feel a click. a suitable riding condition, adjust the gas pressure
If the damper setting fee ls too soft or too stiff, for different course and loading conditions as neces-
adjust it in accordance with the foll owing table. sary. The standard gas pressure is 1200 kPa (12.0
kg/cm 1, 170 psi~ Ordinarily, the heavier the total
load becomes, the higher the gas pressure should be
Compression Damping AdjJstment sel
Softer Harder Gas Pressure Adjustment IAdjusta~ Rangel

16 0 • Gas Pressure
kPa (kg/cm 2 , psi) Setting Load Course
2
" 1000 (10.0 , 142) Soft Light Smooth
12
10 B 6
• t
1500 (15.0, 213)
t
Hard
t
Heavy Rough
t
LStandard
To adjust the gas pressure:
Number of turns counterclockwise
usable r8nge-16 clicks
NOTE
OCheck and adjust the gas pressure when the gas
reservoir is cold (room temperature).
- Use a jack (special tool) under the engine or other

suitable means to raise the rear wheel off the ground.
- Remove the valve cap and check the gas pressure
with the air pressure gauge.
A. Compression Damping Adjuster

B. Mark
A. Valve Cap
- If standa rd pressure is insufficient for you, add nitr()o-

gen gas using a suitable tool until the desired pres-
sure is reached. Change the gas pressure within the
range specified in the table above to suit various
riding conditions.
SUSPENSION " · 17
- For KX125; the sta nda rd adjusting nut posit ion from
the center of the upper mounting hole is 119.5 mm
[US, Canadian model : 118.5 mm). The adjustable
AWARNING range is 109 - 132 mm (US , Ca nadian model: 109
- 134 mm)].
Use onlv nitrogen gas .
- For KX250; the standard adjusting nut position f rom
Do not incinerate the gas reservoir .
t he center of the upper mounting hole is 119.5 mm
(US, Canadian model : 118.5 mm]. The adjustable
range is 109 - 130 mm (US, Ca nadian model: 109
Spring Preload Adjustment
- 132 mm].
- Remove the seat, right and left side covers.
- Loosen the air deaner duct cl amp screw.
- Remove the silencer.
- Unhook the f uel tank rubber band.
- Remove the rear frame and air cleaner case.
A. Adj usting Nut Posit ion C. Adjusting Nut

B. locknut
-T ighten the locknut securely.
- After adj usting, mO\le the spring up and down to
A. Rear Frame B. Ai r Clea ner Case. make su re that the spring is sea ted .
-' nstall the pa rts remo\led .
- Pl ace a jack (specia l tool) under the frame so that
the rea r wheel is raised off the grou nd . ReBr Shock Absorber Removal
- Usi ng the hook wrenches (spec ial tools). loosen the -Remo\le the f ollowing parts.
locknut and tu rn the adjusting nut as required. Turn- Seat
ing the adjusti ng nut down makes the spring preload Right and left Side CO\lers
stronger. Si lencer
,
~ ,~
Rear Frame and Air Cleane r case.
J ;.. '~
'\ - Pl ace a j ack (specia l tool) under the frame so tha t
the rea r wheel is raised off the ground .
~;,;w - Remo\le the tie-rod mounting nut, an d pull ou t
A' the mounting bolt.
., ~ "0s - RemO\le the rear shock absorber lower mounting
- nut, and pull out the mounting bolt.
- '\ - Remo\le the rea r shock absorber upper mounting
:j
., bolt, and pull the rear shock absorber down and
out.
./
.I.
,,
A. Adjusting Nut
B. locknut
-
C. H ook Wrench: 57001 -1101
- For KX125; standard spring preload is 474 N (48.3 kg,

106 Ib) [US. Canadia n model: 447 N (45 .6 kg, 101 Ib)).
The adjusting nut changes the preload 68 N (6.9 kg,
15 Ib)[US, Canadian model: 71 N (7.2 kg, 161b)) turn.
- For KX250; standard spring preload is 772 N (78.75
kg, 174 tb)fUS, Canadian model : 727 N (74.1 kg, 163
Ib)]. The adjusting nut changes t he preload 74 N (7.5
kg, 17.1 Ib) [US, Canadian model : 76 NO.8 k g, 17.2 A. Tie-Rod Front Mounting Nut
Ib}] turn . B. Rea r Shock Absorber lower Mounting Bolt
11 -18 SUSPENSION
A. Rear Shock Absorber A. Adjusting Nut C. Hook W renches: 57001·11 01

B. Rear Shock Absorber Upper Mounting Bolt B. l ockn ut
- Slide down the rubber bumper.

- Remove the spring re tainer clip from the shock
CAUTION absorber and lift off the spring.
When pulling out the mounting bolts, lift the rear
wheel slightly. Forcing or tapping on a bolt could
da mage the bolt. s leeve , a nd bearing .
Rear Shock Absorber Installation Notes

- Installation is the reve rse of removal.
- Tighten the rear shock absorber upper, lower and
tie-rod f ront mounting nuts to the specified torque.
TIghtening Torque :
Rear Shock Absorber Nut (Upper and lower):
39 N-m 14.0 kg-m. 29 ft-Ib) A. Retainer Clip B. Spring
Uni-t,ak Tie-rod Nut:
- Exchange the spring f or an optional part.
81 N-m 18.3 kg-m. 60 ft-Ibl -I nsta ll the spring and retaine r clip.
- Adj ust the spring pre load (see Spring Prel oad Ad·
justment).
- Insta ll the rear shock absorber so that smaller
diameter end faces upward .
Rear Shock Absorber Spring Replacement
In addition to the standa rd spring, heavy a nd
light springs are avai lable. If the standard spring is
improper for your purpose, se lect a proper one ac-
cording to the riders weight or cou rse conditions.
- Remove the following pa rts.
Seat
Right and left Side Covers
Silencer
Rear Frame and Air Cleaner Case
- Remove the rear shock absorber.
- Clea n the threaded portion on the upper of the rear
shock absorber.
-H old the upper of the rear shock absorber w ith a
vise.
- Using the hook wrenches (special tools>. loosen the A. Sma ller Dia meter End
locknut and turn the adj usting nut all way down .
SUSPENSION 11 -19
Rear Shock Absorber Disassembly (Oil Change) - Using a suitab le tool and press. pus h the reservoir
The oi l shou ld be changed in the rea r shock ab- cap in 10 mm .
sorber at least once per racing season . The f requency
for best performance must be based upon riding
conditions and rider abi lity.
- Remove the rea r shock absorber from the frame
(see Rear Shock Absorber Remova l).
- Remove the shock absorber spring (see Rear Shock
Absorber Spr ing Replacement) .
• Poi nt the va lve away f rom you . Slowly release nitro-
gen gas pressu re by pushing down the va lve core
with a screwdriver.
A. Suita ble Too l B. Press
- Remove the ci rclip f rom t he gas reservoir.
A. Cas Reservior B. Va lve
AWARNING
Be sure t o point the reservior valve aw ay from
you when releasing nitrogen gas pressure. An
oil mist is often released with the nitroge n.
Al w ays release nItrogen gas pressure bef ore
disassembling t he rear shoc k absorber to pre-
vent ex plosIve separation of parts .
- Adj ust the gas reservoir damping ad j uster to the A. Circlip

softest position.
- Remove the air bleeder bolt. and p ump t he rear
shock to drain the oil out of the rea r shock body.
- Pull t he gas reservo ir ca p out of the gas rese rvoir.
A. Ai r Bleeder Bolt
- Insta ll the air bleeder bolt. A . Pliers

, , -20 SUSPENSION
_Pry or tap at the gaps in the stop with suitable tools to

free the stop from the rear shock body.
A. 6O - 70 mm
A. Caps B. Tap
- Slide the stop up to the top of the push rod then

- Check that the bladder on the gas reservoir cap is
lightly tap around the seal with a suitable rod and
not partially collapsed .
mallet, and push the seal assembly 10 mm down.
-I f it is, push down the valve core with a screwdriver.
Remove the circlip. - Check the bladder for signs of damage or cracks. If
necessa ry, replace it with a new one.
l@
A. Circlip
- lightly move the push rod back and forth, and pull
out the push rod assembly. A. Bladder B. lip
· Pour the oil out of the rear shock body.
CAUTION
Do not use 8 damaged or partially collapsed blad-
der. because It may burst, gently reducing rear
shock performance .
- Apply grease to the lip of the bladder.

Rear Shock Absorber Assembly Notes - Push the bladder into the gas reservoir slowly until
- Assembly is reverse of disassembly. it just clears the circlip groove. Wipe out any
- Adjust the gas reservoir damper adjuster to the spilled oil.
softest position .
- Insta ll the air bleeder bolt.
OCheck the O-ring on the ai r bleeder bolt, and re-
place it if necessary .
CAUTION
-Pour KYB K2-C (SAE 5W or Bel-Ray SE2 '40) oil into
Ensure that no air remains In the system .
the gas reservoir to 60 - 70 mm from the gas
reservoir upper end .
SUSPENSION 11 -21
- Check the ci rclip for weakening, deformity and
flaws. If necessary, repl ace it with a new one.
AWARNING
If the end of the g8S reservoir cap and the end
of the gas reservoir are not aligned , the circlip is
not correctly fitted in the groove in the gas reser-
AWARNING voir or Is deformed . In this case, the all and inter-
nal parts could explode out of the reservoir when
If weakened, deformed or flawed circlip is used, injecting the nitrogen gas or while riding the
the gas reservoir c ap may not hold when inject - motorcycle.
Ing the nitrogen gas. This would allow oil and in -
ternal parts to explode out of the reservoir.
- Pour KYB KZ-( (SAE SW or Bel-Ray SE2 '40) oil

into the rear shock body to 45 mm from the lower
end of the rear shock body.
- Mount the circlip in the groove in the gas reservoir.
A. 45 mm
A. Circlip
-I nsert the piston end of the push rod assembly into
the rear shock body slowly, and pump the push
rod unlit all the air is for ced out of the rea r shock
body.
- Pu l l up the gas reservoir cap agai nst t he ci rcl ip.

The end of the gas reservoir cap must align with
the end of the gas reservoir.
A. Piston B. Seal Assembly.
- Push the seal assembly into the rear shock body

u ntil it just clears the circlip groove.
- Check the circlip. If it is deformed or damaged, re-
A. Cas Reservoir Cap C. Aligned place it with a new one.
B. Cas Reservoir End - Fit the circlip into the groove in the rea r shock body.
1
11 -22 SUSPENSION
- Check the rear shock body and gas reservoir for oil
"'WARNING and gas leaks.
If the circlip is not 8 certain fit In the groove in
* If there are no leaks, inject the nitrogen gas up to
the specified pressure. The adjusta ble gas pres-
the rear shock body . the push rod assembly may
sure range is 1000 - 1500 kPa (10 - 15 kg/cm 1 ,
come out of t he shock absorber when injecting
142 - 213 psi) and the factory standard gas
t he nitrogen g8S or riding the motorcyc le. pressure is 1200 k Pa (12 kg/cm l , 170 psi).
"'WARNING
Pressurize the gas reservoir with "Itrogen gas
only . 00 not use air or other gases , since they
may cause premature wear, rust, fire hazard or
substandard performance.
High pressure gas is dangerous. Have a qualified
mec hanic perform this procedure .
- Instal l the spring and retainer clip.

- Adjust spring preload .
- Reinstall the rear shock absorber.
A. Cirdip
Spring Tension
- Pull up the push rod assembly agai nst the circlip . Since a spring becomes shorter as it weakens, check
- Force the stop into the rear shock body by lightly its free length to de termine its condition.
tapping around t he edge of the stop with a mallet.
- Hold the lower end of the push rod assembly with
* If the spring is shorter t han the service lim it, it must
be replaced .
a vise.
- Pump the rear shock up and down several times, Rear Shock Absorber Spring Free length
and then leave it in the fu lly extended position for
about three minutes. Standard : 275 mm
- Remove t he air bleeder bolt from the upper part Service Limit : 270 mm
o f the rear shock body.
Scrspping
"'WARNING
Since the rear shock absorber contains nitrogen
gas. do not incinerate or disassemble the rear
shock absorber .
Before a rear shock absorber is scrapped. release
the nitrogen gas completely . 00 not point the
valve toward your face or body .
A. Air Bleeder Bolt
* If oil comes out of the air bleeder bolt hole, let it

overfl ow until it sto ps.
*If oil does not come out of the ai r bleeder bolt
hole, add the specif ied oil into the air b leeder
bolt hole until it overflow (that is, unt il all the
remaining air is forced out).
- Install the air bleeder bolt securely.
- Fully extend the push rod assembly.
- Injection nitrogen gas to a pressu re of 50 kPa
(0.5 kg/cm 1 , 7 psi) through the va lve on the gas
reservoir. A. Va lve
SUSPENSION 11 · 23
Swing Arm :
Swing Arm Removal
- Remove the rear wheel (see Rear Wheel Remova l
in the WheelsfTires ch apter).
- Remove the tie-rod rear mounting bolts.
- Pull out the swing arm pivot shaft. and remove the
swi ng arm .
A. Tie-Rod Front Mounting Bolt C. Tie-Rod

8. Tie-Rod Rear Mounting Bolt
Tie-Rod Installation Notes

A. Rear Mounting Bolt C. Swing Arm Pivot Shaft - Installation is the reverse of removal .
B. Tie-rod D. Sw in g Arm - Apply plenty · of molybdenum disu lf ide grease to
the inside of the needle bearings, and oil sea ls.
- Tighten the tie-rod front and rear mounting nuts to
- Separate the chain guides and chain slippers from the specified torque.
the swing arm.
Tightening Torque :
81 N-m 18.3 kg-m . 60 ft -Ibl
Swing Arm Installation Notes

- Apply plenty of molybdenum disulfide grease to
the inside of the needle bearings and sleeves. Rocker Arm Removal
- Tighten t he swing arm pivot shaft nut. and the - Place a jack (special tool) under the motorcycle so
tie-rod rear mounting nut to the specified torque. that the rear wheel is raised off the ground .
- Remove the tie-rod front mounting bolt.
- Remove the rear shock absorber lower mounting
Tightening Torque : bolt.
Pivot Shaft Nut: - Remove the rocker arm pivot shaft.
81 N·m 18.3 kg ·m. 60 ft·lbl
Tie-rod Rear Mounting Nut:
81 N·m 18.3 kg·m. 60 ft·lbl
- Refer to the W heels/Tires. Final Drive. and Brakes

chapters for wheel installation .
Tie -Rod . Rocker Arm :

Tie -Rod Removal
- Place a jack (spec ial tool) under the motorcycle so
that the rear wheel is raised off the ground .
- Remove the tie-rod front mounting bolt. A. Tie-Rod Front Mounting Bolt
- Remove the tie-rod rear mounting bolt. and then B. Rear Shock Absorber lower Mou nting Bolt
take out the tie-rods . C. Roc ker Arm
11 -24 SUSPENSION
Uni-trak Maintenancce
Check the uni-trak component parts for wear peri-

odica lly, or whenever excessive play is suspected .
• Place a j ack (special tool) under the motorcycle so
that the rear wheel is raised off the ground .
' Push and pullan the swing arm, up and down, to
check for wear.
A. Rocker Arm Pivot Shaft
'Remove the rocker arm .
Rocker Arm Jnsta/Jation Notes

" nstallation is the reverse of removal. A. Swing Arm
' Apply plenty of molybdenum disulfjde grease to
the inside of the rocker arm hole, outside of the
sleeve, and sp herica l bearings .
- Tighten the following parts to the specifi ed torque. • A sma ll amou nt of play on the swi ng arm is normal
and no corrective action is needed . However, if
Tightening Torque : excessive play is felt. remove the uni-trak parts
Rocker Arm Nut: from the frame and check for wear.
8' N-m 18 _3 kg-m_ 60 f1-lbl
* If any spherica l bearing is worn pa st the service
lim it, repl ace it using a press and a su itable driver.
Tie-rod Nut:
81 N-m 18 _3 kg-m_ 60 f1-lbl
AWARNING
Installation of new spherical beatingls) In the uni-
trak link may cause too stiff rear suspension .
Testride the motorcycle slowly and prudently until
the suspension becomes normal.
Sleeve :
• Pu ll out the sleeve of the rocker arm, and measu re
the outside diameter of the sleeve.
* If the sleeve is worn past the service limit, replace
the sleeve.
SUSPENSION 11-25
A. Sleeves
Sleeve Outside Diameter

Standard : 21.987 - 22 .000 mm
Service limit: 21 .85 mm
Rocker Arm:
Mounting Bolt Bend
A bent bolt causes vibration, poor handling, and
instabi lity.
To measure bolt runcut, remove t he bolt, place it
in V blocks, and set a d ial gauge to the bolt at a
point halfway between the blocks. Turn the bolt to
measure the runout. The amount of d ia l variation
is the amount of runout.
A. Tu rn
* If runout exceed s the service limit, replace t he

bo lt.
Bolt Runout
Standard; under 0.' mm
Service Limit : 0.2 mm
STEERING 12-1
Steering
Table of Contents
Exploded View ......... .... ... ............. ,.................................. ...... ". 12·2
Special Tools ............. ......... ..................................................... 12-3
Steering Adjustment ....... ... .. ... ..••.. ...... " .••.......... .•. ... .. ... ..••... ..... , 2-4
Steering Inspection .... ..................... .. ....................... ....... ... 12-4
Steering Adjustment ." ..................... •.... .. ..... .. ... .. .. .. . ,.. ..... ... 12-4
Steering Removal/ Installation .... ....... ......... ......... .•. ........... .. .. ...... 12-5
Steering Stem Removal ...................... , ........ .......... "..... ... ... 12-5
Steering Stem Installation Notes ........ .. .... ..... •... .. ... .. ,........... 12-6
Steering Stem Race Removal ................................ " .. ......... .. 12-6
Steering Stem Race Installation Notes ..... ............. ................ 12-6
Steering Maintenance .............................. ,.... ... ........... .. ... .. .. ... .. 12-7
Steering Stem Bearing Lubrication ............ ........................... 12-7
Bearing Wear, Damage .............................................. ......... 12-7
Steering Stem Warp .. .... .. ... ......... ........... .••. ... ......... ... .. .. ..... 12-7
12-2 STEERING
Exploded View
KX250
r-l-------i
I
:I ~~
I:. 1'--
I
-,
I
! ~-'@ I
I
I
I
I I
: ~d r-- - -:-----~KX125
- - --I
I ~
18 I
L __ _ _ _ _ _ _ _
I I
I I
I I
I I
I I
I I
'----- --- --1
T1 : 25 N-m (2 .6 kg·m. 18 It·lbl

T2: 44 N·m (4.6 kg·m. 33 It·lbl
T3: 3.9 N-m 10.4 kg-m. 36 In-Ibl
T4: 20 N-m 12.0 kg-m. 14.6 ft·lbl
STEERING 12-3
Special Tools Head Pipe Outer Race Remover: 57001-1107
Stem Nut Wrench: 57001 -1100
Head Pipe Outer Race Pre.. Shaft : 57001 -1076
Bearing Driver Sat: 57001 -1129
Head Pipe Oute, Race Driver:

5700' -"06 6700'-'076
Stem Bearing Driver: 67001 -137
Jack : 57001 -1238
Starn Bearing Drive' Adapter: 67001-1074

12-4 STEERING
............................................................. . For KX250 model; loosen the front fork upper clamp
Steering Adjustment
............................................................. bolts, and remove the handlebar, steering stem head nut
and steering stem head.
Steering Inspection
- Remove the front disc cover.
- Using the jack (specia l tool : 57001 ·1238). raise the
front wheel off the ground.
- With the front wheel pointing straight ahead. alter-
nately nudge each end of the handlebar. The front
wheel should swing fully left and right from t he
force of gravity until the fork hits the stop.
* If the steering binds or catches before the stop,
check the routing of the cables, hoses, and harnesses.
* If the steering feels tight, adjust or lubricate the
steering.
-Feel for steering looseness by pushing and pulling the
forks.
* If you fee l looseness. adjust the steering. A. Ha ndlebar Holder C. Stem Head
B. Stem Head Nut D. Upper Clamp Bolts
• Turn the steering stem locknut with the stem nut

wrench (special tool) to obtain the proper adjustment
10(125
Steering Adjustment
. Remove the front disc cover.
• For KX250 model; remove the number plate.
. Using the jack (special tool: 5700,., 2381 raise the front A. Ste m Locknut
wheel off the ground . B. Stem Nut Wrench: 57001-1100
• For KX125 model; loosen the front fori<. lower clamp
bolts and steering stem head nut
KX250
A. Lower Clamp Bolts A. Stem Locknut

B. Stem Head Nut B. Stem Nut Wrench: 57001-11 00
STEERING 12-5
* If the steering is too tight, loosen the stem locknut a Steering RemovalJlnstallation
fraction of a turn; if the steering is too loose, tighten
t he locknut a fraction of a turn. Turn the lock nut
1f8 turn at a time maximum .
- For KX250 model ; install the steerin g stem head.
Steering Stem Removal
- Tighten the stee ring stem head nut to the specified - Remove the following pa rts.
torque. Seat
Radiator Covers
Tightening Torque Fuel Tank
Front W heel
44 N-m (4,5 kg-m. 33 ft-Ibl Brake Hose Clamp
- Tighten the front fork upper o r lower clamp bolts to Ca li per Mounting Bolts
the specified to rque . Maste r Cylinder Clamp
Front Fender
Tightening Torque Handlebar
20 N-m f2 .0 kg-m, 14.5 ft -Ib) Front Fork
-Remove the steering stem head nut and washer.
- For KXlSO model; mount hand leber damp so that the -Remove the steering stem head.
cut side on the clamp points towa rd the rear. -Push up on the stem base, and remove the steering
stem locknut with the stem nut wrench (special tool),
then remove the steering stem and stem base.
A. Handleber Clamp c. Cut Side

B. Bo lts
A. Stem Base
B. Stem Nut Wrench : 57001-1100
C. Steering Stem locknut
- Tighten the clamp bolts, front first and then the rear, D. Steering Stem
to specified torque. If the handl eber clamp is cor-
rectly installed, there wi ll be no gap at the front and - Remove the upper tapered roller bearing inner race.
an even gap at the rear after tightening.
Tightening Torque
25 N-m (2.5 kg-m . 18 ft-Ibl
A. Tapered Roller Bearing

12·6 STEERING
Steering Stem Installation Notes Outer Race Removal
-I nsta llation is the reverse of removal.
- Apply grease to the upper tapered roller bearing and
put it on the outer race.
- Using the stem nut wrench (special tool1 temporarilly
tighten the stem locknut to press the tapered roller
bearing against the outer race.
- Sack out the stem locknut a fraction of a turn until
it turns lightly and then tighten the stem locknut to
the specified torque again.
l1ghtoIW1g Torquo
3.9 N-m 10.4 kg-m, 35 1n"'1
-Tighten the stem head nut to the specified torque.
TIghtening Torque
44 N-m 14.6 kg-m. 33 1t"'1
- Install the parts removed (see appropriate chapters).
- Route the cables, hoses, and harnesses according to
the Cable Routing section in the General Information
chapater. The cables, hose, and wiring harnesses must
not hinder handlebar movement
- Check and adjust the following items.
Steering 1 . Head Pipe Outer Race Remover: 57001·1107
Front Brake
Clutch Cable
Throttle Cable
- Remove the lower inner race (with its grease seal)
which is pressed onto the steering stem.
Steering Stem Race Removal

- Remove the steering stem.
-Remove the outer races from the head pipe.
oRemove the outer races pressed into the head pipe,
using the head pipe outer race remover (specia l tool)
as shown belcm, and hammer the head pipe outer race
remover to drive it out
NOTE
olf either steering stem bearing is damaged, it is
recommended that both the upper and lower A. Rolle r Bearing
bearings (including outer races) should be replaced
with new ones.
Steering Stem Race Installation Notes

-Insta llation is the reverse of removal.
- Apply grease to the outer races, and then drive
them into the head pipe using the head pipe outer race
press shaft and the drivers (special tools).
STEERING 12-7
Outer Race Installation

Steering Maintenance
Steering Stem Bearing Lubrication

- Remove the steering stem (see Steering Stem Re-
moval).
- Using a high flas h-point solvent, wash the upper
and lower tapered rollers in the cages, and wipe
the upper a nd lower outer races, which are press-
fitted into the frame head pipe, clean off grease
and dirt.
- Visually check the outer races and the rollers.
* Replace the bearing assemblies if they show wear
3 or damage.
- Pack the upper a nd lower tapered roller bearings
in the cages with grease, and apply a light coat
of grease to the upper and lowe r outer races.
1. Head Pipe Outer Race Press Shaft: 57001-1075
2. Head Pipe Outer Race Driver: 57001-1106
3. Head Pipe Outer Race Driver: 57001-1076
- App ly grease to the lower tapered roll er bearing,

a nd drive it onto the steering stem using the stem
bearing driver and adapter (special tools).
A. Steering Stem (tapered ro ller) Bearings

B. Grease Sea l
-I nstall the steering stem, and adjust the steering

(see Steering Stem Insta ll ation, Steering Adjust-
ment).
A. Stem Bearing Driver: 57001-137

B. Adapter: 57001 -1074 Bearing Wear, Damage
- Using a high fla sh-poi nt so lvent, wash the upper
and lower tapered rollers in the cages, and wipe
the upper and lower outer races, which are press-
fitted into the frame head pipe, clean off grease
- Apply grease to the upper tapered ro ller bearing and dirt.
and put it on the outer race. - Visually check the outer races and the rollers.
- Refer to Steering Stem Insta ll ation Notes. *Repl ace the bearing assemb lies if they show
damage.
Steering Stem Warp

- Whenever the stee ring stem is removed, or if the
steering can not be adjusted for smooth action,
check the steering stem fo r stra ightness.
* If the steering stem shaft is bent. replace the steer-
ing stem .
ELECTRICAL SYSTEM 13-1
Electrical System
Table of Contents
Wiring Diagram ...... .. ............ , ...... ..•... ,..... ................... ...... ....... , 3-2
Exploded View ..... ... .. "........ ............................ ... ..................... , 3-3
Specifications ..... " ......" ..... .. ... ......... ..................................... . , 3-4
Special Tools , 3-5
Precautions ................ , ..... _. _........... ... ..... , " .......... _,_ .... .. .. .. . ,_.. , 3-6
Electrical Wiring ....... .. .... ... ..... .. .. .•...... .. ... .• ....... ... ........... ... .... 13-6
Wiring Inspection .... ... •. ...........•...... .... .. .......... .......... ..•. .. . , 3-6
Ignition Timing ... .. .. ........................ .. ...... ,. .. .......... ........... ... .. .. 13-7
Ignition Timing Adjustment .... , ............ ... .. ... ..... ..... .... .... .. ,. 13-7
Flywheel Magneto ............... .... .. .............. ... ... ... ... .. ................... 13-8
Flywheel Magneto Removal .... ... .. .. ...... ........ ........ .............. ,. 13-8
Flywheel Magneto Installation ................ .... ..... ,............. ..... . 13-9
Flywheel Magneto Inspection ...... .. ......... .... ,. .... ........... .. ...... 13-9
Ignition System ........................................ , .. , .. ..... ..... ... ... .. .. ... . 13- 10
Safety Instructions ,,,,,,,,, ... .. .. ,,, ... , .... ,, .... ...... ...... ....... ....... 13-10
Ignition Coil Removal ................ '.' .... " ..... ... .... . ~ .... .. .... ....... 13- 10
Ignition Coil In stallation ......... , .. , ... ,., ........... .. ...... .. .... ........ 13-10
Ignition Coil Inspection ........ , .......... . ,...... . ... ........ . ...... ....... 13-10
Spark Plug Cleaning and Inspection .. .... ........................... . " 13-11
Spark Plug Gap Inspection ...... "............ ........ .. .. ................ 13-11
COl Unit Inspection .... ... .... ... ....... ...... " ..... """"" ......... ,, ... 1 3-1 1
Stator Coil Inspection ......•. .. " .. .................... " ........•.. ...... " 1 3- 12
13-2 ELECTRICAL SYSTEM
Wiring Diagram
1. Spark Plug
2. Ignition Coil @
3. COl Unit
4. Pickup Coil
5. Excitor Coil
6. Starter Coils
7. Magneto
8. Engine Stop
Button
@
..............................................................
Exploded View
KX125:
KX250 :
T1: 22 N·m 12.2 kg-m. 16 ft-Ibl

T2: 27 N-m 12.8 kg -m. 20 ft-Ib)
T3 : 78 N-m 18 kg-m, 58 ft-Ibl
.
Specifications
Item Standard
Ignition System:
Ignition timing : KX125 14 0 BTDC @11000r/min (rpm)
KX250 14° BTDC @6000r/min (rp m)
Ignition coi l:
3 needle arcing distance 7 mm or more
Primary winding resistan ce 0.31 n + 15%
Secondary winding resistan ce 4.1 KO ± 15%
cor unit refer to p. 13 - 12
Spark plug : KX 125 NGK B10EG © @ NGK BR10EG
KX250 NGK B9EG © @ NGK BR 9EG
Spark plug gap 0 .5- 0.6 mm
©: Canadian model
@' u. K. model
ElECTRICAL SYSTEM 13-5
Special Tools Hand Tester : 57001 ·983
Along with common hand tools, the following

more specialized tools a re required for complete
e lectrica l system serv icing.
Flywheel Holder: 57001 -1313
Spark Plug Wrench. Hex 21: 57001 · 110
Flywheel Puller : 57001 -252
Coil Tester: 57001 -1242

13·6 ELECTRICAL SYSTEM
... ... .... .. ...... .. ...... ..... .... •....... ........ ..... .... ..
Precautions Electrical Wiring
There are a number of important precautions that Wiring Inspection

are musts wilen servicing the e lectrical system. Learn - Visua lly inspect the wiring for signs of burning.
and o bserve a ll the rules below. fraying, etc. ..
oThe electrical parts should never be struck sharply, as
with a hamme r, or allowed to fa ll on a hard surface.
* If any wiring is poor, replace the damaged wlrmg.
- Pull each connector a part and inspect it for corrosion,
Such a shock to the parts can damage them. dirt. and damage.
oTroubles may involve one or in some cases all items.
Never replace a defective part without determining
* If the connector is corroded o r dirty, clean it care-
fu lly. If it is damaged, replace it
what CAUSE D the failure. If the fai lure was caused - Check the wiring for continuity.
by some other item o r items, they too must be ~ OUse the wiring diagram to find the ends of the lead
paired or replaced, or the new replacement will soon whic h is suspected of being a problem.
fa il again. OCoonect an ohmmeter between the ends of the leads.
oMake sure all connectors in the circuit are clean and OSet the meter to the x 1fl range, and lead the meter.
tight. and examine wires for signs of burning. fraying.
etc. Poor wires and bad connections wi ll affect e lec-
* If the meter does not read zero 0, the lead is de-
fecttive. Rep lace the lead or the wiring harness if
trical system operation. necessary.
OMeasure coil a nd winding resistance when the part is
cold (at room temperature).
oElectrical Connectors
Fernaae Connectors
Male Connectors
Ignition Timing The ignition timing ca n be adjusted for different

power band s to suit the rider's preference and ability.
- Remove the magneto cover.
Ignition Timing Adjustment - Loosen the stator sc rews.
- Remove the magneto cover. - Adjust the timing by shifting the stator pos ition
- loosen the magneto stator screw. within the three lines .
- Check to see if the center mark of the three marks
on the magneto stator is aligned with the mark on
the crankcase.
* If the marks are not aligned, loosen the magneto
stator screws and turn the magneto stator. KX125 :
KX1 25:
A. Timing Ma rk (Crankcase)
B. Stator Plate
C. Standard Timing Mark
D. Screw
E. Adjustable Range
A. Timing Mark (Crankcase)
B. Timing Mark {Stator Plate}
C. Screw KX250:
D. Magneto Stator
KX250 :

B. Stator Plate
C. Standard Timing Mark
D. Screw
E. Adjustable Range
B. Timing Mark (Stator Plate)
C. Screw
D. Magneto Stator NOTE
aFar best engine performance, it is very important to

- Tighten the screws securely. adjust the ignition timing within the adjustable range
-I nsta ll the magneto cover. just explained.
...... ... ........ ....... .... ... ..... .... .............. .........
Flywheel Magneto
... . . ...••.. .. .. .. .... . .... . ..••••••. .....•••.• . ..•••• •••• .•. ..
Flywheel Magnero Removal
- Remove the magneto cover.
- Unscrew the pickup coil mounting screws and
remove the pickup coil.
A. Cra nk shaft Ro tation C. Advance

B. Stator Movement D. Ratard
A. Pickup Coil B. Mounting Screws
-Hold t he flywheel steady with the flywheel holder

(special tool), and remove the ftywheel bolt or nut.
A. Crankshaft Ro tation C. Advance

B. Stato r Movement D. Rata rd
- Tighten the stator screws secu re ly. A. Flywheel Holde r: 57001 -1313
-I nstall the magneto cover. B. Flywhee l Bolt(KX125) or Nut(KX250)
-Test ride the moto rcycle and readjust the ignition -Remove the flywheel holder.
timi ng if necessary. - Screw the flywheel puller (special tool) into the fly-
wheel by turning it counterclockwise (left-hand
thread).
A. Flywheel Puller: 57001 -252

- Remove the flyw heel from the crankshaft by tu rn ing OSet the stator wiring grommet securely in the notch in
in the pulle r center bolt a nd tapping the head of t he the left crankshaft half, and route the wires according
bolt lightly with a hammer, while holding the puller to the Cable Routing section in the General Information
body steady. There is a woodruff key in the crank- chapter.
shaft tapered portion.
CAUTION
Never strike the grab bar or the flywheel itself.
Striking the bar can bend it. If the flywheel is
struck. the magnets may lose their magnetism.
- Unscrew the stator sc rews, and remove the stator

and the wiring gromm et.
A. Stator lead B. Grommet
oFit the woodruff key secure ly in the slot in the crank-

shaft before installing the fl ywheel.
OHoid the ftywheel steady with the flywheel holder
(special tool), and tighten the flywheel bolt or nut to
the specified torque.
Tightening Torque:
10(125 IBottI: 22 N-m 12.2 kg-m. 16 It-lbl
10(250 INutl: 78 N-m (8 kg-m. 58 It~bl
A. Stator Sc rews e. Wi ring Grommet

B. Stator
- Di sconnect the stator lead connectors from the I.e.

igniter con nectors.
Flywheel Magneto Ins tallation

-Insta ll ation is the reve rse of remova l. Note the
following:
OUs ing a high flash-point solvent, clean off any oil or
dirt that may be on the cra nkshaft taper or in the
hole in the fl yw hee l. Dry them with a clea n cloth.
A. Flywheel Holder: 57001 -1313
B. Flywheel Bolt (KX125) or Nut (KX250)
OReplace the gasket if it is hardened or damaged.
Flywheel Magneto Inspection

There are th ree types of magneto problems: short.
open (wire bumed out). or loss in flywheel magnetism.
A short or open in one of the coi l wi res will result
either a low output, or no o utput at all. A loss in
flywheel magnetism. which may be caused by dropping
or hitting the flywheel. or just by aging. will result in
low outpul Inspect the coils and the flywheel (see
A. Clean Off Ign ition System).
13·10 ELECTRICAL SYSTEM
- Remove the ignition coil.
Ignition System - Connect the ignition coil (with the spa rk plug cap
left installed on the spa rk plug lead) to the tester, and
measure the a rcing d ista nce .
Safety Instructions
Ignition Co iI Test
AWARNING
110 i0
Bl ki
~ e
The ignition system produces extremely high vol·
tage . 00 not touch the spark plug , high tension
coil . or spark plug lead while the engine is run- @
ning . or you could receive a severe electrical
shock.
Ignition Coif Removal 0 CV

~
0
- Remove the followi ng pa rts.
Seat
Radiator Covers
Fuel Tank 1. Coil Tester; 57001-1242 2. Ignition Coil
- Di sconnect the ignition coi l primary leads.
. Pull the plug cap off the spark plug. AWARNING
- Unscrew the mounting bolt, and remove the ignition
coi l. To avoid extremely high voltage shocks, do not
touch the call or lead .
* If the distance reading is less than the specified

value, the ignition coil o r spark plug cap is
defective.
3 Needle Arcing Distance
7 mm or more
- To determine which part is defective, measure the
arCing dista nce again with the spark plug cap re-
moved from the ignition coil lead.
* If t he arcing distance is subnormal as before, the
trouble is with the ignition coil itse lf. If the a rci ng
\ distance is now normal. the t rouble is with the spark
plug cap.
A. Ignition Coil C. Plug Ca p
B. Primary lead Measuring coil resista nce;
If the arcing tester is not available, the coil can be
checked for a broken or badly shorted wi nding with
Ignition Coil Installation an ohmmeter. However, an ohmmete r cannot detect
-I nstallation is the reverse of remova l. layer shorts and shorts resulting f rom insu lation
breakdown under high voltage.
- Remove the ignition coil.
Ignition Coif Inspection - Measure the primary winding res istance.
Measuring arcing distance: OConnect an ohmmeter between the coil term inals.
The most accurate test for determining the condi- oSet the meter to the x 10 ra nge, and read the meter.
tion of the ignition coi l is made by measuring arcing - Measu re t he secondary windi ng resistance.
distance with the coil teste r (special tool) for the oPuli the spark plug cap off the lead.
3-needle method . OConnect an ohmmeter between the spark plug lead
and the ground lead terminal.
aSet the meter to the x 1 kO range, and read the
meter.
NOTE * If the meter does not read as specified, replace the
coil.
oSince a tester other than the coil tester (special
tool: 57001-1241) may produce a different arcing Ignition Coli Winding Resistance
distance, the coil tester is recommended for Primary windings : 0 .310 ± 15%
reliable results.
Secondary windings : 4.1 kD ± 15%
Ignition Coil Winding Resistance Spark Plug Gap
CD
'0 6
'-'
'-+< J
@
1. Measure primary winding resistance.

2. Measure secondary wi ndin g resistance.
3. Ignition Coi l 1. Insulator 3. Plug Cap
2. Center Electrode 4. Side Electrode
* If the meter reads as specified, the ignition coil COl Unit Inspection
windings are probably good. However, if the ignition - Remove the seat.
system stili does not perform as it should after all - Remove the left and right radiator covers and the fue l
other components have been checked, test replace tank.
the coil with one known to be good. - Disconnect the COl unit lead.
- Check the spark plug lead for visible damage. - Unscrew the mounting boits, and remove the COl unit
* If the spark plug lead is damaged. replace the coi l.
Spark Plug Cleaning and Inspection

- Remove the spark plug, and visually inspect it
- Clean the spark plug. preferably in a sandblasting
device, and then clean off any abrasive particles.
The plug may also be cleaned using a high flash-
point solvent and a wire brush or other suitable tool.
* If the spark plug electrodes are corroded or damaged,
or if the insulator is cracked. replace the plug. Use
the standard spark plug. A. Mounting Bolts B. COl Unit
CAUTION
Use only the Kawasaki Hand Tester (Special tool :
57001 -9831 for this test. A tester other than the
Kaw.tSaki Hand Tester may show different readngs.
Spark Plug Gap Inspection Do not use a megger or a meter with a large ca-
- Measure the gap with a wire-type thickness gauge. pacity battery, or the COl unit wiN be damaged .
* If the gap is incorrect, carefully bend the side
electrode with a suitable tool to obtain the cor-
rect gap. - Set the Kawasaki Hand Tester to the x 1 kO
range, connect the Tester to the terminals in the COl
unit lead, and check the internal resistance following
the table.
Spark Plug Gap
* If the readings do not correspond to the table. re-
place the COl unit.
0 .5 - 0 .6 mm
COl Unit Test Using the Kaw asa ki Hand Tester
Tester Posi tive ( +) l ead Connect ion

SK/Y BK/W 0 W WIG
lead Color
(Gro und) (Stop) "
(Exciter) (lgn. Coil) (Exci ter)
BKI"
(Exciter)
WI"
(Pickup) (Pickup)
~
BK/Y
6.8 - 19.2 2.2 -4.7 ~ ~ 2.2- 4.8 0 7.7- 13.4
(Ground)
~
BK/W ~ ~ ~ ~ ~ ~ ~
(Stop)
c
0
~
'"•c
u
c
0
u
"
(Exciter)
116 - 330 2.2-4 .6 ~ ~ 272 - 1200 116 -3 30 128- 420
~
"C
••
~
0
2.0 - 4.4 22 .7 - 120 6.8 - 18.2 ~ 7.0 - 19.4 2.0 - 4.4 12.8 - 24.4
-I (Ign. Coil )
~
~
•> W
.~
~ 2.2- 4.7 ~ ~ ~ ~ ~
•
~
(E xci ter)
Z•
~
"
2! SKI"
• 44-114 over 360 44 - 114 68-180
...• (E xc iter)
108 - 540 ~ ~
I~
WI"
0 6.8 - 19.2 2.2 - 4.7 ~ ~ 2.2 - 4.8 7.7- 13.4
(Pickup)
~
WIG 24 - 54.6 13.4-25.6 13.&,26.4
8.0 - 13.8 ~ ~ 8.0 - 13.8
(Pickup)
00 ; Infinity
Range : )( 1 kn Cotor Code
Un it : kO
SK Black
G C reen
0 O range
Stator Coif Inspec tion
Red
- Remove the seat and fu e l tank .
- Disconnect the ma gneto lead .
- Zero the o hmme te r, and co nnect it as shown in the
"
W White
y Ye llow
table.
• Note the res istance re ading.
Stator Coli Resistance * If there is more resistance than shoYln in the table,
the stator has a broken wire, the leads between the
stator and the connector are open, or the connec-
Connectio ns Reading tions are bad. Check the stator and the leads, and
fix or replace the damaged parts.
WhiWRed - White/Creen 188- 2830
* If there is much less resistance than shown in the
Red - Black/Red 41 7- 6270 table, the stator is shorted, or the leads between the
stator and the connector is grounded. Check the
White - Ground 14.3- 21.50 stator and the leads, and fix or replace the damaged
parts.
APPENDIX 14-1
Appendix
Table of Contents
Troubleshooting Guide ..... .••.....••.... •..••••....•. ••••...••••.•.•............•.. 14-2
General Lubrication .............. , ........ .... ........................................ '4~ 5
Unit Conversion Table .. .. ...•.... , ........ .......... .. ........... ................... 14-6

14-2 APPENDIX
........................................................... "
Troubleshooting Guide Poor Running at Low Speed:

.................................. ........... ........ ........ Spark weak:
Spark plug dirty, broken. or maladjusted
Spark plug cap or high tension wiring trouble
NOTE Spark plug cap shorted or not in good contact
Spark plug incorrect
o This is not an exhaustive list, giving every possible COl unit trouble
cause for each problem listed. It is meant simply as a Ignition coil trouble
rough guide to assist the troubleshooting for some of Flywheel magneto damaged
the more common difficulties. Fuel/air mixture Incorrect:
Idle adjusting screw maladjusted
Slow jet or air passage clogged
Engine Doesn't Start; Starting Difficulty: Air cleaner clogged, poorly sealed, or missing
Engine won't tum over: Starter plunger stuck open
Cylinder. piston seizure Fuel level too high or too low
Crankshaft seizure Fue l tank air vent obstructed
Connecting rod small end seizure Carburetor holder loose
Connecting rod big end seizure Air clea ne r duct loose
Transmission gear or bearing seizu re Compresskm low :
Kick shaft retu rn spring broken Spark p lug loose
Kick ratchet gear not engaging Cylinder head not sufficiently tightened down
No fuel flow : Cylinder. piston worn
No fuel in tank Piston ring bad (worn, weak, broken, or sticking)
Fuel tap turned off Piston ring/land clearance excessive
Tank cap air vent obstructed Cylinder head gasket damaged
Fuel tap dogged Cylinder head warped
Fuel line clogged Cylinder base gasket damaged
Float valve clogged Reed valve damaged
Engine flooded : Cylinder nut loose
Fuel level too high KIPS pons stuck open:
Float valve worn or stuck open KIPS exhaust valve stuck open (valve seizure, or
Starting technique faulty carbon accumu lation)
(when flooded, kick with the throttle fully open KIPS exhaust valves assembled incorrectly
to a llow more air to reach the engine.) Exhaust advancer spring damaged
No spafk; spa~ weak: Exhaust valve operating rod seizure
Spark plug dirty, broken, or maladjusted Rod (for KI PS) seized in cylinder
Spark plug cap or high tension wiring trouble Other:
Spark plug cap not in good contact COl unit trouble
Spark plug incorrect Transm ission oil viscosity too high
COl unit trouble Brake d ragging
Ignition coil trouble
Ignition coil resistor open
Flywheel magneto damaged
Wiring shorted or open
Fuellalr mixture incotTect :
Idle adjusting screw maladjusted
Slow jet or air passage clogged
Air cleaner clogged, poorly sealed, or missing
Starter jet clogged
Compression Low :
Spark plug loose
Cylinder head not suffiCiently tightened down Poor Running or No Power at High Speed:
Cylinder, piston worn Firing InCOl'Tect:
Piston ring bad (worn, weak, broken, or sticking) Spark plug dirty, damaged, o r maladjusted
Piston ring/Jand clearance excessive Spark plug cap or high tension wiring damaged
Cylinder head gasket damaged Spark plug cap shorted or not in good contact
Cylinder head warped Spark plug incorrect
Cylinder base gasket damaged COl unit trouble
Reed valve damaged Ignition coil trouble
Cylinder nut loose Flywheel magneto damaged
APPENDIX 14-3
Fuel/air mixture incorrect: Spark plug incorrect
Main jet clogged or wrong size COl unit trouble
Jet needle or needle jet worn
Jet needle clip in wrong position Fue llair mixture incorrect:
Fuel level too high or too low Main jet clogged or wrong size
Air jet or air passage clogged Fuel level in carburetor fl oat bowl too low
Air cleaner clogged. poorty sea led. or missing Ca rbu retor holder loose
Starter plunger stuck open Air cleaner poo rl y sea led . or mi ssing
Fuel to carburetor insufficient Air deaner duct poorly sea led
Water or foreign matter in fuel Air cleaner dogged
Fuel to carburetor insufficient Compression high :
Water or foreign matter in fuel Carbon built up in combustion chamber
Fuel tank air vent obstructed Engine load faulty :
Carburetor holder loose Brake dragging
Air cleaner duct loose Clutch slipping
Fuel tap clogged Transmission oi l level too high
Fuel line clogged Transmission oi l viscosity too high
Compression low : Lubrication inadequate :
Spa rk plug loose Transmission oil level too low
Cylinder head not sufficientl y tightened down Transmission oil poor qua lity or incorrect
Cylinder. piston worn Coolant incorrect:
Piston ring bad (worn, weak. broken, or Coolant level too low
sticking) Coot ant deteriorated
Piston ring/land clearance excessive Cooling system component Incorrect :
Cylinder head gasket damaged Radiator dogged
Cylinder head warped Radiator cap trouble
Cylinder base gasket damaged Water pump not rotating
Reed valve damaged
Cyl inder nut loose
Engine rpm will not rise properly :
Starter plunger stuck open Clutch Operation Faulty:
Fuel level too high or too low Clutch slipping :
No clutch lever play
Main jet clogged
Clutch cable maladjusted
Throttle valve does not fully open
Clutch inner cable catching
Air cleaner clogged
Friction plate worn or warped
Muffler clogged
Steel plate worn or warped
Water or foreig n matter in fuel
Cylinder exhaust port clogged Clutch spri ng broken or weak
Brake dragging Clutch release mechanism trouble
Clutch slipping Clutch hub or housing unevenly worn
Clutch not disengaging properly :
Overheating
Clutch lever play excessive
Transm ission oil leve l too high
Clutch plate warped or too rough
Transmission oil viscosity too high
Clutch spring tension uneven
Crankshaft bearing worn or damaged
Transmi ssion oil deteriorated
KIPS ports stuck closed :
Transmission oil viSCOS ity too high
KIPS exhaust valves stuck closed
Transmission oi l level too high
(valve seiZUre, or carbon accumulation)
Clutch housing frozen on drive shaft
KIPS exhaust valves assembled incorrectly Clutch release mecha nism trouble
KIPS ports clogged (carbon accumulation)
Exhaust valve operating rod seizu re
ROD (for KIPS) seized in cyl inder Gear Shifting Faulty:
Knocking : Does n't go Into gear; shift pedal does 't return :
Carbon built up in combustion cha mber Clutch not di sengaging
Fuel poor qua lity or incorrect Shift fork bent or seized
Spark plug incorrect Gear stuck on the shaft
cor un it trouble Gear positioning lever binding
Shift return spri ng weak or broken
Shift return spring pin loose
Overheating: Shift mechanism arm spring broken
Firing incorrect: Shift mechanism arm broken
Spark plug dirty, broken. or maladjusted Shift drum broken
14-4 APPENDIX
Jumps out o f gear : Abnormal Frame Noise:

Shift fork worn Front fo rk noise ;
Gear groove worn Oil insufficient or too thin
Gear dogs andlor dog holes worn Spring weak or broken
Shift drum groove worn Rear s hock abs orber noise:
Gear positioning lever spri ng weak or broken Shock absorber damaged
Shih fork pin wOrn Disc brake noise ;
Drive shaft. output shaft, and/or gear splines worn Pad installed incorrectly
Overshifts : Pad surface glazed
Gear positioning lever spring weak or broken Disc warped
Shift mec hanism arm spring broken Caliper trouble
Cylinder damaged
Other noise
Bracket, nut, bolt, etc. not properly mounted
or tightened
Abnormal Engine Noise :
Knocking:
COl unit trouble
Carbon bui lt up in combustion cham ber
Fuel poor quality or incorrect
Spark plug incorrect Exhaust Smoke:
Overheating Excessive white smoke :
Pis ton slap: Throttle cable maladjusted
Cylinder/piston clearance excessive Brownish s moke:
Cylinder, piston worn Air deaner clogged
Connecting rod bent Main jet too la rge or fallen out
Piston pin, piston pin holes worn Starter Plunger stuck open
Othe r noise : Fuel level too high
Connecting rod small end clea rance excessive
Connecting rod big end clearance excessive
Piston ring worn, broken or stu ck
Piston seizu re, damage
Cylinder head gasket leaking
bhaust pipe leaking at cylinder head connection
Crankshaft runout excessive Handling andl or Stability Unsatisfactory :
Engine mounts loose Handle bar hard to turn ;
Crankshaft bearing worn Control cable routing incorrect
Primary gear worn or chipped Wiring routing incorrect
Steering stem locknut too tight
Bearing roller damaged
Bearing race dented or worn
Steering ste m lubrication inadequate
Abnormal Drive Train Noise : Steering stem bent
Clutch noise : Tire air pressure too low
Clutch housing/friction plate clearance exccessNe Handlebar s hakes or excesslve ry vibra tes:
Clutch housing gear/primary gear backlash excessive Tire worn
Metal chip jammed in dutch housing gear teeth Swing arm sleeve or needle bearing damaged
Trans mission noise : Rim warped, or not balanced
Crankcase bearing worn or damaged Fro nt, rear axle runout excessive
Transmission gear worn or chipped Wheel bearing worn
Metal chip jammed in gear teeth Hand lebar damp loose
Transmission oil insufficient or too thin Sleering stem head nut loose
Kick ratchet gear not properly disengaging fro m Ha ndlebar pulls to one slda :
kick gear Frame bent
Output shaft idle gear worn or chipped Wheel misalignment
Drive c hain noise: Swing arm bent or twisted
Drive chain adjusted improperly Swing arm pivot shaft runout excessive
Chain worn Steering maladjusted
Rear andlor engine sprocket(s) worn Steering stem bent
Chain lubrication insufficient Front fork leg bent
Rear wheel misaligned Right/left front fork oi l level uneven
APPEN DIX 14-5
Shock absorption unsatisfactory
(Too hard) General lubrication
Front fork oil excessive
Front fork oil viscosity too high
Front fork leg bent
Tire air pressure too high - Before lubricating each part, clean off any rusty
Rear shock absorber maladjusted spots with rust remover and wipe off any grease, oil,
(Too soft) dirt,or grime.
Front fork oil insufficient and/or leaking - lubricate the poinu li sted below with indicated
Front fork oil viscosity too low lubricant.
Front fork, rear shock absorber spring weak
Rear shock absorber gas leaking
Rear shock absorber maladjusted NOTE
o Whenever the vehicle has been operated under wet

Brakes Don 't Hold: or rainy conditions, or especially after using a high-
Air in the brake line pressure spray water, perform the general lubri-
Pad or d isc worn cation.
Brake fluid leak
Disc wa rped
Contaminated pads Pivots: lubricate wfth Motor Oil.
Brake fluid deteriorated Cl utch l ever
Pri mary or secondary cup damaged Front Brake lever
Master cylinder scratched inside Kkk Pedal
Brake maladjustment (lever or pedal playex- Shift Peda l
cessive) Rear Brake Pedal
Drive Chain
Points: lubricate with Grease .

Clutch Inner Cable Upper and lower Ends
Thronle Inner Cable Upper End
Swing Arm Pivot
Tie-Rod Pivot
Rocker Arm Pivot
Wheel Bearing
Steering Stem Bearing
Cables: lubricate with Motor Oil.

Clutch Cable
Thronle Cable
Cable lubrication
, . Cable
2. Pressure Cable l uber: KS6019-021
, 4 -6 APPENDIX
Unit s of Length:
Unit Conve rs ion Table
km x 0.6214 : mile
m x 3 .281 : ft
Prefixes for Units: mm x 0.03937 - in
Prefix Symbol Power

mega M x 1,000,000 Unit s of Torque :
kilo k x 1.000 N-m x 0 .1020 : kg-m
centi c x 0 .01 N-m x 0 .7376 : ft-Ib
milli m x 0.001 N-m x 8.851 : in-Ib
micro
• x 0 .000001 kg-m
kg-m
x
x
9.807
7.233
:
:
N-m
ft-Ib
kg -m x 86.80 - in-Ib
Units of Mllss:
Kg x 2.205 s Ib Units of Pressure:
g x 0 .03527 "" oz kPa x 0 .01020 : kg/cm2
kPa x 0.1450 : psi
kPa x 0.7501 em Hg
kglcm 2 x 98.07 : kPa
Uotta of Volume : kg/cm2 x 14.22 psi
L x 0 .2642 : gallUS) em Hg x 1.333 : kPa
L x 0 .2 200 : gal limp)
L x 1.057 : qt IUS)
L x 0 .8799 : qt (imp) Unit s of Speed :
L x 2.113 : pint (US) km/h x 0 .6214 : mph
L x 1.816 : pint limp)
mL x 0.03381 : oz (US)
mL x 0 .02816 : oz (imp)
mL x 0 .06102 : cuin
Unit s of Force: Units of Power:

N x 0. 1020 : kg kW x 1.360 : PS
N x 0 .2248 - Ib kW x 1.341 : HP
kg
kg
x
x
9.807
2.205
-- N
Ib
PS
PS
x
x
0 .7355
0 .9863
:
:
kW
HP
Unit of Temperature:
9 (OC + 40) 5 (OF + 40)
- 40 : ·F - 40 : ·C
5 9
·F
."I
~
:,
,
" .. . ,..'" ,.. '"' m
'",;220 "., , .of
.. " . ..
24 0 ; m
'"
~,
:I,I "I
: .0 60 :
)
,
I I, I
100 :
I'
: 110
' ) ) I. I '"I
280 :
I.1' '"II I
I
-2 0:
I ,I I:, I !I II,
•
I I I,
•
I
!
~,
·c -17• •
••• " 26 .7 1'8 .9 n .l
•
93 . 3 '" : 120
n' u.
140
'"
·C
SUPPLEMENT - 1991 MODel 15 -1
Supplement - 1991 Model

This "Supplement · 1991 Moder chapter is designed to be used in conjunction with the front part of this
manual (up to the end of the " Appendix" chapter) . The maintenance and repair procedures described in this
chapter are only those that are unique to the 1991 KX125- H2 and 1991 KX2S0 - H2 motorcycles. Most service
operations for these models remain identical to those described in front of this chapter.
Complete and proper servicing of the 1991 KX125 - H2 and 1991 KX2S0 - H2 motorcycles, therefore requires
mechanics to read both this chapter and the text in front of this chapter.
Table of Contents
General Information ..........•..................................... , 5 -2 Brakes ..................................................................15 -27

Model Identification ........................................... 15-2 Exploded View ..... ......... .... ............................. 15 -27
General Specifications ....... ................................ 15-4 Suspension ...................................................... .... 15· 28
Torque and Locking Agen t ................................ 15-8 Exploded View .................................................15-28
Cable Routing ..................................................15-" Specifications ...................................................15- 30
Fuel Svstetn ........................ .................. _........... 15-' 3 Special Tools ....................................................15- 31
Exploded View .................... ............................15-13 Front Fork .........................................................15- 32
Specifications ...................... .. ......... .. ........... ... 15- ' 4 Front Fork Adjustment ........................ .... 15-32
Cooling System ....................................................1 5 -'5 Front Fork Removal ( Each Fork Tube) .. 15- 36
Exploded View ......................•.............. _.......... '5- '5 Front Fork Installation Notes .................. 15-36
Water Pump ............................•.........................15 -16 Front Fork Disassembly ..........................15-37
Water Pump Shaft Installation Notes ..... , 5 -16 Front Fork Assembly ...............................15-39
Mechan ical Seal, Oil Seal RemovaL ..... ' 5· 16 Inner Tube Inspection ............................. , 5 -42
Mechanical Seal, Oil Seal Installation .... , 5-'6 Guide Bushing Inspection ......................15-42
Engine Top End .................................................... , 5-17 Oil Seal and Dust Seal lnspQCtion .......... 15 -42
Exploded View .................................................1 5-' 7 Spring Tension ........................................ 15 -42
Specifications ...................................................1 5-19 Rear Suspension (Uni-Trak) ............................ , 5 -43
Engine Right Side ................................................. 15-20 Rear Shock Absorber: ..................................15-43
Exploded View ................................................. 15-20 Shock Damping Adjustment .................. 15-43
Specifications ................................................... 1 5- 22 Spring Preload Adjustment ....................15-43
Clutch ...............................................................15- 22 Electrical System ................................................... 15 -44
Clutch Installation Notes ....................... 15-22 Wiring Diagram ................................................15-44
Engine Removal/ Installation.......... .... .. 15-23 Exploded View ......•.........................................., 5-45
Exploded View . ........................ .. ............... .... 15-23 Specifications ................................................... 1 5-46
Engine Bottom End/Transmission ......................15- 24 Ignition Svstem ................. ............................... 1 5-46
Exploded View ...............................................15-24 Spark Plug Gap Inspection ................... 15-46
Wheels/Tires .........................................................15-26 COl Unit Inspection ................................ 15-4 7
Specifications ...................................................15-26 Stator Coil Inspection .....................•..... 15·41
Final Drive .............................................................15-26
Exploded View ••............................................... 15-26
15-2 SUPPLEMENT - 1991 MODEL
General Information
Model Identification
KX125- H2 Left Side View
KX125-H2 Right Side View

SUPPLEMENT - 1991 MODEL 15- 3
KX250 - H2 left Side View
KX250- H2 Right Side View

15 -4 SUPPLEMENT - 1991 MODEL
General Specifications
Item KX, 25-H2

Dimensions:
Overall width 815mm
Overall height 1 215mm
Wheelbase '450 mm
Road clearance 395mm
Seat height 950mm
Dry weight 86.5 kg
Curb weight: Front 45.5 kg
Rear 48.5 kg
Engine:
Type 2 ~ stroke , single cylinder, crankcase reed valve
Cooling system liqu id-cooled
Bore and stroke 56.0 x 50.6 mm
Displacement 124 mL
Compression ratio 7.9 : , (E) 7.6 : ' (High speed) , 8.2 : ' (E) 7.8 : ' (Low speed )
Maximum horsepower 29.' kW (39.5 PSI @ " 500 ./ mln (.pm)
MaKimum torque 24.5 N-m (2 .5 kg -m, 18.1 ft- rb) @11 000 rl min (rpm)
Carburetion system Carburetor. KEI HIN PWK 35
Ignition system CO l
Ignition timing 15.8° BTDC @11 000 r/ m;n (rpm)
Spark plug NGK R6254E-'05 (C)(U) NGK R6252E-,05
Port timing: Inlet Open Full open
Close
Scavenging: Open 65.5° BBDC
Close 65.5" ABDC
Exhaust: Open 95.5° BBDC (High speed) , 93.5° B8DC ( Low speed)
Close 95.5° ABDC (High speed). 93.5° A8DC (Low speed)
Lubrication system (Gasoline: oil) Petrol mix (32 : ')
Drive Train :
Type Gear
Reduction ratio 3.500 (63/ '8)
Clutch type Wet. mu lti disc
Transmission: Type 6-speed. constant mesh. retum shift
Gear ratios:
'st
2nd
2.' 42 (30/ ' 4)
1.7'4 (24/ 14)
3.d , .400 (28/ 20)
4,h ' .'8' (26/ 22)
5th 1.04' (25/ 24)
6th 0.920 (23/ 25)
Final drive system :
Type Chain drive
Reduction ratio 4.000 (48/12)
SUPPLEMENT - 1991 MODEL 15 -5
Item KX125 - H2
Transmission oil:
Grade SE ctass
Capacity 0.7 L
Frame :
Type Tubular, semi-double cradle
Steering angle 45' to either side
Caster (rake angle) 25.5-
Trail 108 mm
Front tire: Make/Type DUNLO P K490 (E) DUNLOP 0752, Tube 1ype
Size 80/ 100-21 51 M
Rear tire: Make/ Type DUNLOP K695 (E) DUNLOP 0752, Tube 1ype
Size 100/ 90-1957M
Front suspension :
Type Telescopic fork (up side down)
Wheel travel 310 mm
Rear suspension:
Type Swing arm (Uni-trak)
Wheel travel 330mm
Brake type: Front and Rear Single disc
Effective disc diameter:
Front 220mm
Rear 190 mm
Specifications subject to change without notice, and may not apply to every country.
(e) Canadian model (U) U.K. model

( E) European model
Item KX250- H2
Dimensions:
Overall width 815 mm
Overall height 1215mm
Wheelbase 1480 mm
Road clearance 385mm
Seat height 955mm
Dry weight 96 .5 kg
Curb weight: Front 50 kg
Rear 52 kg
Engine:
Type 2+stroke, single cylinder, piston reed valve
Cooling system LiQuid +cooled
Bore and stroke 67 .4 x 70.0 mm
Displacement 249 mL
Compression ratio 10.1 : 1 (E) 9.6 : 1 (High speed) .
11 .7 : 1 (E) 11 .2 : 1 (Low speed)
Maximum horsepower 39.5 kW (53.5 PS) @8 000 rl min (rpm)
Maximum torque 48.1 N+m (4.9 kg -m. 35.4 ft-Ib) @7 500 rl min (rpm)
Carburetion system Carburetor, KEIHIN PWK 38
Ignition system COl
Ignition timing , 4· BTOC @6 000 rl min (rpm)
Spark plug NGK B9EG (C)(U) NGK BR9EG
Port timing : Inlet: Open Full open
Close
Scavenging: Open 58- BBDC
Close 58- ABDC
Exhaust: Open 90.5" 8BDC (High speed) , 78.5- BBDC (Low speed)
Close 90.5" ABDC (High speed), 78.5" ABDC (Low speed)
Lubrication system (Gasoline: oil) Petrol mix (32 ; ')
Drive Train :
Type Gear
Reduction ratio 2.750 (55/ 20)
Clutch type Wet. multi disc
Transmission : Type 5-speed, constant mesh. return shift
Gear ratios: 1st 2.133 (32/ 15)
2nd 1.687 (27/ 16)
3rd 1.388 (25/ 18)
4th 1.136 (25/ 22)
5th 1.000 (24/ 24)
Final drive system:
Type Chain drive
Reduction ratio 3.428 (48/14)
Transmission oil :
Grade SE class
Capacity 0.8 L
Item KX250- H 2
Fra me :
Tvpe Tubular. semi -double cradle
Steering angle 45· to either side
Caster (rake angle ) 25 .5"
Trait 108 mm
Front tire: Make/ Type DUNLOP K490 (E) 0752. Tube type
Size 80/1 00-21 51 M
Rear tlfe: Make/Type DUNLOP K695 (E) 0752. Tube type
Size 100/ 90-19 62M
Front suspension :
Type Telescopic fork (up side down)
Wheel travel 310 mm
Rear suspension :
TVpe Swing arm (Uni-trak)
Wheel travel 330 mm
Brake type: Front and Rear Single disc
Effective disc d iameter:
Front 220mm
Rear 190mm
Specifications subject to change without notice. and may not apply to every cou ntry.
(C) Canadian model (U) : U .K. model

(E) European model
Torque and Locking Agent
Tighten all bolts and nuts to the proper torque using an accurate torque wrench. If insufficiently lightened. a
bolt or nut may become damaged or fall off. possibly resulting in damage to the motorcycle and injury to the rider.
A bolt or nul which is ovenightened 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 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.
: Left-hand threads.
Fastener Torque Remarks

N -m kg-m ft-Ib
Fuel System :
Rear Frame Mounting Bolts 26 2.7 20.0
Carburetor Holder Mounting Bolts 8.8 0.9 78 in -Ib
Cooling System :
Water Pump Cover Bolts 8.8 0.9 78 in-Ib
Water Pump Cover Elbow Bolts
(KX125) 8.8 0.9 78 in-Ib
(KX250) 4.9 0.5 43 in -Ib
Water Pump Impeller Bolt 6.9 0.7 61 in -Ib
Coolant Drain Plug:
Water Pump Cover (KX125) 8.8 0.9 78 in- Ib
(KX25O) 22 2.2 16.0
Cylinder (10(250) 22 2.2 16.0
Engine Top End:
Cylinder Head Nuts 25 2.5 18.0
Cylinder Nuts (KX125) 25 2.5 18.0
(KX25O) 34 3.5 25 .0
Cylinder Elbow Bolts (KX250) 8.8 0.9 78 in - Ib
Engine Bracket Nuts:
Frame Side 26 2.7 20.0
Engine Side
Shah Lever Nut (KX125)
34
8.3
3.5
0.85
25.0
74 in -Ib .
(KX250) 8.3 0.85 74 in- Ib
Main Exhaust Valve Cover Bolts (KX250) 8.8 0.9 78 in - Ib
Exhaust Valve Operating Rod Right Cover Bolts
(KX125) 5.9 0.6 52 in - Ib
(KX250) 2.5 0.25 22 in- Ib
Exhaust Valve Operating Rod Retaining Screw 4.9 0.5 43 in - Ib
Operating Rod Leh Side Plug 15 1.5 11 .0
Resonator Cover Bolts (KX125) 5.9 0.6 52 in- Ib
Engine Rig ht Side:
External Shih M echanism Return Spring Pin 22 2.2 16.0 l
Clutch Spring Bolts 8.8 0.9 78 in-Ib
Clutch Cover Bolts 9.8 1.0 87 in-Ib
Clutch Hub Nut 98 10.0 72.0
Advancer Lever Mounting Bolts 3.9 0.4 35 in-Ib
SUPPLEMENT - 1991 MODEL 15-9

N -m kg-m ft -Ib
Shaft Lever Nut (KX125) B.3 0.85 74 in -Ib
.
(KX250) B.3 0.85 74 in-Ib
Kick Guide Mounting Bolt
(KX125 ) 9.8 1.0 87 in -Ib
(KX250) 8.8 0.9 78 in -Ib
Kick Shaft Nut (KX250) 49 5.0 36.0
Neutral Set lever Bolt 8.8 0.9 78 in-Ib
Primary Gear Nut (KX125 ) 59 6.0 43.0
Right Engine Cover Bolts 9.8 1.0 87 in-Ib
Eng ine Removal/ Installation:
Engine Mounting Nuts 34 3.5 25
Engine Bracket Nuts:
Frame Side 26 2.7 20
Engi ne Side 24 3.5 25
Engine Bottom End/Trans mission :
Crankcase Bolts 8.8 0.9 78 in-Ib
Transmission Oil Drain Plug 20 2.0 14.5
Output Shaft Bearing Retaining Bolts 5.4 0.55 48 in- Ib
Drive Shaft Bearing Retaining Bolts 8.8 0.9 78 in-Ib
Shift Drum Bearing Retaining Bolts 8.8 0.9 78 in-Ib
Shift Drum Operating Plate Bolt 22 2.2 16.0
Wh eels/Tires :
front Axle Clamp Nuts 9.3 0.95 82 in- Ib
Front Axle Nut 54 5.5 40
Spoke Nipples Not less Not less Not less than
than 1.5 than 0.15 13 in -Ib
Final Drive:
Rear Sprocket Bolts 29 3.0 22
Brakes :
Caliper Mounting Bolts (Front. Rear) 25 2.5 18.0
Brake Hose Banjo Bolts 25 2.5 18.0
Front Master Cylinder Clamp Bolts 8.8 0.90 78 in - Ib
Brake Pad Bolts 18 1.8 13.0
Brake Disc Mounting Screws (Front. Rear) 9.8 1.0 87 in - Ib
Caliper Bleed Valves (Front. Rear) 7.8 0.80 69 in-Ib
Brake Peda l Mounting Bolt 8.8 0.90 78 in-Ib L
Suspension:
Front Axle Clamp Nuts 9.3 0.95 82 in - Ib
Front Fork Clamp Bolts (Upper, Lower) 20 2.0 14.5
Front Fork Compression Valve Assembly 54 5.5 40 L
Front Fork Top Plug 29 3.0 22
Guide Stay Nut 27 2.8 20
Rear Shock Absorber Bracket Bolts 39 4.0 30
Rear Shock Absorber Mounting Bolts 39 4.0 30
Tie- Rod Mounting Nuts (Front. Rear) 81 8.3 60
Rocker Arm Bracket Mounting Bolts 81 8.3 60
Rocker Arm Nut 81 8.3 60

N- m kg - m ft- Ib
Steering :
Steering Stem Head Nut 44 4.5 33
Steering Stem Locknut 3.9 0.4 35 in - Ib
Handlebar Clamp Bolts 25 2.5 18.0
Front Fork Clamp Bolts (l ower) 20 2.0 14.5
Electrical System:
Flywheel Bolt (10(125) 22 2.2 16.0
Flywheel Nut (10(250) 78 8 58
Stator Mounting Screws 4.9 0.5 43 in-Ib
Magneto Cover Bolts 8.8 0.9 78 in-Ib
Spark Plug 27 2.8 20
Cable Routing
1. Throttle Cable
2 . Brake Hose
3. Clutch Cable
4. IgnitIon Coil
5. Stator Lead
6. I.e. Igniter
7. Breather Hose (Crankcase)
8. Air Venl Hose (Carburetor)
9. Ovef Flow Hose (Carburetor)
=
• 10. Engine Stop Bunon
Route all hoses between the rocker arm and the tie- rod .
KX260:
1. Throttle Cable
2. Brake Hose
3. Clutch Cable
4 . Ignition Coil
5. Stator Lead
6. COl Unit
7. Breather Hose (Crankcase )
8. Air Vent Hose (Carburet or)
9. Over Flow Hose (Carburetor)
, O. Engine Stop Button
Route all hoses be tween the rocke r arm e nd the tie-rod .

Fuel System
Exploded View
T1 ; 8.8 N- m (0.9 kg -m . 78 in -Ib )

15-14 SUPPLEMENT - 1991 MOOEl
Specifications
KX125:
Throttle Grip Free Play 2""' 3mm - - -
Make/ type KEIHIN PWK35 - - -
Main jet 158 - - -
Throttle valve cutaway 5 - --
Jet needle NOEJ - - -
Jet needle clip position 2nd groove from the top - - -
Slow jet 48 - - -
Air screw 1 1/ 2 (turns out) - - -
Service fuel level 1.0±lmm - - -
(below the bottom edge of the carbobody)
Bore center 3Zmm ---
Float height 16 ±1 mm - - -
Air Cleaner Element Oil : 2-5troke racing oil or hig h-
quality foam-air filter oil - - -
Reed Valve:
Reed warp - - - O.2mm
KX2SO·
Throttle Grip Free Play 2,.,.. 3mm - - -
Make/ type KEIHIN PW K38 - - -
Main jet 160 - - -
Throttle valve cutaway 6 - - -
J et needle N85C - - -
Jet needle clip position 3rd groove from the top - --
Slow jet 58 - - -
Air screw 1 1/ 2 (turns out) - - -
Service fuel level 1.0±lmm - - -
(below the bottom edge of the carb. body)
Bore center 34mm - - -
Float height 1B±1 mm - - -
Air Cleaner Element Oil : 2·stroke racing oil or high -
quality foam-air filter oil - - -
Reed Valve :
Reed warp - - - O.2mm
SUPPLE MENT - 1991 MODEL 15-15
Cooling System
Exploded View
KX125 ,
KX250,
n · 6.9 N-m (0.7 k9- ~, 78

61 in
in--Ib
Ib)
. 8 N-m (0.9 kg- " 6 ft -Ib)
T3 : 8. (22 kg -m, . Ib )
T4 :: 22
T5
N- m . kg -m, 43 In -
4.9 N-m (05
.
• Press the mechanIcal seal and o il seal into the hole from
Water Pump the outside of the right engine cover with a bearing
driver.
. Set the mechanical seal so that dual lips side face
Water Pump Shaft Installation Notes outward and set the oil seal so thaI a lip faces outward
Refer to p. 3 -8, noting the following. as shown.
Water Pump Shaft Installation
NOTE
O Use a bearing driver larger in diameter than the oil seal,
and press the oil seal in to the hole until the edge of the
oil seal is located 0.5 mm in 'rom the surface of the
hole.
Mechanical Seal , Oil Seal Insta llation
D 4
1. Mechanical Seal 4. Marked Side

2. Oil Seal 5. Right Engine CoV9l'
3. Water Pump Shaft
Mechanical Seal Oil Seal Removal

• Remove the following parts. 1. Mechanical Seal 4. Beating Driver Set 57001 -1 1 29
Impell8f 2. Oil Seal 5. 0 .5 mm 6. Slep
Right Engine Cover (see Right Engine Cover in the 3. Apply High Temperature Grease
Engine Right Side chapter)
Water Pump Shaft
. Insert a bar into the waler pump shah hole from the • Press the ball bearing into the hole with a bearing driver
outside of the right engine cover, and remove the ball set (special tool) until the bearing is bonomed against
bearing by tapping evenly around the bearing inner race . the step.
• insert a bar into the water pump shah hole from the
inside of the right engine cover, and remove the oil seal
and mechanical seal by tapping evenly around the seal
tips.
Mechanical Seal 011 Sea/Installation

CAUTlON
If the mechanical ...1 and oil seal or ball bearing is
ramoved. replace both of them with new on•• at the
•• ma time.
,
• Be $!Ire to replace the mechanical seal end the oil seal.
. Apply plenty of high temperature grease to the oil seal
lips.
Engine Top End
Exploded View
T6 \ - - d
• : l eft- hand threads .

T1 : 25 N - m (2.5 kg -m , 18 ft -Ib)
T2 : 8.3 N -m (0.85 kg-m , 74 in-Ib)
T5 : 4 .9 N-m (0.5 kg- m . 43 in- Ib )
T6: 5.9 N -m (0.6 kg -m . 52 in -Ib)
KX250:
T1 : 25 N -m (2 .6 kg -m . 18 ft -Ib)
T3 : 8.3 N -m (0.85 kg-m . 74 in-Ib)
T4 : 34 N -m (3 .6 kg -m . 25 ft - Ib)
T5 : 15 N-m (1 .6 kg -m . 11 ft -Ib l
T6 : B.8 N -m (0 .9 kg -m , 78 in-Ib)
n : 4.9 N -m (0.5 kg -m . 43 in-I b)
T8 : 2.6 N -m (0.25 kg -m . 22 in-Ib)
Specifications

Cylinder H ead:
Cylinder compression (usable range)
770 ... 1,200 kPa - - -
(7.7 ... 12 kg/em' , 109 -171 psi)
Cylinder head warp - - - O.03mm
Cylinder, Piston :
Cylinder inside d iameter 56.020 ... 56.035 mm 56 .12 mm
Piston diameter 55.935 ... 55.950 mm 55.79mm
Piston / cylinder clearance 0 .071 ... 0.091 mm - - -
Piston ring / groove clearance 0 .04 ... 0.08 mm 0.1a mm
Piston ring groove width 1.03 ... 1.05 mm 1.13 mm
Piston ring thickness 0.97 ... 0.99 mm O.9mm
Piston ring end gap 0.15 ...... 0.35 mm O.7mm
Piston pin diameter 15.995 ...... 16.000 mm 15.96 mm
Piston pin hole diameter , 6.000 .... 16.020 mm 16.07 mm
Small end inside diameter 21 .003 ...... 21 ,014 mm 21 .05 mm

Cylinder H ead :
Cylinder compression (usable range)
840 ..... 1,300 kPa - --
(8 .4 .... 13 kg / cm 2 , 119 .... 185 psi)
Cylinder head warp - - - 0 .03mm
Cylinder, Piston :
Cylinder inside diameter 67 .400 ..... 67 .415mm 67 .48mm
Piston diameter 67.336 .... 67 .351 mm 67.23 mm
Piston / cylinder clearance 0 .054 "'"' 0 .074 mm - - -
Piston ring/ groove clearance 0 .04 ..... 0 .08 mm 0.18 mm
Piston ring groove width 1.23 .... 1.25mm 1.33 mm
Piston ring thickness 1.17"'"' 1.19mm 1.1 mm
Piston ring end gap 0 .15 ..... 0 .35 mm 0 .7mm
Piston pin diameter 17.995 -18 .ooomm 17.96 mm
Piston pin hole diameter 18 .000 - 1 8.020 mm 18.07 mm
Small end inside diameter 22 .003 - 22.014 mm 22.05 mm
Engine Right Side
Exploded View
1.
o
M : Apply molybdenum disulfide grease .

o : Apply transmission oil.
T1 : 9.8 N -m (1 .0 kg -m . 87 in- Ib)
T2 : B.8 N -m (0.9 kg -m . 78 in- Ib)
T3 : 98 N -m (10 kg -m , 72 ft -Ibl
M : Apply molybdenum disulfide grease.

o : Apply transmission oil.
T1 : 8.8 N-m (0.9 kg-m , 78 in -Ib)
T2: 9.8 N -m (1 .0 kg -m . 87 in- Ib)
T3 : 98 N -m (10 kg -m . 72 ft -Ib)
T4 : 3.9 N-m (0.4 kg -m , 35 in -Ib)
T6 : 8.3 N -m (0.85 kg-m . 74 in-Ib )
T7 : 49 N- m (5 kg -m , 36 ft -Ib)
Specifications

Clutc h:
Clutch lever free play 2 .... 3mm - - -
Clutch spring free length: KX125 37.5 mm 36.1 mm
KX250 38.7 mm 37 .2mm
Steel plate thickness 1.41 .... 1.59 mm , .31 mm
Friction plate thickness: KX125 2.92 ...., 3.08 mm 2.7mm
KX250 2.92 .... 3.08 mm 2.8mm
Friction plate tang width : KX125 '1 .8 -12.0mm 11 .3 mm
KX250 13.6 - 13.8 mm 13.1 mm
Friction platelclutch
housing clearance 0.35 .... 0.60 mm O.9mm
Friction and steel plate warp not more than 0 .15 mm a.3mm
Clutch
Clutch Installation Notes

Refer to p. 5-11 , noting the following .
• For KX125 model, replace the clutch hub nut with new
on•.
• Tighten the clutch hub nut to the specified torque .
• Then stake the clutch hub nut in three points to the
spline grooves to secure it in place.
CAIJT10N
When atakl ng the nut. be careful not to hit the shaft
itnlt . Such a s hock could damage the s haft and/or
bearings .
1. Clutch Hub Nut 2. Three Stakes
•
SUPPLEMENT -1991 MODEL 15-23
Exploded View
KX250,
c~
c~
n : 26 N -m (2.7 kg- m. 20 h -Ib)

T2: 34 N-m (3.5 kg- m, 25 ft -Ib)
T3 : 78 N -m (8.0 kg- m, 58 ft -Ib)
15-24 SUPPLEM ENT - 1991 MODEL
Exploded View
KX125:
T1 : 20 N -m (2.0 kg -m, 14.5 ft -Ib)

T3 : 5.4 N -m (0.65 kg -m , 48 in -Ib)
T4 : 8.8 N-m (0.9 kg-m . 78 in- Ib)
T1 : 20 N - m (2.0 kg -m, 14.5 ft- Ib)

T3 : 5.4 N - m (0.55 kg -m, 48 in -Ib)
T4 : B.8 N -m (0.9 kg -m . 78 in- I b)
Wheels/Tires
Specifications
Item Standard Se rvice limit

Wheels:
Rim runout: Axial Under 0 .5 mm 2mm
Radial Under 0 .8 mm 2mm
Axle runout/1 00 mm Under 0 .10 mm O.2mm
Tires:
10(125, Front: Size 80/ 100·21 51 M -- -
Make, type DUNLOP K490 (El DUN LOP 0752 ---
Rear: Size 100/90· 19 57M - - -
Make, type DUNLOP K695 (El DUN LOP 0752 ---
10(250, Front Size 80/ 100· 21 51 M - - -
Make. type DUNLOP K490 (El DUNLOP 0752 -- -
Rear: Size 110/ 90· 19 62M ---
Make, type DUNLOP K695 (El DUNLOP 0752 ---
Air pressure 100 kPa (1.0 kg/ em', 14 psi) -- -
( E) : European model
Final Drive
Exploded View
SUPPLEMENT -1991 MODEL 15-27
Brakes
Exploded View
Front Disc Brake
Rear Disc Brake
T1 : 25 N -m (2.6 kg -m , 18 ft-Ib)
T4: 9.8 N- m (1 .0 kg -m . 87 in -Ib)
15- 28 SUPPLEMENT - 1991 MODEL
Suspension
Exploded View
~~:
~ <s> '--~
KX250:
,----l----l
~ E! _
I
I
I
I
I
I
IL T1
_ _ _ _ _ _ _ _ _ JI
, 0
KX125:
l : Apply a non - permanent locking agent to the

threads.
T1 : 20 N-m (2.0 kg -m . 14.5 ft -Ib)
T2 : 29 N-m (3.0 kg -m . 22 tt- Ib)
T3 : 27 N-m (2.8 kg -m . 20 ft -Ib)
T4 : 9.3 N-m (0.95 kg- m . 82 in-Ibl
T5 : 54 N-m (5.6 kg -m . 40 ft -Ib)
T6 : 78 N-m (8 .0 kg -m . 58 ft -Ib l
T7 : 81 N -m (8.3 kg -m , 60 ft -Ib)
T8 : 39 N -m (4.0 kg -m , 29 ft -Ib)
15-30 SUPPLEMENT - 1991 MODel
Specifications

Front Fork :
Air pressure Atmospheric pressure
Rebound damping adjustment
KX125 9 clicks counterclockwise (from the (adjustable range)
clockwise)
KX250 8 clicks (E) 9 clicks
Compression damping adjustment 7 clicks counterclockwise (from the (adjustable range)
clockwise) (E) 14 clicks
Oil viscosity KAY ABA 01 or SAE 5W
Oit amount (per side)
When changing oil: approx. 440 mL
Aher disassembly and dry completely KX125: 517 ±4 ml
KX250: 521 ±4 mL
(El 513 ,4 mL
Oil level: KX125: 11 5 mm (adjustable range)
KX250: 110 mm (E) 120 mm l00-150mm
(fully compressed. spring removed)
Fork spring free length 514 mm 504mm
Rear Suspension :
Rear Shock Absorber :
Rebound damping adjustment : 9 clicks counterclockwise (from the (adjustable range)
seated position adjuster turned , 6 clicks
fully clockwise) IE) 10 clicks (counterclockwise)
Spring preload:
(adjusting nut position from
the center of the upper
mounting hole)
KX125 126 mm (E) 123 mm 109 - 132 mm
(El 109 - 134 mm
KX250 126 mm (E) 124 mm 109-134mm
(El 109 - 130 mm
Spring free length 275mm 270mm
Gas Reservoir:
Compression damping adjustment : (adjustable range)
KX 125 12 clicks counterclockwise (from 16 turns
the seated position adjuster turned (counterclockwise)
fully clockwise) IE} 14 clicks
KX250 9 clicks IE) , 4 clicks
Gas pressure 1,000 kPa (10 kg/ cm 1 , 142 psi)
(E) : European model

Special Tools
Fork Push Rod Puller: 57001 · 1289

Fork Spring Hokjer: 57001 · 1286
Hook Wrenches : 57001 · 1101

Oil Syring.: 57001-1290
Fork Cylinder Holder: 57001 · 1287 Jack: 57001 · 1238
Forie Oil 5e81 Driver: 57001·1340

15-32 SUPPLEMENT - 1991 MOOEL
Front Fork
Front Fork Adjustment

The front fori< should always be adjusted for the rider's
weight and track conditi()(ls by using one or more of the
following methods.
Basically, there are five adjustment you can make to the
front fork..
OAir pressure - Air pressure acts as a progressive spring
and affects the entire range of forte travel. The air
pressure in the fork increases as the fork heats up, so the
fork action on your KX will get sl iffer as the race
progresses. Because of this, we don't recommended
using air pressure for additional springing. Vour KX A. Screw
forks are designed to work without adding any air.
O Rebound damping adjustment - Th is adjustment
affects how quickly the fork rebounds. The fork
rebound damping adjuster has 16 clicks. The seated
position (full clockwise until the adjuster stops) is tull
hard, and 16 clicks (full counterclockwise untit the
adjuster SlOps) is full soft. Rebound Damping Adjustment
o Compression damping adjustment - This adjustment e Ta adjust rebound damping, turn the adjusters on the
affects how quickly the foOt compresses. The foOt fron t foOt top plugs with the blade of a screwdriver until
compression damping adjuster has 16 clicks. The you feel a click. Adjust the reboun d damping to the
seated position (full counterclockwise until the adjuster specified setting.
stops) is full soft. and 16 clicks (full clockwise until the
adjuster stops) is full hard.
OOillevel adjustment - The effects of higher or lower foOt Softer Harder
oil level are only felt during the final 100 mm of fork
o ---4')
travel. A higher oil level (more oil) will make the fork "
rebound more qu ickly. A lower oil level <less oil) will
make the foOt rebound more slowly.
,
••
o For springs - Optional springs are available that are
softer and stiffer than standard. "" 8
o FoOt clamp position - Steering qualities are greatly
affected by the foOt clamp position (If the amount of the Number of turns counterclockwise
outer tube projecting above the upper fork clamp) . usable ran ge· 16 clicks
When the fork tube height is smaller, the front end
become lighter due to the change in weight bias. Also, A. Seated position with adjuster turned fully clOCkwise
it toods to understeer in turns and ·wash out: When
the height is greater, the results are opposite.
Standard Rebound Damping Adjuster Setting
(tum the adjuster counterclockwise)
I:: 9dw
8dw(E)9dw
(E) , European """'"
Air Pressure
. Park the vehicle on level ground.
e Ta release the air pressure remove the screw at the top
of the front loOt top plug. CAUllON
The leh and right for1t tubes must have the same shock
damping.
CAUTION
The left and right fork tubes must have the same shock
damping .
Oil level Adjustment

Draining Oil
• Remove the front fork tube (see Front Fork Removal in
this chapter) .
• Hold the fork tube vertically, and unscrew the top plug.
• Push the outer tube all the way down away from the top
A. Adjuster
plug and hold it there throughout the following
procedure.
• Pullthe fork spring away from the top plug a little and
slip the fork spring holder {special tool) in on top of the
spring seat and under the rod nut.
Compression Damping Adjustment
. Clean the bottom of the inner tubes.
• Remove the caps on the bottom of the inner tubes.
• To adjust compression damping, turn the adjuster on
the front fork cylinder valve with the blade of a
screwdriver until you feel a click. Adjust the
compression damping to the specified setting.
A. Fork Spring C. Fork Spring Holder:

B. Push Rod Nut 57001-1286
• Use wrenches on the rod nut and the top plug to loosen
the rod nut.
A. Adjuster
Compression Damping Adjustment

Softer Harder
o <--{jy
"
.. 2
12 6 .,.
~ 11../
Number of turns counterclockwise
usable range· 16 clicks
A. Top Plug C. Fork Spring
A. Seated position with adjuster turned fully clockwise B. Spring Seat
Standard Compression Damping Adjuster Setting • Remove the top plug from the push rod.
(turn the adjuster counterclockwise) . lift the fork spfing and its top spring seat out of the
I KX125,250 7 clicks (E) 14 clicks
inner tube.
• Take the rebound damping adjuster rod (short) out of
(E) : European model the push rod.
A. Rebound Damping Adjuster Rod (short) A. Fork Push Rod Puller: 57001 -1289
8 . Push Rod B. Push Rod
• Hold the fork tube upside down over 8 clean container • Purge the air from between the inner and outer lUbes
and pump it to drain the oil. Remove the rebound by pumping the outer tube up and down.
damping adjuster rod (long) from the push rod.
A. Outer Tube B. Inner Tube

A. Push Rod
NOTE
NOTE o While doing this, tske care to keep the oil level topped
oH so that it stsys above the two large holes nesr the top
o To disch(JfQtJ the fork oil, pump the push (od up and of the inner tube.
down ten times.
Filling with Oil

• Hold the fork tube upright, press the outer tube and the
push rod all the way down .
• Insert both the long and short damping adjuster rods
into the push rod.
NOTE
o The spring should not be installed.
• Fill the front fork to the lOp with the specified oiL
• Purge the air from the fork cylinder by gently moving 1 . Large Holes 3. Inner Tube
the rod puller (special tool) up and down five times. 2. Outer Tube
Recommend Oil
CAUTION KAVABA 01 or SAE 5W
Never extend th e fork fuli V. oil w ill b6 forced from
between the tubes into the inner tube through the
Oil Amount (per side)
ho les 8t the top of it . This raises the oil level in the
inner tube. If the fork i s extended to the full length of When changing oil: approx. 440 ml
its normal travel. th e oil level wi ll be raised about JO After disassembly and completely dry:
mm. KX125: 517 ±4 ml
KX250: 521 ±4 ml (E) 513 ±4 ml
Never Extend the Fork Fully Oil level (tully compressed, without spring)
Standard:
KX125: 1'5 mm
KX250: 110 mm (E) 120 mm
Adjustable Range: 100 ,... 150 mm
(E) : European model
a With the fork fully compressed, insert the gauge tube

into the inner tube and position the stopper across the
top of the outer tube.
NOTE
OPosilion the stopper so that the gauge tube is parallel
to and at the back of the inner tube with the handlebars
straight ahead.
• Ahar purging the air from the assembly, let it sit for
about five minutes so that any suspended air bubbles O Puli the handle slowly, pumping out all excess oil.
can surface. *If no oil is drawn out, there is insufficient oil in the fork
tube. Pour in enough oil , then draw out t he excess oil.
• Install the parts removed (see Front Fork Assembly in
this chapter).
Adjusting Oil Level

. Set the o il syringe (special tool) , stopper so that its
lower side shows the oil level distance specified.
Fork Spring
Different fork springs are available to achieve suitable
front fork action in accordance with the rider's weight and
track condition .
• Harder springs make the fo rk stiffer, and rebound action
quicker.
• Softer springs make the fork softer, and rebound action
slower.
Forll. Clamp Position

Steering qualities are greatly affected by the fork clamp
position (the amount of the outer tube projecting above
the upper fork clamp). When the fork tube height is
smaller, the front end becomes lighter due to change in
A. Oil Syringe: 57001 -1290 weight bias. Also, it tends to understeer in turn s and
B. Stopper "wash out." When the height is greater, the results are
opposite.
NOTE NOTE
o The gauge tube is graduated in 1 em division. OAfrer adjusting the fork height. be sure the front tire does
o The syringe body is graduated in 10 mL division. not rub the fender when the forks compress fully.
excluding the gauge tube of about 5 mL capacffy. Normal riding qualities are achieved when the fork tube
top aligns with the upper surface of the upper fork
clamp.
CAUTION
The outer tubes. both right Bnd tah. should be adjusted
evenly.
A. Upper Fork Clamp Bolts B. Lower Fork Clamp Bolts
Front Fork Installation Notes

. Installation is the reverse of removal.
A. Tube Height
. If the lark tube was disassembled, check the fork oil
level.
• Route the cables and hose according to the Cable and
Hose Routing section in the General Information
chapter.
• Tighten the lower and upper clamp bolts to the specified
torque.
Front Fork Removal (Each Fork Tube) . Install the front wheel (see Front Wheel Installation
Front Fork Removal Notes in the Wheels(Tires chapter) . Mount the axle
• Using the jack (special 1001) under the frame, stabilize clamps, and tight6fl the clamp nuts, first tighten the
the motorcycle.
upper clamp nuts and th6fl the lower clamp nuts to the
• Place II stand or block under the engine so that the front specified torque. The arrow mark on the axle clamp
wheel is raised off the ground.
must point upwards.
AWARNING
Lift the front w heel bef ore unscrewing both top p lugs,
or the front fork tube, will full V compress causing
injury or tipping of bike.
• Remove the following:

Front Disc Cover
Brake Hose Holder
Front ForW. Protector
Handlebar
• Remove the caliper from the fork tube to be removed,
and rest the caliper on some kind of stand so that it
doesn't dangle. A. Arrow Mark C. lower Clamp Nuts
. Remove the front wheel (see Front Wheel RemQ\lal in B. Upper Clamp Nuts
the WheelslTires chapter) .
• Release the air pressure from the fork. . Tighten the front fork top plug to the specified torque.
. loosen the front fork top plug temporarily. . Tighten the handlebar clamp bolts to the specified
. Loosen the upper and lower fork clamp bolts. torque.
• With a twisting motion, work the fork tube down and . Tighten the front fork protector mounting bolts to the
ouI. specified torque.
• Install the brake hose holder.
• Tighten the caliper mounting bolts to the specified
torque.
• Check front brake operation after installation .
• Install the front disc cover.
Front fork Disassembly
Spring Guide Removal
. Hold the fork tube vertically, and unscrew the top plug .
• Push the outer tube all the way down away from the top
plug and hold it there throughout the following
procedure.
CAUTION
Be ca reful not to damage the ou t er tube .
• Pull the fork spring away from the top plug a linle and
slip the fork spring holder (special tool) in on top of the A. Rebound Damping Adjuster Rod (short)
spring seat and under the rod nut. B. Push Rod
• Hold the fork tube upside down over a clean container

and pump it 10 drain the oil. Remove the rebound
damping adjuster rod (long) from the push rod.
A. Fork Spring C. Fork Spring Holder.

8 . Push Rod Nut 57001-1286
• Use wrenches on the rod nut and the top plug to loosen
the push rod nut.
A. Push Rod
• Remove the push rod nut, and take out the collar and
the spring guide.
©~- i
C. Spring Seat
• Remove the top plug from the push rod .

• Lift the fort spring and its top spring seat out of the
inner tube. A. Push Rod Nut C. Spring Guide
. Take the rebound damping adjuster rod (short) out of B. Collar
the push rod.
Push Rod Disassembty • Unscrew the guide stay nut 'rom the piston holder, and
• Hold the fork tube horizontallv in a vise. remove th e split ring keepers.
. Clean the bottom of the inner tube. . Remove the O · ring, guide stay nut. Qillock piston and
• Remove the cap on the bottom of the inner tube. piston holder from the push rod.
e Stop the cylinder unit from turning by using the fork
cylinder holder (special tool). Unscrew the
compression valve assembly, and take the compression
valve assembly and gasket out of the bottom of the inner
tube.
1
cp
fil
II I
1. Fork Cylinder Holder: 57001 -1 287
2. Cylind8f Unit
3. Comprnssion Valve Assembly
A. a -ring O. Oil Lock Piston
B. Guide Stay Nut E. Piston Holder
C. Split Ring Keepers
• Pull the push rod assembly out of the bonom of the

inner cylinder.
A. Inner Tube C. O- ring

B. Compression Valve Assembly D. Gasket
• Remove the push rod and cylinder unit from the top of
the outer tube.
NOTE A. Push Rod Assembly B. Inner Cylinder

0 00 not (emOlle the inner tube from the outer tube.
Inner Tube Removal

. Separate the inner tube from the outer tube as follows:
o Slide up the spring band.
o Slide up the dust seal.
A. Push Rod C. Inner Tube

B. Inner Cylinder
SUPPLEMENT - 1991 MODEl 15 -39
A. Spring Band B. Dust Seal A. Guide Bushings C. Oil Seat

B. Washer
o Remove the retaining ring from the outer tube.
Front Fork Assembly

Inner to Outer Tube Assembly
e Assembly is the reverse order of disassembly .
• Replace the following with new parts:
Dust Seal
Retaining Ring
Oil Seal
Guide Bushing
e Place an oil coated plastic bag over the end of the inner
tube to protect the oil seals.
O The inner tube bushing groove has a sharp edge that
can out the sealing lip of the seals as they are pushed
down over the inner tube.
e Slip a plastic bag over the fork inner tube upper end to
A. Retaining Ring protect the dust and oil seals. A light coating of fork
oil on the outside of the bag will make the seals slide
down a linle easier.
OGrasp the inner tube and stroke the outer tube up and e lnstall in order these parts on the inner tube:
down several times. The shock to the fork seal separates
the outer tube from the inner tube.
1. Dust Seal 5. Outer Tube Guide Bushing

2. Retaining Ring 6. Inner Tube Guide Bushing
3. Oil Seal 7. Sharp Edge
4. Washer 8. Plastic Bag
e Remove the guide bushings, washer, oil seal. retaining e When installing the new outer tube guide bushing, hold
ring. dust seal from the inner tube. the washer against the new bushing. and tap the
washer with the fork oil seal driver (special tool) until it
stops.
15 -40 SUPPLEMENT - 1991 MOOEL
A. Guide Bushing C. Fork Oil Seal Driver: A. Piston Holder D. Guide Stay Nut
B. Washer 57001 -1340 B. Oil Lock Piston E. O -ring
C. Grooved Sido
. After installing the washer, install the oil seal by using
the fork oil seal driver (special tool) .
Install Inner Cylinder

Inner Cylinder Assembly . Check the O- ring on the compression valve assembly.
• Install the oil lock piston on the piston holder so that the and replace it with a new one if damaged .
grooves face down. . Replace the gasket with a new one.
o First. insert the push rocl into the canridge, then, install . Apply a non - permanent locking agent to the threads of
the anli· bonoming piston. The hardened steel keepers the compression valve and screw the valve into the
that hold the anti-bottoming piston to the push rod can bonom of the inner tube.
cause severe damage to the fork if nOt installed securely.
A. Compression Valve C. Gasket

B. O- ring D. Threads
• Hold the inner cylinder with the inner cylinder holder

(special tool. and tighten the valve t o the specified
1. Push Rod 4 . Oil lock PislOfl torque.
2. Guide Stay Nut 5. Piston Holder elnstall the spring guide so that the longer end is down.
3. Split Ring Keepers 6. Upward pressure on piston Then install the ~oHar wit h the large end down.
holder positions keepers
while guide stay nut is
tightened .
eTighten the guide stay nut to t he specified torque .

• Check the O-ring on the guide stay nut, and replace it
with a new one if damaged.
• Pour in the type and amount of fork oil specified and
adjust the o il level (see Oil Level Adjustmen t in this
chapter) .
• Screw the fork push rod puller (special 1001) onto the
end of the rod .
• Pull the push rod up w it h the special tool for the next
procedures.
NOTE
O Pull up the push rod slowly so as not to spill the fork
®{ oil out of the fork tube .
• Install the fork spring into the inner tube and then set
the spring seat in place.
A. Longer End B. large End . Pull the fork spring down while pulling up on t he fork
push rod puller (special tool) and insert the fork spring
holder (special toot) under the push rod nut .
• Screw on the push rod nUl so that the chamfered side
is down.
o Position the push rod nut at 18.5 mm or more from the
top of the push rod.
A. Fork Push Rod Puller. 57001 -1 289

B. Fork Spring Holder. 57001 -1286
• Remove the fork push rod puller (special tool) .

1. 18.5mm 4. Chamfered Side • Check the O -ring on the top plug, and replace it with a
2. Push Rod Nut 5. Spring Gu ide new one if damaged.
3. CoUar . Unscrew the rebound damping adjuster fully, then
screw the front fork top plug onto t he push rod .
• Holding the top plug with a wrench, tight en the push
• Insert the rebound damping adj uster rod (long) into the rod nut against the top plug to t he specified torque.
push rod .
• rnsen the rebound damping adjuster rod (shon) inlo the
push rod so that the holes are down.

8 . Spring Seat
A. Rebound Damping Adj uster Rod (short) . Pull out the fork spring holder (special tOOl), raise the
B. Holes outer tube, and screw the top plug into it.
. Install the front fork (see Front Fork Installation Notes
in this chapter) .
Inner Tube Inspection

. Visually inspect the inner tube, repair any damage.
• Nicks or rust damage can sometimes be repaired by
using a weI -stone to remove sharp edges or raised areas
which cause seal damage.
* If the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repaired A. Oil Seal B. Dust Seal
or replaced .
• Temporarity assemble the inner and outer tubes, and
pump them back and forth manually to check for
smooth operation.
CAUTION Spring Tens;on

Since a spring becomes shorter as it weakens, check its
If the Inner tube I. badly ben t o r creased. rep lace it.
free length to determine its condition.
Excessive beflding, fo llowed by s ubseque nt straight-
ening. can weaken the Inne r tube. * If the spring of either fork tube is shoner than the service
limit. it must be replaced. If the length of a replacement
spring and that of t he remaining spring vary greatly, the
remaining spring should also be replaced in order to
keep the fork tubes balanced for motorcycle stability.
Guide Bushing Inspection Fork Spring Free length

e Visually inspect the guide bushings. and replace them Standard : 514 mm
if necessary. Service Umit: 504 mm
---"'-'
A. Guide Bushings
Oil Seal and Oust Seal Inspection

. Inspect the dust seal for eny signs of deterioration or
damage.
* Replace t hem if necessary.
• Replace t he oil seal wi th a new one w henever it has
been removed.
SUPPLEMENT - 1991 MODEl 15-43
Rear Suspension (Uni-Trak)
Rear Shock Absorber:

Refer to p. '1 -15, noting the following.
Shock Damping Adjustment

Gas Reservoir
Gas Pressure
The standard gas pressure is 1000 kPa (10.0 kg /cm 2 ,
142 psi). Kawasaki recommends to maintain this standard
gas pressure at any course and loading conditions.
Sp,;ng Preload Adjustment

Spring Prelaod Setting
Standard adjusting nut position from the 'center of

the upper mounting hole:
KX125 : 126 mm (E) 123 mm
KX25O : 126 mm (E) 124 mm
Nut adjusting range:

KX125 : 109 ,.., 132 mm (E) 109 ,.., 134 mm
KX25O : 109 ,.., 134 mm (El 109 - 130 mm
Standard spring preload:

KXl25 : 7ff7 N (782 kg, 1n Ib)
(EI 659 N (67.2 kg. 148 Ib)
KX25O : 000 N (81 .6 kg. 1BO Ibl
(EI 736 N (75.0 kg. 165 Ib)
Preload change per turn of the nut:

KXl25 : 68 N (6.9 kg. 15 Ibl
(EI71 N (7.2 kg. 16 Ibl
KX25O : 74 N (72 kg. 16 Ibl
(El 74 N (7.5 kg. 16.5 Ibl
(El : European model
Electrical System
Wiring Diagram Color Code
BK Black
KX125
G Green
0 Orange
1. Spark Plug
R Red
2. Ignition Coil
3. COl Unit W White
4. Pickup Coil y Yellow
5. Exciter Coil
6. M agneto o
7. Engine Stop Button
CD
o @
I.
KX250
1. Sparit Plug
2. Ignition Coil
Color Code
3. COl Unit
4. Pickup Coil BK Black
5. Exciter Coil
G Green
6. Magneto
7. Eng ine SlOP Button 0 Orange
R Rod
W White
!! !!
y Yellow
o
I.
lL
@
Exploded View
KX125:
T4: 4.9 N-m (0.5 kg -m. 43 in -Ib)

T5: 8 .8 N-m (0.9 kg -m . 78 in -Ib)
Specifications
Item Standard
Ignition System :
Ignition timing: KX125 15.8' BTDC @11 ,000 r/ min (rpm)
KX250 14' BTOC @6,OOO r/ min (rpm)
Ignition coil: 3 needle arcing distance 7 mm or mare
Primary winding resistance 0 .130.15%
Secondary winding resistance 4.1 KO. 15%
COl unit : KX125 refer to p. 13-12.
KX250 refer to p. 15-47.
Spark plug : KX125 NGK R6254E·105 (C)(U) NGK R6252E - 105
KX250 NGK B9EG (C)(U) NGK BR9EG
Spark plug gap: 0.5 - 0.6 mm
(C) : Canadian model (U) , U .K. model
Ignition System
Spark Plug Gap Inspection

Refer to p. 1 3- 11, noting th e following.
Spark Plug Gap

0 .5 - 0 .6 mm
SUPPLEM ENT - 1991 MOD EL 15-47
COl Unit Inspection
Refer to p. 13· 1 1, noting the following.
COl Unit Tel t Using t he Kawasaki Hand Taster
KX250
Tester Positive (+) l ead Connection
BK/Y BK/W A 0 BKiA W/ A WIG
Lead """" ( G"'" od) (SlOP) (Excim<) (!gn. (>;1) (Exc""') (Pickup) (Pdup)
~
BK/Y
2.3 "'" 5.0 2.3 - 5.0 24"'" 5.3 0 8.0 -- 13.8
0
(G"",od) ""
~
0
SK/W
.~ 128 "'" 420 0 400 "'" 1200 128 "'" 420 152"", 480
0
0
(SlOP) ""
~
0 A
u 128 "'" 420 0 400 '- 1200 128 "'" 420 152 "'" 480
>!
•
(Ex6te<) ""
--,
~
0
(Ign. Coil)
23"'" 5.0 7.5"", 22.2 7.5 -222
~ 7.7 "'" 23.4 23"", 5.0 B.O "'" 28.8
••
~
SKiA
50.4"'" 150 120 .... 1080 120 .- 1080 512"'" 156 76"", 216
z"
if (Ex6te<) ""
~
W/A
~
0 23 .... 5.0 2.3 .... 5.0 2.4 .... 5.3 8.0 "", 13.8
>-
(Pickup) ""
~
W IG
8.4"'" 14.4 14.0 .... 282 14.0"", 28.8 14.4 ..... 28.8 8.4"", 14.4
(Pdup) ""
00 : Infinity Range : x 1 kO Unit : kO
Stator Coil Inspection

Refer to p. 13· 12, noting the following.
Stator Coil Resistance

KX2SO
ConnecOOns Reading
Whits/ Red - White/ GI8E!fl 188..., 2830
Red - Black/Red 359 "'" 5390
•
MODEl APPLICATION
Year Model Beginning Frame No.
1990 KX125-Hl JKAKXRH1 D LAOOOOOl or
KX125H -OOOOOl
KX250-Hl JKAKXMH10LAOOOOO1 or
KX250H -000001
1991 KX125- H2 JKAKXRH 1 D MAOO7001 or
KX125H -007001
KX250- H2 JKAKXMH1 D MAOO6001 or
KX250H -OOBOOl
o : This digit In the frame number changes from one
machine to another.

KX125 KX250: Service Manual

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KX125

Engine Top End

Engine Right Side

Engine Bottom End/Transmission

This warning may apply to any of the follow·

Brake Shoes or Pads

WARNING SAFETY INSTRUCTIONS

Read OWNER'S MANUAL before operating.

OThis note symbol indicatBs points of partic-

In most chapters an exploded view illustra-

Especlaly not. the foIowing :

Wire (cross-section) Name of Wire Color

(17) Replacement Parts

KX 125-H 1 Right Side View

KX2S0-H1 Left Side View

KX2S0-H1 Right Side View

Items KX12S -Hl

Item KX125 -H1

Torque and Locking Agent

Letter used in the " Rema rks" column mean:

Threads diameter Torque

Imm) N-m kg-m ft-Ib

KX125 : 1. Throttle Cable

Pressure Cable luber: K56019-021

Fuel Level Gauge: 57001 -122

If the throttle grip has excessive free play due to

Throttle Grip Free Play Inspection

- Turn the handlebar from side to side whi le idling the

Throttle Cable Adjustment

Operation with an Incon'ectty routed or Improperly

- lubricate the cable with penetrating rust inhibitor

1. Cable 2. Pressure Cable Luber: K56019-021

- Read the fuel level in the gauge and compare it to

1 , Fuel Level Cauge: 57001-122

- Remove the carburetor, and drain the fuel into a

1. Float Bowl Mating Surface

Ofloat height is the distance from the float bowl

• Place a suitable conta iner beneath the ca rburetor.

- Afte r re movi ng the carburetor, push a clea n. lint-

AWARNING Carburetor Installation Notes

- Route the air vent hose properly. o-@ 7. Connector

- After installing the carburetor, do the following.

OAdjust the following items if necessary.

A. Choke knob/starte r plunger Assembly

-Remove the following parts from the ca rburetor

-Make sure the fuel tap is in the OFF position .

- Remove the carburetor.

Roat Valve Wear

Push and release

1. Rod 3. Va lve Needle Wear

Air Cleaner Housing InstaiJation Notes

Air Cleaner Element Cleaning and Inspection

Ofn dusty areas, the element should be cleaned more

Fuel Tank Removal

A. Mounting Bolt B. Rubber Band

-Drain the fuel tank.

Fuel Tank Installation Notes

Fuel Tank Cap Inspection

A. Fuel Tank Breather Hose